Espar Hydronic 10, Hydronic M User Manual

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Hydronic 10/ Hydronic M (Water Heater)

Espar Heater Systems

P/N 20 2900 81 01 24 0B 02.2007 Subject to Change Printed in Canada

HHyyddrroonniicc 1100

25 2081 05 - 12 Volt

25 2044 05 - 24 Volt

TTeecchhnniiccaall DDeesscc rriippttiioonn IInnsstt aallllaattiioo nn IInn ssttrr uuccttiioonnss OOppeerraattiinngg IInnssttrruuccttiioo nnss MMaaiinntteennaannccee IInnssttrruuccttiioonnss TTr

roouubblleesshhoooottiinngg aanndd RR eepp aaiirr IInnssttrruuccttiioonnss

PPaarrttss LLiisstt

Espar Products, Inc. 6099A Vipond Drive Mississauga, Ontario Canada L5T 2B2

(905) 670-0960 (800) 387-4800 Canada & U.S.A. (905) 670-0728 Fax

www.espar.com

HHyyddrroonniicc MM

25 2160 05 - 12 Volt

25 2161 05 - 24 Volt

25 2227 05 - 24 Volt

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.

Table of Contents Page

Introduc tio n

Heater Warnings ........................................................ 3

Introduction ........................................................ 4

Specifications ........................................................ 4

Heater Components ........................................................ 5

Principal Dimensions ........................................................ 6

Installation Procedures

Heater Location ........................................................ 7

Heater Mounting ........................................................ 7

Heater Plumbing ........................................................ 8

Fuel System ........................................................ 9

Electrical Connections ........................................................ 11

Exhaust/Intake Connections ........................................................ 12

Operating Switches ........................................................ 13

Heater Operation

Pre-Start Procedures ........................................................ 17

71........................................................pU-tratS

71........................................................gninnuR

Switching Off ........................................................ 17

Safety Equipment ........................................................ 17

Operational Flow Chart ........................................................ 18

Wiring Diagram

(12V-24V boxed) ....................................................... 19

Wiring Diagram (12V-24V boxed-Universal) ........................................................ 20

Wiring Diagram (Engine heat only) ........................................................ 21

Wiring Diagram Universal ........................................................ 22

Maintenance,

Periodic Maintenance ........................................................ 23

Troubleshooting &

Basic Troubleshooting ........................................................ 23

Repairs

Self Diagnostic Troubleshooting ....................................................... 23

Fault codes/Description/Repair ........................................................ 24

Fuel Quantity Test ........................................................ 28

Repair Steps ........................................................ 28

Resistance Values ........................................................ 28

Heater Components

Parts Diagram ........................................................ 32

Description & Part #’s ........................................................ 33

Parts Diagram - Boxed units ........................................................ 36

Description & Part #’s ........................................................ 37

Parts Diagram - Universal ........................................................ 40

Description & Part #’s ........................................................ 41

Parts - Accesories ........................................................ 42

Description & Part #’s ........................................................ 43

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.

IInnttrroodduuccttiioonn

• 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.

• 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.

• 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.

• 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.

• The use of Espar coolant heaters requires that the coolant in the system to be heated contains 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.

WWaarrnniinngg TToo IInnssttaalllleerr

WWaarrnniinngg -- EExxpplloossiioonn HHaazzaarrdd

WWaarrnniinngg -- FFiirree HHaazzaarrdd

WWaarrnniinngg -- AAsspphhyyxxiiaattiioonn HHaazzaarrdd

WWaarrnniinngg -- SSaaffeettyy HHaazzaarrdd oonn CCoooollaanntt HHeeaatteerrss UUsseedd WWiitthh IImmpprrooppeerr AAnnttiiffrreeeezzee MMiixxttuurreess

HHeeaatteerr WWaarrnniinnggss

CCaauuttiioonn

During electrical welding work on the vehicle disconnect the power to the heater in order to protect the control unit.

NNoottee::

All measurements contained in this manual contain metric and approximate SAE equivalents in brackets eg 25mm (1”).

Direct questions to Espar Heater Systems:

CCaannaaddaa && UU..SS..AA.. 11--880000--338877--44880000

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.

IInnttrroodduuccttiioonn

EEssppaarr’’ss HHyyddrroonniicc 1100 CCoooollaanntt HHeeaatteerr

Quality engineered to provide a dependable means of heating, the Espar Hydronic 10 is a diesel fired coolant heater capable of between 1.5 kW to 9.5 kW/hr (5,100 to 32,400 BTU/hr). The heater can be purchased either in a weather resistant box to protect it from the elements and provide for ease of installation or in the universal form.

This light weight and compact coolant heater offers an affordable heating solution to many applications. The Hydronic 10 is ideal for pre-heating the engines of class 7 and 8 trucks, off-road equipment, buses, boats and in Fuel + Hydraulics in conjunction with appropriate heat exchangers.

The heater pumps coolant from the engine, heats it and returns it to the engine. It features automatic heat regulation while being fuel and power efficient. Since the heater runs on diesel fuel and 12 or 24 volt power, it is able to perform this completely independently of the vehicle engine. A temperature regulating switch in the unit regulates the coolant temperature between a low of 68°C (154°F) and a high of 85°C (185°F) by automatically cycling the heater.

The Hydronic 10 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 10 a safe and dependable heating system.

HHyyddrroonniicc 1100 SSppeecciiffiicc aatt iioonnss

HHeeaatt oouuttppuutt ((±±1100%%))

9.5 kW (32,400 BTU/hr)

-- BBoooo sstt

7.5 kW (25,600 BTU/hr)

-- HHiigghh

3.2 kW (10,900 BTU/hr)

-- MMeeddiiuumm

1.5 kW (5,100 BTU/hr)

-- LLooww

CCuurrrreenntt ddrra

aww ((±±1100%%)) 1122VVoolltt 2244VVoolltt

10.4 -

BBoooosstt --

5.2 amps

6.3 -

HHiigghh --

3.2 amps

3.5 -

MMeeddiiuumm --

1.8 amps

2.9 -

LLooww --

1.5 amps

FFuueell ccoonnssuummppttiioonn ((±±1100%%))

1.2 l/hr (0.32 USgal/hr)

BB ooooss tt

0.9 l/hr (0.24 USgal/hr)

HHiigghh

0.40 l/hr (0.11 USgal/hr)

MMeed

diiuumm

0.18 l/hr (0.05 USgal/hr)

LLooww

OOppeerraattiinngg VVoollttaaggee RRaannggee

MMii nniimmuumm VVoollttaaggee

10 V (20V on 24 volt systems)

MMaaxxiimmuumm VVoollttaagg ee

15 V (30 V on 24 volt systems)

CCoooollaanntt ppuummpp ffllooww ((±±1100%%))

1400 Litre/hr 370 U.S. Gal/hr

CCoooolla

anntt TTeemmppeerraattuurree RRaannggee ((±±55%%))

68-85°C (154-185°F)

OOvveerrhheeaatt ccoooollaanntt tteemmppeerraattuurree sshhuuttddoowwnn ((±±55%%))

115°C (240°F)

WWeeiigghhtt

6.5 kg. (14.3 lbs.)

CCoonnttrroollss aavvaaiillaabbllee

On/Off switch, 99hr. timer or 7 day timer.

NNoottee::

The heater is equipped with a high voltage cutout as well a low voltage cutout.

IInnttrroodduuccttiioonn

HHeeaatteerr CCoommppoonneennttss

1 Combustion motor 2 Flame sensor 3 Combustion chamber 4 Control unit 5 Heater plug 6 Temperature sensor 7 Flame tube 8 Heat exchanger 9 Overheating switch

10 Water pump 11 Exhaust silencer 12 Combustion air silencer 13 Fuel feeder pump 14 Fuel branch piece 15 Cable tree

16 Fuse bracket 17 Relay for switching on the vehicle’s fan 18 Automatic switch

WWEE == WWaatteerr iinnlleett WWAA == WWaatteerr oouuttlleett VV == CCoommbbuussttii oonn aaiirr BB == FFuueell AA == FFuummeess

17 18 16

09:20

–

67 9 8

IInnttrroodduuccttiioonn

PPrriinncciippaall DDiimmeennssiioonnss

* 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.

