Espar Hydronic M10, Hydronic M12, Hydronic M-II User Manual
Hydronic M-II (Water Heater)
Espar Heater Systems
P/N 20 2900 81 0102 08.2010 Subject to Change Web Edition
HYDRONIC M8 Biodiesel
25 2470 05 - 12 Volt
25 2471 05 - 24 Volt
Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts List
Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
HYDRONIC M12
25 2472 05 - 12 Volt
25 2473 05 - 24 Volt
*
HYDRONIC M10
25 2434 05 - 12 Volt
25 2435 05 - 24 Volt
P
leas e c h e c k EsparÕs websit
e
at
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. e s p a r
. c o m
und er t h e
Te
c
hnic al D o w nloads section
,
for th e m o st current and
up-t o- d a t e manuals.
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
Introduction Heater Warnings .............................................. 3
Technical Data Hydronic M8 Biodiesel .............................................. 4
Technical Data Hydronic M10 ............................................. 5
Technical Data Hydronic M12 .............................................. 6
Heater Components .............................................. 7
Principal Dimensions .............................................. 8
Installation Procedures Heater Location / Mounting/ Fastening .............................................. 9
Heater & Engine Plumbing .............................................. 10
Fuel Quality .............................................. 11
Fuel System .............................................. 12
Electrical Connections .............................................. 14
Exhaust / Intake Connections .............................................. 15
Operating Switches: 7 Day Timer .............................................. 16
Push/Pull Switch, Programmable Timer .............................................. 18
Heater Operation Pre-Start Procedures / Start-Up .............................................. 20
Heating Mode / Termperature Drop .............................................. 20
Switching Off /Safety Equipment .............................................. 20
Heater Wiring .............................................. 21
Parts List for Wiring Diagram .............................................. 22
Heater Wiring Diagram .............................................. 23
Controler wireing diagrams .............................................. 24
Maintenance, Periodic Maintenance .............................................. 25
Troubleshooting & Basic Troubleshooting / Self Diagnostics .............................................. 25
Repairs Fault codes / Description / Repair .............................................. 26
Repair Instructions .............................................. 30
Repair Steps .............................................. 31
Fuel Quantity .............................................. 47
Heater Components Parts Diagram .............................................. 48
Description & Part #ʼs .............................................. 49
Parts Diagram - Boxed units .............................................. 50
Description & Part #ʼs .............................................. 51
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.
3
Introduction
! 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 marine
vessals.
! "nstall the exhaust system so it will maintain a minimum
distance of 50mm (2Ó) from any flammable or heat sensitive material.
! #nsure that the fuel system is intact and there are no leaks.
! Route the heater exhaust so that exhaust fumes cannot
enter any passenger compartments.
! "$%running exhaust components through an enclosed com-
partment, ensure that it is vented to the outside.
! &he use of #'()*%coolant heaters requires that the coolant
in the system to be heated contains a proper mixture of
water and antifreeze to prevent coolant from freezing or
slushing.
! "$% the coolant becomes slushy or frozen, the heater+'
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.
! &his situation could cause engine damage and/or person-
al injury. #,-*./.%care should be taken to ensure a proper mixture of water and antifreeze is used in the coolant
system.
! Refer to the engine manufacturer+' or coolant manufactu-
rer+' recommendations for your specific requirements.
Warning To Installer
Warning - Explosion Hazard
Warning - Fire Hazard
Warning - Asphyxiation Hazard
Warning - Safety Hazard on Coolant Heaters
Used With Improper Antifreeze Mixtures
Heater Warnings
"0'-)11)-230%of the heater is permitted in vehicles used
for the transport of dangerous goods as per ADR.
Caution:
During electrical welding work on the vehicle disconnect the power to the heater in order to protect the
control unit.
Heating at high altitudes
&4.%53/67'-230%6.4)8237*%3$%-4.%4.)-.*%54)09.'%:2-4%205*.)'ing altitude, due to the lower air density.
&4.%heater has an automatic altitude detection device which it
uses to automatically compensate for the change in air density, i.e. the combustion ratio between fuel and air is adapted to
the ambient conditions by reducing the fuel quantity.
!%&4.%usual switching limit for altitude detection lies between
1000 m asl and 2000 m asl and solely depends on the local
climatic conditions.
