HeatStar HSP40E Assembly instructions

WARNING: If the information in this manual is not followed exactly, a fire or

explosion may result causing property damage, personal injury or loss of life.

— Thisheaterhashotorarcingpartsinside.Donotuseitinareaswheregasoline,paintorother

flammableliquidsareusedorstored.

— Servicemustbeperformedbyaqualifiedserviceagency.

Languages included

• English

For Indoor Use Only

Not For Use Outdoors

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

OPERATING INSTRUCTIONS

AND OWNER’S MANUAL

READ INSTRUCTIONS CAREFULLY:Readandfollowallinstructions.Placeinstructionsinasafe

placeforfuturereference.Donotallowanyonewhohasnotreadtheseinstructionstoassemble,

light,adjustoroperatetheheater.

Model#

HSP40E

Electric Construction

HEATER

HEATSTARbyENERCO,4560W.160THST.,CLEVELAND,OHIO44135•866-447-2194

HEATSTAR Electric Construction Heater Operating Instructions and Owner’s Manual

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

WARNING: UNITNOTINTENDEDFORUSININDOORAREAS

WHEREHEATERMAYBEEXPOSEDTOWATER.AVOIDUSEIN

BATHROOMS,LAUNDRYROOMSORANYOTHERAREASWHERE

THEUNITMAYCOMEINCONTACTWITHWATER.NEVERLOCATE

THEHEATERWHEREITMAYFALLINTOABATHTUBOROTHER

LIQUIDCONTAINER.

WARNING:Donotoperateanyheaterwithadamagedcord

orplugoraftertheheatermalfunctions,hasbeendroppedor

damagedinanymanner.Returnheatertoauthorizedservice

facilityforexamination,electricalormechanicaladjustmentor

repair.

WARNING:Donotpointatflammablematerials.

WARNING:Donotinsertorallowanyforeignobjectsto

entertheunitviatheintakeorexhaustventsontheunit.

Failuretoobservethiswarningmayresultinelectricshock,fire

ordamagetotheunit.

WARNING:Topreventfiredonotblockeithertheairintake

orexhaustinanymanner.Donotuseonsoftsurfaceslikea

bed,whereopeningsmaygetblocked.

WARNING:Unitisequippedwithinternalactiveelectrical

componentsthatsparkduringuse.Donotuseinareaswhere

fumesfromgasoline,paintorotherflammableliquidsmaybe

present.

WARNING:Extremecautionmustbeusedwhenanyheater

isusedbyornearchildrenorinvalidsandwhenevertheheater

isleftoperatingandunattended.

WARNING: Donotuseoutdoors.

WARNING: Usethisheateronlyasdescribedinthismanual.

Anyotherusenotrecommendedbythemanufacturermay

causefire,electricshock,orinjurytopersons.

SAVE THESE INSTRUCTIONS.

WARNING: DO NOT OPERATE THIS

HEATER UNTIL YOU READ AND UNDER-

STAND THIS INSTRUCTION MANUAL FOR

SAFETY, OPERATION, AND MAINTENANCE

INSTRUCTIONS.

CAUTION:Useofthisheaterinanymeansnotdescribedin

thismanualmaycausefire,electricshock,personalinjuryand/

orpropertydamage.

CAUTION:Thisheaterishotwheninuse.Toavoidburns,

donotletbareskintouchhotsurfaces.Usehandlewhen

movingthisheater.Keepcombustiblematerials,suchas

furniture,pillows,bedding,papers,clothes,andcurtainsat

least6feet(2m)fromthefrontoftheheaterandkeepthem

awayfromsidesandrear.

CAUTION:Inordertoavoidunintendedcyclingoftheheater,

alwaysunplugorunitfrompowersourcewhennotinuse.

CAUTION: TODISCONNECTHEATER,reduceambient

thermostattozero.Fanwillcontinuetorununtilunitcoolsand

shutsdownautomatically,turnswitchesoff,disconnectpower.

CAUTION:Donotcoverthepowersupplywiringor

runthewiringunderanycarpetorrugs.Arrangecordand

connectionsawayfromtrafficpatternssoitisnotatripping

hazard.