Permissible installation positions

Combustion air

Exhaust air

Water Inlet

HYDRONIC 10

20.2

Espar

HYDRONIC 10

IInnssttaallllaattiioonn PPrroocceedduurreess

PPrriinncciippaall DDiimmeennssiioonnss -- BBooxxeedd VVeerrssiioonn

Always mount the heater in a protected area. Eg: storage compartment, engine compartments, step box or battery box. Espar recommends you use the boxed unit. Boxed heaters can be mounted by utilizing one of the existing brackets. See following page.

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.

Mount the heater using the four (4) shock mounts provided and one of the following mounting methods:

• Use the

CCrroossss FFrraammee MMoouunnttiinngg TTrraayy

to mount the

heater behind the cab and on top of the frame rails.

• Use the

SSiiddee MMoouunntt BBrraacckkeett

to mount the heater on the

side of the frame rail.

• Use a spare step box or battery box.

• Use the saddle bracket and hardware provided

CCaauuttiioonn::

Guard the heater against excessive road spray to avoid internal corrosion.

HHeeaatteerr LLooccaattiioonn

HHeeaatteerr MMoouunnttiinngg

CCrroossss FFrraammee MMoouunnttiinngg TTrraayy P/N CA0 10 028 P/N CA0 10 022 with hardware

SSiiddee MMoouunntt BBrraacckkeett P/N CA0 10 057

Espar Heater Systems

IInnssttaallllaattiioonn PPrroocceedduurreess

HHeeaatteerr PPlluummbbiinngg

Engine

Radiator

Shut-off valves

(Optional)

Hydronic 10

Water

Heater

The heater is incorporated into the engine’s cooling system for engine preheating

Follow these guidelines and refer to the engine plumbing diagram shown below.

• Install hose fittings into the engine block for pick-up and return lines.

• Use existing holes in the engine block (ie. remove blanking plugs when possible).

• Use shut off valves to ensure the system can be isolated from the engine when not in use. Alternatively “T” piece connectors in existing coolant hoses can be used if no blanking plugs are available

• Provide 20mm (3/4” ) hose barbs for hose connections.

• Use 20mm (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.

• If a bunk heat exchanger is incorporated into the system, proper plumbing layouts must be followed.

CCaauuttiioonn::

The coolant must contain a minimum of 10% antifreeze at all times as a protection against corrosion. Fresh water will corrode internal heater parts.

Hydronic10

water heater

WWaatteerr iinn

WWaatteerr oouutt

EEnnggiinnee PPlluummbbiinngg

HYDRONIC 10

IInnssttaallllaattiioonn PPrroocceedduurreess

FFuueell SSyysstteemm

FFuueell SSyysstteemm TToolleerraanncceess

FFuueell LLiinnee

NNoottee::

Butt joints and clamps on all connections.

• Route fuel lines from the fuel pick-up pipe 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

• Use a sharp utility knife to cut plastic fuel lines to avoid burrs.

NNoottee::

Fuel line limits must not be exceeded. Ensure that the following conditions are met.

Bottom of the fuel metering pump must be within a height of 2’6” of the bottom of the fuel pick-up pipe.

Fuel metering pump must be within a total distance of 6’6” from the fuel pick-up pipe.

Pressure Runs of less than 1.3 mtrs (50”) use only 3.5mm rubber (360 75 300)

The Hydronic 10 boxed unit is most commonly provided with the fuel metering pump mounted inside the box. This is to reduce installation time and to protect the pump from corrosion. If specifications cannot be met the pump must be mounted externally. See illustration for connections and specifications. All parts necessary to do the installation are included in the kit as shown.

1. Fuel Pick-Up Pipe

2. 11mm Clamp

3. 5.0mm Fuel Line

4. Fuel Metering Pump

5. 9mm Clamp

6. 3.5mm Rubber Connector

7. 2.0mm White Plastic Fuel Line See notes if length is less than 1.3 mtr (50”)

Right Wrong

Correct

Bubble

Wrong

MAX. 2’6”

FUEL TA N K

MAX. 6’6”

HYDRONIC 10

MAX. 20’

IInnssttaallllaattiioonn PPrroocceedduurreess

FFuueell MMeetteerriinngg PPuummpp IInnssttaallllaattiioonn

NNoottee::

Drill the two (1/4”) holes first.

(( OOppttiioonnaall PPiicckk--UUpp PPiippee wwiitthh NNPPTT ffiittttiinngg ))

• 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 as shown

NNoottee::

NPT fittings are available in various sizes (Refer to parts section).

Fuel Pick-Up Pipe

Nut

Sheet Metal Washer

Rubber Gasket

Steel Safety Washer

Holding Tabs

Allow 4” from fuel pick-up to tank bottom. Allow only 1” for flat bottom tanks.

End tip of the fuel pick-up pipe should have angle so as to avoid picking up dirt and subsequent blockage

FFuueell PPiicckk--UUpp PPiippee IInnssttaallllaattiioonn ((SSttaannddaarrdd PPiicckk--UUpp))

• Choose a protected mounting location close to the 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 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.

NNoottee::

Proper mounting angle of the pump is necessary to allow any air or vapor in the fuel lines to pass through the pump rather than cause a blockage.

If the pump needs to be mounted externally follow these guidelines:

• Choose a protected mounting location close to the fuel pick-up pipe and heater.

• Using the bracket and rubber mount provided, install pump as shown.

FFuueell PPiicckk--UUpp PPiippee IInnssttaallllaattiioonn

((SSttaannddaarrdd PPiicckk--UUpp))

15° to vertical

1.5 cm 1.5 cm 9 / 16” 9 / 16”

15°

Ø 2.5 cm (Ø 1.0”)

Ø 0.625 cm

(2 HOLES) (

Ø 1 / 4”)

IInnssttaallllaattiioonn PPrroocceedduurreess

EElleeccttrriiccaall CCoonnnneeccttiioonnss

NNoottee::

All harnesses should be cut to length. All exposed electrical connections should be coated with protective grease.

• 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.

• Insert fuse. (15A-24V, 20A-12V)

• 4 core harness (red/yellow, brown, yellow, blue/white)

• Run to location of switch. Make terminal connections at switch. Espar has 3 available switches. See switch instructions for more information.

• 2 core harness (green, green).

• Fuel Metering Pump Harness is pre-connected when

box is provided with pump pre-mounted.

• If mounted externally, connect wires to fuel metering

pump using connector and terminals supplied, boots provided with the heater-(no polarity required ).

77 DDaayy TTiimm eerr

77 DDaayy TTiimm eerr sswwiittcchh hhaarr nneessss

CCaauuttiioonn::

To avoid potential short circuit damage during installation, insert 20 amp fuse into the power harness after all electrical connections are complete.

AA)) PPoowweerr HHaarrnneessss......................................................................................................................................

BB)) SSwwiittcchh HHaarrnneessss.

...................................................................................................................................

CC)) FFuueell MMeetteerriinngg PPuummpp HHaarrnneessss......................................................................................

Shown is a Hydronic 10 boxed version,12 volt with StandardPower, Switch, Fuel Metering Pump harnesses and optional 7 day timer.

Other timers or switch options are available.

NNoottee::

Wire must be inserted into fuse holder prior to terminating.

IInnssttaallllaattiioonn PPrroocceedduurreess

EExxhhaauusstt CCoonnnneeccttiioonn

The exhaust is hot, keep a minimum of 5cm (2”) clearance from any heat sensitive material. Failure to comply with this warning could result in serious injury.

A 30 mm flexible tube exhaust pipe with a length of 1M long is supplied with the kit for the exhaust. An exhaust clamp is needed to secure the exhaust to the the heater.The exhaust hose cannot be any longer than 2 m. Connect the exhaust as follows:

• Connect the exhaust pipe to the exhaust port on the heater and attach with clamp provided. Feed the exhaust pipe through the silicone (white) grommet on the bottom of the box.

• 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 off. Any restriction

in exhaust will cause operational problems.

• Route the exhaust pipe from the heater using holders provided.

CCaauuttiioonn::

Run exhaust so that it cannot be plugged by dirt, water or snow. Ensure the outlet does not face into the vehicle slip stream.

Route exhaust beyond the skirt of the cab and outside of the frame area. Route exhaust so that the exhaust fumes cannot enter the passenger compartment. Failure to comply with this warning could result in Asphyxiation.