!%&4.%maximum heating output of the Hydronic M10 / M12 in
ÒAltitude ModeÓ is 8.5 kW.
!%&4.%Hydronic M8 Biodiesel does not have an altitude detec-
tion device. Unrestricted heating mode is possible up to
1500 m asl.
!%;.)-.*'%'72-)61.%$3*%4294%)1-2-7<.'%4)8.%=;%>2-?%/)*@.<%30%-4e
side of the nameplate.
&4.% heater must only be used and operated for the range of
application stated by the manufacturer in compliance with the
ÒOperating instructionsÓ included with every heater.
Direct questions to #'()*%Heater Systems:
U.S.A. & Canada 1-800-387-4800
&42'%(76125)-230%:)'%53**.5-%)-%-4.%-2/.%3$%(*20-A%%;3:.8.*,
#'()*% has a policy of continuous improvement and
reserves the right to amend any specifications without
prior notice.
Safety instructions for application and
proper purpose
Note: All measurements contained in this manual contain
metric and approximate BC# equivalents in brackets eg
25mm (1Ó).
Note: Only one kit from the listed above is needed.
Please note!
Please note!
4
Introduction
Technical data
Heater type
HYDRONIC M-II
Heater HYDRONIC M8 Biodiesel
Version D 8 W
diulf gnilooC ,retaWmuidem gnitaeH
LowMediumHighPowerwolf taeh eht fo lortnoC
Heat flow (BTU) (Watt)
Figures for operation with diesel fuel. If operated with Biodiesel
the heat flow can reduce by up to 15 %.
27297 17061 11943 5118
8000
BTU
Watt 5000 3500 1500
0.050.110.170.24
0.180.400.650.90
g/h
l/h
) (l/h)h/g( noitpmusnoc leuF
Electrical power (Watt) in operation 55 46 39 35
002Sec. 52 retfa – trats ta
23Stand by
tloV 42tloV 21egatlov detaR
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
tloV 02tloV 01
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
tloV 03tloV 51
up to 200 kPa - 30 psierusserp gnitarepo elbareloT
1400 l/h
500 l/h
370 g/h
132 g/h
2 psi ta pmup retaw eht fo etar wolF
retaeh eht fo etar wolf retaw muminiM
gninnur toNnoitarepOerutarepmet gnitarepo elbareloT
Heater / Control box
Diesel
Biodiesel
Biodiesel
Dosing pump
Diesel
Weight with controller and water pump,
without dosing pump
approx. 6.2 kg - 13.7 lb
– 40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C
+17.6 °F to +176 °F / –8 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C
– 40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C
+17.6 °F to +122 °F / –8 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C
Caution:
Failure to comply with the technical data can
result in malfunctions.
5
Introduction
Technical data
Heater type
HYDRONIC M-II
Heater HYDRONIC M10
Version D 10 W
diulf gnilooC ,retaWmuidem gnitaeH
wolf taeh eht fo lortnoC
5118119432729732415BTU wolf taeH
0.050.110.240.32
0.180.40.91.2
(g / h ) noitpmusnoc leuF
Electrical power (Watt)
021 52 retfa – trats ta
23
tloV 42tloV 21egatlov detaR
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
tloV 02tloV 01
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
tloV 03tloV 51
up to 200 kPa - 30 psierusserp gnitarepo elbareloT
1400 l/ h - 370 g/h2 psi ta pmup retaw eht fo etar wolF
500 l/ h - 132 g/hretaeh eht fo etar wolf retaw muminiM
gninnur toNnoitarepOerutarepmet gnitarepo elbareloT
Heater / Control box
Dosing pump
Weight with controller and water pump,
without dosing pump
approx. 6.2 g/ h - 13.7 lb
–40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C
–40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C
in operation 86 60 39 35
LowMediumHighPower
9500Watt 8000 3500 1500
(l / h )
Sec.
Stand by
Caution:
Failure to comply with the technical data can
result in malfunctions.