CAUTION:Connectunittoonlyproperlygroundedoutlets

andadequatelysizedandgroundedelectricalsystems.Always

plugheatersdirectlyintoawalloutlet/receptacle.Neveruse

withanextensioncordorrelocatablepowertap(outlet/power

strip)

CAUTION:Donotusethisunitwithunapprovedorunder

sizedelectricalconnectionsorwiring.Theymayoverheatand

causeariskoffire.

Definitions: Safety Guidelines IMPORTANT INSTRUCTIONS.

Thedefinitionsbelowdescribethelevelofseverityforeachsignalword.Pleasereadthemanualandpayattentiontothesesymbols.

Danger:Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultindeath or serious injury.

Warning:Indicatesapotentiallyhazardoussituationwhich,ifnotavoided,couldresultindeath or serious injury.

Caution: Indicatesapotentiallyhazardoussituationwhich,ifnotavoided,may resultinminor or moderate injury.

NOTICE: Indicatesapracticenotrelatedtopersonalinjurywhich,ifnotavoided,mayresultinproperty damage.

CONTENTS

WARNINGS................................................................................. 2

HEATERSPECIFICATIONS............................................................. 3

PRINCIPALOFOPERATION.......................................................... 3

SETUPANDOPERATIONINSTRUCTIONS.................................... 4

MAINTENANCEANDSTORAGE.................................................. 4

HEATERSIZINGANDCORDSELECTION....................................... 4

TROUBLESHOOTING.................................................................... 5

WIRINGDIAGRAMS................................................................. 6-7

PARTSLIST..............................................................................8-10

WARRANTY...............................................................................12

INSTRUCTIONSFORORDERINGPARTS.......................................12

Operating Instructions and Owner’s Manual

HEATSTAR Electric Construction Heater

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

SPECIFICATIONS

HeatOutput(MaxBTU’s) 136,000

(FirstStage) 51,200

(SecondStage) 102,400

(ThirdStage) 136,500

Watts(Max) 40,000

(FirstStage) 16,000

(SecondStage) 32,000

(ThirdStage) 40,000

ElectricalRating 480V60Hz3Ø

Min.VoltageatHeater 440

AmpDraw(Max) 50

(FirstStage) 20

(SecondStage) 40

(ThirdStage) 50

AirFlow 1,800CFM

(3,000Cu.m/hr)

PRINCIPAL OF OPERATION

AmbientThermostat 32to100˚F

Weight 130lbs.

Ducting(Max) 14”x50’(straight)

DuctPN-WD1425

14”x25’Long

TempRise(from0˚Fambient) 100˚F

dBNoise 82dB(A)1m

ULListed Ye s

Dimensions 46”Lx20”Wx25”H

Clearance to Combustibles

Outlet 6’(1.8M)

Sides 1’(.3M)

Rear 2’(.6M)

Top 2’(.6M)

Floor Combustible

Ambient Thermostat

Sensor Tube

Solid Plastic

Wheels

Overheat Sensors

Rugged Galvanized

Steel Housing

Power Selector

Contactors

Thermostat +

Switches

Fully Sealed, Non-Glowing

Stainless Steel Heating Element

(15 pcs)

Electric Fan

Motor

Steel

Handle

Aluminum

Fan Blades

WARM

AIR

OUT

COOL

AIR

HEATSTAR Electric Construction Heater Operating Instructions and Owner’s Manual

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

Assembly

• Removetheheaterandallofthepackagingmaterialfromthe

box.

• Checkallofthepackingmaterialforloosepartsandset

aside.

• Thoroughlyinspecttheheaterfordamage.Ifanyisfound

donotcontacttheplaceofpurchase.Pleasecallthe

Manufacturerat866-447-2194.

Starting Instructions

IMPORTANT:Reviewandunderstandallwarningsinthismanual.They

areessentialforsafeuseoftheheater.Followalllocalcodes.

1. Placetheheateronastableandlevelsurface.Makesurethatno

explosiveorcombustiblefumesordustarepresent.Seethatthe

heaterisnotexposedtowaterspray,rain,ordrippingwater.Insure

clearancetocombustiblesareobserved(Seeclearancesinthe

specificationtable).