Universal versions only:

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.

CCaauuttiioonn::

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.

Flexible Exhaust

& Air intake hose

cannot be any

longer than

Max 2M (80”)

Holding clamps

Exhaust & Intake

Clamps

End Sleeve

Air Intake Hose -

oonn llyy uusseedd

oonn uunniivv eerrssaall vveerrss ii oonnss

IInnttaakkee CCoonnnneeccttiioonn

WWaarrnniinngg:: AAsspphhyyxxiiaattiioonn HHaazzaarrdd WWaarrnniinngg:: FFiirree HHaazzaarrdd

NNoottee::

1. Exhaust hose cannot be any longer than 2m.

2. Minimum lenght 14”.

AAvvooiidd eexxhhaauusstt lleennggtthhss ooff 33..55 ttoo 55 fftt lloonngg..

IInnssttaallllaattiioonn PPrroocceedduurreess

OOppeerraattiinngg SSwwiittcchheess

NNoottee::

If installing a remote starter, refer to remote starter instructions before terminating wires.

A Push/Pull switch, or a 7 Day Timer are available for the heater. Both are discussed on the following pages. Connect the operating switch as follows.

The 7 Day Timer has been designed to provide a simple means to control the operation of the heater system and to include the capability for diagnostics. This timer connects to the diagnostic circuit of the heater. The timer then displays any heater fault codes in three digit number form automatically. The timer allows for pre-selection of turn on time, up to 7 days in advance, as well as an option for run times up to 2 hours before automatically turning off. In addition, there is an on/off switch for manual operation. By default the timer is pre-set by Espar to operate for two hours. Refer to instructions provided with timer for setting options.

• Mount bezel into dash and insert timer or use Espar’s optional mounting bracket and secure to dash.

• Use hardware supplied for connections.

• Connect the switch harness to the connector at the heater and run harness to switch location. (Harness should be neatly routed and secured under dashboard).

• Cut harness to length and terminate wires. Attach using connectors provided.

• Refer to timer instructions for other wiring options.

OOppttiioonn ##22::

Operate heater continuously - connect wire from ignition circuit to terminal #10. See also multifunction (7 day) timer in instructions.

NNoottee::

An alternative to connecting the black wire to the vehicle ignition accessories “On” circuit may also be considered for some applications where extended run times are desired. Connecting the black wire with the red wire will enable the heater to run continuously whether the heater is switched on manually or through the preset function.

aa))

Power from battery “+”

bb))

Switch control to the heater

cc))

Power from battery “-”

dd))

Diagnostic from heater

Mounting Bracket

(optional)

P/N CA0 10 061

Bezel

P/N 25 1482 70 01 00

CA1 00 135 (12v / 24v)

MMuullttiiffuunnccttiioonn

aa))

bb))

cc ))

dd))

OOppttiioonn ##11::

Dash lights to timer - connect wire between dash lights circuit and timer at terminal #1.

NNoottee::

The timer display is automatically illuminated while the heater is operating. Connecting the grey wire to the vehicle dimmer switch will allow the timer display to illuminate with the vehicles dash lights.

Red Yellow Brown Blue

Yellow

Blue

TRS

DIAG

1 2

18:00

Red

Brown

12 11 10 9 8 7 6 5 4 3 2 1

The 7 Day Timer has been designed to provide a simple means to control the operation of the heater system and to include diagnostics capability. This timer connects to the diagnostic circuit of the heater. The timer then displays any heater fault codes in three digit number form automatically. The timer allows for pre-selection of turn on time, up to 7 days in

adv

ance, as well as an option for run times up to 2 hours before automatically turning off. In addi-

tion, there is an on/off switch for manual operation. By default the timer is pre-set by Espar to operate for two hours.

1 Mount bezel into dash and insert timer or use Esparí s optional mounting bracket and secure to dash. 2 Use hardware supplied for connections. 3 Connect the switch harness to the connector at the heater and run harness to switch location. (Harness should be neatly routed and secured under dashboard). 4 Cut harness to length and ter- minate wires. Attach using connectors provided.

1 Time set 2 Preheat time set 3 Heater “On” 4Backward scan 5Forward scan 6 Memory location 7 Time and day display 8 Air temperature display

(optional)

9Heater “On” symbol 10 Temperature set

(air heater only)

Note: Upon connection to power the entire timer display will begin to flash. The heater will not function until the time is programmed.

Setting Time and Weekday

Push button once. 12:00 will begin to flash (this will occur upon initial hook up to power). Using or set the present time of day (24 hour clock). When the time stops flashing the time has been stored. The weekday will now begin to flash. Use or to set the present weekday. When the weekday stops flashing the weekday has been stored. When the vehicle ignition is turned “on” the time display will appear

When the vehicle ignition is turned

“off” the timer display will go off

after 15 seconds.

Coolant Heater

Air Heater

IInnssttaallllaattiioonn PPrroocceedduurreess

PPuusshh//PPuullll SSwwiittcchh

MMoo uunnttiinngg BBrraa cckk eett && BBeezzeell P/N 25 1482 70 01 00

Mounting Bracket

Bezel

77 DDaayy TTiimmeerr IInnssttrruuccttiioonnss

OOppeerraattiinngg IInnssttrruuccttiioonnss

• 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 described below

NNoottee::

Wired described the switch light glows when pulled out and is off when pushed in.

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)

P/N CA1 00 003 (12v) P/N CA1 00 004 (24v)

14.5mm

9/16”

K (15)

15 (K)

IInnssttaallllaattiioonn PPrroocceedduurreess

SSuubbttiittllee RRiigghhtt PPaaggee

Changing the Time or Day

77 DDaayy TTiimmeerr IInnssttrruuccttiioonnss

Push and hold button until the time display begins to flash. Continue to set the time as listed in setting time and weekday.

Using the Timer with the Vehicle Ignition “Off”

Push button.

will appear on the display as well as the operation countdown timer. The running time is factory set to a maximum of 120 minutes. This running time can be reset once or permanently as desired.

Adjusting Preheat Time Once

Press button. The will appear in the display and the preselected run time will appear in the display (maximum time of 120 minutes). Use the or to adjust the desired run time.

Adjusting the Heater Preheat Time Permanently

(Maximum Preheat Time of 120 minutes)

Push and hold (about 3 seconds) until the display lights up and flashes. Release button. Use or to set the new fixed preheat time. When the display goes off the new prehea

Note: At the end of a preheat cycle the timer will turn the heater off. The heater will complete a cool down cycle and turn itself off.

Using the Heater Manually with the Vehicle Accessory “On”

Push button. The symbol will appear in the display next to the time of day. The time of day will remain displayed during ignition on operation. The heater will function continually as long as the vehicle ignition is “on”. When the vehicle ignition is turned “off” the heater will continue to operate for an addtional 15 minute The run time can be altered by pressing the or buttons. The heater can be turned off by pressing button.

t time is set.

To Use Preset Start Times

Press the button until the desired memory location appears in the display.

The heater will start at the day and time displayed. The display will go off in 15 seconds. The memory location number will stay displayed (1, 2 or 3).

Note: When preset is chosen this symbol will flash red.

To Turn Heater “Off” - All Modes

Press the button once. The heat signal to the he The heater will do a normal cooldown and turn itself “off”.

Note: When the vehicle ignition is turned “on” the time of day and day of the week will appear in the timer display. This will stay on as long as the vehicle ignition is “on”.

Note: When the vehicle lights are turned “on” the timer backlight will come “on” also.

Note: An outside temperature sensor is available as an option

Wiring Connections at connector

Terminal 1 Power from vehicle dash lights - grey wire Terminal 2 Heater switch wire - yellow wire Terminal 4 Connect to vehicle ground - brown wire Terminal 6 Temperature setting “+” (air only) - grey/red wire Terminal 8 Heater diagnostic lead - blue wire or blue/white wire (air) Terminal 9 Temperature setting “-” (air only) - brown/white Terminal 10 To vehicle “ACC” accessory for continuous overnight use Terminal 11 Positive power from heater - red “+” Terminal 12 Ground lead from heater - b

erminal 3,5,7 Left blank, not required

ater will be turned “off”.

rown “-”

Set Preheat Times into Memory

Press button until the desired memory location is shown in the display (Three memory locations are available). Using the or buttons set the desired preheat start time of day. When the time stops flashing the time of day is set. Using the or button When the day of the week stops flashing the day is set.

s set the desired day of the week.