6
Introduction
Technical data
Heater type
HYDRONIC M-II
Heater HYDRONIC M12
Version D 12 W
diulf gnilooC ,retaWmuidem gnitaeH
Low3 muideM2 muideM1 muideMHighrewoPwolf taeh eht fo lortnoC
wolf taeH
noitpmusnoc leuF
in operation 132 86 46 39 35 34
02152 retfa – trats ta
23
tloV 42tloV 21egatlov detaR
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
tloV 02tloV 01
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
tloV 03tloV 51
erusserp gnitarepo elbareloT
ta pmup retaw eht fo etar wolF
retaeh eht fo etar wolf retaw muminiM
gninnur toNnoitarepOerutarepmet gnitarepo elbareloT
Heater / Control box
Dosing pump
Weight with controller and water pump,
without dosing pump
409511943 5118170613241542000
.04.11 .05.17.32.40
0.150.40 0.180.651.21.5
(g / h )
(l / h )
Electrical power (Watt)
2 psi
approx. 6.2 g/ h - 13.7 lb.
Sec.
BTU
up to 200 kPa - 30 psi
1400 l/ h - 370 g/h
500 l/ h - 132 g/h
–40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C
–40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C
Stand by
Caution:
Failure to comply with the technical data can
result in malfunctions.
1
3
F
2 WO
WI
E
CA
9 8 7
54
6
7
Introduction
Heater Components
1 Control box
2 Burner motor
3 Glow plug
4 Flame pipe
5 Overheating sensor
6 Heat exchanger
7 Water pump
8 Combustion chamber
9 Flame sensor
WI = Water inlet
WO = Water outlet
CA = Combustion air
F = Fuel
E = Exhaust
8
Introduction
Principal Dimensions
F WO
WI
CA E
M8 (x4)
* All measurements in millimeters 25.4 mm = 1”
Boxed Heaters Insure:
Minimum installation distance (clearance) to
open the lid and to dismount the glow pin and
the control unit.
Insure:
Minimum installation distance (clearance) to
take in combustion air.
Permissible installation positions
E Exhaust
F Fuel
CA Combustion air
WO Water outlet
WI Water inlet
1 Water outlet socket, heater
2 Water inlet socket, water pump
9
Installation Procedures
Principal Dimensions - Boxed Version
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. Refer to fig. 1
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
with kit and one of the following mounting methods:
• Use the Side Mount Bracket 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
Caution: Guard the heater against excessive road spray to
avoid internal corrosion.
Fix the unit holder from the installation kit to the heater
using 4 hexagon screws M8 and 4 spring washers.
Fix the heater and the mounted unit holder in a suitable
place in the vehicle using 5 hexagon screws M8, 5 spring
washers and 5 hexagon nuts M8
Heater Location
Heater Mounting
Side Mount Bracket
P/N 20 2900 40 00 75
Parts of the structure and other components near the heater
must be protected from excess heat exposure and possible
contamination from fuel or oil.
The heater must not pose a fire hazard even when it
overheats.
– This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and fireproof
materials or heat plates are used.
The heater must not be located in the passenger compartment.
A unit may however be used in a hermetically sealed housing
which also corresponds to the conditions stated above.
The factory nameplate or duplicate must be affixed so that it
can still be easily read when the heater is installed in the
vehicle.
All appropriate precautions must be taken when
arranging the heater to minimise the risk of injuries
to persons or damage to other property.
Arrangement of the heater
197 mm
(7.76”)
317 mm
(12.4”)
430 mm (16.9”)
Mounting and Fastening
1 Heater
2 Heater bracket
Fig. 1
Box Base
P/N 25 2800 40 10 02
Box Lid
P/N 25 2800 40 10 03
Intake Silencer
always needed
P/N 25 1786 80 02 00
10
Installation Procedures
Heater Plumbing
4 2
3
1
The heater is incorporated into the engineʼs 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 pos-
sible to allow the purging of air.
• If a bunk heat exchanger is incorporated into the system,
proper plumbing layouts must be followed.
Water
in
Water out
Engine Plumbing
Caution: It is possible for the coolant and components of the
coolant circuit to get very hot.
• Parts conveying water must be routed and fastened in such
a way that they pose no temperature risk to man, animals or
material sensitive to temperature from radiation / direct
contact.
• Before working on the coolant circuit, switch the heater off
and wait until all components have cooled down completely,
if necessary where safety gloves.
Caution:
• When installing the heater, please take note of the direction
of flow of the coolant circuit.