2. Connectheatertoa480V,60Hzthreephase,50Amppower

source.

IMPORTANT:ALLPOWERSOURCESNEEDTOBEEQUIPPEDWITHA

CIRCUITBREAKER!

NOTE:Whenpowerisfirstappliedtounit,theheaterfanmayblowair

outofheaterINLET.Ifthisconditionoccurs,(afterfirstremovingpower

fromcord)reversethefirsttwohotwiresatheaterterminalinletblock.(3

PhaseModelsOnly)

3. Settheremotethermostattoatemperatureabovetheambient

roomtemperaturebyturningtheknob.

NOTE:Theheaterwillstartonlyifthethermostat“callsforheat”,

meaningthatitissettohigherthanprevailingambienttemperature.

4. Settheselectorswitchtothedesiredheatingsetting.Theswitches

arelabeledS1withaheatoutputof16Kw(54,600Btu’s),S1and

S2withaheatoutputof32Kw(109,200Btu’s)orS1,S2andS3with

aheatoutputof40Kw(136,000Btu’s).

Theheaterwillnowoperateautomatically,controlledbythethermostat.

To Stop Heating

1. Turnallswitchesto“Off”.

2. Allowfantorununtilunitstopsautomatically,controlledby

unitcooldownthermostat(fanswitch).Heatermaycycle

morethanonce.

3. Unplugthepowersupplycableafterthefanhasstopped

coolingdowntheheatercompletely.

NOTE:Thisheaterisequippedwithanoverheatlimitswitchwhich

maycausetheheatertostop.Checkandremovethecauseofthe

overheatingbeforerestarting.

IMPORTANT:Neverdisconnectsupplyplugtostoptheheater

whileinoperation!!

Maintenance

WARNING:

Neverattempttoservicetheheaterwhiletheunitishot,In

use,orpluggedin.Severebodilyinjuryorelectricshockmay

occur.Onlyqualifiedservicetechniciansshouldservicethese

units.

1. Keepheaterclean(ex.drywalldust).Usepressurizedairto

blowfanbladesclean.

NOTE:Usemoderatepressuretoavoiddamagetofan

blades.

2. Inspectheaterbeforeandaftereachuse.

3. Thebearingsofthefanmotorarepermanentlylubricated

andsealed.Noadditionallubricationisneeded.

Storage

Whennotinuse,theheatermustbedisconnectedfrompower

source,dustedoffandthecordshouldbelooselywoundaround

thehandle.

For service :

PleasecallToll-Free866-447-2194orvisitwww.

heatstarbyenerco.com.

Ourofficehoursare8:00AM–5:00PM,EST,Mondaythrough

Friday.Pleaseincludethemodelnumber,dateofpurchase,and

descriptionofprobleminallcommunication.

General Electric Heater Sizing Issues

WhenrunningHEATSTARelectricheatersfromagenerator,itis

extremelyimportanttomakesurethatthegeneratorselected

foryourheaterisnotundersized.Thesinglelargestserviceissue

withHEATSTARelectricheatersisimpropersetuprelatingto

inadequatevoltageduetotoosmallofanelectricsourceand/or

toosmallofapowercord.

The HSP40E heater would require a minimum 40,000 Watt

(40KW), 480 volt three phase generator that can provide 50

amps of continuous power.

NOTE:Thisheater’sHeatingCoilOhmReadingis85.

Electrical Cord Selection for

HEATSTAR Electric Heaters

Onceyouhaveestablishedthatyouhaveenoughpowerto

properlyrunaHEATSTARElectricHeater,youstillneedtodeliver

thepowertotheheateradequately.YouwillneedtodoaVoltage

DropFormula.TheVoltageDropFormulaisamps(source),times

resistance(cord’swiresize)equalsvoltagedrop.Acordswiresize

resistancechartisbelow:

Wire Size Resistance Chart

#4 0.000308ResistanceperFoot

#6 0.000403ResistanceperFoot

#8 0.000641ResistanceperFoot

#10 0.00102ResistanceperFoot

# 12 0.00162ResistanceperFoot

# 14 0.00258ResistanceperFoot

#16 0.00409ResistanceperFoot

#18 0.00651ResistanceperFoot

Asampleformulaislistedbelow:

MinimumVoltageRequired=440V

150ft.x18gaugewire(0.00651)=.98

50ampsx.98=49.0voltdrop

480v(atsource)–49v=431volts

Conclusion:Heaterwillnotrun,wiretoosmallorcordtoolong.

