Espar AIRTRONIC D2, AIRTRONIC D4 Installation Instructions Manual
AIRTRONIC D2/D4
Installation, Troubleshooting & Parts Manual
AIRTRONIC
For Heater Models Release period
AIRTRONIC D2 - 12 volt 25 2069 05 00 00 November 2001
AIRTRONIC D2 - 24 volt 25 2070 05 00 00 November 2001
AIRTRONIC D4 - 12 volt 25 2113 05 00 00 November 2001
AIRTRONIC D4 - 24 volt 25 2114 05 00 00 November 2001
Espar
P/N: 610-103-0901 November 2001
Table of Contents Page
Introduction Heater Warnings ........................................................ 3
Introduction ........................................................ 4
Specifications ........................................................ 5
Principal Dimensions ........................................................ 6
Heater Components ........................................................ 7
Installation Procedures Heater Location ........................................................ 8
Heater Mounting ........................................................ 8
Heater Plate installation ........................................................ 8
Mounting Pattern ........................................................ 9
Ducting Components ........................................................ 9
Heater Air Ducting ........................................................ 9
Fuel System ........................................................ 10
Electrical Connections ........................................................ 12
Exhaust/Intake Connections ........................................................ 13
Operating Switches ........................................................ 13
Heater Operation Switch on ........................................................ 14
Start-Up ........................................................ 14
Temperature setting ........................................................ 14
Temperature Control ........................................................ 15
Switching Off ........................................................ 15
Controls & Safety Equipment ........................................................ 15
Operational Flow Chart ........................................................ 15
Function Diagrams ........................................................ 16
Schematic AIRTRONIC D2/D4 ........................................................ 17
Maintenance, Periodic Maintenance ........................................................ 18
Troubleshooting & Basic Troubleshooting ........................................................ 18
Repairs Self Diagnostic Troubleshooting ....................................................... 18
Fuel Quantity Test ........................................................ 23
Overheat/Flame sensor values ........................................................ 23
Control and Resistance values ........................................................ 24
Repair Steps ........................................................ 25
Heater Parts AIRTRONIC D2/D4 ........................................................ 30/32
-Service Parts Diagram
AIRTRONIC D2/D4
-Parts List ........................................................ 31/33
Special Notes
Note: Highlight areas requiring special attention or clarification.
Caution: Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed.
Warning: Indicates that serious or fatal injury may result if specific guidelines are not followed.
This publication was correct at the time of going to print. However, Espar Inc. has a policy of continuous improvement
and reserves the right to amend any specifications without prior notice.
Heater Warnings
3
Warning To Installer:
Correct installation of this heater is necessary to ensure
safe and proper operation.
Read and understand this manual before attempting to
install a heater.
Warning - Explosion Hazard
1. Heater must be turned off while re-fueling.
2. Do not install heater in enclosed areas where
combustible fumes may be present.
3. Do not install heaters in engine compartments of
gasoline powered boats.
Warning - Fire Hazard
1. Install heater so it will maintain a minimum distance of
2” from any flammable or heat sensitive material.
2. Install the exhaust system so it will maintain a
minimum distance of 2” from any flammable or heat
sensitive material.
3. Ensure that the fuel system is intact and there are no
leaks.
Failure to follow these instructions could cause fire resulting in serious or fatal injury.
Warning - Asphyxiation Hazard
1. Route the heater exhaust so that exhaust fumes can
not enter any passenger compartments.
2. Ensure an air tight seal will be maintained between
the heater and mounting surface and at any exhaust
connection points.
3. Ensure that heating air supply is taken from an area
where poisonous gases will not be present.
4. If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
ATTENTION
Operation with bio-diesel
AIRTRONIC D2
AIRTRONIC D2 is not certified for use with bio-diesel.
Admixtures of bio-diesel up to a magnitude of approx. 10%, as
in some countries, are allowed.
AIRTRONIC D4
AIRTRONIC D4 is certified for operation with bio-diesel as per
DIN V 51606 in free-flowing state when installed in “normal
horizontal position (exhaust pipe downwards)”; bio-diesel is not
permitted for any other installation positions.
