Table of Contents
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DIESEL SPACE HEATER-SERVICE MANUAL
INDEX
1. CONTROLS AND COMPONENTS
2. FLAME CONTROL CYCLES
3. MAINTENANCE SCHEDULE
4. REPAIR PROCEDURES
1. FAN MOTOR ASSEMBLY
2. FUEL FILTER ASSEMBLY
3. FUEL PUMP ASSEMBLY
4. ELECTRIC PANEL ASSEMBLY
5. AIR PRESSURE SWITCH
6. COMBUSTION HEAD ASSEMBLY
7. COMBUSTION CHAMBER
5. TROUBLESHOOTING GUIDE
6. WIRING DIAGRAMS
7. TECHNICAL SHEETS
HS2000ID, HS3000ID
HS3500DF, HS6000DF
The operations described in this booklet must be carried out by qualified and instructed personnel only.
Incorrect maintenance may result in improper operation and serious injury.
!
WARNING
1
L-S 102.00-BM
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Summary of Contents for Enerco Heatstar HS2000ID
- Page 1 DIESEL SPACE HEATER-SERVICE MANUAL INDEX 1. CONTROLS AND COMPONENTS 2. FLAME CONTROL CYCLES 3. MAINTENANCE SCHEDULE 4. REPAIR PROCEDURES 1. FAN MOTOR ASSEMBLY 2. FUEL FILTER ASSEMBLY 3. FUEL PUMP ASSEMBLY 4. ELECTRIC PANEL ASSEMBLY 5. AIR PRESSURE SWITCH 6. COMBUSTION HEAD ASSEMBLY 7.
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Page 2: Controls And Components
1. CONTROLS AND COMPONENTS HS2000ID & HS3000ID INDIRECT HEATER WITH STACK: 1 COMBUSTION CHAMBER 2 BURNER ASSEMBLY 3 NOZZLE 4 FUEL VALVE 5 DIESEL PUMP 6 MOTOR 7 FAN 8 FUEL FILTER 9 FUEL CIRCUIT 10 FUEL TANK 11 FUEL TANK PLUG HS3500DF &... - Page 3 CONTROL SYSTEM The heater has all operational controls located in a watertight control panel mounted on the lateral side of the unit. The control panel consists of: • a 3-position switch for heating function: normal operation, stop or thermostat operation • plug to connect a remote room thermostat • power cord • high voltage transformer that generates a spark to ignite the flame • control flame box to handle starting / running cycle (see paragraph 2.). The control flame box is equipped with a reset The control system utilizes: • a safety shut off switch that is an overheat thermostat shutting down the unit if the temperature of combustion chamber and outlet air exceed the maximum allowed level • an air pressure switch, that stops the unit if the air flow is not sufficient for combustion • a flame detector, that is a photocell monitoring constantly the flame presence and its integrity • a pair of ignition rods to create the ignition spark FUEL SYSTEM The fuel system consists of: • fuel tank, that is steel, corrosion proof The fuel tank has a drain plug located underneath it to allow discharge of residual fuel before cleaning.
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Page 4: Starting Cycle
2. FLAME CONTROL RUNNING / FAILURE CYCLE 2.1 STARTING CYCLE Room thermostat Burner Fan Ignition Transformer Fuel Valve Photocell Reset Lamp TP 20 s TS 5 s 30 s The flame control unit starts the sequence of operation after a heating request (normal operation or thermostat operation) and it consists of the following steps: • Self-test (less than 3 s): self-check of electronics efficiency; • Purging time TP (20 seconds): fan motor and ignition transformer are simultaneously switched on while the fuel valve remains closed to eliminate any fuel or unburnt residual. During the purging stage, the flame signal is constantly monitored for any kind of failure leading to combustion prevents the burner ignition. - Page 5 2.3 FLAME FAILURE DURING STARTING CYCLE Room thermostat Burner Fan Ignition Transformer Fuel Valve Photocell Reset Lamp TS 5 s TP 20 s If during the safety time TS, the photocell monitors a flame failure (signal to photocell becomes lower than minimum), at the end of safety time the unit goes in lock out condition: • burner fan, ignition transformer and fuel valve are de-energized; • alarm lamp on rest button becomes red Unit can re-start only if pressing the reset button 2.4 EXTRANEOUS LIGHT OR FLAME DURING PRE-PURGE TIME TP Room thermostat Burner Fan Ignition Transformer Fuel Valve Photocell...
- Page 6 2.5 FLAME FAILURE DURING RUNNING STATUS (ONE TRIAL RECYCLING) Room thermostat Burner Fan Ignition Transformer Fuel Valve Photocell Reset Lamp TP 20 s TS 5 s 90 s In case of flame failure in running status, the flame control unit make one trial restarting the unit. If the reason of flame failure is confirmed, then the unit stops in lock-out mode, and the reset lamp becomes red. 2.6 RESET LAMP COLOR WARNING The reset button may have different colours: • light off: unit is in stand-by status, waiting for heating request. • steady orange light: function not active •...
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Page 7: Maintenance Schedule
3. MAINTENANCE SCHEDULE Periodic maintenance of the heater is necessary to ensure proper performance and to prevent failures and it shall be performed at the following periodic intervals: • Daily maintenance i. Inspect air inlet / air outlet and exhaust stack, remove debris if any ii. If any air hose is installed, secure it. Minimize bends and keeps ducts straight iii. Verify fuel tank is full iv. Verify that exhaust stack is properly installed • Weekly maintenance i. Disassemble, inspect and clean fuel filter with clean fuel ii. Remove top cover and clean the motor, fan blade and the interior shell iii. Inspect the fuel hose assembly and check for any leaks • 6 months maintenance i. Disassemble burner head 1. Inspect and clean burner diffuser 2. Inspect and replace nozzle as necessary 3. Clean ignition electrodes and adjust settings 4. Check air combustion setting ii. Check overheat thermostat iii. Inspect and clean the combustion chamber iv. Open electric board, inspect electrical components and check connections v. Check fuel pressure setting of fuel pump vi. Inspect and test the burner... -
Page 8: Repair Procedures
4. REPAIR PROCEDURES WARNING Before carrying out any maintenance operation the heater must be disconnected from power supply. Refer to instruction manual to fully stop the heater. Therefore: • Stop the machine as instructed • Turn off the on/off switch on the main electric switchboard •... - Page 9 b) To replace the fan blade and the electric motor, carry out the following procedure. i) Remove the air inlet grille (a) by removing four screws that secure it to the machine. ii) Loosen the screw (d) on the fan hub iii) Extract the fan blades and replace with a new one respecting blades orientation iv) Remove the top cover access panel (b) by removing four screws v) Loosen three allen screws (e) on the fuel pump casing (be sure not to remove the screws) vi) Remove fuel pump from electric motor and keep plastic coupling for next reassembly vii) Loosen and remove eight screws (f) that fix the motor on the motor flange viii) Open main electric board on side/front of the heater ix) Trace the electric motor power cords and disconnect the three wires (white, black, green) from control panel x) Position a new motor on the motor flange and reassemble eight screws (f) to fix it xi) Check alignment of the motor to the heater axis and tighten eight screws (f) on motor flange xii) Reassemble fuel pump on electric motor being sure that plastic coupling is aligned xiii) Tighten three allen screws (e) xiv) Position fan blade on the motor shaft being sure there is no interference with any parts when rotating xv) Tighten screw (d) and check free rotation of the fan blades xvi) Reinstall the fan grille and the top cover.
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Page 10: Fuel Filter Assembly
2) FUEL FILTER ASSEMBLY To clean / replace the pre-heated type fuel filter, carry out the following procedure. i) Remove the screw (a) that secures the cover to the housing and remove o-ring (b) ii) Using a suitable container, collect the fuel when removing from the fuel filter assembly iii) Remove the fuel cell (c) and wash it with clean diesel oil iv) If necessary replace the fuel filter (c) v) If necessary to replace the heating element, loosen the nut (d) and remove the electric element (e) vi) Inspect the o-ring, replace it if it is cracked, damaged, or deformed vii) Reassemble the filter assembly checking the o-ring is placed in the right position viii) Tighten screw (a) -
Page 11: Fuel Pump Assembly
b) To clean / replace the standard type fuel filter, carry out the following procedure. i) Loosen the casing (a) that secures to the housing ii) Using a suitable container, collect the fuel when removing from the fuel filter assembly iii) Remove fuel cell (c) and o-ring (b) and wash with clean diesel oil iv) If necessary replace the fuel cell (c) v) Inspect the o-ring, replace it if it is cracked, damaged, or deformed vi) Reassemble the filter assembly checking the o-ring is placed in the right position vii) Tighten casing (a) by hand, checking the o-ring is pressed 3) FUEL PUMP ASSEMBLY To replace fuel pump, carry out the following procedure. i) Remove the top cover access panel (b) by removing six screws ii) Loosen three screws (e) on the fuel pump casing (be sure not to remove the screws) iii) Remove fuel pump from electric motor and keep plastic coupling for next reassembly iv) Disconnect wires lead to fuel solenoid valve (g) v) Reassemble new fuel pump on electric motor being sure that plastic coupling is aligned vi) Tighten three screws (e) vii) Reinstall the top cover. -
Page 12: Electric Panel Assembly
b) To set fuel pressure on fuel pump, carry out the following procedure. i) Remove the top cover access panel (b) by removing screws ii) Loosen cap (a) on front of fuel pump and connect a fuel pressure meter iii) Disconnect wires leading to fuel solenoid valve (to avoid fuel spray inside combustion chamber) WARNING The following operation shall be done with top cover and possible access to rotating fan. Fan rotating area is covered by fan support even if accessible Take measure to avoid touching any rotating parts while setting fuel pressure iv) Start the heater and check the fuel pressure value listed in the final technical sheet v) Correct the pressure by screwing (to increase pressure) or unscrewing (to decrease pressure) screw (b) -
Page 13: Air Pressure Switch
iii) Check that all connections are complete and tight iv) Reassemble top cover (b) and fix electric board to the heater 5) AIR PRESSURE SWITCH To check / replace air pressure switch, carry out the following procedure. i) Remove four screws (a) on side of heater ii) Pull air pressure switch assembly out of the base iii) Check silicone tube are not pinched and tightened to connectors iv) Check there is no debris inside silicon tube v) Reassemble pressure switch assembly and tighten screws (a) 6) COMBUSTION HEAD ASSEMBLY a) To clean combustion head assembly, carry out the following procedure. i) Remove the top cover access panel (b) by removing six screws ii) Loosen screw (a) and remove wire connector of yellow/green wire) (c) - Page 14 iii) Turn counterclockwise burner support (d) and pull it out of burner tube (e) iv) Check / Clean diffuser ring (f) (1) be sure any debris or soot is eliminated on every wing and opening on front surface of ring (2) if necessary loosen screw (f) and remove it to wash using clean diesel (3) check for any damage or bended part: if any replace it v) Check / clean ignition electrodes (g) (1) Clean and remove any debris or soot on sharp ends of electrodes (2) If necessary remove both electrodes and replace (3) Check alignment as by following image: electrodes shall be centered and symmetric (4) Check electrode connectors (h) to tighten and clean...
- Page 15 vi) Check/replace fuel nozzle (1) Refer to technical data sheet for specific indication of nozzle type (2) Remove electrodes (g) (3) Remove diffuser ring (f) (4) Loosen fuel nozzle and replace with a new one (5) Reassemble diffuser ring and electrodes taking care of each correct positioning as previous instructions vii) Check / clean photocell (1) Remove photocell (i) and check it is clean (2) Check photocell support be clean and clean hole (m) viii) Check / adjust air openings (1) Loosen nut (n) (2) Adjust lever (p) until the requested opening is obtained (check final tech. sheet)
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Page 16: Combustion Chamber Assembly
ix) Reassemble combustion head x) Reassemble top cover 7) COMBUSTION CHAMBER ASSEMBLY To clean combustion chamber assembly, carry out the following procedure. i) Remove the top cover access panel (b) by removing six screws ii) Loosen and remove three nuts (a) iii) Remove the burner head tube assembly (c) iv) Check and clean inside combustion chamber with a cloth, removing liquid fuel residual v) Reassemble burner head tube assembly (c) vi) Reassemble top cover (b) -
Page 17: Troubleshooting Guide
5. TROUBLESHOOTING GUIDE A. HEATER DOES NOT START a. Main control lamp is off i. Missing connection to main supply line 1. Check main supply is switched on 2. Check connection of extension power cord 3. Check integrity of main fuse b. Motor does not run and reset lamp is red i. Flame control box in locking condition for a previous problem 1. Reset and repeat the starting cycle one time only. 2. Refer to following if any new problem occurs c. Motor does not run and rest lamp lights up after 30 secs i. Air flow failure 1. Check fan motor connections 2. Check fan is tightened on fan motor axle... - Page 18 C. HEATER STARTS BUT IT DOES NOT RUN REGULARLY a. Heater stops in lock-out and reset lamp is on (red light) i. Flame failure because of missing fuel 1. Check fuel tank is not empty 2. Check fuel type be correct, clean and without water 3. Check and clean fuel filter cartridge 4. Check all connections of fuel line from tank to fuel pump: untightened connections can cause suction of air to fuel pump 5. Check fuel line are not obstructed or damaged and eventually replace 6. Check adjustment of fuel pump pressure ii. Flame failure because of bad combustion 1. Check and clean fuel nozzle (eventually replace it) 2. Check and clean combustion head (nozzle, nozzle support and diffuser disc) 3. Check adjustment of fuel pump pressure 4. Check adjustment of combustion air iii. Flame failure because of air pressure switch PA not working. 1. Check fan is tightened on fan motor shaft.
- Page 19 E. WHEN HEATER IS SWITCHED OFF, IT DOES NOT STOP a. Heater still runs with flame i. Room thermostat / main switch failure 1. Check room thermostat and room thermostat connections 2. Check main switch on heater control board ii. Fuel flow to nozzle is not interrupted 1. Check fuel solenoid valve close fuel line to nozzle...
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Page 20: Wiring Diagram
6. WIRING DIAGRAM HS2000ID, HS3000ID, HS3500DF Fuse 20 A Main switch Room thermostat plug H.T. Transformer Flame control box LI1 Overheat thermostat Heated fuel filter (optional) EV1 Fuel solenoid valve Air pressure switch Photocell FUA Fuse 6,3 A Capacitor RELAY Fan motor FUSE 20 A Control lamp NOTE Air pressure switch PA and overheating thermostat LI1 are connected in serie to fuel valve EV1. Therefore in case PA and LI1 opens, the fuel valve EV1 is switched off and the flame control unit goes in lock-out in the “flame failure mode”. - Page 21 HS6000DF Fuse 20 A Main switch Room thermostat plug H.T. Transformer Flame control box LI1 Overheat thermostat Heated fuel filter (optional) EV1 Fuel solenoid valve Air pressure switch Photocell FUA Fuse 6,3 A Capacitor RELAY Fan motor FUSE 20 A Control lamp NOTE Air pressure switch PA and overheating thermostat LI1 are connected in serie to fuel valve EV1. Therefore in case PA and LI1 opens, the fuel valve EV1 is switched off and the flame control unit goes in lock-out in the “flame failure mode”.
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Page 22: Technical Specifications
7. TECHNICAL SPECIFICATION TECHNICAL SPECIFICATIONS HS2000ID HS2000ID HS3500DF HS6000DF Heat input [kBTU/h] 204.873 293.982 361.439 599.524 Air flow [cfm] 1,530 2,531 1.795 2.800 Heat output [kBTU/h] 183.362 258.704 Fuel consumption [gal/h] 1.48 2.17 2.60 4.32 Phase Voltage Power supply Frequency [Hz] 1,330 1,240 Electric consumption 7.65...
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