• Fill the heater and water hoses with coolant before con-
necting to the coolant circuit.
• Route the water hoses without any kinks, and in a rising
position if possible.
• When routing the water pipes, observe a sufficient clea-
rance to hot vehicle parts.
• Protect all water hoses / water pipes from chafing and from
extreme temperatures.
• Secure all hose connections with hose clips.
• After the vehicle has been operating for 2 hours or travelled
100 km, tighten the hose clips again.
• The minimum water flow rate is only guaranteed if the tem-
perature difference of the heating medium does not exceed
15°C (60°C) between water inlet and water outlet during
heating.
• Only overpressure valves with an opening pressure of min.
6 psi – max. 30 psi bar may be used in the coolant circuit.
• The coolant liquid must contain at least 10 % antifreeze all
year round as corrosion protection.
• The cooling liquid must contain sufficient antifreeze for low
temperatures.
• Before commissioning the heater or after changing the
cooling liquid, the whole coolant circuit including heater must
be vented free of bubbles according to the instructions issued
by the vehicle manufacturer.
• Only top up with coolant approved by the vehicle manufac-
turer.
1 Heater
2 Non-return valve (Optional)
3 Heat exchanger
4 Vehicle engine
11
Installation Procedures
• The exhaust outlet must end in the open air.
• The exhaust pipe must not protrude beyond the lateral limits of
the vehicle.
• Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm at the lowest
point to drain off condensation.
• Important functional parts of the vehicle must not be impaired
(keep sufficient clearance).
• Mount the exhaust pipe with sufficient clearance to heat-sensitive parts. Pay particular attention to fuel pipes (plastic or
metal), electrical cables and brake hoses etc.!
• Exhaust pipes must be fastened safely (recommended clearance of 50 cm) to avoid damage from vibrations.
• Route the exhaust system so that the emitted fumes are not
sucked in with the combustion air.
• The mouth of the exhaust pipe must not get clogged by dirt
and snow.
• The mouth of the exhaust pipe must not point in the direction
of travel.
• Always fasten silencer to the vehicle.
• The exhaust end pipe should be much shorter than the flexible
exhaust pipe from the heater to the exhaust silencer.
Fuel Quality
This means that difficulties are only to be expected for extreme
drops in temperature, as also apply to the vehicle engine. Please
also refer to the vehicle manual.
If no special diesel fuel is available for low temperatures, then
kerosene or gasoline should be mixed with the fuel according to
the following table:
Temperature Winterdiesel Addition
0 °C to –25 °C 100 % –
(32 °F to –13 °F) 100 % –
–25 °C to –40 °C 50 %* 50 % paraffin or petrol
(32 °F to –13 °F) 50 %* –
* or 100 % special cold diesel fuel (Arctic diesel).
Caution: The coolant must contain a minimum of 10%
antifreeze at all times as protection against
corrosion.
Fresh water will corrode internal heater parts.
Note: HYDRONIC M8 Biodiesel
The heater is approved for operation with biodiesel up to a temperature of – 8°C (17.5°F) (the fuel flow reduces at temperatures below 0 °C (35°F)).
• When using 100 % biodiesel, the heater should be run on diesel fuel twice a year (in the middle and at the end of a heating
period) to burn off possibly accumulated biodiesel deposits. To do so, let the vehicle tank run almost empty and fill with diesel fuel
without adding any biodiesel. While running on this tank filling, switch the heater on 2 to 3 times for 30 minutes at a time at the
highest temperature setting.
• If constantly operated with diesel / biodiesel mixtures of up to 50 % biodiesel, intermediate operation with pure diesel fuel is not
necessary.
HYDRONIC M10 / HYDRONIC M12
Both heaters are not approved for operation with biodiesel. Up to 10 % biodiesel may be added.
12
Installation Procedures
Fuel System
FUEL
TANK
Fuel System Tolerances
Fuel Line
Note: Butt joints and clamps on all connections.
• Route fuel lines from the fuel pick-up pipe to the heater.
• Use Espar approved fuel lines.
• 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.
Note: 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 2ʼ6” of the bottom of the fuel pick-up pipe.