NNootteess

NNoottee::

During operation the heater continually senses the input voltage from the batteries, if the input voltage drops to approximately 10.5V (20V on a 24 volt system) or rises above 15V (30V on a 24 volt system) the heater will automatically shut down.

• 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 is extinguished.

• The combustion air blower and water pump continue to run for 130 seconds to cool down.

• The heater shuts off.

The control unit, 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.

• If the heater flames out during operation, the heater automatically attempts to restart. If the heater fails to ignite within 90 seconds of fuel delivery, or ignites but flames out again within 10 minutes, “flame out” shutdown follows. After troubleshooting the problem, the heater can be started again by switching the heater off and then back on.

• Overheating due to lack of water, a restriction or a poorly bled coolant system results in an “overheat shut down”.

• If at any time the voltage drops below 10.5V (20V on a 24 volt system), or rises above 15V (30V on a 24 volt system), a “high/low voltage” shutdown follows (after a 20 second delay).

HHeeaatteerr OOppeerraattiioonn

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 running the engine and refilling the antifreeze as needed. Resecure heater hose.

• Run engine to further bleed the system

• Top up engine coolant.

Once switched on, the following sequence occurs:

• Control unit does a systems check ( flame sensor, temperature, safety thermal sensor and various other control unit checks).

• Water pump starts circulating coolant fluid.

• Combustion air blower starts.

• Glow pin begins to preheat 20-30 secs.

• After about 20-30 seconds the Fuel Metering Pump starts delivering fuel and the combustion air blower ramps 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).

NNoottee::

If the heater fails to start the first time it will automatically attempt a second start. If unsuccessful the heater will shut down completely.

NNoottee::

On initial start up the heater may require several start attempts to self prime the fuel system.

Once ignition is successful the following operations take place:

• Heater runs in full heat mode and the temperature is monitored at the heat exchanger.

• Once the coolant reaches 72°C (162°F) the heater will start to cycle down between levels (High,Medium,Low).

• If the coolant temperature continues to rise, the heater will automatically switch off. This occurs when temperature reaches 85°C (185°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 68°C (154°F).

• The heater continues to run as described above until it is switched off, either manually, automatically by a timer or heater malfunction shutdown.

NNoottee::

If the heater should flame out while in running mode, it will automatically attempt one restart. If successful it will continue to run, if not it will turn itself off.

PPrree--SSttaarrtt PPrroocceedduurreess

SSttaarrtt UUpp

RRuunnnniinngg

SSwwiittcchh OOffff

SSaaffeettyy EEqquuiippmmeenntt

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.

WWaarrnniinngg::

HHeeaatteerr OOppeerraattiioonn

OOppeerraattiioonnaall FFllooww CChhaarrtt

OOppeerraattiioonn PPrrooffiillee

SSttaarrtt uupp sseeqquueennccee

Vehicle Blower 55°C On Power - 7300 rpm

Power - High 72°C High - 5600 rpm

High - Medium 78°C Medium - 3000 rpm

Medium - Low 79°C Low - 1800 rpm

Low - Off 85°C

Off - Medium 68°C

Medium - High 68°C

Low - Medium 73°C

High - Power 53°C

CCoonnttrrooll tteemmppeerraattuurreess SSppeeeedd ooff bblloowweerr mmoottoorr

CCoooollaanntt TTeemmppeerraattuurree CCoonnttrrooll PPrrooffiillee

Power

High

Medium

Mittel

Medium

Low

Off

68°

85°

Power

Max. Operation in Heat Levels Power = 2 h ( 15 min. High) High Medium Low = 20 h ( Off then On) Generally = 40 h (Off then On)

Glow pin cycle for 40 sec. After 4 h if no heater off-on cycle

High

Medium

Mittel

Medium

Time

Low

Off

68°

85°

Temperature in C

-10

Operating

Mode

Water Pump

System

Pre-heat Pre-heat

Check

Off

STARTING PHASE

Ignition Attempt

2nd. attempt

Ignition

Attempt

2nd. attempt

RUNNING PHASE SHUT DOWN PHASE

Controlled

Heating

OnOnOnOnOn On

After Glow

Cool Down

Stand by

if in stand by

Off

On:

Blower

Glow

Pump

Fuel

Time

Off

Off Off Off Off Off

Off

1- 3 sec.

80 sec.

Note: During the controlled heating cycle, if the coolant temperature exceeds 85°C(185°F) the heater will cycle off.

OnOnOnOn

On On

80 sec

Up to

90 sec.

Heater will automatically restart in high mode once coolant temperature reaches 68°C(154°°F)

If Required

Up to 90 sec.

OnOnOnOff

Off

High/Low

Operation

until switched off

manually or automatically

20 sec.

OffOn

Off

2.5 min.

Glow plug

Speed of blower motor (rpm)

Blower motor

Metering pump

Frecuency of metering pump (Hz)

0 20 40 60 80 100 120 140 160 180 200

Time (s)

HHeeaatteerr OOppeerraattiioonn

HHyyddrroonniicc 1100 WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt ++ 2244 VVoo lltt

2255 22008811 0055 -- 1122VV 2255 22004444 0055 -- 2244VV

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

2.7.1 5 amp switch fuse

3.2.9 7 day timer, push/pull switch or 99hr. timer

5.1 Battery

a) Optional - supply for vehicle blower b) Power c) Diagnostics d) Switch e) Ground h) Optional - LED for flashing code

2.2

2.1

RED

GREEN

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PINK

BLUE

GREY

BLACK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

ORANGE

VIOLET

WHITE

GREEN

YELLOW

RED

BROWN

RED

BROWN

2.7

2.7.1

RED

5.1

RED

RED/YELLOW

BLUE/WHITE

YELLOW BROWN

3.2.9

Optional

Diagnostic

LED

YELLOW

BLUE

Push/Pull switch

b c d e

RED

YELLOW

BROWN

3.1.1

0 0

K (15)

15 (K)

7 Day timer

Red Yell ow Brown Blue

Grey

Black

TRS

Brown

DIAG

12 11 10 9 8 7 6 5 4 3 2 1

1.2 1.5

WHITE

BROWN

BLUE

BLACK/RED

2.12

BLUE

BROWN/BLACK

141213

YELLOW

GREY

YELLOW

GREY

RED

VIOLET

GREEN

ORANGE

1.121.13

ORANGE

1.1

1232527291011121314151617

HHeeaatteerr OOppeerraattiioonn

HHyyddrroonniicc 1100 WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt ++ 2244 VVoolltt -- UUnniivveerrssaall HHaarrnneessss

2255 22008811 0055 -- 1122VV 2255 22004444 0055 -- 2244VV

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

2.5.7 Vehicle blower relay

2.7 20 amp main fuse (12V)

2.7.1 5 amp switch fuse

2.7.5 15 amp blower fuse

3.2.9 7 day timer, push/pull switch

or 99hr. timer

5.1 Battery

a) vehicle blower step switch b) vehicle ignition terminal c) external control (water pump) d) diagnostics e) switch f) power g) ground h) LED for flashing code

2.5.7

2.2

RED

BLACK

BLACK/VIOLET

RED/GREY

BROWN/WHITE

3.2.9

RED/YELLOW

BLUE/WHITE

YELLOW BROWN

2.7.2

acb

GREEN

GREEN/GREY

RED/WHITE

BROWN

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PINK

BLUE

GREY

BLACK

ORANGE

VIOLET

WHITE

GREEN

YELLOW

RED

BROWN

2.7.1

2.7

BROWN

b c d e

Red Yellow Brown Blue

5.1

Diagnostic

YELLOW

BLUE

Push/Pull switch

RED

YELLOW

BROWN

K (15)

7 Day timer

TRS

3.1.1

0 0

15 (K)

LED

2.1

1.2 1.5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

WHITE

BROWN

BLUE

BLACK/RED

2.12

BLUE

BROWN/BLACK

141213

YELLOW

RED

GREY

VIOLET

GREEN

YELLOW

ORANGE

1.121.13

1232527291011121314151617

1.1

Brown

Optional

Grey Black

DIAG

12 11 10 9 8 7 6 5 4 3 2 1

HHeeaatteerr OOppeerraattiioonn

HHyyddrroonniicc MM WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt aanndd 2244 VVoolltt -- EEnnggiinnee HHeeaatt OOnnllyy

