SECTION B

SERVICE MANUAL
LOW PRESSURE
PORTABLE FORCED AIR HEATER

SPARK PLUG IGNITION MODELS

Spark Plug Ignition Models Service Manual

SAFETY INFORMATION h) Fuel storage shall be in accordance with the federal,

state, or local authority having jurisdiction.
WARNINGS • Never use heater where gasoline, paint thinner, or other
highly flammable vapors are present.
IMPORTANT: Read this owner’s manual carefully and • Follow all local ordinances and codes when using heater.
completely before trying to assemble, operate, or ser- • Heaters used in the vicinity of tarpaulins, canvas, or simi-
vice this heater. Improper use of this heater can cause lar enclosure materials shall be located a safe distance
serious injury or death from burns, fire, explosion, from such materials. The recommended minimum safe
electrical shock, and carbon monoxide poisoning. distance is 10 feet. It is further recommended that these
enclosure materials be of a fire retardant nature. These
DANGER: Carbon monoxide poisoning may lead enclosure materials shall be securely fastened to pre-
to death! vent them from igniting or from upsetting the heater due
to wind action.
Carbon Monoxide Poisoning: Early signs of carbon monoxide • Use only in well-vented areas. Before using heater, pro-
poisoning resemble the flu, with headaches, dizziness, and/ vide at least a three-square-foot opening of fresh, outside
or nausea. If you have these signs, the heater may not be air for each 100,000 Btu/Hr of rating. This heater produces
working properly. Get fresh air at once! Have heater ser- carbon monoxide, which is listed by the State of California
viced. Some people are more affected by carbon monoxide as a reproductive toxin under Proposition 65.
than others. These include pregnant women, persons with
heart or lung disease or anemia, those under the influence of • Use only in places free of flammable vapors or high dust
alcohol, and those at high altitudes. content.
• Use only the electrical voltage and frequency specified
Make certain you read and understand all warnings. Keep this on model plate.
manual for reference. It is your guide to safe and proper
operation of this heater. • Use only a three-prong, grounded extension cord.
• Use only kerosene or No. 1 fuel oil to avoid risk of fire or • Minimum heater clearances from combustibles:
explosion. Never use gasoline, naphtha, paint thinners, Outlet: 8 Ft. Sides: 4 Ft. Top: 4 Ft. Rear: 4 Ft.
alcohol, or other highly flammable fuels. • Locate heater on a stable and level surface if heater is
• Fueling hot or running or a fire may occur.
a) Personnel involved with fueling shall be qualified and • When moving or storing heater, keep heater in a level
thoroughly familiar with the manufacturer’s instructions position or fuel spillage may occur.
and applicable federal, state, and local regulations re- • Keep children and animals away from heater.
garding the safe fueling of heating units.
b) Only the type of fuel specified on the heater’s data • Unplug heater when not in use.
plate shall be used. • When used with thermostat, heater may start anytime.
c) All flame, including the pilot light, if any, shall be ex- • Never use heater in living or sleeping areas.
tinguished and the heater allowed to cool, prior to fu-
• Never block air inlet (rear) or air outlet (front) of heater.
eling.
d) During fueling, all fuel lines and fuel-line connections • Never move, handle, refuel, or service a hot, operating,
shall be inspected for leaks. Any leaks shall be re- or plugged-in heater.
paired prior to returning the heater to service. • Never attach duct work to front or rear of heater.
e) At no time shall more than one day’s supply of heater • Approved by the New York City Fire Department under
fuel be stored inside a building in the vicinity of the certificate of approval #4803, #4860, #4908, or #4909.
heater. Bulk fuel storage shall be outside the struc- To be used only at construction sites in accordance with
ture. applicable New York City Codes, Regulations, Rules,
f) All fuel storage shall be located a minimum of 25 feet Directives, Permits, etc.
from heaters, torches, welding equipment, and similar
• Warning to New York City Residents For Use Only At
sources of ignition (exception: the fuel reservoir integral
Construction Sites in accordance with applicable NYC
with the heater unit).
codes under NYCFD certificate of approval #4803, #4899,
g) Whenever possible, fuel storage shall be confined to
#4908, #4909, or #4934.
areas where floor penetrations do not permit fuel to
drip onto or be ignited by a fire at lower elevation.

