Espar Hydronic D4 SC, Hydronic B4 SC, Hydronic D5 S, Hydronic B5 SC, Hydronic B5 S User Manual
...
Hydronic 4/5 (Coolant Heaters)
Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts Diagrams and List
Heater Model 12 V
Hydronic D4 SC 25 2096 05
25 2257 05
Hydronic B4 SC 20 1824 05
Hydronic D5 SC 25 1920 05
25 2098 05
25 2219 05
FMP OUT 25 2325 05
Espar Heater Systems
Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
Heater Model 24 V
Hydronic D5 SC 25 2147 05
Hydronic D5 S 25 2146 05
25 2218 05
Hydronic D5 S 25 2031 05
25 2217 05
Hydronic B5 SC 20 1820 05
Hydronic B5 S 20 1793 05
20 1819 05
08.2013 Subject to Change Web Edition
Table of Contents Page
Introduction Heater Warnings ........................................................ 3
Introduction ........................................................ 4
Specifications ........................................................ 4
Heater Components
Hydronic 4/5 SC, 12 + 24 volt, Diesel ........................................................ 5
Hydronic 5 S, 12 + 24 volt, Diesel + Gas ........................................................ 6
Hydronic 4/5 SC, 12 volt, Gasoline ........................................................ 6
Principal Dimensions ........................................................ 7
Installation Heater Location ........................................................ 7
Procedures Heater Mounting ........................................................ 8
Heater Plumbing ........................................................ 9
Fuel System ........................................................ 10
Electrical Connections ........................................................ 12
Exhaust / Intake Connections ........................................................ 13
Control Options ........................................................ 14
Heater Operation Pre-Start Procedures ........................................................ 15
Start-Up ........................................................ 15
Running ........................................................ 15
Switching Off ........................................................ 16
Safety Equipment ........................................................ 16
Operational Flow Chart ........................................................ 17
Heater Diagnostics Schematics ........................................................ 18
Maintenance / Periodic Maintenance ........................................................ 24
Troubleshooting / Basic Troubleshooting ........................................................ 24
Repairs Self Diagnostic Troubleshooting ....................................................... 24
Troubleshooting Chart ....................................................... 26
Fuel Quantity Test ........................................................ 28
Heater Disassembly / Repair Steps ........................................................ 29
Heater Components Parts Diagram / Scope, Face Lift “SC” Heaters ........................................................ 32
Description & Part #’s, Face Lift “SC” Heaters ........................................................ 33
Parts Diagram / Scope, Face Lift “S” Heaters ........................................................ 40
Description & Part #’s, Face Lift “S” Heaters ........................................................ 41
Parts Diagram / Scope, Early “SC” Heaters ........................................................ 46
Description & Part #’s, Early “SC” Heaters ........................................................ 47
Parts Diagram / Scope, Early “S” Heaters ........................................................ 58
Description & Part #’s, Early “S” Heaters ........................................................ 59
Parts Diagram / Scope, North American Heaters ....................................................... 64
Parts Diagram / Scope, North American Heaters (F/L) ....................................................... 65
Description & Part #’s, North American Heaters ....................................................... 66
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.
2
Introduction
Heater Warnings
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 the heater. Failure to follow all these instructions
could cause serious or fatal injury.
Warning - Explosion Hazard
• Heater must be turned off while re-fueling.
• Do not install heater in enclosed areas where combustible
fumes may be present.
• Do not install heaters in engine compartments of gasoline
powered boats.
Warning - Fire Hazard
• Install the exhaust system so it will maintain a minimum
distance of 50mm (2”) from any flammable or heat sensitive
material.
• Ensure that the fuel system is intact and there are no leaks.
Warning - Asphyxiation Hazard
• Route the heater exhaust so that exhaust fumes cannot
enter any passenger compartments.
• If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
ATTENTION
Operation with bio-diesel
HYDRONIC D4 / D5
HYDRONIC D4 / D5 is not certified for use with bio-diesel.
Admixtures of bio-diesel up to a magnitude of approx. 10%.
ATTENTION
Heating at high altitudes
Up to 1500 meters (4920’) - unrestricted heating operation is
possible.
Above 1500 meters (4920’) - heating operation is in principle
possible for short periods, e.g. when crossing a mountain
pass or 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.