OptionstoCorrecttheSituation:

1.Increasegaugeofwire:Ifyouincreasedyourwiretoa12gauge

wire,thenyourformulawouldbeasfollows:

MinimumVoltageRequired=440V

150ft.x12gaugewire(0.00162)=0.24

50ampsx0.24=12voltdrop

480volts(atsource)–12volts=468volts

Now,yourheaterwillrunproperly.

Operating Instructions and Owner’s Manual

HEATSTAR Electric Construction Heater

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

Troubleshooting

Symptom Cause Check Remedy

Turnthermostatupandmotordoes

notcomeon

•Nopoweronanyphase

•OverheatLimit(TO)

•MainSwitchassembly

•Motor

•MotorRelay

•ControlTransformer

•Checkfor240VbetweenL1andL2(for

singlephasemodels).Checkforpower

betweenL1andL2,L2andL3,and

betweenL1andL3(for3phasemodels).

OverheatLimit(TO)

•Checkforcontinuity.Theswitchshould

beclosed.

•Checkforcontinuity

•Checkforpropervoltagetomotor

•Checkfor24voltstocontactor

•Checkfor24voltsoutfromControl

Transformer

•RefertoSetupand

Operationsection

•Replace

•Makesurecontactor

pullsin.Ifnot,replace.

•Replace

MotorStartsbutaircomesoutthe

inlet

•Reversedpower(hot)wires •Checkpoweratterminalblock •Switchfirsttwopower

wiresatterminalblock

Motorstartsbutnoheat •AmbientThermostat

•Overheatlimit(s)

•Contactors

•HeatingElements

•Turnthermostataboveambient

temperature

•Checkforcontinuity.Itisaclosedswitch

•Makesuretheyareclean,tight,and

thattheypullinwhenvoltageisapplied

•Visualcheckforburns.Checkresistance

ofeachindividualelement

•Replace

•85KOhms

Heateroperates,fandoesn’tcool

theunitafterthermostatissatisfied

•FanCooldownThermostat •Checkforresistance

•Checkforproperwiring

•Replace

•Rewire

Highlimittripping •LowVolumeofAir •Ductrestrictions

•Dustbuilduponinletgrill

•Straightenduct

•Cleanfanarea

BeforebeginningtheTroubleshootingsection,pleasereviewtheSet-upandInstallationsectionofthismanual.Mosttechnicalissuescanbe

resolvedwithproperset-upandpreventativemaintenance.

2.Runashortercord.Ifbychanceyoucouldusea50ftcord

insteadofa150ftcord,thenyourformulawouldbeasfollows:

MinimumVoltageRequired=440V

50ft.x18gaugewire(0.00651)=.33

50ampsx.33=16.5voltdrop

480volts(atsource)–16.5volts=463.5volts

Now,yourheaterwillrunproperly.

HEATSTAR Electric Construction Heater Operating Instructions and Owner’s Manual

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

WIRING DIAGRAM HSP40E

480 Volt 60 Hz 3 PH

14 1312

# P/N DESCRIPTION

14115 8 Transformer

24115 6 Fuse

34116 5 FanMotor

44113 5 OverheatLimitSwitch

541170 AmbientThermostat

64113 7 OverheatLimitSwitch-AirOutlet

74113 6 UnitCooldownThermostat

84115 4 ToggleSwitch(foroutput16KW)

# P/N DESCRIPTION

94115 4 ToggleSwitch(foroutput+16KW)

10 4115 4 ToggleSwitch(foroutput8KW)

11 4115 2 Contactor&Coil(foroutput16KW)

12 41151 Contactor&Coil(foroutput+16KW)

13 41151 Contactor&Coil(foroutput+16KW)

14 41151 FanContactor

15 4115 2 Pole4ofContactorC1

16 4114 2 HeatingElements,2.7KWeach

WARNING: USE ONLY MANUFACTURER’S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR

DEATH. REPLACEMENT PARTS ARE ONLY AVAILABLE DIRECT FROM THE FACTORY AND MUST BE INSTALLED BY A QUALIFIED

SERVICE AGENCY.