1
For replacement parts contact: www.MasterParts.net 1-800-446-1446
2
 Spark Plug Ignition Models Service Manual

TABLE OF CONTENTS GENERAL INFORMATION

General Information I. ARRANGEMENT OF MANUAL
I. Arrangement of Manual ..................................... 3 This manual contains information and service procedures to
assist the service technician in understanding and correcting
III. Service Preparation ........................................... 3 problems on DESA International oil-fired portable forced air
heaters. The first section of the manual contains basic infor-
IV. Tools Required .................................................. 4
mation concerning the operation of the different components
V. Parts .................................................................. 4 in the heater. This information should be reviewed by service
personnel to provide a basic understanding of how the com-
Specifications
ponents function in the working system. Section four of this
I. General Specifications manual is intended to provide a quick reference concerning
1. Fuel Selection ............................................... 5 conditions which result in customer complaints. These proce-
2. Electrical ....................................................... 5 dures will help the service technician quickly diagnose a
3. Ventilation ..................................................... 5 malfunctioning heater. The illustrations in this manual may
4. Heater Sizing ................................................ 6 not necessarily depict the actual heater model, and are
Heater Performance Specifications ................... 6 intended for reference ONLY.
Component Operation
I. Air System III. SERVICE PREPARATION
1. Air Pump ....................................................... 7 A clean work area at the start of each job is essential for
2. Air Filters ...................................................... 7 efficient service work. Heaters which are extremely dirty
3. Nozzle .......................................................... 7 should be cleaned prior to service. Cleaning will occasionally
II. Electrical System uncover the problem area. Tools needed for the job should be
1. Motors .......................................................... 7 obtained before work is started. Delays resulting from locating
2. Solid State Relay .......................................... 8 tools result in lost time and wages.
3. Safety Control/Photocell ............................... 8 Clean fuel should always be used when testing heaters. Many
4. Electronic Ignitor ........................................... 9 problems are often traced to the use of the wrong type of fuel
III. Fuel System ...................................................... 9 or dirty fuel.
IV. Combustion System .......................................... 9 Use caution and common sense when working on a heater.
V. All Systems Working Together .......................... 9 Always remember that kerosene is flammable, electrical parts
can result in the potential shock and the heater parts are hot
Troubleshooting during operation, which could result in burns if one is not
I. Safety Requirements ....................................... 10 careful.
II. Cautions .......................................................... 10
III. Using the Ohmmeter
1. Setting Up the Ohmmeter ........................... 10
2. Calibration .................................................. 10
IV. Diagnostic Charts ............................................ 10
Diagrams and Charts
I. Wiring Diagrams .............................................. 23
II. Motor Resistance Chart .................................. 23

2
For replacement parts contact: www.MasterParts.net 1-800-446-1446
3
Spark Plug Ignition Models Service Manual

IV. TOOLS REQUIRED V. PARTS

In addition to common hand tools, the service shop should Accessories
have the following tools and instruments for proper repairing
of the heaters. These instruments will be referred to through- In addition to the standard parts we now offer parts kits. Listed
out this manual. below are the item numbers and the accessory description

INSTRUMENT RANGE PART NUMBER ITEM NUMBER ACCESSORY

Pressure Gauge 0-15 PSI HA1180

Feeler Gauge .001 to .1 inch None* HA1180 Air Gauge/All Models
Volt Ohmmeter RX1/AC 250V None** HA1210 Thermostat/Forced Air & LP Forced Air
*Available at any auto parts store. HA1202 Heavy Duty Wheel Kit
**Available at most electronic stores. 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
.025
.00
15

HA2210 Filler Neck Screen

PP203 Flame Out Safety Control
PP204
5

Rotor Kit 1/2"

4 6
3 7
2 8
15
10 20 9
1

5 25
10

PP206 Nozzle (35, 40 Models)