When using 100% bio-diesel, AIRTRONIC D4 should be operated with pure diesel fuel twice per year, preferably in the middle and at the end of a winter period, to burn off any possible
PME residues: For this purpose, drain your vehicle tank as far
as possible (caution: do not forget to leave enough fuel in the
tank to get to the next fuel station!) and then fill the tank with
pure diesel fuel without bio-admixture.
While using this tank filling, let AIRTRONIC D4 run at the maxi-
mum temperatures pre-selection stage at least twice or three
times for 30 minutes at a time. You can use this for example to
pre-heat your vehicle before setting off. After this “diesel operation” of your AIRTRONIC D4, you can use bio-diesel again as
required.
When using mixtures of diesel / bio-diesel with up to 50% bioshare, it is not necessary to use pure diesel fuel now and then.
ATTENTION
Heating at high altitudes
Up to 1500 meters - unrestricted heating operation is possible
Above 1500 meters - heating operation is in principle possible
for short periods, e.g. when crossing a mountain pass of during
a brief stop. In cases of extended stays , the fuel supply at the
fuel metering pump has to be adapted to high altitude conditions. Please call
Failure to follow these instructions could cause oxygen
depletion resulting in serious or fatal injury.
Direct questions to Espar Heater Systems
USA 1-800-387-4800
CDA 1-800-668-5676
USA 1-800-387-4800
CDA 1-800-668-5676
for special circumstances.
Introduction
Espar ‘s AIRTRONIC bunk heaters
The AIRTRONIC D2 is a compact diesel-fired 7,500 BTU/hr air
heater, quality engineered to provide a dependable means of
space heating. This heater is uniquely designed for inside
mounting and ease of installation. The AIRTRONIC D4 is a
12,000 BTU/hr air heater for larger bunks.
These heater provide hot air to the interior of vehicles
for passenger comfort. Since the heater runs on diesel
fuel and 12 or 24 volt power, it is able to provide space
heat completely independently of the vehicle engine.
The heater is operated by a rheostat switch or room thermo-
stat. It cycles through four temperature settings (boost-high-
medium-low) in order to maintain the desired temperature.
If, in special cases, less heating capacity is required than
the heater supplies in the “Low” setting, the heater switches to
a “stand-by” setting. Temperature and overheat sensors, and a
specially designed heat exchanger are among the safety features which make this heater a safe and dependable unit.
4
For illustration purposes only
5
Specifications
AIRTRONIC D2 AIRTRONIC D4
Heat Output (±10%) 7,500 BTU/hr Boost (2.2 kW) 13,650 BTU/hr Boost (4.0 kW)
6,150 BTU/hr High (1.8 kW) 10,200 BTU/hr High (3.0 kW)
4,100 BTU/hr Medium (1.2 kW) 6,800 BTU/hr Medium (2.0 kW)
2,900 BTU/hr Low (0.85 kW) 3,400 BTU/hr Low (1.0 kW)
Current at 12v (±10%) 8.3 amps - Start 8.3 amps - Start
2.8 amps - Boost 3.3 amps - Boost
1.9 amps - High 2.0 amps - High
1.0 amps - Medium 1.1 amps - Medium
0.7 amps - Low 0.6 amps - Low
Current at 24v (±10%) 4.2 amps/hr - Start 4.2 amps/hr - Start
1.4 amps/hr - Boost 1.7 amps/hr - Boost
1.0 amps/hr - High 1.0 amps/hr - High
0.5 amps/hr - Medium 0.5 amps/hr - Medium
0.3 amps/hr - Low 0.3 amps/hr - Low
Fuel Consumption (±10%) U.S. Litre/hr U.S. Litre/hr
Gal/hr Gal/hr
Boost 0.07 0.28 Boost 0.13 0.51
High 0.06 0.23 High 0.10 0.38
Medium 0.04 0.14 Medium 0.07 0.25
Low 0.03 0.10 Low 0.03 0.13
Air Flow (±10%) 48 cfm Boost 85 cfm Boost
40 cfm High 69 cfm High
27 cfm Medium 50 cfm Medium
19 cfm Low 30 cfm Low
Operating Voltage Range 10.5 - 16 vdc at 12 vdc 10.5 - 16 vdc at 12 vdc
21 - 32 vdc at 24 vdc 21 - 32 vdc at 24 vdc
Overheat Temperature 240°F (115°C) 240°F (116°C)
Shutdown (±10%)
Ambient Operating -40°F to 158°F (-40°C to 70°C) -40°F to 158°F (-40°C to 70°C)
Temperature
Weight 6.0 lbs. (2.7 kg) 9.9 lbs. (4.5 kg)
Note: The heater control unit is equipped with a low
voltage cutout to prevent vehicle battery drain and
a high voltage cutout to protect heater electrical
parts.
