I have had this problem before on some of those units. The fan control switch is faulty. You have to open the unit and locate the switch. One of the side panels covers it along with a shut off thermal switch and the ends to the heating elements. Use a multimeter to test both thermal switches one should be closed one should be open . The one that is open is the fan control switch, REPLACE IT with the exact match. I have bought them from Grainger for about $20. Don't hesitate to replace it. Test the fan by connecting both leads from that switch and energize the unit. Does the fan kick on? if not the fan is the issue, if the fan kicks on then replace the thermal switch. Be sure to get the switch that is normally open.
What you have is a very dangerous situation. It may not be a newness smell. It may be the plastic melting. Many of the Comfort Zone heaters were recalled in December 2010. Search Google for Comfort Zone Heater Recall to see if your specific model was included
Big Lots has some great pricing and deals, but some of their electric appliances are Factory Refurbished Units. If that is the case, it is required that the box it came in must indicate that.
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