30
0

CAUTION: OBSERVE SAFETY RULES

OFF
PP207 Nozzle (50 Models)
1000 1000

PP208
AC

300 300

Nozzle (70 Models)

V

100 100
DC

30 30
10 10
3 3

PP209
1 x1

.1

D
10
100
x100
x1K
x10

V- MA Nozzle (100, 110 Models)

M 1000 T x10K
CA

PP210
E
S

Nozzle (150, 155 Models)

T COM-

PP211 Spark Plug

(70, 100, 150, 155, 165, 200 Models)
PP212 Spark Plug (35, 50 Models)
PP213 Air Filter Kit (30, 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

3
For replacement parts contact: www.MasterParts.net 1-800-446-1446
4
 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 Best overall 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. Requires
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 a three
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. As a
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.

4
For replacement parts contact: www.MasterParts.net 1-800-446-1446
5
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 I use?" A simple
formula that can be used to determine heater BTU 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.) ANSWER: A 50,000 BTU
X .133 (Factor) heater should be selected
1662.5 for this application.
X 30 (Temp. Rise)
49,875 (Proper Heater Size)

II. HEATER PERFORMANCE SPECIFICATIONS (SPARK PLUG MODELS)

Reddy Heater Brand Technical Service Heater Performance Data

Heater Model BTU Pump Nozzle Nozzle Motor Motor Motor Motor Start Fuel Hot AMPS Spark Plug
Rating P.S.I. Part No. Flow Part No. R.P.M. Horsepower Relay or Tank Air (Running) Gap
+1 GPH Solid State Capacity Output (inches)
+5% Relay (Gal) (C.F.M.)

R30 30,000 3.0 M29681 0.23 102001-01 1725 1/15 Not Used 3.0 165 2.8 .050/.060
R35,R35A, 35,000 3.0 100735-02 0.27 102001-01 1725 1/15 Not Used 3.0 165 2.8 .050/.060
R35B
R50, R50A 50,000 3.6 M50597 0.37 102001-01 1725 1/15 Not Used 4.0 165 2.9 .050/.060
R50B
R55 55,000 3.4 100735-17 0.40 102001-01 3450 1/15 Not Used 5.0 175 2.9 .050/.060
R70, R70A 70,000 4.0 100235-04 0.52 097308-02 3415 1/8 M25061-1 5.0 250 3.0 .050/.060
R70B, R70BT
R100, R100A 100,000 4.0 100735-06 0.74 097300-02 3450 1/5 097061-01 9.0 480 5.5 .070/.080
R110 110,000 4.0 100735-06 0.80 097300-02 3450 1/5 097061-01 9.0 490 5.5 .070/.080
R150B, R150D 150,000 3.4 100735-07 1.10 097300-02 3450 1/5 099061-01 13.5 550 5.0 .070/.080
R165 165,000 5.4 100735-10 1.10 102001-07 3450 1/4 097061-01 13.5 575 5.0 .070/.080
R200 200,000 6.0 100735-13 1.4 102001-07 3450 1/4 097061-01 13.5 600 4.5 .105/.115

102482-01 Transformer or Electronic Ignitor will apply to all models for service.

5
For replacement parts contact: www.MasterParts.net 1-800-446-1446
6
 Spark Plug Ignition Models Service Manual

COMPONENT OPERATION 3. Nozzle

As mentioned previously, the purpose of the air pump is to
I. AIR SYSTEM compress air and deliver it to the nozzle. The compressed air, as
it travels through the nozzle, creates a negative pressure that
1. Air Pump extends back through the center of the nozzle. This negative
The heater’s air pump consists of a rotor with four carbon pressure lifts the fuel from the fuel tank. The fuel from the fuel tank
blades rotating inside a pump body. The rotor is driven directly and the compressed air are mixed at the nozzle which results in
by the motor and is attached to the motor shaft by means of a very fine mist of fuel being sprayed into the combustion
a plastic insert. As the motor rotates, the carbon blades travel chamber. The air pump/nozzle combination eliminates the need
outward rubbing against the inside surface of the steel pump for a conventional type fuel pump. It is important for the service
body. The rotor’s position inside the pump body is such that technician to understand the nozzle operation. In many cases
it is not concentric with the pump body and a .003/.004 of an concerning improper operation of a heater, the problem is the
inch gap is set at the uppermost quadrant. As the motor result of a seal leak or a restriction (dust/dirt) being present within
rotates, the air between the blades is compressed and routed the nozzle. It should also be pointed out that each model heater
to the nozzle through the air line. requires different nozzles due to different fuel flow rates.
Gap Adjusting Rubber Seal
Screw .003/.004 Separating
Clearance Air/Fuel Channels
Motor Shaft Measured in Nozzle
with Feeler
Insert Gage