Principal Dimensions AIRTRONIC D2
6
* All measurements in millimeters
25.4 mm = 1”
Minimum installation distance
(clearance) to open the lid and to
dismount the glow pin and the
control unit.
Minimum installation distance
(clearance) to take in heating air.
Principal Dimensions AIRTRONIC D4
(12.2 inches)
(4.5 inches)
(14.8 inches)
(5.5 inches)
Heater Components
7
1 Hot Air Blower Wheel
2 Control Unit
3 Combustion Air Blower Wheel
4 Glow Pin
5 Cover
6 Heat Exchanger
7 Overheat/Flame sensor
8 7 Day Timer with thermostat (optional)
9 Operating Unit (Thermostat)
10 Operating Unit (Rheostat)
11 Blower Motor
12 Fuel Connection
13 Flange Seal
14 Combustion Chamber
15 Hot Air Outlet Hood
16 Combustion Air Intake Hose
17 Fuel Metering Pump
18 Fuel Filter built into FMP
19 Hot Air Output Deflector
20 Flexible Exhaust Pipe
21 Main Fuse: -
AIRTRONIC D2 - 20 A
AIRTRONIC D4 - 10 A
C = Combustion Air
D = Fuel Intake from tank
E = Exhaust
F = Fresh Air Intake
H = Hot Air Output
8
Installation Procedures
Heater Location
Depending on the type of vehicle, the best location for mounting the heater will vary. Typically, air heaters are mounted
inside tool or luggage compartments. However, the heater may
be mounted anywhere inside the vehicle provided you adhere
to the following conditions:
• Combustion air intake, exhaust and fuel inlet must be
located outside of the vehicle.
• Heater must be mounted on flat horizontal surface
providing an air tight seal between heater and vehicle.
• Do not mount the heater outside the vehicle, unless care is
taken to protect the heater from the weather. When selecting
the location, consider the following:
• Combustion air and exhaust connections.
• Ducting.
• Fuel line connections.
• Electrical connections.
Heater Mounting
Heater Mounting Plate Installation
Hex Head Tek Screw
Flat washer
Nut
Spring Washer
Cab Floor
Note: Tighten screws sufficiently to ensure positive seal
between mounting plate and mounting surface.
Do not over tighten.
Silicon gasket (flange)
Stainless Steel Plate
Plate seal
A mounting plate and hardware are provided with the truck
heater kit.
• Choose heater location.
• Using template provided, drill and cut center hole. Cut (1)
four and one half inch (4 1/2”) diameter hole or one rectangular hole four (4”) by five (5”) inches to accommodate
mounting plate and seal. Secure mounting plate to vehicle
floor with “Tek” screws provided.
• Use Heater flange as a template if not using mounting plate
and seal
• Mount heater on mounting plate with nuts and spring
washers provided.
• For ease of installation make the exhaust, combustion air
intake and fuel connections at base of heater before mounting the heater into the vehicle. See following pages for
instructions and restrictions on exhaust, combustion and fuel
hook-ups.
Wiring harness connection, right or left
Wiring harness can be converted to the opposite side of the
heater if it makes the installation more practical. To do this you
must remove the AIRTRONIC cover and then the control unit.
On the control unit (underneath) is a semicircular clip protecting the harness. This must be removed. The harness should be
moved to the other side of the control unit then reassembled.
The grommet on the heater casing (side) must also be taken
out and secured into the opposite lower side of heater casing.
