Sealey Ab502.v3 User manual

INSTRUCTION MANUAL FOR:

PARAFFIN/DIESEL HEATERS

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions

and properly maintained, give you years of trouble free performance.

1. SAFETY INSTRUCTIONS

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND

CAUTIONS. USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY

CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

1.2. GENERAL SAFETY

 Check that the heater is in sound condition and good working order. Take immediate action to repair or replace damaged parts.

 Use recommended parts only. Unapproved parts may be dangerous and will invalidate the warranty.

 Only use paraffin or diesel to fuel your heater, in accordance with instructions contained in this manual.

 WARNING! Only use heater in well ventilated areas. Ensure continuous ventilation is provided to the heater operating area. Allow at least

0.03ft² opening/1000Btu/h output (0.01m²/kW). This should be divided equally between floor and high level. Ventilation must be to the outside

of the premises in which the heater is to be operated. If your operating area has no direct access to clean fresh air we recommend that you

run a large gauge duct from the outside of the building to the back of the heater in order to provide a clean air intake. For more details see Section 4.

 Keep the heater a minimum of 3 metres from any combustible materials (i.e. wooden items, cloth, plastics, paper, etc).

 Maintain a minimum distance of 50cm from non-combustible materials (i.e. brick, steel, concrete, etc).

 WARNING! DO NOT use the heater near flammable material, liquids, solids, gases or compressed gas cylinders and the like.

 DO NOT use the heater in closed rooms, living areas, basements or below ground level.

 DO NOT allow untrained persons to operate the heater and DO NOT operate the heater without the cover.

 DO NOT use an external fuel tank. Only use that which is part of the heater.

 DO NOT leave the heater unattended when in use. Switch the heater off and unplug from the mains before leaving work area.

 DO NOT stand or place any object less than 3 metres from the heater output.

 DO NOT obstruct the air inlet and outlet sections of the heater.

 DO NOT operate the heater when you are tired or under the influence of alcohol, drugs or intoxicating medication.

 DO NOT over-fill the fuel container. Wipe up any spilt fuel immediately.

 DO NOT touch the heater outlet or dome when first switched off as these are very hot and will take time to cool.

 Ensure that the heater is correctly turned off when not in use and store in a safe, dry area, out of reach of children.

 DO NOT unplug the heater to switch it off. Use the ON/OFF switch. This will allow the aftercooling fan to run for 2 mins after shutdown.

1.1. ELECTRICAL SAFETY

WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:

You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other

connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices. A

Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current

Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected

by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your Sealey dealer.

You must also read and understand the following instructions concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified

electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances

and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2.

and use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all

connections to ensure that none are loose.

1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply

to be used and that the plug is fitted with the correct fuse - see fuse rating at right.

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty

item repaired or replaced by a qualified electrician. When an ASTA/BS approved UK

3 pin plug is damaged, cut the cable just above the plug and dispose of the plug safely.

Fit a new plug according to the following instructions (UK only).

a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b) Connect the BROWN live wire to the live terminal ‘L’.

c) Connect the BLUE neutral wire to the neutral terminal ‘N’.

d) After wiring, check that there are no bare wires, that all wires have been correctly

connected, that the cable outer insulation extends beyond the cable restraint and

that the restraint is tight.

Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only.

To rewire, connect the wires as indicated above - DO NOT connect either wire to the earth terminal.

1.1.10. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance

plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the

capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use

of 2.5mm² section cable.

FUSE RATING 13 AMP

Blue

Neutral

Wire

Yellow & Green

Earth Wire

Cable

Restraint

Brown

Live

Wire

MODELS: AB502.V3, AB902.V4, AB1452.V3

Original Language Version AB502.V3, AB902.V4, AB1452.V3 Issue: 3 - 18/02/10

NOTE: Your heater is set to be used with paraffin, to adjust for diesel use refer to Section 4.