Air Output Air Intake Side

Compressed Air
Side From Pump
Rotor
Nozzle Face
Pump Body Fuel Lifted From Tank
Blade
by Negative Pressure
Direction of Rotation-Clockwise I. ELECTRICAL SYSTEM
2. Air Filters 1. Motors
The air filtering system consists of an air input filter and an air The motors used on the low pressure heaters are fractional
output filter. The air input filter is located at the right rear of the horsepower motors ranging from 1/15 HP on the smallest
motor and its purpose is to filter all incoming air prior to heater to 1/4 HP on the largest heaters. The motors used can
entering the air pump. The filter design is such that it can be be grouped into two categories. The first category is the shaded
cleaned in a mild, soapy solution, thoroughly dried and used pole motor. The shaded pole motor contains a single winding
over again. The air output filter is located under the plastic end and does not require an external start relay for operation.
cover. This filter’s purpose is to prevent any carbon dust (from
rotor or blade wear) from entering the air passages in the These motors are easily identified by observing that only two
nozzle. This filter is non-cleanable and should be replaced wires (usually red and white) are necessary for operation.
when considerable buildup of carbon dust is observed. (See The second category is the split-phase motor. This motor
drawings below). contains two separate windings. The first winding being the
Air Output Filter auxiliary or start winding and the second being the main or run
Air Output Filter
winding. This motor requires and external means of switching
Air Input the power off to the auxiliary winding after the motor reaches
Filter a predetermined speed. This power off switching is accom-
Air Input plished by a motor start relay or solid state relay. These motors
Filter are identified by observing that three wires (black, red and
white) are routed from the motor.
X
AU

MA CAPACITOR
MOTOR IN
30,000, 35,000, 50,000, 55,000, 100,000, 110,000, 150,000, AC LINE
AC LINE
and 70,000 BTU Filter System 155,000, 165,000, and 200,000
BTU Filter System Shaded Pole Motor Split-Phase Motor

6
For replacement parts contact: www.MasterParts.net 1-800-446-1446
7
Spark Plug Ignition Models Service Manual

2. Solid State Relay 3. Safety Control/Photocell

Applicable models use 097061-01 Solid State Relay. The safety control circuit consists of a photocell (light sensitive
cell) and a safety control. The photocell is used to sense the
The solid state relay is used to de-energize the start winding
presence of light inside the combustion chamber. The photo-
on split-phase motors. As mentioned in the Motor Section,
cell varies its electrical resistance in relation to the light rays
remember that split-phase motors have both an auxiliary
which contact its surface. When the heater is operating
(start) and a main (run) winding. For proper motor operation,
properly, the photocell sees sufficient and proper color light,
both the auxiliary and main winding are energized during start
which keeps its resistance low. When the photocell does not
up. After the motor starts and reaches approximately 80% of
sense the proper color or amount of light, the resistance of the
rated speed, the auxiliary winding must be de-energized to
photocell increases and forces an electrical current to flow
prevent overheating. This is accomplished by the use of a
through the solid state trigger circuit. The current flows into the
solid state relay. The operation of the relay functions as a
circuit breaker and heats a metal bar causing the bar to warp
positive temperature coefficient resistor. When voltage is
(bimetal). The warpage releases the spring loaded reset
applied to the motor, the main and auxiliary windings are
button, which breaks all power to the heater. As a service
energized as current flows through the solid state relay which
technician, it is important to understand the operation of the
is connected in series with the auxiliary winding only. The
safety control. In the past, it has been the single most
resistance is increased over time in the solid state relay where
misdiagnosed part of the heater. It is suggested that all
it eventually rises to the point that theoretically no current
controls be checked per instructions listed in the Trouble-
flows, de-energizing the auxiliary winding.
shooting Section, prior to replacement.