The following high altitude kits are available:
Note: P/N: 24 0221 00 00 00 (Contains high altitude fuel
pump)
or
P/N: 20 2900 70 00 07 (Contains high altitude
compensator, no extra fuel pump needed)
Only works with heaters that do not have “M-kit”
on the factory label.
or
P/N: 22 1000 33 22 00 (Only works with Hydronic Heaters
that have “H-Kit” on the factory label)
Warning - Safety Hazard on Coolant Heaters
Used With Improper Antifreeze Mixtures
• The use of Espar coolant heaters requires that the coolant
in the system to be heated contain a proper mixture of water
and antifreeze to prevent coolant from freezing or slushing.
• If the coolant becomes slushy or frozen, the heater’s
coolant pump cannot move the coolant causing a blockage
of the circulating system. Once this occurs, pressure will
build up rapidly in the heater and the coolant hose will either
burst or blow off at the connection point to the heater.
• This situation could cause engine damage and/or personal
injury. Extreme care should be taken to ensure a proper
mixture of water and antifreeze is used in the coolant
system.
• Refer to the engine manufacturer’s or coolant manufacturer’s recommendations for your specific requirements.
Note: Only one kit from the listed above is needed.
This publication was correct at the time of print.
However, Espar has a policy of continuous improvement and reserves the right to amend any specifications without prior notice.
3
Introduction
Espar’s Hydronic D4/D5 Heater
Quality engineered to provide a dependable means of heating.
The Espar Hydronic 4/5 is a diesel fired coolant heater capable of between:
Hydronic 4 - 2.4 kW to 4.3 kW/hr (8,200 to 14,781 BTU/hr).
Hydronic 5 - 2.4 kW to 5 kW/hr (8,200 to 17,100 BTU/hr).
This compact coolant heater offers an affordable heating solution to many applications. The Hydronic 4/5 is ideal for preheating the engines of trucks, cars, off-road equipment, small
trucks and boats. It features automatic heat regulation while
being fuel and power efficient. Since the heater runs on fuel
and 12 or 24 volt power, it is able to perform this completely
independently of the vehicle engine. The unit regulates the
coolant temperature between a low of 65°C (149°F) and a high
of 80°C (176°F) by automatically cycling the heater between
heat levels.
The Hydronic 4/5 can be operated from the vehicle cab by an
on/off switch, a pre-select timer or a combination of both.
A flame sensor, temperature regulating sensor and overheat
sensor are among the safety features which makes the
Hydronic D4/D5 a safe and dependable heating system.
Specifications Hydronic 4 Hydronic 5
Heat output (±10%) 4.3 kW (14,781 BTU/hr) - High 5 kW (17,000 BTU/hr) - High
2.4 kW (8,188 BTU/hr - Low 2.4 kW (8,200 BTU/hr) - Low
12 volt 24 volt
Current draw (±10%)
4.0 amps High 4.16 amps High 2.08 amps High
1.91 amps Low 1.91 amps Low 0.95 amps Low
Fuel consumption (±10%)
0.53 l/hr (0.13 US gal/hr) High 0.62 l/hr (0.16 US gal/hr) High
0.27 l/hr (0.07 US gal/hr) Low 0.27 l/hr (0.08 US gal/hr) Low
Operating Voltage Range
Minimum Voltage 10.2 V 10.2 V 20.4 V
Maximum Voltage 16 V 16 V 32.0 V
Working pressure 2.5 bar (36 psi) 2.5 bar (36 psi)
Ambient operating temperature -40°C to +80°C (-40°F to 176°F) -40°C to +80°C (-40°F to 176°F)
Weight 2.7 kg. (5.94 lbs.) 2.9kg. (6.4lbs)
Controls available On/Off switch or 7-day timer On/Off switch or 7-day timer
(Multi-Function Timer) (Multi-Function Timer)
Note: The heater is equipped with a high-voltage
cutout as well as a low-voltage cutout.
4
Note: For specifications of gasoline heaters, please
see original manual in heater packaging.
