HeatStar HS 3500DF Assembly instructions

05-15 JM 50125ENERCO GROUP, INC., 4560 W. 160TH ST., CLEVELAND, OHIO 44135 • 800-251-0001

DIRECT FIRED

PORTABLE HEATER

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.

WARNING:

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any

other appliance.

— Service must be performed by a qualified service agency.

This is an unvented portable heater. It uses air (oxygen) from the area in which it is used. Adequate

combustion and ventilation air must be provided.

Model #

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.

OPERATING INSTRUCTIONS

AND OWNER’S MANUAL HS3500DF

HS6000DF

ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual

WARNING:

FIRE, BURN, INHALATION, AND EXPLOSION HAZARD.

KEEP SOLID COMBUSTIBLES, SUCH AS BUILDING MA-

TERIALS, PAPER OR CARDBOARD, A SAFE DISTANCE

AWAY FROM THE HEATER AS RECOMMENDED BY THE

INSTRUCTIONS NEVER USE THE HEATER IN SPACES

WHICH DO OR MAY CONTAIN VOLATILE OR AIRBORNE

COMBUSTIBLES, OR PRODUCTS SUCH AS GASOLINE,

SOLVENTS, PAINT THINNER, DUST PARTICLES OR UN-

KNOWN CHEMICALS.

WARNING:

COMBUSTION BY-PRODUCTS PRODUCED WHEN US-

ING THIS PRODUCT CONTAIN CARBON MONOXIDE,

A CHEMICAL KNOWN TO THE STATE OF CALIFORNIA

TO CAUSE CANCER AND BIRTH DEFECTS (OR OTHER

REPRODUCTIVE HARM).

GENERAL HAZARD WARNING:

FAILURE TO COMPLY WITH THE PRECAUTIONS AND

INSTRUCTIONS PROVIDED WITH THIS HEATER, CAN

RESULT IN DEATH, SERIOUS BODILY INJURY AND

PROPERTY LOSS OR DAMAGE FROM HAZARDS OF FIRE,

EXPLOSION, BURN, ASPHYXIATION, CARBON MONOX-

IDE POISONING, AND/OR ELECTRICAL SHOCK.

ONLY PERSONS WHO CAN UNDERSTAND AND FOLLOW

THE INSTRUCTIONS SHOULD USE OR SERVICE THIS

HEATER.

IF YOU NEED ASSISTANCE OR HEATER INFORMATION

SUCH AS AN INSTRUCTIONS MANUAL, LABELS, ETC.

CONTACT THE MANUFACTURER.

WARNING:

NOT FOR HOME OR RECREATIONAL VEHICLE USE

WARNING:

YOUR SAFETY IS IMPORTANT TO YOU AND TO OTHERS,

SO PLEASE READ THESE INSTRUCTIONS BEFORE YOU

OPERATE THIS HEATER.

The State of California requires the following warning:

CONTENTS

WARNINGS.................................................................................. 2

SPECIFICATIONS........................................................................... 3

OPERATION ................................................................................. 4

SAFETY DEVICES.......................................................................... 4

MAINTENANCE............................................................................ 5

TROUBLESHOOTING .................................................................... 6

WIRING DIAGRAMS..................................................................... 7

PARTS LIST................................................................................... 8

WARNING:

READ THE INSTRUCTIONS GIVEN IN THIS

MANUAL BEFORE USING THE APPLIANCE.

• DO NOT USE GASOLINE, NAPHTHA OR VOLATILE

FUELS.

• THE ELECTRICAL SYSTEM TO WHICH THE APPLIANCE

IS CONNECTED MUST COMPLY WITH ALL SAFETY

REGULATIONS IN FORCE. A RESIDUAL CURRENT

CIRCUIT BREAKER MUST BE PROVIDED ON THE MAIN

DISTRIBUTION BOARD.

• UNPLUG THE HEATER BEFORE ATTEMPTING ANY

SERVICE OR MAINTENANCE.

• ALWAYS CHECK THE POWER SUPPLY CABLE BEFORE

USE. IT MUST NOT BE BENT, CRUSHED, OR ANYWAY

DAMAGED.

• THE POWER SUPPLY CABLE MUST BE REPLACED ONLY

BY QUALIFIED PERSONNEL.

• ONLY USE AN ORIGINAL H07RN-F POWER CABLE

WITH WATERPROOF PLUG.

• DO NOT TOUCH THE EXHAUST GAS OUTLET. DANGER

OF BURNS!

3Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Direct Fired Portable Heater

TECHNICAL SPECIFICATIONS HS 3500DF HS 6000DF

Heat input [kBTU/h] 400 610

Air flow [cfm] 2.500 2.800

Fuel Type Diesel/Kerosene/#1-2 Fuel Oil

Heat output [kBTU/h] 360 610

Fuel consumption [gal/h] 12.83 4.46

[lb/h] 19.58 30.84

Power supply

Phase 1 1

Voltage [V] 120 120

Frequency [Hz] 60 60

Electric consumption [W] 1, 170 1,040

[A] 8.30 10.50

Nozzle [USgal/h] 2.00-30° S 3.00-80°S

Pump pressure [psi] 174 217

Adjustment of combustion air flap [in] a=0.59 a=1.00

Tank capacity [gal] 27. 7 35.7

Dimensions, L x W x H [in] 62.4x27.6x39 67.9x27.6x41.2

Net Weight [lb] 222 246

IMPORTANT

Before using the heater, read and understand all instructions and

follow them carefully. The manufacturer is not responsible for

damages to goods or persons due to improper use of units.

GENERAL RECOMMENDATIONS

The direct-fired heater runs on diesel fuel. This direct combustion

heater exhausts hot air and the combustion products into

the room, while those with indirect combustion are fitted

with a flue to take the fumes away through the chimney.

Always follow local ordinances and codes when using this

heater:

• Read and follow this owner’s manual before using the

heater.

• Use only in places free of flammable vapors or high dust

content.

• Never use heater in immediate proximity of flammable

materials (the minimum distance must be 6 ft.).

• Make sure fire fighting equipment is readily available.

• Make sure sufficient fresh outside air is provided according

to the heater requirements. Direct combustion heaters

should only be used in well vented areas in order to avoid

carbon monoxide poisoning.

• Never block air inlet (rear) or air outlet (front).

• In case of very low temperatures add kerosene to the

heating oil.

• Make sure heater is always under surveillance and keep

children and animals away from it;

• Before starting the heater always check free rotation of

ventilator fan.

• Unplug heater when not in use.

ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual

Models X Y Z

3500 DF 0.157 in 0.098 in 0.157 in

6000 DF 0.157 in 0.098 in 0.157 in

• Floors and ceilings must be made of fireproof materials in

the room where the heater is operated.

•The air inlet and outlet must never be blocked for any reason

• Install the heater on a flat, level floor in a steady position.

• It is forbidden to connect direct-fired heaters to air ducts.

WARNING

• DO NOT USE GASOLINE, NAPHTHA OR VOLATILE FUELS.

• STOP HEATER BEFORE ADDING FUELS.

• ALWAYS FILL OUTDOORS AWAY FROM OPEN FLAME

• DO NOT USE EXTERNAL FUEL SOURCE.

• DO NOT OPERATE HEATER WHERE FLAMMABLE LIQUIDS

OR VAPORS MAY BE PRESENT.

• DO NOT START HEATER WHEN CHAMBER IS HOT

• DO NOT START HEATER WHEN EXCESS FUEL HAS ACCUMU-

LATED IN THE CHAMBER.

• DO NOT PLACE COOKING UTENSILS ON TOP OF THE

HEATER.

• PLUG ELECTRICAL CORD INTO A PROPERLY GROUNDED

THREE-PRONG RECEPTACLE.

The generator can only work automatically when a control device,

such as for example a thermostat or a timer, is connected to the

generator. Connection to the generator is made by removing the

socket cover(4) and inserting the thermostat plug.

To start the machine you must:

•If connected to the thermostat, turn the switch to (ON + );

•If not connected to the thermostat, turn the switch to (ON).

When unit is started for the first time or is started after the oil

tank has been totally emptied, the flow of oil to the burner may

be impaired by air in the circuit. In this case the control box will

cut out the heater and it might be necessary to renew the starting

procedure once or twice by depressing the reset button (1).

Should the heater not start, check that oil tank

is full and depress reset button (1).

Should the heater still not work, please refer to chapter

“OBSERVED FAULTS, CAUSES AND REMEDIES”.

STOPPING THE HEATER

Set main switch (3) on “0” position or turn thermostat or other

control device on lowest setting.

The flame goes out and the fan continues to work for approx.

90sec. cooling the combustion chamber.

SAFETY DEVICES

The unit is fitted with an electronic flame control box. In case of

malfunction this box will cut in and stop the heater, at the same

time the pilot lamp in the control box reset button (1) will light up.

Heaters are also equipped with an overheat thermostat safety

cutout which will stop the heater in case of overheating. This

thermostat will reset automatically but you will have to depress

button (1) on control box before being able to restart the heater.

TRANSPORT

WARNING

• Before making any attempt to restart heater find and elimi-

nate reason of overheating.

Before heater is moved it must be stopped and unplugged. Before

moving the heater wait till it has totally cooled off and make sure

oil tank cap is securely fixed.

l k

1 RESET BUTTON WITH CONTROL LAMP

2 CONTROL LAMP

3 MAIN SWITCH

4 ROOM THERMOSTAT PLUG

5 POWER CORD

OPERATION

Before any attempt of starting the heater is made, check that

your electrical supply conforms to the data on the model plate.

Control Board

Gap of Electrodes

Clearances

The following minimum safety clearances from materials or objects

in the surroundings of the heater must be ensured:

Sides 2.5 ft. Air Inlet 2.5 ft.

Top 6 ft. Air outlet 12 ft.

1 3 425

5Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Direct Fired Portable Heater

The hot air generators with wheels must be wheeled. The

suspended version which has no wheels must be transported with

adequate machinery.

MAINTENANCE

Preventive and regular maintenance will ensure a long trouble free

life to your heater.

WARNING

• Never service heater while it is plugged in, operating or hot.

Severe burns or electrical shock can occur.

Every 50 hours of operation: disassemble filter and wash with

clean oil, remove upper body parts and clean inside and ventilator

with compressed air, check correct attachment of H.V. connectors

to the electrodes and check H.V. cables, remove burner assembly,

clean and check electrode settings, adjust according to scheme

“GAP OF ELECTRODES”.

COLUMN INTENTIONALLY LEFT BLANK

ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual

TROUBLESHOOTING

TROUBLE CAUSE SOLUTION

Motor does not start, no ignition No electrical current Check mains (should be 120 V – 1~ – 60 Hz)

Check proper positioning and functioning of switch

Check fuse

Wrong setting of room ther-

mostat or other control

Check correct setting of heater control. If thermostat, make

sure selected temperature is higher than room temperature

Thermostat or other control

defective

Replace control device

Electrical motor defective Replace electrical motor

Electrical motor bearings

defective

Replace electrical motor bearings

Burned out condenser Replace condenser

Motor starts, no ignition or cuts out Electric ignitor defective Check connection of H.V. Ieads to electrodes and transformer

Check electrodes setting (see scheme “GAP OF ELECTRODES”)

Check electrodes for cleanliness

Replace H.V. transformer

Flame control box defective Replace control box

Photocell defective Clean or replace photocell

Not enough or no fuel at all

at burner

Check state of motor-pump plastic coupling

Check fuel line system including fuel filter for possible leaks

Clean or replace oil nozzle

Solenoid defective Check electrical connection

Check thermostat LI

Clean or replace solenoid

Motor starts, heater emits smoke Not enough combustion air Make sure air inlet and outlet are free

Check setting of combustion air flap

Clean burner disc

Too much combustion air Check setting of combustion air flap

Fuel contaminated or con-

tains water

Drain fuel in tank with clean fuel

Clean oil filter

Air leaks in fuel circuit Check the seals on the ducts and the diesel filter

Not enough fuel at burner Check pump pressure

Clean or replace fuel nozzle

Too much fuel at burner Check pump pressure

Replace nozzle

Heater does not stop Solenoid Replace solenoid coil or complete solenoid

If heater still not working properly, please revert to nearest authorized dealer.

7Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Direct Fired Portable Heater

WIRING DIAGRAM

3500 AND 6000 SERIES MODELS

FU Fuse

IT Transformer H.V.

LI1 Overheat Thermostat

EV1 Solenoid Valve 1°

FO Photocell

CO Condenser

MV Fan Motor

ST Electric pilot

RV Control

TA Room Thermostat

RE Relays

AP Control Box

PA Air pressure control

RF Heater filter

FA Fan thermostat

PE Ground

DRAWING LEGEND

ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual

3500DF Series Direct-Fired Portable Heater

06 12

36 44

82 84

66 67

71 73

100

98 99

101

102

103

16 14 17

108

107

106

104 105

Optional

109

110 111

9Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Direct Fired Portable Heater

3500DF Series Direct-Fired Portable Heater

POS P/N ALT # DESCRIPTION

01 40494 G06408-9010 Outlet cone

03 50446 G06230 Combustion chamber

05 50447 G06233-9010 Upper body

06 40495 G06409-9010 Lower body

08 50160 E10678-110 Motor AACO

09 50161 E 112 3 0 Capacitor AACO

08 E10771 Motor SIMEL

09 E10771-1 Capacitor SIMEL

10 50163 G06125-9010 Air conveyor

11 50165 T10260 Fan

12 50167 P 30169 Inlet grill

13 5 0 051 I40330 Flex diesel pipe

14 50729 I20104 Iron fitting

15 50 410 02 AC 513 Diesel pre-heaters filter kit

16 50054 G06104-9005 Filter support bracket

17 50055 I40329 Flex diesel pipe

18 50 451 P20176-9005 Handle

19 40477 C30355 Pipe cap

20 50058 P20177-9005 Support

21 50060 I40331 Flex diesel pipe

22 50061 I30696 Suction pipe

23 50063 I30737 Brass fitting

24 50064 G06068-9005 Power cord support

25 50170 G06127-9005 Fuel tank

26 50070 C30367 Tank cap

27 G06465-9005 Wheel axle

28 G06106-9005 Wheels axle support bracket

29 C10510 Wheel

30 50513 M20507 Cotter pin

31 40532 I25020 Drain cap

32 40479 C30375 O-ring

33 50434 G00248 El. control box

35 50077 P 5 0127 Control box cover

36 40496 G06410-9010 Base

42 50057 C 30319 Hole cap

44 5 0 411 C30372 Cable protection

45 50085 E50102 Safety thermostat

46 G06072 Spacer

51 50246 G06153 El. control box panel

52 50093 E20508 Fuse holder

53 50092 E 10313 Fuse

56 E20319 Ground terminal board

57 50097 E 1112 5 Relay

58 50731 E20305 Terminal board

59 50319 E10930 H.T. Transformer

63 50320 E40124 Flame control box

64 G06073 Support plate

65 5 0 013 E10102-P Switch

66 5 0 012 E20640 Thermostat plug

67 5 0 011 E20665 Thermostat plug cover

68 50009 E30443-1 Power cord

69 50008 E 110 3 0 Lamp

70 50321 T20357 Nozzle

71 50126 G01077 Diffuser ring

72 50440 I33005 Nozzle support

73 50425 G06228 Burner support disc

74 50131 I31034 Brass lock nut

76 50133 I40192 Micropipe

77 50048 E 10215 Ignition electrode

78 50322 G02078 H.T. Cable connect.

79 50323 E50328 Photocell

82 50442 T20410-1 Diesel pump

83 5014 0 T 2 0118 Solenoid coil

84 50141 T 2 0117 Solenoid valve body

85 50195 E 10513 Motor-pump coupling AACO

85 50237 E10698 Motor-pump coupling SIMEL

86 5014 4 T 20241 Filter seal kit

87 50145 T20242 Filter cartridge

90 50325 E20 418 Stop button protection

91 50336 E50327 Photoresistor support

92 40492 G06406-9010 Pressure switch support bracket

93 50337 E5 0 4 41 Pressure switch

94 40501 I40335 Silicone pipe

95 50429 I 31131 Brass hose connection

96 50433 T20442 Solenoid valve cable

98 50450 G06266 Blast tube

99 50 413 E20671 Terminal board

100 50 419 G06183 Air adjustment shutter

101 50081 I20325 Fitting

102 50079 I 3113 0 Brass hose connection

103 50024 T20201 Diesel filter

104 50025 T20234 Filter seal kit

105 50030 T20206 Filter cartridge

106 50251 T 20212 Filter container

107 50082 E20953 Cable fastener

108 50083 E20954 Cable fastener nut

109 40533 M 2 0111 Washer

110 E20965 Cable fastener nut

111 E20964 Cable fastener

ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual

6000DF Series Direct-Fired Portable Heater

16 14 17

36 44

82 84

66 67

71 73

100

98 99

101

102

103

104 105

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