Flameout Safety Controls

Enclosed Design
Solid State Relay

Photocell

7
For replacement parts contact: www.MasterParts.net 1-800-446-1446
8
 Spark Plug Ignition Models Service Manual

4. Electronic Ignitor IV. COMBUSTION SYSTEM (Burner Head)

All models use 102482-01 Electronic Ignitor Kit. The burner head is mounted to the rear of the combustion
The electronic ignitor operates on 120V/60Hz. It delivers chamber. The purpose of the burner head is to meter and mix
approximately 6,000 volts average to the spark plug causing the amount of air entering the chamber to obtain proper
the kerosene sprayed from the nozzle assembly to ignite. The combustion characteristics. The nozzle is mounted in the
ignitor operates on a pulse basis. The ignitor has no internal center of the burner head and is surrounded by fins, so that the
service parts and must be replaced when found defective. amount of air entering the chamber from the burner head is
equal and balanced. The size of the slots in the burner head
Note: It is important for the service technician to be cautious differ between models.
when working with the electronic ignitor due to its high voltage
output.

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 of the motor shaft forces air through
III. FUEL SYSTEM (Fuel filters) the air line (G) and out the burner nozzle (I). The moving air
There are several types of fuel filters used on different model creates a pressure differential in the burner head (N) causing
heaters. The filters are always located in line with the fuel fuel to be drawn from the tank (J). The fuel-air mixture is
pickup tube. The purpose of the filter is to eliminate the sprayed into the combustion chamber (L) in a fine mist.
possibility of dirt, dust, etc. from entering the nozzle and Addition air is supplied to the combustion chamber by a fan
restricting the flow. The filters should be inspected and (O) to enter the combustion chamber where it mixes with the
cleaned whenever a heater is brought in for service. It is also air and fuel from the nozzle. The remaining air is directed
important that the bottom of the tank be inspected for sedi- around and over the combustion chamber. This air mixes with
mentation or dirt buildup. The filter's design is such that a the heated air from the combustion chamber and is ejected as
possible restriction in the filter screen can be present during a jet of clean, heated air (K).
operation and be dislodged back into the tank when the heater
is shut off. 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.
L M N O A

J
I G E

Air For Fuel System Air For Combustion Fuel

8
For replacement parts contact: www.MasterParts.net 1-800-446-1446
9
Spark Plug Ignition Models Service Manual

TROUBLESHOOTING 2. Calibration
A. Zero meter - connect the alligator clips to each other.
I. SAFETY REQUIREMENTS The meter pointer should move to far right of ohms
scale (see Figure B).
This service manual is intended for use by individuals with an B. Use the OHM thumb adjustment knob to set the pointer
adequate knowledge of electrical and mechanical skills. At- at the "0" mark on the scale. If pointer will not zero,
tempts to repair this heater by individuals without those skills replace battery.
can result in personal injury, as well as property damage. Note: If you are using a digital readout ohmmeter, cali-
II. CAUTIONS brate according to manufacturer’s instructions.
1. Before servicing, disconnect the heater from the electri-
cal power source by removing the electrical plug from Thumb
the wall receptacle. 3
4 5 6
7
Adjustment
2 8
15
10 20 9

Note: When certain tests require electrical power to be

1
5 25

10
30
0
applied, connect electrical power only for the time nec- Range
essary to complete the test. CAUTION: OBSERVE SAFETY RULES
Switch
OFF

1000 1000

2. Do not bypass safety devices.

AC
300 300

V
100 100

DC
30 30
10 10
3 3

3. If replacement parts are necessary, do not substitute with 1

.1
x100
x10
x1

non-factory parts (use only factory authorized replace-

10 V- MA
x1K
D 100
M 1000 T x10K
CA
E
S COM-
T

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.

