hydronic4_5.pdf

Hydronic 4/5 (Coolant Heaters)

Technical Description

Installation Instructions

Operating Instructions

Maintenance Instructions

Troubleshooting and Repair Instructions

Parts Diagrams and List

Espar Heater Systems

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

Heater Model 12 V

Heater Model 24 V

Hydronic D4 SC

25 1917 05

25 2096 05

25 2257 05

Hydronic D5 SC

25 2147 05

Hydronic D5 S

25 2009 05

25 2146 05

25 2218 05

Hydronic B4 SC

20 1789 05

20 1824 05

Hydronic D5 SC 25 1920 05

25 2098 05

25 2219 05

FMP OUT 25 2325 05 (Same as 25 2219 05 except where indicated)

Hydronic D5 S

25 2031 05

25 2100 05

25 2217 05

Hydronic B5 SC

20 1791 05

20 1820 05

Hydronic B5 S

20 1793 05

20 1819 05

P/N

Table of Contents

Page

Introduction

Heater Warnings

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

Introduction

........................................................ 4

Specifications

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

Heater Components

Hydronic 4/5 SC, 12 + 24 volt, Diesel

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

Hydronic 5 S, 12 + 24 volt, Diesel + Gas

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

Hydronic 4/5 SC, 12 volt, Gasoline

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

Principal Dimensions

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

Installation

Heater Location

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

Procedures

Heater Mounting

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

Heater Plumbing

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

Fuel System

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

Electrical Connections

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

Exhaust / Intake Connections

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

Control Options

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

Heater Operation

Pre-Start Procedures

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

Start-Up

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

Running

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

Switching Off

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

Safety Equipment

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

Operational Flow Chart

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

Heater Diagnostics

Schematics

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

Maintenance /

Periodic Maintenance

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

Troubleshooting /

Basic Troubleshooting

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

Repairs

Self Diagnostic Troubleshooting

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

Troubleshooting Chart

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

Fuel Quantity Test

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

Heater Disassembly / Repair Steps

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

Heater Components

Parts Diagram / Scope, Face Lift “SC” Heaters

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

Description & Part #’s, Face Lift “SC” Heaters

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

Parts Diagram / Scope, Face Lift “S” Heaters

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

Description & Part #’s, Face Lift “S” Heaters

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

Parts Diagram / Scope, Early “SC” Heaters

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

Description & Part #’s, Early “SC” Heaters

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

Parts Diagram / Scope, Early “S” Heaters

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

Description & Part #’s, Early “S” Heaters

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

Parts Diagram / Scope, North American Heaters

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

Parts Diagram / Scope, North American Heaters (F/L) .......................................................

Description & Part #’s, North American Heaters

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

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.

Introduction

Heater Warnings

Warning To Installer

Caution: During electrical welding work on the vehi-

cle disconnect the power to the heater in

order to protect the control unit.

• 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.

Note: All measurements contained in this manual

contain metric and approximate SAE equiva-

lents in brackets eg 25mm (1”).

Warning - Explosion Hazard

Direct questions to Espar Heater Systems:

• Heater must be turned off while re-fueling.

• Do not install heater in enclosed areas where com-

bustible fumes may be present.

• Do not install heaters in engine compartments of gaso-

line powered boats.

Canada & U.S.A.

1-800-387-4800

Warning - Fire Hazard

• Install the exhaust system so it will maintain a minimum

distance of 50mm (2”) from any flammable or heat sensi-

tive material.

•

Ensure that the fuel system is intact and there are no leaks.

Warning - Asphyxiation Hazard

• Route the heater exhaust so that exhaust fumes cannot

enter any passenger compartments.

• If running exhaust components through an enclosed

compartment, ensure that it is vented to the outside.

Warning - Safety Hazard on Coolant Heaters

Used With Improper Antifreeze Mixtures

• The use of Espar coolant heaters requires that the

coolant in the system to be heated contain a proper mix-

ture 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 block-

age 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 per-

sonal 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 manufac-

turer’s recommendations for your specific requirements.

This publication was correct at the time of print.

However, Espar has a policy of continuous improve-

ment and reserves the right to amend any specifica-

tions without prior notice.

Introduction

Espar’s Hydronic D4/D5 Heater

Quality engineered to provide a dependable means of heat-

ing, the Espar Hydronic 4/5 is a diesel fired coolant heater

capable of between

Hydronic 4 - 1.6 kW to 4 kW/hr (5,500 to 13,700 BTU/hr).

Hydronic 5 - 2.4 kW to 5 kW/hr (8,200 to 17,100 BTU/hr).

This compact coolant heater offers an affordable heating

solution to many applications. The Hydronic 4/5 is ideal for

pre-heating the engines of trucks, cars, off-road equipment,

small trucks and boats. It features automatic heat regulation

while being fuel and power efficient. Since the heater runs on

fuel and 12 or 24 volt power, it is able to perform this com-

pletely independently of the vehicle engine. The unit regu-

lates the coolant temperature between a low of 65°C (149°F)

and a high of 80°C (176°F) by automatically cycling the

heater between heat levels.

The Hydronic 4/5 can be operated from the vehicle cab by an

on/off switch, a pre-select timer or a combination of both.

A flame sensor, temperature regulating sensor and overheat

sensor are among the safety features which makes the

Hydronic D4/D5 a safe and dependable heating system.

Specifications

Hydronic 4

Hydronic 5

Heat output (±10%)

4 kW (13,700 BTU/hr) - Boost

3.3 kW (11,300 BTU/hr - High

5 kW (17,000 BTU/hr) - High

1.6 kW (5,500 BTU/hr - Low

2.4 kW (8,200 BTU/hr) - Low

12 volt

24 volt

Current draw (±10%)

4.3 amps Boost

3.0 amps High

4.16 amps High 2.08 amps High

2.0 amps Low

1.91 amps Low 0.95 amps Low

Fuel consumption (±10%)

0.51 l/hr (0.13 US gal/hr) Boost

0.40 l/hr (0.11 US gal/hr) High

0.62 l/hr (0.16 US gal/hr) High

0.20 l/hr (0.05 US gal/hr) Low

0.27 l/hr (0.08 US gal/hr) Low

Operating Voltage Range

Minimum Voltage

10 V

20.4 V

Maximum Voltage

16 V

32.0 V

Working pressure

2.5 bar (36 psi)

Ambient operating temperature

-40°C to +80°C (-40°F to 176°F)

Overheat temperature shutdown (±5%)

105°C (221°F)

Weight

2.5 kg. (5.5 lbs.)

2.9kg. (6.4lbs)

Controls available

On/Off switch or 7-day timer

(Multi-Function Timer)

Note: The heater is equipped with a high-voltage

cutout as well as a low-voltage cutout.

Introduction

Heater Components - Hydronic 4 & 5 SC versions - 12 + 24 Volt - Diesel

25 2219 05

25 2147 05

25 2257 05

09:20

A = Combustion air

E = Exhaust

F = Fuel supply line

WO = Water Outlet

WI = Water Inlet

1 Combustion air blower wheel

2 Electric motor

3 Heat exchanger

4 Combustion chamber

5 Glow pin

6 Flame sensor

7 Temperature sensor

8 Overheat temperature sensor

9 Control unit

10 Combustion air tube

11 Exhaust tube

12 Fuel-metering pump

13 Coolant pump

14 Main fuse

15 Interface/8-pin connector

16 Bleed screw

17 Push/Pull switch

18 7-day timer

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