The Sealey AB heaters are made to DIN30697 standard and built to survive the rigor of bodyshops, workshops and large work areas (these

heaters are not for domestic use). A sensor will automatically cut off the motor and fuel supply if the flame is inadvertently extinguished. The

heater can be fuelled with paraffin or (with minor adjustments to air pressure systems) diesel. Diesel, however, will not burn as cleanly as

paraffin. DO NOT use any other type of fuel. A specially constructed stainless steel combustion chamber is vertically vented through a flue,

dramatically reducing the amount of fume emitted through the hot air nozzle. The cast alloy compressor unit is protected by a large filter

element and the fuel line is fitted with an in-line filter to ensure trouble free operation. These AB heaters will operate for between 15 and 25

hours on a single tank of fuel.

2. INTRODUCTION & SPECIFICATIONS

2.1. Specifications

Model: ......................AB502.V3 ......AB902.V4 .......AB1452.V3

Output (Btu/h/kW): ................. 50,000/14.5.........90,000/26.5.........132,600/41.7

Tank capacity (litres): . . . . . . . . . . . . . . . 30 ................46 . . . . . . . . . . . . . . . .51

Fuel oil: ......................... Paraffin/Diesel.......Paraffin/Diesel ......Paraffin/Diesel

Electrical input: ................... 230V 1.7A ..........230V 5A ...........230V 3.8A

Approx. hours operation per filling: .... 25 ................18 . . . . . . . . . . . . . . . .15

Transport wheels: ................. Standard ...........Standard ...........Standard

Air flow (cfm):..................... 380 ...............530 . . . . . . . . . . . . . . .885

Automatic shut-off:................. Yes ...............Yes ...............Yes

Heated volume (ft3): ............... 12500 .............17865 . . . . . . . . . . . . .35875

Heated volume (m3): ............... 355 ...............525 . . . . . . . . . . . . . . .1015

Flue diameter (mm): ............... 100 ...............140 . . . . . . . . . . . . . . .150

Net weight (kg): ................... 35 ................40 . . . . . . . . . . . . . . . .60

Quality standard: . . . . . . . . . . . . . . . . . . CE Norm ...........CE Norm...........CE Norm

4.1. Principles of heat generation

When the heater is switched on the air compressor draws in air, pressurises it and passes it through an air line to the burner head

nozzle. The air flow causes fuel to be drawn from the tank. The fuel and air mix is then sprayed into the combustion chamber. The

mixture is automatically ignited by the spark plug and a high temperature heat stream is generated in the combustion chamber.

Air is drawn into the unit by a fan and is pushed around the

cool chamber situated between combustion chamber and

outer casing. This fast flowing air sucks the heat stream out of

the combustion chamber, providing the required heat.

If the system malfunctions a “flame-out” control will operate

and automatically cut off the motor and fuel supply. Should

this happen, switch off machine and unplug from mains

supply. Refer to trouble shooting chart in Section 7 and/or

return unit to supplier for maintenance.

This heater is indirectly fired which means that the warm air

and the exhaust gases are not mixed. Warm clean air is

blown out of the heater outlet and the exhaust gases are expelled through the flue pipe. On these heaters the front dome does not

glow as on the other direct fired AB heaters.

4.2. Fuel

The AB series will operate with two types of fuel, paraffin or diesel. Before operating the heater you must determine which type of

fuel you will use in order to effect the correct heater settings. The following information must be understood before use.

4.2.1. Paraffin

The heat output is governed by the compressor - the higher the air pressure the hotter the flame. The AB series heaters have had the

air pressure pre-set at the factory to accommodate paraffin (because it will burn more cleanly than diesel). When the heater is new

however (or when the unit has been returned from service) the settings may require minor adjustment to accommodate reductions

in air flow through a new air filter. Incorrect settings will cause flame problems and may emit fuel odours resulting in damage to the

unit and an uncomfortable working environment. Paraffin will sometimes cause condensation. If the unit is stored unused (i.e. during

the summer) such condensation will cause the fuel tank to corrode and, when next used, the flame to pulsate due to water in the

tank. To overcome the problem, paraffin must be drained off and replaced if the heater is to be unused for a long periods.

4.2.2. Diesel

AB series heaters are pre-set at the factory to accommodate paraffin. If diesel is used without changing the settings, the air

pressure will be greater than is required resulting in an excessively hot flame which will damage the unit. Before using diesel the

system must be adjusted by decreasing the air pressure to the point at which the diesel will burn to generate the correct heat output.