III. USING THE OHMMETER

Continuity Check: Throughout the diagnostic procedures,
you will be required to check continuity of the electrical IV. DIAGNOSTIC CHARTS
circuits. A brief description of how to set up the ohmmeter for
The following pages contain various diagnostic charts. To use
these tests follows.
the charts, find the “Observed Fault” that exists and follow test
1. Setting Up the Ohmmeter procedure.
A. use a small screwdriver to adjust the plastic screw on
the zero "0" mark to the far left of the scale. Observed Fault Index
B. With the battery installed, set the switch to the "RX1"
Motor starts-Unit does not ignite ..................................... 11
position.
C. Plug in test wires and use insulated alligator clips. Motor does not run or runs at slow
speeds. Spark is observed at plug .................................. 14
Heater does not start/motor and
Screw transformer does not operate .......................................... 17

2
3
4 5 6
7
8
Heater ignites and burns; However,
Safety control trips and heater shuts off .......................... 19
15
10 20 9
1

5 25
10
30
0

Frequent plug fouling/delayed ignition ............................ 22

CAUTION: OBSERVE SAFETY RULES
OFF

1000 1000
AC

300 300
V

100 100
DC

30 30
10 10
3 3
1 x1
x10
.1
x100
10 V- MA
x1K
D 100
M 1000 T x10K
CA
E
S COM-
T

Typical Ohmmeter

9
For replacement parts contact: www.MasterParts.net 1-800-446-1446
10
 Spark Plug Ignition Models Service Manual

OBSERVED FAULT
Motor Starts - Unit Does Not Ignite

Check for Spark at Plug

No Spark Observed Spark is Observed

1 Check Spark Plug for 4 Check for Proper Pump Pressure

Proper Gap
5 Check for Restricted Fuel Flow
2 Defective Transformer or Due to:
Electronic Ignitor A. Seal leak
B. Filter Blocked
3 Cracked Spark Plug C. Restriction in Nozzle of Burner Head

6 Fuel Filter Restriction

TEST PROCEDURE Bend Here

to Adjust
1 Check Spark Plug for Proper Gap Gap
See Heater Performance Specifications “Spark Plug
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 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.

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.

10
For replacement parts contact: www.MasterParts.net 1-800-446-1446
11
Spark Plug Ignition Models Service Manual

4 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 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.
5 Check for Restricted Fuel Flow
Remove the burner head from heater. Using a socket Burner
wrench, carefully remove the nozzle from burner head. Head
(Be extremely careful not to scratch or score the face of
the nozzle).
A. Seal Leak
Nozzle
Remove the rubber seal washer from stem of nozzle
Face
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. Outlet Nozzle
End 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.

11
For replacement parts contact: www.MasterParts.net 1-800-446-1446
12
 Spark Plug Ignition Models Service Manual
B. Filter Blocked 6 Fuel Filter Restriction
On certain models, a drop-in fuel filter is located in
the copper or aluminum line that attaches to the fuel The fuel filter should be inspected and cleaned. The fil-
fitting on the back side of the burner head. Lift the ters are located in the fuel line either at tank location, in
filter out of the copper or aluminum fuel line and clean, the copper or aluminum tubing or in line with the fuel line
if necessary. at access cover.
C. Restriction in Nozzle or Burner Head
Fuel Filter, Bushing,
Using a compressed air source, blow the compressed and Lower Fuel Line
air through the outlet end of nozzle to dislodge any
possible restriction.

CAUTION: NEVER DRILL OUT OR TRY TO INCREASE Note: Fuel Filter

NOZZLE SIZE. Location May Vary
According To Model
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.

12
For replacement parts contact: www.MasterParts.net 1-800-446-1446
13
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 is Difficult to Rotate Fan Rotates Easily by Hand

1 Broken Rotor or Blades 5 Open Motor Winding

2 Improper Rotor Clearance 6 Defective Solid State Relay
3 Oversized Rotor 7 Low Voltage to Heater
4 Dry Motor Bearing

TEST PROCEDURE
1 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.

