MrHeater heatstar 4000DF 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 MODEL
4000DF 6000DF 4000DF 6000DF
07/08 #50125ENERCO GROUP, INC., 4560 W. 160TH ST., CLEVELAND, OHIO 44135 • 800-251-0001
DIRECT FIRED
PORTABLE HEATER
HEATSTAR
BY ENERCO
MR. 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. Refer to page 5.

2
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 MH 4000DF
HS 4000DF
MH 6000DF
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] - -
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
Max static pressure [in WC] - -
Recommended max. temp. in the air
duct [°F] - -
Adjustment of combustion air flap [in] a=0.59 a=1.00
N° - -
Flue diameter [in] - -
Compulsory flue draft [in WC] - -
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-red 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 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.
• 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.

4
ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual
Models X Y Z
4000 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 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 position.
• 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 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 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.
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. |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

6
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
4000 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

8
ENERCO GROUP, INC. |Direct Fired Portable Heater Operating Instructions and Owner’s Manual
4000DF and 6000DF Series Direct-Fired Portable Heater
25
27
29
03
47
A
05
15
08
09
B
46
17
10
06
01
04
37
30
12
20
11
16 14 17
14
13
86
12
82
84
83
76
75
70
51
56
57
58
59
63
69
65
66
68
80
72
74
77
52
53
67
54
61
60
64
62
19
33
34
32
45
18
22
23
21
19
24
26
28
35
31
36
38
38
44
39
39
37 42
43
38
79
78
76
71
81
87
88
55
48
49
50
73
75
02
07
85
A
31
B
13

9Operating Instructions and Owner’s ManualENERCO GROUP, INC. |Direct Fired Portable Heater
4000DF and 6000DF Series Direct-Fired Portable Heater
NO. STOCK NO. 4000 6000 DESCRIPTION
01 G01 042-901 0 • Outlet cone
G06139-9010 • •
02 G01040 •Flame guard shield
G06140 •
03 G01038 •Combustion chamber
G06142 •
04 G06143-9010 • Protection
05 G01510-9010 • Upper body
G06144-9010 •
06 G01500-9010 • Lowerbody
G06145-9010 •
07 G01061-1 • Right air flap
G01061-2 • Left air flap
G01513 •Air flap
08 E10679-110 • • Motor 750W with condenser
09 E11231 • • Condenser 100 ~F
10 G01515-9010 • • Motor flange
11 T10215-B • Fan 0496 18”
T10263 • • Fan 0500 18”
12 P30129 • • Inlet grille
13 140330 • • Tube BP 1/4” FF L.420mm
14 12010 4 • • Nipplo FE 1/4” MM
15 T20239 • • Oil pre-heaters lter 1/4”
16 G06104-9005 • • Filter support
17 140329 • • Tube BP 1/4” FF L.260mm
18 P20176-9005 • • Handle
19 C30319 • • Plug 025
20 P20177-9005 • Foot
P20180-9005 •
21 140331 • • Tube BP 1/4” F L.580mm
22 130696 •Pascante L.220mm
130698 •Pascante L.290mm
23 130737 • • Nipplo OT 1/4” M -M12x1,75 M
24 G06068-9005 • • Power lead hook
25 G06128-9005 • Fuel tank 105 I
GO1146-9005 • Fuel tank 135 I
26 C30367 • • Drain plug
27 G06129-9005 • • Wheel axle
28 G061 06-9005 • Wheels axle support
G06151-9005 •
29 C10546 • • Wheel 0 260-0 25
30 M20202 • • Spring washer 025
31 125 019 • • Fuel tank
32 C30350 • • OR 030 x 2,62
33 G00215 • • EI. componets drawer
34 C30425 • • Seal
35 P50127 • • Control box cover
36 G06147-9010 • • Base
37 131130 • • Conn. Straight 06 1/8”
38 140332 • • Silicone pipe 05x9
39 120325 • • Connection 1/8”
NO. STOCK NO. 4000 6000 DESCRIPTION
42 E20953 • • Cable holder PG11
43 E20954 • • Ring nut PG11
44 C30307 • • Protection cable 0 35
45 E50102 • • Limit Thermostat
46 G060N • • Sleeve 08 x 06 x 9,5
47 E50104 • • Fan Thermostat
48 M20409 • • Nut M6
49 G01047 • • Air regulatoin flap
50 M10312 • • Screw TCEI M6x25
51 P50126 • • Electr. componets drawer
52 E20508 • • Fuse holder
53 E10313 • • Fuse (6x30) 20A
54 G06102 • • Switch support
55 E50437 • • Pressure switches HONEYWELL
56 E20319 • • Terminal board
57 E11125 • • Relay Finder 65.31 AC
58 E20305 • • Terminal board
59 E10917-2 • • Transformer H.T. 818C 11OV
60 G06109 • • Transformer H.T. flange
61 G06103 • • Support
62 E40107 • • LANDIS LOA 21-24 base
63 E40113 • • Control box LANDIS LOA 21-24
64 G06073 • • Plate for electrical components
65 E10102-P • • Switch 0-1
66 E20640 • • Thermostat plug 3P+T
67 E20665 • • Drain plug
68 E30443 • • EI. wire with plug and cable fastener
69 E11030 • • Lamp230V
70 T20306 •Nozzle 1,25 GPH 80· S
T20327 •Nozzle 3,00 GPH 80· S
71 G01077 • • Turbo disc
G07024 •
72 G06150 • • Nozzle support
73 G01890 •Burner flange 0 80mm
P20530 •Burner flange 0 102mm
74 13103 4 • • NutM14
75 120115 • • Nipplo FE 1/8” MM
76 140192 • • Micropipe
77 E10215 • • Electrode
78 G02076 • • H.T. Cable connect. 90·
79 E50306 • • Ld ph. Unit L&G QRB1A
80 E50307 • • Fixing clamp
81 E50308 • • Photoresistance flange
82 T20411-1 • • Pump Danfoss BFP11 R3 Danfoss
83 T20118 • • Solenoid spool Danfoss
84 T20129 • • Solenoid valve Danfoss (NO)
85 T20117 • • Solenoid valve Danfoss (NC)
86 E10514 • • Coupling K1
87 T20241 • • OR KIToil filter
88 T20242 • • Filter cartridge

10
ENERCO GROUP, INC. |Direct 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 MODEL
HEATSTAR
BY ENERCO
MR. HEATER
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.
07/08 #50125
4000DF 6000DF 4000DF 6000DF