Introduction
18
17
15
12 16 13
4
11 2110
56
9
1
2
7
8
3
19
20
A
A
E
E
WO
WO
WI
WI
F
F
14
Heater Components - Hydronic 4 & 5 SC versions - 12 + 24 Volt - Diesel
25 2219 05
25 2147 05
25 2257 05
A=Combustion air
E=Exhaust
F=Fuel supply line
WO = Water Outlet
WI = Water Inlet
1 Combustion air blower wheel
2 Electric motor
3 Heat exchanger
4 Combustion chamber
5 Glow pin
6 Flame sensor
7 Temperature sensor
8 Overheat temperature sensor
9 Control unit
10 Combustion air tube
11 Exhaust tube
12 Fuel-metering pump
13 Coolant pump
14 Main fuse
15 Interface/8-pin connector
16 Bleed screw
17 Mini Timer
18 Push/Pull switch
19 7-day timer
20 Programmable Timer
21 Exhaust silencer
5
Introduction
18
17
11 2110
19
20
8
1316
3
4567
1
15
2
9
A
A
E
E
WO
WO
WI
WI
14
12
F
F
14
13
15
9
2
1
18
17
19
20
74
8
3
5216
12
10
11
A
A
E
E
WO
WO
WI
WI
WI
WI
F
F
Heater Components - Hydronic 5 S - 12 & 24 volt versions - Diesel & Gasoline versions
25 2217 05
25 2218 05
Heater Components - Hydronic 4 & 5 SC - 12 volt version - Gasoline
20 1820 05
20 1824 05
6
Introduction and Installation Procedures
Ma in di me nsion s diese l heater
WI = Water inle t
WO = Water outl et
E = E xhaus t
F = F uel
A = C ombus tion air
F
A E
WO
WI
Principal Dimensions - Hydronic D4/D5 SC
Heater Location
Always mount the heater in a protected area. Eg: storage
compartment, engine compartments or step box. Espar
recommends you use the boxed unit. Boxed heaters can be
mounted by utilizing one of the existing brackets. See following page.
If mounting on frame rail use an optional Espar Inside frame
bracket to mount to inside of frame rails. Heaters can also be
mounted on a cross tray behind the cab and on top of the
frame rails.
When mounting the heater adhere to the following conditions:
• Situate the heater below the normal coolant level of the engine.
• Guard against excessive road spray.
• Keep coolant hoses, fuel lines and electrical wiring as short
as possible.
* All measurements in millimeters
25.4mm = 1”
Caution: Guard the heater against excessive road spray to
avoid internal corrosion.
For Illustration purposes only
7
15° to
vertical
15°
Installation Procedures
Espar Heater Systems
Heater Mounting
Mount the heater in the heater bracket and secure with
hardware provided. If heater is not a boxed unit, mount
bracket onto inside frame rail bracket. Boxed unit can also be
secured to the inside frame bracket or mounted to the Cross
Frame Mounting Tray.
Cross Frame Mounting Tray
Hydronic 4/5 box
Inside frame mounting bracket
Inside frame
mounting bracket
Hydronic
Water Heater
Mounting
thru bolt
Hydronic D4 SC boxed unit P/N 25 2822 57 04 55
Hydronic D5 SC boxed unit P/N 25 2822 19 05 55
(Please refer to product catalogue for more kits)
1 Heater bracket
2 HYDRONIC
3 Fastening screw
Heater bracket
Inside frame rail
For “S” and gasoline version heaters which have external
fuel metering pumps:
• Choose a protected mounting location close to the fuel
pick-up pipe and heater.
• 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.
8
Heater bracket
FMP and bracket assembly
Installation Procedures
Heater Plumbing
The heater is incorporated into the engine’s cooling system
for engine preheating.
Engine Plumbing
Follow these guidelines and refer to engine plumbing diagram
shown.
• Use existing holes in the engine block (ie. remove
blanking plugs when possible). Install fittings into the block
for pick-up and returns.
• If possible, use 5/8 ball shut off valves minimum to ensure
the system can be isolated from the engine when not in
use.
• Provide (3/4”) hose barbs for hose connections.
• Use (3/4”) hoses to ensure adequate coolant flow.
• Keep the pick up and return points as far apart as
possible to ensure good heat distribution.
• Take the coolant from a low point on the engine to reduce
aeration in the system.
• Ensure proper direction of coolant flow by taking coolant
from a high pressure point in the engine and returning it to
a low pressure point. (ie. pickup from back of block and
return to the suction side of the engine's water pump).
• Ensure adequate flow rate through the heater by comparing
the incoming and outgoing coolant temperatures while
the heater is running. If the rise in temperature exceeds
10°C (18°F), coolant flow must be increased by modifying
the plumbing.
• Ensure the heater and water pump are installed as low as
possible to allow the purging of air. Bleed system via
radiator or bleed screw located on heater.