Wiring Harness
Right or Left
Stainless Steel
Mounting Plate
and seal
Combustion
Air intake
Fuel line
Heater
Flange
Exhaust
Tubing
Mounting Pattern
inches millimeters
Heater Air Ducting Installation
A 60mm flexible duct 40 inches long, hot air outlet and clamps
are provided with the heater kit. In routing and installing the
ducting the following criteria must be observed:
9
• Route ducting with smooth bends. Avoid crushing duct.
• Position hot air outlet so that it cannot be obstructed.
• When not using return ducting. Use a protective air intake
grille on air inlet side of heater to prevent objects from
being sucked in.
• Ensure provisions are made for proper air return ventilation.
• Use return air ducting for best heating efficiency.
Ducting Components
Return Ducting
For illustration
purposes only
No Return Ducting
For illustration
purposes only
1. Protective Grill 5. Air Outlet - Rotatable
2. Air Outlet Hood AIRTRONIC D2 - ø60 or75mm 6. Connection Piece
AIRTRONIC D4 - ø75 or 90mm 7. Protective Grill
3. Hose Clamp 2-2 3/4” 8. 90° Bend Ducting 2 3/8”
4. Flex Duct 2 3/8” (ø60 or 75mm) (ø90mm on D4)
Warning: Do not use existing vehicle ducting or outlets.
Ducts and outlets must be capable of withstanding a minimum of 300°F operating temperatures.
Caution: Do not over tighten duct clamps.
Do not position outlet so that it will blow hot air
directly at operator or at room thermostat.
Fuel System
The fuel metering pump is the heart of the system and must be
installed properly to ensure a successful heater operation.
Fuel System Overview
10
7
6
Max. 2’6”
Fuel
Tank
1
1. Fuel Pick-Up Pipe
2. 5.0 Rubber Connector
3. 11mm Clamp
2
3
Max. 6’6”
Fuel
Tank
Optional
Max. 6’6”
4
2
3
Max. 2’
Max. 20’
6
5
3
9
3
1
4. 2.0mm Black Plastic Fuel Line
5. Fuel Metering Pump
6. 9mm Clamp
8
7
5
Note: Butt joints and clamps on all connections.
7. 3.5mm Rubber Connector
8. 1.5mm White Plastic Fuel Line
9. 5mm Rubber Fuel Line
Fuel Pick-Up Pipe Installation (Standard Pick-Up)
• Choose a protected mounting location close to the fuel
pump and heater.A spare fuel sender gauge plate provides an ideal mounting location.
• Drill the mounting holes as shown
• Cut the fuel pick-up pipe to length.
• Mount the fuel pick-up pipe as shown.
• Lower the fuel pick-up pipe (with reinforcing washer) into
the tank using the slot created by the two 1/4” holes.
• Lift the assembly into position through the 1” hole.
• Assemble the rubber washer, metal cup washer and nut.
Note: Drill the two 1/4” holes first.
Optional
Custom Pick-Up Pipe with NPT fitting - optional
• Remove an existing plug from the top of the fuel tank.
• Cut the fuel pick-up pipe to length.
• Secure the fuel pick-up pipe into position using the
combined NPT compression fitting
11
NPT fitting and pipe
optional
Note: NPT fittings are available in various sizes (Refer
to parts section).
Fuel Metering Pump
• Choose a protected mounting location close to the fuel
pick-up pipe and heater if not using standard assembly as
shown on right.
• Using the bracket and rubber mount provided, install fuel
pump as shown
Note: Proper mounting angle of the fuel pump is
necessary to allow any air or vapor in the fuel
lines to pass through the pump rather than cause
a blockage.
Fuel Line
• Route fuel lines from the fuel pick-up pipe to the fuel
metering pump then to the heater.
• Use fuel lines provided.
• Other sizes or types of fuel lines may inhibit proper
fuel flow.
• Make proper butt joints using clamps and connector
pieces as shown on previous page
• Use a sharp utility knife to cut plastic
fuel lines to avoid burrs and pinching
fuel line shut.
Typical standard assembly, if
not using this format please
adhere to specifications on
pg.10
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