Fuel metering pump must be within a total distance of
6ʼ6” 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 MII 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”)
Control and Safety Devices
Emergency shutdown – EMERGENCY OFF
If an emergency shutdown – EMERGENCY OFF – is necessary
during operation, proceed as follows:
• Switch the heater off with the control
• pull the fuse out
• disconnect the heater from the battery.
Max. 6ʼ6”
Max. 20”
Max. 6ʼ6”
Max. 2ʼ6”
1
2
3
4
5
6
7
5
2
6
13
Installation Procedures
Fuel Metering Pump Installation
Note: Drill the two (1/4”) holes first.
( Optional Pick-Up Pipe with NPT fitting )
• 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
Note: NPT fittings are available in various sizes
(Refer to parts catalogue).
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 pickup pipe should have
angle so as to avoid
picking up dirt and
subsequent blockage
• 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.
Note: 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 pickup pipe and heater.
• Using the bracket and rubber mount provided, install pump as
shown.
Fuel Pick-Up Pipe Installation (Standard Pick-Up)
Note: Some pick-up pipes can be installed by either drill or
NPT.
14
Installation Procedures
Electrical Connections
• 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, brown, yellow, blue/white)
• Run to location of switch. Make terminal connections at
switch. Espar has different 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, with the
heater - (no polarity required).
++
--
A
B
C
7 D
a
y
Timer
7 Day Timer
switch harness
Caution: To avoid potential short circuit damage during instal-
lation, insert main fuse into the power harness after
all electrical connections are complete.
A) Power Harness...................................................................
B) Switch Harness..................................................................
C) Fuel Metering Pump Harness...........................................
Shown is a Hydronic MII boxed version, 12 volt with
Standard - Power, Switch, Fuel Metering Pump harnesses
and optional 7 day timer.
Other timers or switch options are available.
Easy Start Mini Timer
Programable Push and
Timer Pull Switch
Note: Wire must be inserted into fuse holder prior to
terminating.
Note: All harnesses should be cut to length.
All exposed electrical connections should be coated
with protective grease.
I
A
U
T
O
O
R
U
N
P
P
1
.
.
.
7
h
m
1
2
3
4
5
6
7
P
M
R
15
Installation Procedures
Exhaust Connection
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 fire and 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 1.8 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.
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.
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.
Combustion air must be drawn in from the outside of vehicle.
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 vehi-
cle 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
P/N 25 1786 80 02 00
Air Intake silencer
Always needed
Intake Connection
Warning: Asphyxiation Hazard Warning: Fire Hazard
Note: 1. Exhaust hose cannot be any longer than 2m (80”)
2. Minimum length 0.2 m (8”)
3. Air intake silencer always needed.
ATTENTION: Refer to pg. #3 for High altitude capabilities.
16
Installation Procedures
Operating Switches
Note: If installing a remote starter, refer to remote starter
instructions before terminating wires.
A 7 Day Timer, a Push/Pull switch, a Programmable Timer or an
easy start timer are available for the heater.
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 Esparʼs 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.
7 Day Timer Instructions
Option #1: Dash lights to timer - connect wire between dash
lights circuit and timer at terminal #1.
Note: The timer display is automatically illuminated while the
heater is operating. Connecting pin 1 to the vehicle
dim- mer switch will allow the timer display to illuminate with
the vehicles dash lights.
Mounting Bracket & Bezel
P/N 25 1482 70 01 00
Mounting Bracket
Bezel
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, if optional connection on pin 10 is insatlled.
When the vehicle ignition is turned “off” the timer display will go
off after 15 seconds.
Changing the Time or Day
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 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 preheat time is set.
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.
I
A
U
T
O
O
R
U
N
P
P
1
.
.
.
7
h
m
1
2
3
4
5
6
7
P
M
R
Option #1
Option #2
Yellow
Red
Brown
Blue
DIAG
TRS
Yellow
Red
Blue
Brown
12 11 10 9 8 7 6 5 4 3 2 1
P
a4)
a
3)
a
5)
a
2)
Option #2: Operate heater continuously - connect wire from
ignition circuit to terminal #10.
Note: An alternative to connecting pin 10 to the vehicle
ignition accessories “On” circuit may also be considered for some applications where extended run
times are desired. Connecting pin 10 with the red
wire will enable the heater to run continuously on
manual mode.
Operating Instructions
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