13
For replacement parts contact: www.MasterParts.net 1-800-446-1446
14
 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 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
5 Open Motor Windings
Motors Without Relay (30,000, 35,000, 50,000, and
55,000 BTU) Note: Motor may vary
according to model
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 2
3
4 5 6
7
8

between motor types.

15
10 20 9
1

5 25
10
30
0

Main Winding
CAUTION: OBSERVE SAFETY RULES
OFF

1000 1000
AC

300 300
V

100 100
DC

30 30
10 10
3 3
1 x1
x10

Connect the ohmmeter on the RX1 scale to the red and

.1
x100
10 V- MA
x1K
D 100
M 1000 T x10K
CA
E
S COM-
T

white wires coming from 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.

4 5 6
3 7
2 8
15
10 20 9
1

5 25
10
30
0

CAUTION: OBSERVE SAFETY RULES

OFF

1000 1000
AC

300 300
V

100 100
DC

30 30
10 10
3 3
1 x1
x10
.1
x100
10 V- MA
x1K
D 100
M 1000 T x10K
CA
E
S COM-
T

14
For replacement parts contact: www.MasterParts.net 1-800-446-1446
15
Spark Plug Ignition Models Service Manual

6 Defective Solid State Relay

Red Wire
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 Solid State
the motor that is connected to the solid state relay termi- Relay
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.

CAUTION: DO NOT TOUCH ELECTRICAL CONNEC- Jumper

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 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- 2
3
4

10
5

15
6

20
7

25
8
9

30
10

trical Section of this manual (page 5) for proper exten-

1

5
0

sion cord sizing.

Y RULES
VE SAFET
N: OBSER
CAUTIO OFF
A
1000
C

1000 300
V

100
300
30
DC V

100
10
30
3
10
3 x1

1 x10
x100 V- MA
.1
x1K
10
100 x10K
D T
MC 1000 E
A S COM-
T

15
For replacement parts contact: www.MasterParts.net 1-800-446-1446
16
 Spark Plug Ignition Models Service Manual

OBSERVED FAULT

Heater Does Not Start/Motor and

Transformer/Ignitor Does Not Operate

Possible Causes External to Heater Possible Causes Internal to Heater

Check for Broken or Frayed 1 Check That Reset Button on Safety

Wires on Cord Control is Fully Depressed

If External Thermostat is Used, 2 Check Wiring Connections at Safety

Plug Heater directly to Control and Wire Nuts for Proper Fit
AC Source 3 Check for Continuity of
Circuit Breaker

TEST PROCEDURE
1 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.

16
For replacement parts contact: www.MasterParts.net 1-800-446-1446
17
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 “0”.

17
For replacement parts contact: www.MasterParts.net 1-800-446-1446
18
 Spark Plug Ignition Models Service Manual

OBSERVED FAULT

Heater Ignites and Burns; However, Safety

Control Trips and Heater Shuts Off

Safety Control Trips out Within the Safety Control Trips out After Several
First Minute of Operation Minutes of Operation

1 Defective Safety Control 4 Dirty Photocell

2 Defective Photocell 5 Check for Proper Pump Pressure
3 Loose Wire Nut or Terminal 6 Check for Restricted Fuel Flow
Board Connection Due to:
A. Seal Leak
B. Fuel Filter Blocked
C. Restriction in Nozzle of Burner Head
7 Fuel Cap and Gasket Not Vented

8 Fuel Cap has More than one Gasket

TEST PROCEDURE
1 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.