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 (12V)

2.7.1 5 amp switch fuse

3.2.9 7 day timer, push/pull switch or 99hr. timer

5.1 Battery

a) vehicle blower step switch b) vehicle ignition terminal c) external control (water pump) d) diagnostics e) switch f) power g) ground h) LED for flashing code

LED

2255 22116600 0055 -- 1122VV 2255 22222277 0055 -- 2244VV

2.2

RED

BLUE

WHITE

GREEN

BROWN

C4C3C2C1B4B3B2B1A4A3A2

2.1

8 9 2 7 11 17 3 6 14 18 15 16 10 13 5 4 1 12

BLUE

WHITE

BROWN

BLACK/RED

BROWN/BLACK

YELLOW

GREY

RED

YELLOW

VIOLET

GREEN

ORANGE

BLACK

BROWN

RED

2.7

BROWN

RED

2.7.1

Optional

RED

BROWN

Red Yellow Brown Blue

Grey Black

5.1

Diagnostic

LED

YELLOW

3.1.1

0 0

K (15)

15 (K)

a6)

a2)

a3)

a4)

a5)

BLUE

25 2227 05 only

Push/Pull switch

RED

YELLOW

BROWN

7 Day timer

TRS

Brown

DIAG

12 11 10 9 8 7 6 5 4 3 2 1

1.2 1.5

2.12

1.121.13

1.1

HHeeaatteerr OOppeerraattiioonn

HHyyddrroonniicc MM WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt aanndd 2244 VVoolltt -- UUnniivveerrssaall HHaarrnneessss

2255 22116600 0055 -- 1122VV 2255 22222277 0055 -- 2244VV

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

2.5.7 Vehicle blower relay

2.5.18 Relay, changeover water circuit.

2.7 20 amp main fuse (12V)

2.7.1 5 amp switch fuse

2.7.5 15 amp blower fuse

3.2.9 7 day timer, push/pull switch or 99hr. timer

5.1 Battery

5.10 Vehicle fan

a) vehicle blower step switch b) vehicle ignition terminal c) external control (water pump) d) diagnostics e) switch f) power g) ground h) LED for flashing code

2.5.7

2.5.18

2.2

5.10

RED

BK/VT

BLACK

RED

BLUE

WHITE

GREEN

BROWN

C4C3C2C1B4B3B2B1A4A3A2

2.1

8 9 2 7 11 17 3 6 14 18 15 16 10 13 5 4 1 12

BLUE

WHITE

BROWN

BLACK/RED

BROWN/BLACK

YELLOW

BROWN

GREY

RED

YELLOW

VIOLET

GREEN

ORANGE

BLACK

BROWN

RED

BROWN

RED/YELLOW

2.7

c) c)

RED

BROWN

RED

2.7.12.7.1

Optional

5.1

Red Yell ow Brown Blue

Grey Black

Diagnostic

LED

YELLOW

3.1.1

0 0

K (15)

15 (K)

a6)

a2)

a3)

a4)

a5)

BLUE

25 2227 05 Only

Push/Pull switch

RED

YELLOW

BROWN

7 Day timer

TRS

Brown

DIAG

12 11 10 9 8 7 6 5 4 3 2 1

1.2 1.5

2.12

1.121.13

1.1

SSuubbttiittllee RRiigghhtt PPaaggee

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

PPeerriiooddiicc MMaaiinntteennaannccee

• Check coolant hoses, clamps, and make sure all valves are open. Maintain the engine manufacturers recommended coolant level and ensure that the heater is properly bled after service on or involving the coolant system.

• Visual check of all fuel lines for leaks. Check and if necessary replace fuel filter inserts.

• Visual check of electrical lines and connections for corrosion.

• Run your heater at least once a month during the year (for a minimum of 15 minutes).

• Maintain your batteries and all electrical connections in good condition. With insufficient power the heater will not start. Low and high voltage cutouts will shut the heater down automatically.

• Use fuel suitable for the climate (see engine manufacturers recommendations). Blending used engine oil with diesel fuel is not permitted.

In the event of failure there are several items which should be checked first before any major troubleshooting is done.

CChheecckk ::

• Fuses.

• Electrical lines and connections

• Interference in Combustion air and Exhaust pipes.

• Fuel in the tank.

• Battery voltage

• Coolant flow

The heater is equipped with self diagnostic capability. You can retrieve information on the heaters last 5 faults using the Espar 7 day timer or Espar’s Fault Code Retrieval Device.

Espar’s 7 day timer has a fault code retrieval device built into the unit. This function automatically activates if the heater is experiencing problems.

• Fault codes appear on the LCD display screen

• Codes can then be translated from the charts on the following pages.

• See instruction sheet that comes with the timer

Symbols seen on the display face are as follows:

AAFF

Actual fault.

FF11--FF55

Up to five stored faults can be accessed. The AF and F1 are the same number.

This sign is displayed when the heater is in operation.

DDIIAAGG

The word (Diagnostic) will come on when the diagnostic number is requested.

000000

Three digit diagnostic fault code number.

• Disconnect the main harness from heater and insert adapter cable harness between them

• Connect adapter cable to the cable loom of the Fault code retrieval device

• Start diagnostic unit - switch heater on from switch

• Switch the fault code retrieval device on and wait 10 seconds.

• Press the "D" button.

• Wait 3-5 seconds for the current fault code to appear

(AF).

• To review the previous faults use the arrow buttons

(F1= Most Recent, F5= Oldest).

• To erase the faults that are in memory press both "L"

keys at the same time.

• See the fault code chart on following pages for code

number descriptions.

FFaauulltt ccooddee rreettrriieevvaall ddeevviiccee

P/N CA1 05 020

FFaauulltt ccooddee

rreettrriieevvaall

ddeevvii ccee

hhaarrnneessss

P/N CA1 05 030

Rounded end

or CA1 05 044

Squared end

TTrroouubblleesshhoooottiinngg

BBaassiicc TTrroo uu bblleesshhoooottiinngg

SSeellff DDiiaaggnnoossttiiccss

MMuullttiiffuunnccttiioonn

FFaauulltt CCooddee RReettrriieevvaall DDeevviiccee

EEqquuiippmmeenntt FFaaccee aanndd CCoonnttrroollss

HHooookk UUpp

IInnssttrruuccttiioonnss::

LDL

WERFEN

man e

NICHT

ade

ONIC

24 V

HYDR

2 530

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

FFaauulltt CCooddee FFaauulltt DDeessccrriippttiioonn CCaauusseess // RReeppaaiirr FFaauulltt SSiiggnnaall // FFllaasshhiinngg CCooddee

000 Normal Operation

001 Advanced warning - overvoltage Check to see if voltage between pins 13 and 14 of control

unit (external plug) is greater than 15 V or 30V.

002 Advanced warning - undervoltage Check to see if voltage between pins 13 and 14 of control

unit(external plug) is less than 10 V or 20V

010 Overvoltage shutdown Check voltage between pins 13 and 14 at the control unit

(external plug) is greater than 15 V or 30V. Check vehicle

charging system.

011 Under voltage shut down Check voltage between pins 13 and 14 at the control unit

(external plug) is less than 10 V or 20V. Check batteries

and connections.

012 Overheating Check for possible causes of overheat, check water

through flow (water circuit), sensor.Temperature at

temperature sensor is greater than 115°C. Impedance at

temperature sensor < 400Ω. Check difference at the

control unit, dismantle the control unit, disconnect the

internal plug from the control unit and measure the

difference between pins 5 and 8.

Overheat sensor values: 150 kohms at -25°C

10 kohms at +25°C.

013 Excessive temperature at flame sensor Flame sensor signals temperature of greater than 700°C.

Difference at flame sensor > 3400 ohms. Check the

impedance at the control unit (internal plug), dismantle

the control unit, disconnect the internal plug from the

control unit and measure the impedance between pins 10

and 12. Flame sensor values: 900 ohms at -25°C

1100 ohms at +25°C.