Operating Instructions and Owner’s Manual

HEATSTAR Electric Construction Heater

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

WIRING DIAGRAM HSP40E

WARNING: USE ONLY MANUFACTURER’S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR

DEATH. REPLACEMENT PARTS ARE ONLY AVAILABLE DIRECT FROM THE FACTORY AND MUST BE INSTALLED BY A QUALIFIED

SERVICE AGENCY.

HEATSTAR Electric Construction Heater Operating Instructions and Owner’s Manual

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

HSP40E

20 12 13

14 21

19 8

164

36A

Operating Instructions and Owner’s Manual

HEATSTAR Electric Construction Heater

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

HSP40E

# P/N DESCRIPTION

14112 5 HeatExchangerChamber

44112 6 Hood(includingConnectionHatch)

54112 7 ConnectionHatchOnly

64112 8 Handle

74112 9 FrontPanel

84113 0 DuctAdapter

941131 BottomFrame

10 4113 2 SupportLeg

11 4113 3 WheelShaft

12 4113 4 Plate,FanThermostat

13 4113 5 OverheatLimitSwitch(Inner)

14 4113 6 CooldownThermostat

15 4113 7 OverheatLimitSwitch,AirOutlet(PETE)

16 4113 8 MetalBracket,orBulb

17 4113 9 Wheel

18 4114 0 LockingWasher

19 41141 Gasket,Rubber

20 4114 2 HeatingElement(15PerHeater)

21 4114 3 GuardRing,Rubber

24 4114 4 RearPanel

25 4114 5 PartitionPanel/Bracket

26 4114 6 ContactorMountingPlate

28 4114 7 MountingPlate,FanMotor

29 4114 8 FanGuardGrill

# P/N DESCRIPTION

30 4114 9 Bushing,Medium

31 4115 0 Bushing,Large

32 41151 Contactor(3PerHeater)

S/Npriorto2142use41152

33 4115 2 Contactor(1PerHeater)

34 4115 3 StrainReliever(Qty2)

35 4115 4 ToggleSwitch

36 4115 5 FuseHolder

36A 4115 6 Fuse

37 4115 7 TerminalBlock

38 4115 8 Transformer

39 4115 9 LockingClamp+EndPlate

40 4116 0 PlasticBracket

41 41161 AmbientThermostat(KnobNotIncluded)

S/N2022&Beyond

42 4116 2 ThermostatKnob(For180017)

4116 3 ThermostatKnob(For20220)

43 4116 4 GroundBolt

45 4116 5 FanMotor

47 4116 6 FanBlade

48 4116 7 Bushing,Small

41168† Duct(14”x25’long)

4116 9 † BracketforTerminalBlock

†NotShown

WARNING: USE ONLY MANUFACTURER’S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR

DEATH. REPLACEMENT PARTS ARE ONLY AVAILABLE DIRECT FROM THE FACTORY AND MUST BE INSTALLED BY A QUALIFIED

SERVICE AGENCY.

HEATSTAR Electric Construction Heater Operating Instructions and Owner’s Manual

NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!NEVER LEAVE THE HEATER UNATTENDED WHILE BURNING!

# P/N DESCRIPTION

141161 AmbientThermostat

241151 Contactor,3-Pole(S/Npriorto2142use41152)

2A 4115 2 Contactor,4-Pole

34115 4 ToggleSwitch

44113 7 OverheatLimitSwitch(PETE)

54115 7 TerminalBlock

# P/N DESCRIPTION

64115 8 Transformer(PETR)

74115 6 Fuse

84114 2 HeatingElement

94113 5 OverheatLimitSwitch(Inner)

10 4113 6 CooldownThermostat

11 4116 5 FanMotor

CONTROL BOX HSP40E

WARNING: USE ONLY MANUFACTURER’S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR

DEATH. REPLACEMENT PARTS ARE ONLY AVAILABLE DIRECT FROM THE FACTORY AND MUST BE INSTALLED BY A QUALIFIED

SERVICE AGENCY.

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