WARNING! Failure to adjust to the correct air pressure will damage the combustion chamber and invalidate your warranty.

The spark plug will require cleaning every 50 hours of use in order to remove carbon deposits (see Maintenance Section 6). We

recommend cleaning the plug at least once every standard working week if less than 50 hours.

4. OPERATING CONDITIONS

3. ASSEMBLY

Unpack the heater and check contents. Should there be any damaged or missing parts contact your

supplier immediately. If your model is supplied with wheels refer to fig.1 for assembly as follows:

3.1. Slide axle (4) through wheel support frame (3).

3.2. Install wheels (5) then cap nuts (9) on axle ends and tap lightly into place.

3.3. Place heater on wheel support frame and line up holes on the fuel tank flange with holes on the wheel

support frame.

3.4. Place handle on fuel tank flange and line up with the wheel support frame fixing holes. Insert bolts (6)

through the fuel tank flange and both frames and secure finger tight only with nuts (7) and washers (8).

3.5. When assembly is complete, securely tighten all nuts.

These heaters are supplied with an exhaust hood to link the heater to an exhaust for indoor use.

NEVER operate the heater without this part fitted, even if not connected to a flue.

fig. 1

fig 2

Original Language Version AB502.V3, AB902.V4, AB1452.V3 Issue: 3 - 18/02/10

5.1. Running the heater on paraffin

The heater has been factory pre-set for paraffin and will produce the correct heat output when first

used from new. You should run the heater at the pre-set output in order to ensure the long life,

safety and reliability of the unit. Minor adjustments to heat output may be required during the first

60 hours of use. These adjustments are made to the air pressure valve (see fig.4.A). Once the unit

has completed the running-in period it should not be necessary to alter the air pressure again until

a new air filter is fitted or a change of fuel takes place.

5.1.1. Ensure that the unit is unplugged from the mains supply.

5.1.2. Fill the fuel tank with paraffin. Do not over-fill. Wipe away any spillage before use.

5.1.3. Plug into the main power supply and switch on the heater. The heater will ignite and will build to its

maximum heat in approximately two minutes.

5.1.4. Always shut down the heater using the ON/OFF switch. Leave the heater plugged into the

mains supply for at least 3 minutes. ( The heater is fitted with an aftercooling timer that allows

the fan to rotate for approximately 2 minutes after shutdown, to cool the combustion chamber and

release residual heat.) NEVER SHUT DOWN THE HEATER BY PULLING OUT THE PLUG.

DO NOT touch the heater outlet as this will remain hot for some time. Store in a dry, safe, childproof

area.

5.2. Running the heater on diesel

The heater has been pre-set in the factory for the use of paraffin. Because diesel burns hotter than

paraffin it will be necessary to decrease the air pressure to give out the correct heat output. Failure

to make this adjustment will damage the combustion chamber and invalidate your warranty.

5.2.1. Ensure that the unit is unplugged from the mains supply.

5.2.2. Fill the fuel tank with diesel. Do not over-fill and wipe away any spillage before use.

5.2.3.

To ensure correct combustion set the air pressure using an accurate pressure gauge.

5.2.4. Use a pressure gauge which will measure up to 10 p.s.i. and has a 1/8” BSP thread.

With the heater turned off and unplugged from the mains, remove the threaded plug

from below the air pressure valve and attach the gauge, see fig.4.B. Start the heater and

compare the pressure reading with the pressure chart shown on the right.

5.2.5. To adjust, locate the air pressure valve (fig.4.A), which is in the centre portion of the air

inlet grill at the back of the unit. Hold the adjusting screw steady with a screw driver and loosen the locking nut. Turn the screw

anticlockwise to decrease the pressure until it compares with the diesel figures in the pressure chart.

5.2.6. To adjust the heater back to paraffin follow the process in section 5.2.5, but turn air pressure valve screw clockwise until the

pressure compares with the paraffin figures in the pressure chart.

5.2.7. Shut down the heater using the ON/OFF switch. Leave the heater plugged into the mains supply for at least 3 minutes.