014 Possible overheating detected Difference of measured values at temperature sensor

>70°C (difference evaluation) Check temperature sensor

and overheating sensor, open heater slide valve and

check water throughflow. Check the impedance between

5 and 8 at the control unit (internal plug). Over

temperature sensor values: 150 kohms at -25°C

10 kohms at +25°C.

88 sseeccoonnddss

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

FFaauulltt CCooddee FFaauulltt DDeessccrriippttiioonn CCaauusseess // RReeppaaiirr FFaauulltt SSiiggnnaall // FFllaasshhiinngg CCooddee

015 Too many overheats The control unit is interlocked after three successive

overheats (error codes 012, 013 and 014). Eliminate the

case of the overheat. Cancel the interlock by clearing the

error memory with the diagnostic unit/PC.

020 Open circuit - glow pin Check glow pin (nominal value: 2 ohms), replace if

necessary. Check pin 4(white) on the control unit

021 Short circuit - glow plug (internal plug) leading to glow plug to terminal 3 (brown)

for continuity/short-circuit. If O.K.-> replace control unit.

033 Combustion air blower motor Speed deviation for longer than 60 seconds. Nominal

values: 5600 rpm (full-load), 1850 rpm (part load)

* Check burner motor: apply supply voltage to motor.

Connect + to 1.5 black and - to 1.5 orange. Motor does

not turn —> replace burner motor with integrated sensor.

* Check sensor supply. Switch on heater and measure

voltage between output 13 (0.25 red) and 14 (0.25 green)

at the control unit (internal plug). Nominal value: 8 V. If

deviation —> replace control unit.

* Check sensor: Measure voltage between terminal 15

(0.25 violet) and 14 (0.25 green) with an analog voltmeter

when the blower is running. Nominal value: 4 V (+ 0.3 V)

average value (8 V square-wave signal). If deviation —>

replace motor with integrated sensor. If sensor signal is

O.K., then the speed controller is defective —> Change

control unit.

037 Water pump is not working Check water pump (driven externally).

042 Water pump short-circuit Check water pump and leads.

043 Short circuit at external components Check terminal 2 (1 green) of control unit (external plug)

for short-circuit. Check connected components (max.

current 6A), replace them if necessary.

047 Short circuit - fuel metering pump Check terminal 1 (1 blue) of control unit (external plug)

and leads up to metering pump for short-circuit/

interruption. Check the metering pump. Nominal value:

048 Open circuit - fuel metering pump approx. 20 ohms. Replace if necessary.

88 sseeccoonnddss

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

FFaauulltt CCooddee FFaauulltt DDeessccrriippttiioonn CCaauusseess // RReeppaaiirr FFaauulltt SSiiggnnaall // FFllaasshhiinngg CCooddee

050 Too many no start attempts The control unit is interlocked after it has been switched

on 10 times in succession (=20 failed starts) without

flame detection (fault code 052). Check the fuel supply,

glow plug, exhaust piping, combustion air piping and

flame sensor. Cancel the interlock by clearing the error

memory with the diagnostic unit/PC.

051 Faulty flame recognition Flame sensor signals a temperature of greater than

80ºC despite 4 minutes of cooling with cold air.

Impedance at flame sensor > 1300 ohm. If no

combustion takes place —> check the flame sensor,

replace it if necessary. Flame sensor values:900 ohms

at -25°C, 1100 ohms at +25°C.

052 No start safety time exceeded No flame was detected during the start-up phase.

Flame sensor value of less than 90∞C (1350 ohms).

Check the fuel supply, glow plug, exhaust piping, com

bustion air piping and flame sensor. Flame sensor

values: 900 ohms at -25°C, 1100 ohms at +25°C.

053 Flame cutout in boost mode Heater has started (flame detected) and indicates flame

loss in a power setting. Check fuel flow rate, blower

054 Flame cutout in high mode speed, fuel supply, exhaust pipe and combustion air

056 Flame cutout in medium mode piping. If combustion is O.K., check flame sensor,

056 Flame cutout in low mode replace if necessary. Flame sensor values:900 ohms

at -25°C, 1100 ohms at +25°C.

059 Water temperature rises to quickly Check water circulation (012) and temperature control

sensor (060/061).

060 Temperature control sensor interruption Control sensor signals temperature value outside

measurement range. Check the connecting leads (0.35

yellow). For this purpose, dismantle the control unit,

061 Short circuit - temperature control disconnect the internal plug from the control unit and

measure the impedance between 9 and 11. Impedance

between terminals 9 and 11 of the control unit (internal

plug): greater than 10 kohms (in the event of

interruption) less than 100 ohms (in the event of short

circuit).Temperature sensor values: 650 ohms at -25°C,

1000 ohms at +25°C.

88 sseeccoonnddss

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

FFaauulltt CCooddee FFaauulltt DDeessccrriippttiioonn CCaauusseess // RReeppaaiirr FFaauulltt SSiiggnnaall // FFllaasshhiinngg CCooddee

064 Open circuit - flame sensor Flame sensor signals temperature value outside

measurement range. Check the connecting leads (0.35

green). Impedance between terminals 10 and 12 of the

065 Short circuit - flame sensor control unit (internal plug): greater than 50 kohms (in the

event of interruption) less than 100 ohms (in the event

of short-circuit). Flame sensor values:

900 ohms at -25°C, 1100 ohms at +25°C.

071 Open circuit - overheat sensor Overheat sensor signals temperature value outside

measurement range. Check the connecting leads (0.35

072 Short circuit - overheat sensor blue). Impedance between terminals 5 and 8 of the

control unit (internal plug): greater than 700 kohms

(in the event of interruption) less than 100 ohms (in the

event of short-circuit). Overheat sensor values:

150 kohms at -25°C, 10 kohms at +25°C.

090 Control unit defect (internal fault) Internal control unit error in microprocessor/memory

detected. Replace control unit.

093 Control unit defective(RAM error)

094 Control unit defective(EPROM fault)

097 Control unit defective (power failure)

88 sseeccoonnddss

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

FFuueell QQuuaannttiittyy TTeesstt

The fuel Quantity should be tested if the heater has difficulty starting or maintaining a flame.

NNoottee::

Measure the fuel quantity when the battery is sufficiently charged. At least 11V/22V and at most 13V/26V should be applied at the control unit during measurement.

• Pull the fuel line from the heater and insert into a

graduated measuring glass (size: 25cm3).

Espar # 5520005.

• Switch the heater on, when fuel delivery is uniform (approximately 63 seconds after switching on), the fuel line is full and bled.

• Switch the heater off and empty the measuring glass.

• Switch heater on.

• Fuel delivery stars automatically approximately 63 seconds after switching on.

• After 105 seconds of fuel delivery, it will shut off automatically.

• Wait for restart.

• Fuel pump is automatically switched off after another 75 seconds.

• Switch off the heater.

• Measure the fuel in the measuring glass.

NNoommiinnaall vvaalluuee:: 1188 mmll±± 1100%%

If the quantity is less than the tolerance, replace the fuel metering pump.

Control unit HYDRONIC 10 (on installation of control unit, grease the gasket with sealing paste).

PPrreeppaarraattiioonn

RReeppaaiirr SStteeppss

DDiissaasssseemmbbllyy // AAsssseemmbbllyy

MMeeaassuurreemmeenntt

EEvvaalluuaattiioonn

TTeemmppeerraattuurree sseennssoorr --2255°°CC 665500

oohhmm ss

2255°°CC 11000000

oohhmm ss

FFllaammee sseennssoorr

--2255°°CC 990000

oohhmm ss

2255°°CC 11110000

oohhmm ss

OOvveerrhheeaatt sseennssoorr

--2255°°CC 115500 KK

oohhmm ss

2255°°CC 1100 KK

oohhmm ss

GGll ooww PPiinn ~~22 oohhmmss

FFuueell MMeetteerriinngg PPuummpp ~~2200oohhmmss

CCoooollaanntt PPuummpp vvaarriieess wwiitthh mmoottoorr ssppeeeedd

CCoommbbuussttiioonn AAii rr BBllo

owweerr vvaarriieess wwiitthh mmoottoo rr ssppeeeedd

RReessiissttaannccee VVaalluueess

Control unit

Glow pin cable

Glow pin

Overheat sensor / temperature sensor

Cover Blower

Flame sensor/heat exchanger fastening screws

Housing including heat exchanger, dismantled

Burner

Burner dismantled

1100

Heat exchanger

1111

Heat exchanger dismantled

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

Overheat sensor / temperature.