(If using silicone coolant line use appropriate clamps)
Radiator
Engine
Shut-off
valves
(Optional)
Hydronic SC Heater
External Water Pump
Hydronic “S” version
Optional Outlets available
in 18mm and 20mm
See Product Catalogue
Bleed Screw
Water out
Water in
Caution: The coolant must contain a minimum of 10%
antifreeze at all times as a protection against
corrosion. Fresh water will corrode internal
heater parts.
9
Installation Procedures
Fuel System
Some Hydronic water heaters (2219) typically have the fuel
metering pump mounted inside the unit. This is to reduce
installation time and to protect the pump from corrosion. Some
versions have an external fuel metering pump. Refer to
graphics for connections and specifications.
All parts necessary to do the installation are included in the kit
as shown.
Note: For 25 2219 and similar “SC” Heaters:
Fuel line limits must not be exceeded.
Ensure that the following conditions are met.
Hydronic heater must be within a height of 76cm (2’6”)
from the bottom of the fuel pick-up pipe.
Fuel-metering pump must be within a total distance of
200 cm (6’6”) from the fuel pick-up pipe.
If the above conditions cannot be met, a heater with
external fuel metering pump must be used.
Fuel System Tolerances
1. Fuel Pick-Up Pipe
2. Fuel Pipe Reducer
3. 9mm Clamp
4. 3.5mm Rubber Connector
5. 2.0mm White Plastic Fuel Line
6. Fuel Metering Pump
7. 1.5m White Plastic Fuel Line
Fuel Line
• Route fuel lines from the fuel pick-up pipe to the heater.
• Use only 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.
• Use a sharp utility knife to cut plastic fuel lines to avoid fuel
line pinching.
Note: Butt joints and clamps on all connections.
Hydronic Heater
Max. 76cm (2’6”)
Max. 76cm (2’6”)
2
4
3
1
Max. 2 M (6’6”)
2
4
3
1
Max. 2 M (6’6”)
Max. 2 M (6.5’)
4
3
5
4
6
3
5
“SC” Models
25 2219 05
and similar
Max. 6 M (19.8’)
4
4
3
6
7
3
“S” Models
25 2217 05
and similar
10
Installation Procedures
Ø 1.0”
9 / 16” 9 / 16”
Ø 1 / 4” (2 HOLES)
Fuel Pick-up Pipe
Ferrul Nut (Tighten before installing)
Nut
Sheet Metal Washer
(raised center to top)
Reinforc ing Washer
Holdin g Tabs
Allow 4" from Fuel
Pick-up to tank bottom.
Allow only 1" for flat
bottom tanks.
Fuel Tank
FMP bracket
Fuel Pick-Up Pipe Installation (Drill Option)
• Choose a protected mounting location close to the pump and
heater. A spare fuel sender gauge plate provides an ideal
mounting location. If one is not available...
• Drill mounting holes in tank to accommodate pick-up pipe as
shown.
• Tighten Ferrule nut to pick-up pipe at desired height.
• Cut the fuel pick-up pipe to length. Allow 2-2.5” from bottom of
tank.
• 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 0.6cm (1/4”) holes.
• Lift the assembly into position through the 2.5cm (1”) hole.
• Assemble the rubber washer, metal cup washer and nut.
ø 2.5cm (ø1.0”)
ø 0.625 cm (2 Holes)
(ø 1/4”)
1.5 cm
(9/16”)
1.5 cm
(9/16”)
Note: Drill the two (1/4”) holes first.
Note: Some pick-up pipes can be installed by either
drill or NPT.
Typical standard assembly, if
not using this format please
adhere to specifications on
pg. 10
Note: NPT fittings are available in various sizes
(Refer to ESPAR Product Catalogue).
11
-
+
B
C
D
A
E
Vehicle
Chassis
Installation Procedures
Electrical Connections
All parts needed are included with the kit. ( * ) indicates external mounted fuel and or water pump versions of Hydronics.
A. Main Heater Harness...................................................
B. Power Harness............................................................
C. Switch Harness............................................................
D.* Fuel Metering Pump Harness........................................
E.*Water Pump Harness......................................................
Hydronic Heaters
• Connects switch and power harness to the heater harness.
( * in some cases power to fuel metering pump).
• 2 core harness (red, brown).
• Connect red wire to fuse link and terminal.
• Attach ring terminal to vehicle battery (+).