NEVER SHUT DOWN THE HEATER BY PULLING OUT THE PLUG.

Remove the gauge and replace the plug before turning on the heater again.

5.2.8. DO NOT touch the heater outlet as this will remain hot for some time. Store in a dry, safe, childproof area.

IMPORTANT! This heater can be connected to a remote room thermostat ABT04 (not supplied) via the socket situated in the side

panel. If no thermostat is connected then the grey socket cover supplied MUST be inserted into the socket or else the heater will

not operate. Note that the heaters have a pre-purge time and an after cooling time. This means that a) the burner will ignite

approximately ten seconds after motor start and b) the fan will run for approximately two minutes after shut down. This is normal and

correct operation.

5.3. Monitoring the heat output

5.3.1. If, after a period of time, the heat output begins to fall this indicates that either the unit requires maintenance, as laid out in Section 6,

or that the environmental conditions the unit is operating in are not correct, see Section 4.

DO NOT ATTEMPT TO TURN UP THE AIR PRESSURE TO COMPENSATE FOR HEAT LOSS as this could result in damage to the

combustion chamber and would invalidate the warranty.

4.3. When used in the construction or agricultural industries ensure that the safety regulations in force are adhered to with regard to

distances from

flammable materials and any other specified substances. Refer to General Safety in Section 1 for recommended clearances.

WARNING! Air contaminants taken into the heater may affect the heat output, damage the unit and may cause health problems.

Example: Bodyshop filler dust will damage the motor bearing, clog the filter and compressor and contaminate the combustion chamber

causing flame flutter and health hazards. If contaminants are present the heater must be supplied with ducted clean air, see 4.4.

Please note that any parts damaged by filler dust will not be covered by warranty. Additionally, a cleaning charge will be made

for any heaters damaged by filler dust.

4.4. VENTILATION. Minimum recommended opening for fresh air intake, AB502.V2 = 0.17m2,AB902.V3 = 0.27m2, AB1452.V2 = 0.42m2,

 WARNING! Only use the heater in well ventilated areas. Careful consideration must be given to the placing of the heater to provide safe

and comfortable heating. Ensure continuous ventilation is provided to the heater operating area. Allow at least 0.01m2/kW heater output.

This should be divided equally between floor and high level. A ventilation opening must run to the outside of the premises in which the

heater is to be operated. If the operating area has no direct access to clean fresh air we recommend you run a large gauge duct from

the outside of the building to the inlet of the heater in order to provide a clean air intake. Ensure that the duct is laid so as to not

compromise safety.

4.5. Flue connection

For indoor use this heater must be connected to a flue pipe to vent exhaust gases outside. The heater can only be operated

without a flue when it is outside. To obtain a good draught, the flue gases must rise as much as possible vertically. Ensure that there is a

minimum 2 metre vertical flue length without any bends. Avoid horizontal sections and ensure that any bends are smooth.

fig. 3

5. OPERATING INSTRUCTIONS

fig. 4

Working Pressures bar/psi

Diesel Paraffin

AB502.V3 0.30/4.35 0.32/4.64

AB902.V4 0.31/4.50 0.33/4.78

AB1452.V3 0.34/4.90 0.34/4.90

Original Language Version AB502.V3, AB902.V4, AB1452.V3 Issue: 3 - 18/02/10

6. MAINTENANCE

WARNING! MAINTENANCE MUST ONLY BE UNDERTAKEN BY A QUALIFIED PERSON. WE STRONGLY RECOMMEND THAT

ALL SERVICING IS DONE BY YOUR LOCAL SERVICE AGENT.

Looking after your AB heater will pay dividends, ensuring heat as and when you need

it and avoiding frustrating operational problems.

IMPORTANT! We strongly recommend that you arrange for heater servicing

during the summer months to avoid being left without heat during the winter.

WARNING! Unplug unit from mains power supply before opening or

servicing heater. See Section 1 regarding electrical safety and maintenance.

6.1. General. Keep the heater clean; wipe outer case with a damp, clean cloth.

Do not use abrasives. Clean fuel tank with a dry cloth. Oil wheels if necessary.

Check heater for damage and immediately repair or replace with authorised

parts. Contact your Sealey Service Agent.