18
For replacement parts contact: www.MasterParts.net 1-800-446-1446
19
Spark Plug Ignition Models Service Manual

2 Defective Photocell 3 Loose Wire Nut or Terminal Board Connection

Inspect the lens of the photocell for soot/dirt, etc... If dirty, Physically check that all electrical connections are se-
wipe off with a clean, damp cloth. cure and making electrical contact.
Remove photocell from heater and connect ohmmeter
4 Dirty Photocell
on the 1000 Ohm (RX1K) scale. Hold the lens up to a
light source (60 watt light bulb, direct sunlight, etc.) with See step #2, column 1.
the lens of the photocell pointed toward the light source.
5 Check for Proper Pump Pressure
The resistance of the meter should be low (less than 500
ohms). Install HA1180 Pressure Gauge or equivalent to rear of
air filter housing. Start heater and adjust air pressure to
By blocking off the light source by putting thumb over
opening of photocell, the resistance on meter should be specified pressure. Turning adjustment screw clockwise
increases pressure, counterclockwise decreases pres-
high. Replace the photocell if a change in resistance is
sure. The screwdriver must be removed from the slot
not observed during the above test.
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).

4 5 6
3 7
2 8
15
10 20 9
1

5 25
10
30
0

CAUTION: OBSERVE SAFETY RULES 5

4 6
OFF 3 7
2 8
1000 1000 15
10 20 9
AC

300 300
1
V

100 100 5 25
DC

10

30 30
10 10
30
0

3 3
1 x1
x10
.1
x100
10 V- MA
x1K
D 100
M 1000 T x10K
CA CAUTION: OBSERVE SAFETY RULES
E
S COM- OFF
T
1000 1000
AC

300 300
V

100 100
DC

30 30
10 10
3 3
1 x1
x10
.1
x100
10 V- MA
x1K
D 100
M 1000 T x10K
CA
E
S COM-
T

Burner
Head

Nozzle
Face

19
For replacement parts contact: www.MasterParts.net 1-800-446-1446
20
 Spark Plug Ignition Models Service Manual

Restricted Fuel Flow cont. Outlet

A. Seal Leak End
Remove the rubber seal washer from stem of nozzle and Nozzle
discard. (To be safe, always replace nozzle sleeve dur- Seal
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 compressed
air through the outlet end of nozzle to dislodge any pos-
sible 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 Filter, Bushing,

and Lower Fuel Line

Note: Fuel Filter

Location May
Vary According
To Model

20
For replacement parts contact: www.MasterParts.net 1-800-446-1446
21
Spark Plug Ignition Models Service Manual

7 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.
8 Fuel Cap Has More Than One Gasket
Make sure cap has only one gasket installed.

OBSERVED FAULT
Frequent Plug Fouling/
Delayed Igniton

1 Spark Plug Too Close to Spray

Pattern of Nozzle

2 Wrong Fuel

TEST PROCEDURE
1 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.
2 Wrong Fuel
Refer to Fuel Selection on page 5 of this manual.

21
For replacement parts contact: www.MasterParts.net 1-800-446-1446
22
 Spark Plug Ignition Models Service Manual

DIAGRAMS AND CHARTS

I. WIRING DIAGRAMS

Red
Reset R
Button Blue
Blue
Safety White Red
Control Black
B Photocell
W Red

White Electronic
Ignitor
Power Green
Motor
Plug
White

Green
120V White
Spark
60HZ Plug White

30,000, 35,000, 50,000, & 55,000 BTU Heaters

B WHITE WHITE
R U
E T SAFETY BLUE
S CONTROL R
T B PHOTOCELL
E O W WHITE
T N WHITE MOTOR

IGNITOR
WHITE
BLUE GREEN
BLACK
RED
POWER
PLUG RED SOLID
GREEN STATE
RELAY

RED
120 V
60 HZ SPARK PLUG

BLACK RED RED

70,000 - 200,000 BTU Heaters - Heaters Equipped With Solid State Relay

II. MOTOR RESISTANCE CHART

OHMS
RED TO WHITE BLACK TO WHITE
MOTOR MAIN (+ 7%) AUXILIARY (+ 7%)
100088-01 6.2 —
097130-02 7.5 16.5
097134-02 3.5 18.3
101898-01 2.8 9.1

22
For replacement parts contact: www.MasterParts.net 1-800-446-1446
23
 INTERNATIONAL
www.desatech.com

079337-01
Rev. D
08/00

23
For replacement parts contact: www.MasterParts.net 1-800-446-1446