Cover Blower (on installation of the cover, clean the sealing surface and apply liquid seal).

Glow plug cable HYDRONIC 10.

Glow plug cable HYDRONIC M.

Glow plug HYDRONIC 10.

Glow plug HYDRONIC M.

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

Flame sensor / heat exchanger fastening screws.

Housing including heat exchanger, dismantled.

Burner dismantled.

Burner.

1100

Heat exchanger.

1111

Heat exchanger dismantled.

NNootteess

HHeeaatteerr CCoommppoonneennttss

HHyyddrroonniicc 1100 aanndd HHyyddrroonniicc MM PPaarrttss DDiiaaggrraamm

HYDRONIC 10

25 2081 05 - 12 volt 25 2044 05 - 24 volt

HYDRONIC M

25 2160 05 - 12 volt 25 2161 05 - 24 volt 25 2227 05 - 24 volt

(FCRD Adapter)

RFEN

CHT

e in G

NIC

302 00 10 05

Model #

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

DDeessccrriippttiioonn && PPaarrtt ##’’ss

HHeeaatteerr CCoommppoonneennttss

25 2044 05 24V

25 2081 05 12V

1 Outer casing 25 1997 01 00 02 • • • • •

2 Combustion air blower with cover 25 1815 99 15 00 •

25 1816 99 15 00 • 25 2160 99 15 00 • 25 2161 99 15 00 • •

3 Burner assembly 25 2044 99 11 00 • • •

25 2161 99 11 00 • • •

4 Flame tube and burner 25 2044 11 01 00 • • • • •

5 Seal 25 1816 99 11 07 • • • • •

6 Water pump 25 1815 25 01 00 • •

25 1816 25 01 00 • • •

7 Temperature Sensor 25 1816 99 01 11 • •

25 1816 99 01 11 • • •

8 Overheat sensor 25 1997 99 41 00 • • • • •

9 Flame sensor 25 1816 01 03 00 • • • • •

10 Glow pin 12V 25 1996 99 01 01 • •

24V 25 1997 99 01 01 • • •

11 Seal 25 2044 01 00 12 • • • • •

12 Glow plug cable 25 2044 01 04 00 • • • • •

13 Heat exchanger 25 1816 06 00 01 • • • • •

14 Cover 25 2044 01 00 11 • • • • •

15 Screw 100 61 317 • • • • •

16 Washer 171 22 118 • • • • •

17 Seal 25 1816 01 00 04 • • • • •

18 Seal 25 1816 01 13 00 • •

19 Sleeve 25 1816 01 00 12 • • • • •

20 Clamp 10 2065 05 00 70 • • • • •

21 O-ring 22 1000 70 00 01 • • • • •

22 O-ring 22 1000 70 00 09 • • • • •

23 O-ring 22 1000 70 00 03 • • • • •

24 Fillister head bolt 109 10 107 • • • • •

25 Spring washer 171 22 101 • • • • •

26 Taptite screw 109 10 153 • •

109 10 104 • • •

27 Taptite screw 109 10 106 • • • • •

28 Taptite screw 109 10 107 • • • • •

29 Clip 156 22 021 • • • • •

30 Indented Hexagon nut 171 19 254 • • • • •

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

Model #

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

DDeessccrriippttiioonn && PPaarrtt ##’’ss

HHeeaatteerr CCoommppoonneennttss

31 Control unit 12V 25 2081 99 50 03 •

24V 25 2044 99 50 07 • 12V 22 5301 00 10 01 • 24V 22 5302 00 10 01 • 24V 22 5302 00 10 04 •

32 Twist tie 209 31 080 • • • • •

33 Retrieval harness for fault code device (FCRD Adapter) CA1 05 030 • •

CA1 05 044 • • •

25 2044 05 24V

25 2081 05 12V

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

NNootteess

HHeeaatteerr CCoommppoonneennttss

HHyyddrroonniicc 1100 aanndd HHyyddrroonniicc MM PPaarrttss DDiiaaggrraamm ffoorr BBooxxeedd UUnniittss

2424

2222

1313

3737

303030

Model #

25 2044 05 24V

25 2081 05 12V

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM BBooxxeedd -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

1 Hydronic 10 heater 12V • •

24V • • •

2 Heater mounting bracket 25 1816 80 00 01 • • • • •

3 Molded hose 20 2900 60 10 23 (CA0 11 023) •••••

4 Spring loaded clamp 17-32mm 556 00 13

(CA1 10 046) •••••

5 Flexible Exhaust w/ end cap 25 1816 80 08 00 • • • • •

6 Bolts 5/16x1/2 #18 stainless 559 00 07 (CA3 00 102-001) •••••

7 Box Base 20 2900 40 90 01

(CA0 10 069-001) •••••

8 Fuel metering pump 25 1894 45 00 00 • •

25 1963 46 00 00 • • •

9 FPM rubber ring 20 1449 00 10 01 • • • • •

10 Fuel metering pump holder 20 1156 20 00 11 • • • • •

11 Clamp 11mm 10 2063 08 10 98 • • • • •

12 Bulk head hose connector 3/4” 20 2900 60 10 11 (CA0 11 011) •••••

13 Washer Bulkhead 559 00 86

(CA3 00 311) •••••

14 Connector 206 31 290 • • • • •

15 Dust Cap - bulkhead fitting 556 00 03 (CA0 11 016) •••••

16 Grommet 20 2900 60 10 61

(CA0 11 061) •••••

17 Silicon Seal - exhaust 25 1216 88 03 01 • • • • •

18 Blower relay block 203 00 085 • • • • •

19 Relay 203 00 065 • •

203 00 066 • • •

20 Fuse holder 204 31 004 • • • • •

21 Fuse Inserts 5 amp 204 00 079 • • • • •

15 amp 567 00 53

(CA1 07 002) •••••

20 amp 567 00 55 (CA1 07 005) •••••

22 Fuse holder cover 204 31 005 • • • • •

23 Fuel hose 360 75 350 • • • • •

24 Hex bolt M6x12 559 00 08 (CA3 00 103) •••••

25 Clamp 9mm 10 2068 00 90 98 • • • • •

26 Fuel hose 3.5mm 360 75 300 • • • • •

27 Hex nut 559 00 64

(CA3 00 208) •••••

28 Plastic fuel line 2mm 090 31 117 • • • • •

29 Grommet 20 1280 09 01 03 • • • • •

30 Washer 6mm 559 00 84

(CA3 00 308) •••••

31 Screw M3x30 559 00 25 (CA3 00 115-001) •••••

32 Bolt M8x16 559 00 37 (CA3 00 137) •••••

DDeessccrriippttiioonn && PPaarrtt ##’’ss

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

HHeeaatteerr CCoommppoonneennttss

Model #

25 2044 05 24V

25 2081 05 12V

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM BBooxxeedd -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

33 Washer 8mm 559 00 85 (CA3 00 309) •••••

34 Nut hex 8mm 559 00 65 (CA3 00 209) •••••

35 Bolt M8x50 559 00 31

(CA3 00 128) •••••

36 Washer fender 5/16”x1.25 559 00 80 (CA3 00 305) •••••

37 Shock mount 8mm CA0 00 061-001 • • • • •

38 Washer for Shock CA3 00 333-001 • • • • •

39 Threaded washer 559 00 99

(CA3 00 333) •••••

40 Spring washer 8mm 559 00 78 (CA3 00 302) •••••

41 Hex nut 8mm 559 00 65

(CA3 00 209) •••••

42 Fuse holder cover 20 2900 60 70 09

(CA1 07 009) •••••

43 Fuse holder base 567 00 55 (CA1 07 005) •••••

44 Ring terminal 3/8” awg 10-12 267 01 78 (CA1 90 014) •••••

45 Box cover 20 2900 40 00 70

(CA0 10 070) •••••

46 Exhaust clamp 30-33mm 152 10 061 • • • • •

47 Coolant hose for boxed unit 20 2900 60 10 23 (CA0 11 023) •••••

48 Clamp “P” 34mm 152 10 043 • • • • •

49 End sleeve 25 1785 80 02 00 • • • • •

50 Harness boxed 12V FMP in 20 2900 70 09 10

(CA1 60 910) •

24V FMP in (CA1 60 912) •

12V FMP out 25 1801 80 02 00

(CA1 60 911) •

24V FMP out 25 1864 80 00 02 (CA1 60 913) • 24V FMP out 20 2900 70 10 02 (CA1 60 1002) ••