6.2. Spark plug (electrode). Remove, clean and check that the plug gap is 3mm

(fig.6). For paraffin check the plug on a monthly basis (or if you have starting

problems). If using diesel clean plug every 50 hours (or once every working

week if less than 50 hours).

6.3. Air filter. The cast alloy compressor unit is protected by an extra large filter

element. The filter should be cleaned regularly, especially if the appliance is

used in a dusty environment. Remove filter end cover, take out the filter, wash it

using a light detergent and dry thoroughly before re-installing. Replace the filter at least once a year.

6.4. Fuel filter. The fuel line is fitted with an in-line filter. To clean the filter, remove and wash in paraffin.

6.5. Flame-out device. The AB heaters are fitted with a flame-out device (a cadmium cell, see fig.5) which cuts the fuel

supply should the flame be inadvertently extinguished, or if the unit overheats. If this happens, switch off the heater and

unplug rom the mains supply. Check the heater to determine the fault. In particular check that the air intake is

not obstructed and that the internal fan is rotating freely. Wait a few minutes and restart the unit. If the problem persists

contact your local Sealey Service Agent.

6.6. Fan. Fan blades should be cleaned every 500 operating hours (depending on environment). Remove the outer case and

clean the fan blades with a paraffin moistened cloth or very light solvent. Dry fan thoroughly using compressed air.

fig. 6

fig. 5

THE PROBLEM THE CAUSE THE SOLUTION

7. TROUBLESHOOTING

1. Pulsation or uneven firing.

2. Motor does not start.

3. Motor runs slowly.

4. Motor starts, but heater

does not ignite and after a

short time locks out.

5. Flames come out of the

heater mouth.

6. Motor starts, heater ignites

but flame-out system shuts

off the appliance.

1.1. Low fuel level or unit not level.

1.2. Air leak.

1.3. Water in fuel.

1.4. Low air pressure.

2.1. No power to unit, low voltage.

2.2. Defective motor.

2.3. Flame out device activated.

2.4. Fan jammed on outer case.

3.1. Low voltage.

3.2. Tight compressor.

3.3. Motor defective.

4.1. Low fuel level. 4.2. Leak in fuel line.

4.3. Burner nozzle blocked. 4.4. Diesel viscosity high.

4.5. Fuel filter blocked. 4.6. Defective spark plug.

4.7. Dirty fuel. 4.8. Fault in flame-out system.

5.1. Wrong fuel. 5.2. Excess air pressure.

5.3. Improper air flow. 5.4. Air leak in air line.

6.1. Dirty flame-out cadmium cell.

6.2. Fault with flame-out cadmium cell.

6.3. Defective connection between cell and flame-out control.

6.4. Faulty flame-out control.

1.1. Fill tank, level unit.

1.2. Check air and fuel lines for air leaks.

1.3. Drain, flush and refill with clean fuel.

1.4. Adjust air pressure, Clean air filter.

2.1. Check outlet and fuse. Check power lead, check fan not fouling on outer case.

2.2. Replace motor or motor parts (contact service agent).

2.3. Check reason, wait three minutes and restart.

2.4. Switch off mains, open case and check fan clearance.

3.1. Check length and size of extension cord.

3.2. With unit unplugged turn fan by hand. If fan does not turn freely adjust

compressor ring. Also check to ensure the outer cover is not fouling on the fan.

3.3. With unit unplugged fan turns freely. Replace motor (contact service agent).

4.1. Check fuel and fill tank it required. 4.2. Tighten or replace 4.3. Clean nozzle.

4.4. Low temperature, mix 10-20% paraffin to the diesel.

4.5. Clean or replace filter. 4.6. Check for wear or adjust properly.

4.7. Drain, flush and refill tank. 4.8. Contact local service agent.

5.1. Use correct fuel only. 5.2. Adjust pressure to nominal.

5.3. Dirty or loose fan, air entrance blocked. 5.4. Replace.

6.1. Clean and check “Cad Cell” to ensure that it responds to light.

6.2. Check as in 6.1. and replace if necessary.

6.3. Check that connection is correct.

6.4. Check and replace if necessary.

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.