• Connect brown wire to vehicle battery (-) using ring terminal
provided.
• 20 amp fuse - 12V.
15 amp fuse - 24V.
• 4 core harness (red/yellow, brown, yellow, blue/white).
• Run to location of control option. Make terminal connections
at control option. Espar has 2 available switches, see control
option instructions on following pages.
• 2 core harness (green, green) or (green, brown).
• Connect to fuel metering pump using terminals and protective
seals + connector block (no polarity required).
• 2 core harness (black, brown).
• Connect to main harness at heater.
Caution:
To avoid potential short circuit
damage during installation, insert
20 amp fuse on power harness
after all electrical connections are
complete.
Important: Negative battery terminal must always be
grounded.
If a vehicle is equipped with switch on negative battery wire, install additional 20 A fuse in negative wire of
heater’s harness.
Connector
Block
(Multi Functional)
Note: All harnesses should be cut to length.
All exposed electrical connections should be coated with
protective grease.
Installation Note: Wire must be inserted into fuse
holder prior to terminating.
7 Day Timer
12
Installation Procedures
Exhaust Connection
A 24mm flexible tube exhaust pipe is required for the exhaust.
An exhaust clamp is used to secure the exhaust to the heater.
Connect the exhaust as follows:
• Connect the exhaust pipe to the exhaust port on the heater
and attach with clamp provided.
• Run exhaust to an open area to the rear or side of the vehicle
so that fumes can not build up and enter the passenger compartment or the heater combustion air intake.
• Install exhaust pipe with a slight slope or drill a small hole in
the lowest point to allow water to run out. Any restriction in
exhaust will cause operational problems.
• Route the exhaust pipe from the heater using “p” clamps
provided.
Caution: Run exhaust so that it cannot be plugged by
dirt, water or snow. Ensure the outlet does not
face into the vehicle slip stream.
Intake Connection
Combustion air must be drawn in from the outside. The combustion air opening must be kept free at all times.
• Connect the air intake pipe to the intake port on the heater and
secure with clamp provided.
Caution: Do not install the intake opening facing the
vehicle slipstream. Ensure that the opening
cannot become clogged with dirt or snow and that
any water entering the intake can drain away.
Exhaust
Clamp
(27mm - 30mm)
24mm Flexible Exhaust
Min 8” (0.4 mtr)
Max 78” (2 mtr)
Air Intake Hose
Min 8” (0.04 mtr)
Max 39” (1 mtr)
(When not mounted in
a Protective Box)
End Sleeve
Warning - Fire Hazard
The exhaust is hot, keep a minimum of 5cm (2”)
clearance from any heat sensitive material.
Route exhaust so that the exhaust fumes cannot enter
the passenger compartment.
Warning - Asphyxiation Hazard
Route exhaust beyond the skirt of the cab and
outside of the frame area.
Failure to comply with this warning could result in
Carbon Monoxide Poisoning.
13
Installation Procedures
Yellow
Red
Brown
Blue
DIAG
TRS
Yellow
Red
Blue
Brown
12 11 10 9 8 7 6 5 4 3 2 1
MO
1
2
3
18:00
P
Control Options
A Push/Pull switch or a Multifunction (7 Day Timer) are available.
7 Day Timer
Multifunction
The multifunction is capable of multiple start functions within a
7 day period. Other functions include current time display and
automatic heater numeric fault code. Display refer to instructions provided with timer for setting options.
• Mount timer and bracket in a suitable location.
• Connect the switch harness to the connector at the heater
and run the harness to the control location.
• Cut harness to length at the control and install terminals.
• Connect switch harness to timer as shown below.
• Refer to timer instructions for other wiring options.
a)
b)
c)
d)
a) Power from battery “+”.
b) Switch control to the heater.
c) Power from battery “-”.
d) Diagnostic from heater.
Option #1: Dash lights to timer - connect wire between
dash lights circuit and timer at ter minal #1.
Option #2: Operate heater continuously - connect
wire from ignition circuit to terminal #10.
See also multifunction (7 day) timer in
instructions.
14
Heater Operation
Push/Pull Switch
• Mount switch in a location where it is easily accessible.
• Mount using hardware supplied.
• Connect the switch harness to the connector at the heater
and run the harness to the switch location.
• Cut harness to length at the switch and install terminals.
• Connect wiring as shown.