12V FMP in 20 2900 70 10 06

(CA1 60 1006) •

12V FMP out 20 2900 70 10 07 (CA1 60 1007) •

24V FMP in 20 2900 70 10 08 (CA1 60 1008) ••

51 Power pig tail 12V 20 2900 70 09 20 (CA1 60 901-002) •

24V 20 2900 70 10 01

(CA1 60 901-001) •

52 Cup sieve 20 1312 00 00 06 • • • • •

53 Fuel connection piece 20 1621 45 00 02 • • • • •

DDeessccrriippttiioonn && PPaarrtt ##’’ss

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

HHeeaatteerr CCoommppoonneennttss

NNootteess

HHeeaatteerr CCoommppoonneennttss

HHyyddrroonniicc 1100 // MM PPaarrttss DDiiaaggrraamm -- UUnniivveerrssaall VVeerrssiioonn -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

35a

11a

12/12a

Model #

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM -- UUnniivveerrssaall VVeerrssiioonn -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

DDeessccrriippttiioonn && PPaarrtt ##’’ss

HHeeaatteerr CCoommppoonneennttss

25 2044 05 24V

25 2081 05 12V

1 Universal harness 25 1816 80 07 00 • •

25 1816 80 06 00 •

1a Universal harness 25 2160 80 07 00 • • •

2 Cable 20 1668 80 05 00 • • • • •

3 Fuse holder bottom 204 31 004 • • • • •

4 Fuse holder cover 204 31 005 • • • • •

5 Fuse inserts 5 amp 204 00 079 • • • • •

15 amp 567 00 53 (CA1 07 002) • • 20 amp 567 00 55 (CA1 07 005) • • 25 amp 204 00 089 • • • • •

6 Relay 203 00 065 • •

203 00 066 • • •

7 Ring terminal 3/8” awg 10-12 567 01 78 (CA1 90 014) • • • • •

8 Twin leaf spring contact awg 12 206 73 033 • •

206 73 058 • • • • •

9 Socket housing 206 31 290 • • • • •

10 Female terminals 206 00 182 • • • • •

11 Seal 206 75 022 • • • • •

12 Tie cables 5 x 200 559 00 03 (CA1 00 005) • • • • •

12a Tie cables 5 x 360 25 1816 80 02 00 • • • • •

13 Fuel metering pump 25 1894 45 00 00 • •

25 1963 46 00 00 • • •

14 Fuel connection piece 20 1621 45 00 02 • • • • •

15 Cup sieve 20 1312 00 00 06 • • • • •

16 Fuel line 090 31 108 • • • • •

17 Fuel hose 360 75 350 • • • • •

18 Fuel hose-pressure side 360 75 300 • • • • •

19 Clamps 10 2063 00 90 98 • • • • •

20 Clamp (suction side) 10 2063 01 10 98 • • • • •

21 “P” clamp 152 10 040 • • • • •

22 Metal rubber buffer 20 1185 00 00 01 • • • • •

23 Angle 20 1348 03 00 04 • • • • •

24 Intake silencer 25 1786 80 02 00 • • • • •

25 Exhaust (flexible) 25 1816 80 08 00 • • • • •

26 Flexible spiral tubing 360 61 580 • • • • •

27 End sleeve 25 1785 80 02 00 • • • • •

28 Muffler 25 1806 80 01 00 • • • • •

29 Coolant hose 20 1673 80 00 01 • • • • •

30 Coolant hose 20 1673 80 00 03 • • • • •

31 Connection piece 25 1534 88 00 01 • • • • •

32 Clamps 10 2065 02 00 32 • • • • •

33 Hose clamps 152 10 061 • • • • •

34 Muffler clamps 152 10 049 • • • • •

35 Round Socket housing 25 1766 65 02 00 • •

35a Square Socket housing 22 1000 31 93 00 • • •

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

HHeeaatteerr CCoommppoonneennttss

HHyyddrroonniicc 1100 AAcccceessoorriieess

(FCRD Adapter)

Model #

RReeff.. NNoo.. DDeessccrriippttiioo nn PPaarrtt NNuummbbeerr

HHyyddrroonniicc 1100 // MM AAcccceessssoorriieess

DDeessccrriippttiioonn && PPaarrtt ##’’ss

HHeeaatteerr CCoommppoonneennttss

25 2044 05 24V

25 2081 05 12V

1 7 day timer bezel 25 1482 70 01 00 • • • • •

2 Bracket for 7 day timer 20 2900 40 01 58 • • • • •

3 Complete 7 day timer bracket kit with bezel and bracket 25 1482 70 01 00 • • • • •

4 7 day timer 25 2900 70 02 30 • • • • •

5 Fuse link power harness 12V

(CA1 60 901-002) 20 2900 70 09 20 • •

24V

(CA1 60 901-001) 20 2900 70 10 01 • • •

6 Push / Pull switch 12V

(CA100 003) 567 00 07 • •

24V

(CA100 004) 567 00 08 • • •

7 Bulb (push/pull switch) 12V 207 00 005 • •

24V 207 00 006 • • •

8 Fault code harness adapter (CA1 05 030) 20 2900 70 50 30 • • • • •

9 Fault code harness adapter

(CA1 05 044) 20 2900 70 50 44 • • • • •

10 Fault code retrieval device (CA1 05 020) 20 2900 70 50 20 • • • • •

11 Bolt M8x50 (CA3 00 128) 559 0031 • • • • •

12 Fender Washer 5/16 CA0 00 305 • • • • •

13 Shock

(CA0 00 061-001) 554 0007 • • • • •

14 Special Washer for Shock (CA3 00 333-001) 559 0100 • • • • •

15 Threaded nut / washer (CA3 00 333) 559 0099 • • • • •

16 Lock washer 8mm

(CA3 00 302) 559 0078 • • • • •

17 Nut 8mm (CA3 00 209) 559 0065 • • • • •

18 Side mount bracket (CA0 10 057) 20 2900 40 00 57 • • • • •

19 Cross frame mounting tray (CA0 10 022) 20 2900 40 00 28 • • • • •

20 90° bulkhead hose connector

(CA0 11 037) 20 2900 60 10 37 • • • • •

21 Washer - bulkhead (CA3 00 086) 559 00 86 • • • • •

22 Water thermostat 3x18 330 00 160 • • • • •

23 Reducing piece 20x18mm 20 1645 89 00 06 • • • • •

24 Connecting pipe 20 1534 88 00 01 • • • • •

25 Clamp 20mm - 32mm 10 2065 02 00 32 • • • • •

26 Coolant hose 90° 20 1673 80 00 01 • • • • •

27 T-piece 20x20x20mm 20 1673 80 11 00 • • • • •

28 Coolant hose 180° 20 1673 80 00 03 • • • • •

29 Fuel pick up pipe

(CA0 12 058) 20 2900 20 20 58 • • • • •

30 Gasket

(CA0 12 040) 552 00 14 • • • • •

31 Single pick up with ring fitting 25 1864 80 00 02 • • • • •

32 Custom straight pick up 16”

(CA0 00 030) 552 00 01 • • • • •

33 Compression fittings 1/4” NPT (CA0 12 044) 20 2900 20 20 44 • • • • •

3/8” NPT

(CA0 00 031) 552 00 02 • • • • •

1/2” NPT

(CA0 12 006) 552 00 06 • • • • •

25 2160 05 12V

25 2227 05 24V

25 2161 05 24V

A member of the Worldwide

EEbbeerrssppääcchheerr

Group of Companies

2nd Printing - February 2007 Printed in Canada P/N: P/N 20 2900 81 01 24 0B

EEssppaarr PPrroodduuccttss,, IInncc..

6099A Vipond Drive

Mississauga, Ontario

Canada L5T 2B2

(905) 670-0960 Canada

(905) 670-0728 Fax

(800) 387-4800 Canada & U.S.A.

www.espar.com

Espar Hydronic 10, Hydronic M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual