Enerco HEATSTAR HS1000ID, Service Manual

Page 1: ... 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 INDEX HS1000ID L S 101 00 BM WARNING 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 1 ...

Page 2: ...SET BUTTON LAMP OF CONTROL FLAME 14 MAIN SWITCH 15 ROOM THERMOSTAT PLUG 16 CONTROL LAMP 17 POWER CORD 18 OVERHEAT THERMOSTAT 19 AIR PRESSURE SWITCH GAUGE LOW PRESSURE SIDE 20 AIR PRESSURE SWITCH GAUGE HIGH PRESSURE SIDE 21 FLAME DETECTOR PHOTOCELL 22 STACK 1 CONTROLS AND COMPONENTS INDIRECT HEATER WITH STACK AND METAL FUEL TANK HS1000ID CONTROL PANEL 2 13 16 17 15 14 ...

Page 3: ...l tanks have a drain plug located underneath the fuel tank to allow discharge of residual fuel before cleaning fuel filter fuel pump A screw fitted on the fuel pump allows the adjustment of fuel pressure setting fuel ON OFF solenoid valve during normal operation the valve is open and the pressurized fuel flows to the nozzle where it is atomized mixed with primary combustion air and ignited by the ...

Page 4: ...t the end of the purging time TP the fuel valve is switched on and opens the fuel to the nozzle In case of flame detection failure by the end of the TS safety time the control unit goes to lockout and the fan motor the ignition transformer and the fuel valve are de energized while the lockout signal is enabled Otherwise at the end of the TS safety time the control unit disables the ignition transf...

Page 5: ... can re start only if pressing the reset button 3 seconds 2 4 EXTRANEOUS LIGHT OR FLAME DURING PRE PURGE TIME TP If during the pre purge time the photocell monitors any residual flame then the unit goes in stand by condition burner fan goes on to purging combustion chamber fuel valve and ignition transformer are de energized reset lamp is off Room thermostat Reset Lamp Photocell Fuel Valve Ignitio...

Page 6: ...n may have different colours light off unit is in stand by status waiting for heating request steady orange light the heater stops temporarily to allow H T transformer cooling down and automatically restarts when the time has passed steady green light unit is working normally starting cycle or working cycle steady red light the heater stops permanently in lock out status and can restart only if re...

Page 7: ... 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 com...

Page 8: ... Severe burns or electrical shock can occur 1 FAN MOTOR ASSEMBLY a To clean the fan blades and motor carry out the following procedure i Remove the air inlet grille a by removing four screws that secure it to the machine ii Remove the top cover access panel b by removing screws iii Inspect and if necessary clean the motor using compressed air being carefully not to direct the air jet to the air pr...

Page 9: ...e 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 four screws f to fix it xi Check alignment of the motor to the heater axis and tighten four screws f on motor flange xii Reassemble fuel pump on electric motor being sure that plastic coupling is aligned xiii Tig...

Page 10: ...essary 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 b To clean replace the standard type fuel filter carry out the following procedure i Loosen the casing a that secures to the housing ...

Page 11: ...carry out the following procedure i Remove clips a and fuel hoses ii Replace fuel filter iii Reassemble the filter assembly checking clips a are tightened 3 FUEL PUMP ASSEMBLY a To replace fuel pump carry out the following procedure i Remove the top cover access panel b by removing screws ii Loosen three screws e on the fuel pump casing be sure not to remove the screws iii Remove fuel pump from el...

Page 12: ...peration 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 scre...

Page 13: ...s are complete and tight iv Reassemble top cover b for EC 100 PT only and fix electric board to the heater a 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 Reassemb...

Page 14: ...hed and tightened to connectors 2 Check there is no debris inside silicon tube iii Reassemble electric board 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 screws ii Loosen screw a and remove wire connector of yellow green wire c iii Turn counterclockwise burner support d and pull it out of burner t...

Page 15: ...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 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...

Page 16: ...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 ix Reassemble combustion head x Reassemble top cover i m n p ...

Page 17: ...cedure i Remove the top cover access panel b by removing 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 c a b ...

Page 18: ...d reset lamp is orange unit is in stand by i Cooling down time of ignition transformer 1 Wait till end of cooling down time unit will re start automatically B HEATER STARTS BUT DOES NOT COMPLETE STARTING CYCLE a Motor runs continuously there are no flame and reset lamp is off i Extraneous light or flame during pre purge cycle 1 Check positioning of photocell 2 Make service of combustion head and c...

Page 19: ...eset lamp is off i Voltage lower than 70 V or higher than 150 V 1 Check supply voltage is correspondent to rating plate 2 Unit will automatically restart when voltage becomes higher than 80 V or lower than 140 V c Heater starts and stops flames and main fan remains on unit is in stand by and rest lamp is off i Air bubbles in the suction line to fuel pump 1 Check oil filter casing is tightened 2 Ch...

Page 20: ...el valve EV1 is switched off and the flame control unit goes in lock out in the flame failure mode FU Fuse 20 A IT H T Transformer LI1 Overheat thermostat EV1 Fuel solenoid valve FO Photocell CO Capacitor MV Fan motor ST Control lamp RV Main switch TA Room thermostat plug AP Flame control box RF Heated fuel filter optional PA Air pressure switch FUA Fuse 6 3 A ...

Page 21: ...eat ouput kBTU h 94 759 Fuel consumption USgal h 0 81 lb h 5 733 Power supply 1 V 120 Hz 60 Electric consumption W 440 A 4 05 Nozzle USgal h Delevan 0 55 80 W Pump pressure psi 196 Adjustment of com bustion air flap in a 0 118 N A Static pressure in WC 0 5 Flue diameter in 5 9 Compulsory flue draft in WC 0 05 ...