Control Wiring
Push/Pull Switch
Brown- 31 Power from battery “-”
Red- K(15) Power from battery “+”
Yellow-15(K) Switch control to the heater
Blue/White Diagnostic from heater (disregard - tape end
and tie off to the side)
Note: Wired as above the switch light glows when pulled
out and is off when pushed in.
Ø
Ø
Heater Operation
Pre-Start Procedures
Upon completion of installation prepare the heater as follows:
• Check all fuel, electrical and plumbing connections.
• Refill the engine coolant.
• Bleed air from the coolant system by loosening the bleed
screw on top of the heater to allow air to escape.
• Loosen rad cap and run engine to allow air to be purged.
• Top up engine coolant.
Start Up
Once switched on the following sequence occurs:
• Control unit does a systems check (flame sensor, glow pin,
motors, temperature sensor and various other control unit
checks).
• Water pump starts circulating coolant.
• Combustion air blower comes on.
• Glow pin begins to preheat 20-50 secs.
• Metering pump starts and combustion air blower speeds up
gradually.
• Once ignition takes place the flame sensor alerts the control
unit and the control unit shuts off the glow pin (ignition time:
1.5 - 2 minutes).
Running
Running
Once ignition is successful the following operations take place:
• Heater runs in high heat mode and the temperature is monitored at the heat exchanger.
• Once coolant reaches 80°C (176°F) the heater automatically
switches to low heat mode and continues to run.
• If coolant temperature drops to 75°C (167°F) the heater will
automatically switch back to high heat mode.
• If the coolant temperature continues to rise, the heater will
automatically switch off once temperature reaches 86°C
(187°F).
• The water pump will continue to circulate coolant to allow the
heater to monitor engine temperature.
• The heater will automatically re-start once coolant temperature reaches 75°C (167°F).
• The heater continues to run as described above until it is
switched off, either manually, automatically by a timer or
heater malfunction shutdown.
Note: If the heater should shut down due to flame out
while in running mode, it will automatically
attempt one restart. If successful, it will continue
to run. If not, it will shut down completely with a
cool-down cycle.
Note: If the heater fails to start the first time it will
automatically attempt a second start.
If unsuccessful, the heater will shut down completely.
Note: On initial start up the heater may require several
start attempts to self prime the fuel system.
Note: During operation the heater continually senses
the input voltage from the batteries. If the input
voltage drops to approximately 10.5 volts or
rises above 16 volts the heater will automatically shut down with a cool-down cycle, and display
a fault code when using a multifunction timer.
15
Heater Operation
Switching Off
• When the heater is switched off, manually or automatically,
it starts a controlled cool down cycle.
• The fuel metering pump stops delivering fuel and the flame
goes out.
• The combustion air blower and water pump continue to run
for 3 minutes to cool down.
• The heater shuts off.
Safety Equipment
The control unit, temperature sensor, overheat sensor and
flame sensor continually monitor heater functions and will shut
down the heater in case of a malfunction.
• The control unit ensures electrical circuits (fuel pump, combustion air blower etc.) are complete prior to starting the
heater.
• If the heater fails to ignite within 90 seconds of the fuel
pump being started, the starting procedure will be repeated.
If the heater again fails to ignite after 90 seconds of fuel
being pumped, a “no start safety shutdown” follows. (Fault
#52)
• If the heater flames out during operation, the heater automatically attempts to restart. If the heater fails to i g n i t e
within 90 seconds of fuel delivery, the heater will turn off the
fuel pump and complete a cool down and display a F052
code. After troubleshooting the problem the heater can be
started again by switching the heater off and then back on
again.
• Overheating due to lack of water, a restriction or a poorly
bled coolant system results in the overheat shutdown
(F012). Fuel delivery will cease and an “overheat shut
down” follows. If heater overheats 3 consecutive times, a
lockout on the control unit will occur. To unlock the control
unit you will need to use the Fault Code Retrieval Device.
See following pages for self diagnostics.
• If at any time the voltage drops below 10.5V for 20 seconds,
or rises above 16.0V for 20 seconds the heater will shut
down and display the associated Fault Code.
Warning
The heater must be switched off while any fuel tank on
the vehicle is being filled.
The heater must not be operated in garages or enclosed
areas.
16
Heater Operation
STARTING PHASE
RUNNING PHASE SHUT DOWN PHASE
Operating
Mode
Time
Fuel
Pump
Glow
Pin
Blower
Water Pump
System
Check
Pre-heat Pre-heat
2nd. attempt
Ignition
Attempt
Ignition
Attempt
2nd. attempt
Controlled
Heating
Off
Off
Off
OffOn
Off
Off
On:
if in stand by
OnOnOnOnOn On
OnOnOnOn
Momentarily
OnOnOnOn
On
On
On
On
Off
Off
Off
Off Off Off Off Off
On
On On
After
Glow
Cool
Down
Off
or
Stand by
1- 3 sec.
40 sec.
20 sec.
40 sec
.
Up to
80 sec.
Up to 80 sec.
If Required
High/Low
Operation
until switched off
manually or automatically
2.5 min.
Note: During the controlled heating cycle, if the coolant temperature exceeds 86°C (187°F) the heater will cycle off.
Heater will automatically restart in high mode once coolant temperature reaches 75°C (167°F)
17
Heater Diagnostics
Red
K(15)
15(K)
Yellow
Brown
31
0
3.1.1
Optional
Brown
e)
Optional
Optional
f)
M
M
Yel low
Yel low
Red
Brown
Brown
Brown
Blue
Blue/White
Blue/White
DIAG
TRS
a) Power from battery “+”.
b) Switch control to heater.
c) Power from battery “-”.
d) Diagnostics from heater.
e) To vehicle dimmer switch for light display.
f) To vehicle ignition accessories for continuous
operation of heater.
121110 9 8 7 6 5 4 3 2 1
4 3 2 1
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1 2
3 4
b)a)d)
c)
4 3 2 1
2 4 6 8
1 3 5 7
8 6 4 2
7 5 3 1
P
3.2.9
2.5.8
5.1
2.7
RedRed
Red
Brown
Red
Brown
Green
Light Green
Blue/White
Black
Blue
S1 B1
S1 B1
B2
B2
B3
2.1
2.12
1.1
1.2
2.2
1.5
1.13
1.12
Violet
Brown
Light Brown
Black
White
Brown
Green
Green
Red
Red
Blue
Blue
Brown
Blue
14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 3 5 7 9 11 13
2 4 6 8 10 12 14
2 4 6 8 10 12 14
1 3 5 7 9 11 13
87
87a
85
30
86
Red/Yellow
Hydronic D4 SC 12 Volt
Model 25 1917 01
Wiring Harness P/N:
20 2900 70 04 01
(CA0 60 401)
Push/Pull switch
7 day timer
3.12
2.2 Fuel metering pump
2.5.8 Blower lock out resistor
2.7 20 amp main fuse
3.12 Push/Pull switch
3.2.9 7 day timer
5.1 Battery
1.1 Blower motor
18
1.2 Glow pin
1.5 Overheat sensor
1.12 Flame sensor
1.13 Temperature sensor
2.1 Control unit
2.12 Water Pump
Heater Diagnostics
Brown
Violet
Brown
Light Brown
Black
White
Brown
Green
Green
Red
Red
Blue
Blue
Brown
Blue
1 2 3 4 5 6 7 8 9 10 1 12 13 14
Yel low
Brown
Red
Brown
Brown
Blue
Blue/White
DIAG
TRS
Yel low
a) Power from battery “+”.
b) Switch control to heater.
c) Power from battery “-”.
d) Diagnostics from heater.
e) To vehicle dimmer switch for light display.
f) To vehicle ignition accessories for continuous
operation of heater.
12 11 10 9 8 7 6 5 4 3 2 1
4 3 2 1
123
4
567
8
123
4
567
8
b)a)d)
c)
4 3 2 1
2 4 6 8
1 3 5 7
8 6 4 2
7 5 3 1
3.2.9
5.1
2.7
RedRed
Red/Yellow
Red
Brown
Red
Brown
Black/Red
Light Green
Blue/White
Blue
Yel low
Black/White
S1 B1
S1 B1
B3
2.1
2.12
1.1
1.2
2.2
1.5
1.13
1.12
1 3 5 7 9 11 13
2 4 6 8 10 12 14
87
87a
85
30
86
M
1 2
3 4
B2
B2
M
P
h)
Optional
e)
Optional
f)
Optional
Red
K(15)
15(K)
Yellow
Brown
31
0
3.1.1
Hydronic D4 SC 12 Volt
Model 25 2096 05
Wiring Harness P/N:
20 2900 70 05 03
Push/Pull switch
7 day timer
3.12
3.2.9 7 day timer
5.1 Battery
1.1 Blower motor
1.2 Glow pin
1.5 Overheat sensor
1.12 Flame sensor
1.13 Temperature sensor
2.1 Control unit
2.12 Water Pump
2.2 Fuel metering pump
2.7 20 amp main fuse
3.12 Push/Pull switch
19
Heater Diagnostics
M
Optional
Brown
Black
Brown
Violet
Brown
White
Green
Green
Red
Red
Blue
Blue
Brown
Blue
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Yel low
Yel low
Red
Brown
Brown
Brown
Blue
Blue/White
Black/Red
DIAG
TRS
Blue
a) Power from battery “+”.
b) Switch control to heater.
c) Power from battery “-”.
d) Diagnostics from heater.
e) To vehicle dimmer switch for light display.
f) To vehicle ignition accessories for continuous
operation of heater.
12 11 10 9 8 7 6 5 4 3 2 1
4 3 2 1
1
2
3
4
5
6
7
8
b)a)d)
c)
4 3 2 1
2 4 6 8
1 3 5 7
8 6 4 2
7 5 3 1
3.2.9
5.1
2.7
2.5.8
RedRed
Red/Yellow
Red
Brown
Red
Brown
Black/Red
Green
Blue/White
Blue
Yel low
Black/White
S1 B1
S1 B1
B3
2.1
1.1
2.12
1.2
2.2
1.5
1.13
1.12
1 3 5 7 9 11 13
8 7 6 5 4 3 2 1
87
87a
85
30
86
1 2
3 4
B2
B2
P
2 4 6 8 10 12 14
M
h)
Optional
e)
Optional
f)
Brown
Red
K(15)
15(K)
Yellow
Brown
31
0
3.1.1
Hydronic D5 SC 12 Volt
Model 25 1920 05
Wiring Harness P/N:
20 2900 70 04 01
Push/Pull switch
7 day timer
3.12
2.1 Control unit
2.12 Water Pump
2.2 Fuel metering pump
2.5.8 Blower lock out resistor
2.7 20 amp main fuse
3.12 Push/Pull switch
3.2.9 7 day timer
5.1 Battery
1.5 Overheat sensor
1.12 Flame sensor
1.13 Temperature sensor
1.1 Blower motor
1.2 Glow pin
20
Heater Diagnostics
M
1 2 3 4 5 6 7 8 9 10 11 12 13 14
B2
P
M
Optional
e)
Optional
Optional
f)
Red
2.7.1
Yel low
Brown
Brown
Blue
Blue/White
Yel low
Red
Red/Yellow
Red
Brown
4 3 2 1
b)a)d)
c)
4 3 2 1
Brown
RedRed
DIAG
TRS
Brown
a) Power from battery “+”.
b) Switch control to heater.
c) Power from battery “-”.
d) Diagnostics from heater.
e) To vehicle dimmer switch for light display.
f) To vehicle ignition accessories for continuous
operation of heater.
121110 9 8 7 6 5 4 3 2 1
3.2.9
5.1
2.7
Red
Brown
Black/Red
Green
Blue/White
Blue
Yel low
Black/White
S1 B1
1
2
3
4
5
6
7
8
8 7 6 5 4 3 2 1
1 2
3 4
Brown
Black
Brown
Violet
Brown
White
Green
Green
Red
Red
Blue
Blue
Brown
Blue
1.1
2.12
1.2
2.2
1.5
1.13
1.12
h)
S1 B1
B3
2.1
B2
2 4 6 8
1 3 5 7
8 6 4 2
7 5 3 1
1 3 5 7 9 11 13
87
87a
85
30
86
2 4 6 8 10 12 14
Red
K(15)
15(K)
Yellow
Brown
31
0
3.1.1
Hydronic D5 SC 12 Volt
Model 25 2098 05
25 2219 05
25 2257 05
Wiring Harness P/N:
20 2900 70 05 03
No Blower Relay
Internal FMP
Push/Pull switch
7 day timer
3.12
2.12 Water Pump
2.2 Fuel metering pump
2.7 20 amp/12V main fuse
15 amp/24V main fuse
2.7.1 5 amp fuse
3.12 Push/Pull switch
3.2.9 7 day timer
5.1 Battery
1.12 Flame sensor
1.13 Temperature sensor
2.1 Control unit
1.1 Blower motor
1.2 Glow pin
1.5 Overheat sensor
21
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