HeatStar 4000ID HD Assembly instructions

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
4000ID HD
11/09 #50287ENERCO GROUP, INC., 4560 W. 160TH ST., CLEVELAND, OHIO 44135 • 800-251-0001
INDIRECT FIRED
PORTABLE HEATER
HEATSTAR
BY ENERCO
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 a vented portable heater. It uses air (oxygen) from the area in which it is used. Adequate
combustion air and ventilation must be provided. Refer to page 5.

2
ENERCO GROUP, INC. |Indirect 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
VENTILATION............................................................................... 5
TROUBLESHOOTING .................................................................... 6
WIRING DIAGRAMS..................................................................... 7
PARTS LIST..................................................................................10
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. |Indirect Fired Portable Heater
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
This indirect-red heater runs on diesel fuel. Those with direct
combustion send 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 ammable vapors or high dust
content.
• Never use heater in immediate proximity of ammable
materials (the minimum distance must be 6 ft.).
• Make sure re ghting equipment is readily available.
• Make sure sufcient 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.
• The heater is installed near a chimney to take away the
fumes (see “Ventilation” on page 5) and connected to an
electrical switchboard.
• When the heater is connected to a ue pipe, the ue pipe
shall terminate in a vertical section at least 3 feet long and
sufficient draft shall be created to assure safe and proper
operation of the heater.
• 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.
• Indirect red units only can be connected to air ducts to
distribute warm air, with respect to the max. static pressure
declared (see “TECHNICAL SPECIFICATION” sheet).
• Unplug heater when not in use.
TECHNICAL SPECIFICATIONS HS 4000ID HD
Heat input [kBTU/h] 412
Air flow [cfm] 3,250
Fuel Type
Diesel/Kero-
sene/#1-2 Fuel
Oil
Heat output [kBTU/h] 354.3
Fuel consumption [gal/h] 2.89
Power supply
Phase 1
Voltage [V] 120
Frequency [Hz] 60
Electric consumption [W] 1.820
[A] 13.20
Nozzle [USgal/h] 2.00-80° W
Pump pressure [psi] 240
Max static pressure [in WC] 0.5
Recommended max. temp. in
the air duct [°F] 250
Adjustment of combustion air
flap
[in] -
N° B=1.14
Flue diameter [in] 5.9
Compulsory flue draft [in WC] 0.05
Tank capacity [gal] 57
Dimensions, L x W x H [in] 82.7x32.7x48
Net Weight [lb] 328

4
ENERCO GROUP, INC. |Indirect Fired Portable Heater Operating Instructions and Owner’s Manual
Models X Y Z
ID4000 HC .158 in .098 in .158 in
• Floors and ceilings must be made of reproof 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 at, level oor in a steady postion.
• It is forbidden to connect direct-red 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 heater can only work automatically when a control device,
such as for example a thermostat or a timer, is connected to the
heater. Connection to the heater 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 nd 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.
The hot air heaters with wheels must be wheeled. The suspended
version which has no wheels must be transported with adequate
machinery.
1 4
O N
O N
0
3 2 5
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.
X
Z
Y

5Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Indirect Fired Portable Heater
5
4
A
3
2
D
C
1
B
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.T. connectors
to the electrodes and check H.T. cables, remove burner assembly,
clean and check electrode settings, adjust according to scheme
“GAP OF ELECTRODES”.
Flue Connections Diagram
A
6
2
D
C
1
B
5
E
VENTILATION
Description
A) Minimal 39”
B) Minimal 39”
C) Avoid installing parts of the chimney horizontally. When
unavoidable, non-vertical short sections can be used as
long as the angle provides proper discharge
D) diameter of chimney must not be reduced from outlet of
the unit
E) Minimum 3’
1) Anti-wind device provided with the heater
2) Horizontal crossing with minimal upside angle pitch of 5°
3) Chimney dimensions must adhere to local building codes
4) Chimney inspection access if required by local codes
5) External wall
6) Chimney vent anti-wind cover
6 “

6
ENERCO GROUP, INC. |Indirect 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. |Indirect Fired Portable Heater
WIRING DIAGRAM
4000ID HD SERIES MODELS
FU Fuse 20A
IT Transformer H.V.
LI1 Overheat Thermostat
EV1 Solenoid Valve 1°
EV2 Solenoid Valve 2°
FO Photocell
CO Condenser
MV Fan Motor
ST Electric pilot lamp
RV Control
TA Room Thermostat plug
RE Relay
AP Control Box
FA Fan thermostat
RF Heated filter
CN Connector
LI2 Overheat safety
thermostat
PE Ground
DRAWING LEGEND

8
ENERCO GROUP, INC. |Indirect Fired Portable Heater Operating Instructions and Owner’s Manual
4000ID HD Series Indirect-Fired Portable Heaters
62
63 64
67
66
53
54
55
57
58
60
61
59
50
48
65
01
02
04
44
05
10
08
09
11
12
A
43
51
B
49
06
20
25
26
24
27
28
45
43
03 47
40
41
42
39
33
32
88
91
90 89
87
85
86
92
93
94
95
80
14
77
84
83
82
81
68
69
70
71
100
79
77
72
76
75
74
46
30
73
07
31
99
15
19 14 20
14
13
107
108
102
103
104 105
106
101
109
52
A
40
B
15

9Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Indirect Fired Portable Heater
4000ID HD Series Indirect-Fired Portable Heaters
110
111
119
118
117
116
115
114
113
120
112
121
37
38

10
ENERCO GROUP, INC. |Indirect Fired Portable Heater Operating Instructions and Owner’s Manual
4000ID HD Series Indirect-Fired Portable Heater Parts List
NO. STOCK No. PART LIST
01 G06185-9010 Outlet cone
02 G06186 Combustion chamber
03 G06187 Combustion chamber support
04 G06188-9010 Upper body
05 G06189-9010 Cover inspection
06 G06190-9010 Lower body
07 E10695-110 Motor 750W with condenser
08 E11242 Condenser 50 µF
09 G06191 Motor flange
10 T10267 Fan Ø550 18°
11 G06192-9010 Air flap
12 P30151 Inlet grille
13 I40330 “Tube BP 1/4”” FF L.420mm”
14 I20104 “Nipplo FE 1/4”” MM”
15 02AC575-1 “Oil pre-heaters lter 1/4”””
19 G06104-9005 Filter support
20 I40329 “Tube BP 1/4”” FF L.260mm”
24 I40331 “Tube BP 1/4”” FF L.580mm”
25 I30696 Pascante L.290mm
26 I30737 “Nipplo OT 1/4”” M - M12x1,75 M”
27 G06193 Air adjustment panel
28 E20676 Thermostat plug 4P+T
30 C30367 Drain plug
31 G06243-9005 Fuel tank 57 US gal
32 I25019 “Drain plug M30x1,5 mm”
33 C30350 “OR Ø30 x 2,62 mm”
39 G06068-9005 Power lead hook
40 G00250 El. componets drawer
41 P50127 Control box cover
42 G06224-9010 Base
43 E50767 Thermostat TY95A 105 °C Campini
44 G06196 Centrifuge air fan
45 M20413 Bulb support
46 E50102 Limit Thermostat
47 M20107 “Washer Ø5 x Ø15 x 1,5 mm”
48 E50104 Fan Thermostat
49 G06197 Blast tube
50 E20671 Terminal board
51 I40804 Air duct L=220 mm
52 E11229 Condenser 80 µF
53 G06154 Electr. componets drawer
54 E20508 Fuse holder
55 E10313 Fuse (6x30) 20A
57 E20319 Terminal board
58 E20305 Terminal board
59 E10930 Transformer H.T. BRHAMA
60 E40121 Control box BRAHMA TGRD 92 120V
61 G06073 Plate for electrical components
62 E10102-P Switch 0 - 1
63 E20640 Thermostat plug 3P+T
64 E20675 Plate plug 90° 3P + T
65 E10112-P Switch 0 - 1
66 E30443 El. wire with plug and cable fastener
67 E11030 Lamp 230V
68 T20357 “Nozzle 2,0 GPH 80° W”
69 G06225 Turbo disc
70 I33006 Nozzle support
71 G06226 Burner flange Ø 102mm
72 I31034 Nut M14
73 G06199 Electrodes stirrup
74 E10215 Electrodes
75 C30368 Cable protection Ø12 mm
76 G02076 H.T. Cable connect. L=1000 mm
77 I40192 Micropipe L=250 mm
79 E50328 Ld ph. Unit FC13
80 T20441-1 Pump Suntek AT2 45 BK 2S - 120V
81 T20131 Solenoid spool AT2 45 BK 2S Suntek
-120V
82 T20130 Solenoid valve body torque Suntek
83 I20115 “Nipplo FE 1/8”” MM”
84 E10513 Coupling K1
85 E11208 Condenser 20µF
86 E10677-110 Motor 200W with condenser - 120V
87 G06200-9010 Support fan and motor
88 C10328 Leitungskanal
89 C30372 Cable protection Ø35 mm
90 G06201-9010 Support fan and motor
91 C10329 90° elbow connection
92 T10262 “Fan AP 160x55 F12,7”
93 C10326 Spiral fan
94 G06202 Shutter for air regulation
95 G06203 Air adjustment level
99 G06204 Air adjustment protection
100 E50327 Protection de la photoresistence
101 E20418 Stop button protection
102 G06227 Fitting support
103 G06222-9010 Support du pressostat
104 E50441 Presostat 100 Pa
105 I40332 Silicone pipe Ø4x9

11 Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Indirect Fired Portable Heater
COLUMN INTENTIONALLY
LEFT BLANK
4000ID HD Series Indirect-Fired Portable Heater Parts List
106 I31131 Conn. Straight Ø6
107 T20241 OR KIToil filter
108 T20242 Filter cartridge
109 T20442 Solenois valve cable
110 G06205-9005 Lifting frame
111 G06206-9005 Body support
112 G06207-9005 Front protection
113 G06208 Reinforcement plate
114 G06209 Fork guides
115 C10545 “Wheel Ø 400 - Ø 25,4 mm”
116 G06244-9005 Support
117 G06211-9005 Handle
118 C10203 Handle
119 G06212-9005 Bracket
120 G06245-9005 Tank structure
121 G06246-9005 “Wheel axle Ø25,4”

12
ENERCO GROUP, INC. |Indirect Fired Portable Heater Operating Instructions and Owner’s Manual
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
4000ID HD
HEATSTAR
BY ENERCO
ENERCO GROUP, INC., 4560 W. 160TH ST., CLEVELAND, OHIO 44135 • 800-251-0001
Mr. Heater is a registered trademark of Enerco Group, Inc.
© 2004, ENERCO GROUP, INC. All rights reserved
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.
PARTS ORDERING INFORMATION:
PURCHASING: Accessories may be purchased at any Mr. Heater/HeatStar local dealer
or direct from the factory
FOR INFORMATION REGARDING SERVICE
Please call Toll-Free 800-251-0001 • www.enerco-mrheater.com
Our office hours are 8:30 AM – 5:00 PM, EST, Monday through Friday.
Email to: [e-mail]
Please include the model number, date of purchase, and description of problem in all
communication.
LIMITED WARRANTY
The company warrants this product to be free from imperfections in material or workmanship,
under normal and proper use in accordance with instructions of The Company, for a period
of one year from the date of delivery to the buyer. The Company, at its option, will repair or
replace products returned by the buyer to the factory, transportation prepaid within said one
year period and found by the Company to have imperfections in material or workmanship.
If a part is damaged or missing, call our Technical Support Department at 800-251-0001.
Address any Warranty Claims to the Service Department, Enerco Group, Inc., 4560 W. 160TH
ST., Cleveland, Ohio 44135. Include your name, address and telephone number and include
details concerning the claim. Also, supply us with the purchase date and the name and address
of the dealer from whom you purchased our product.
The foregoing is the full extent of the responsibility of the Company. There are no other
warranties, express or implied. Specifically there is no warranty of fitness for a particular
purpose and there is no warranty of merchantability. In no event shall the Company be liable for
delay caused by imperfections, for consequential damages, or for any charges of the expense
of any nature incurred without its written consent. The cost of repair or replacement shall be
the exclusive remedy for any breach of warranty. There is no warranty against infringement of
the like and no implied warranty arising from course of dealing or usage of trade. This warranty
will not apply to any product which has been repaired or altered outside of the factory in any
respect which in our judgment affects its condition or operation.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you. This Warranty gives you specific legal
rights, and you may have other rights which vary from state to state.
Enerco Group, Inc. reserves the right to make changes at any time, without notice or obligation,
in colors, specifications, accessories, materials and models.
11/09 #50287