Espar 25 2113 05, 25 2114 05, 25 2327 05 Technical Description

Add to My manuals
37 Pages

advertisement

Espar 25 2113 05, 25 2114 05, 25 2327 05 Technical Description | Manualzz

**

M

T ec

IIn stta

Trro ub

P arrtts all D es pttiio n sttrru cttiio

O pe

M aiin an ce sttrru cttiio sttrru cttiio s

Re pa sttrru cttiio s

AIIR TR C D 2

25 2069 05 - 12 Volt

25 2070 05 - 24 Volt

AIIR TR NIIC 2 C mp

25 2326 05 - 12 Volt

AIIR TR NIIC M D 3 C

25 2317 05 - 12 Volt mp

Espar Heater Systems

AIIR TR NIIC M D 4

25 2113 05 - 12 Volt

25 2114 05 - 24 Volt

AIIR TR NIIC M D S

25 2144 05 - 12 Volt

25 2145 05 - 24 Volt

AIIR TR NIIC M D 4 C

25 2318 05 - 12 Volt mp

AIIR TR NIIC M D 4 C

25 2327 05 - 12 Volt mp

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

AIIR TR NIIC M B 4

20 1812 05 - 12 Volt

20 2900 81 01 03 0A 02.2007 Subject to Change Printed in Canada

T ab Co ntte

IIn stta oc ed urre s

H

M

R

H ea aiin ep ea

Op na es erra ho

P ag

Heater Warnings

Introduction

Technical Data

Dimensions

Heater Components

Heater Location

Heater Mounting

Heater Plate installation

Mounting Pattern

Heater Air Ducting

Ducting Components

Fuel System

Electrical Connections

Exhaust/Intake Connections

Operating Switches

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

3

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

4

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

5

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

6

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

7

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

8

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

8

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

8

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

9

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

9

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

9

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

10

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

12

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

13

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

13

Switch on

Start-Up

Temperature setting

Temperature Control

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

14

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

14

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

15

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

16

Switching Off ........................................................

16

Controls & Safety Equipment ........................................................

16

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

16

Function Diagrams ........................................................

17

AIIR TR NIIC 2//D 18

Periodic Maintenance

Basic Troubleshooting

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

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

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

20

20

21

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

25

Overheat/Flame sensor values ........................................................

25

Control and Resistance values ........................................................

26

Repair Steps ........................................................

27

AIIR TR C D 2//D

-Service Parts Diagram

AIIR TR C D 2//D

-Parts List

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

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

33/35

34/35 pe ciia otte

W arrn g:: Indicates that serious or fatal injury may result if specific guidelines are not followed.

This publication was correct at the time of going to print. However, Espar Inc. has a policy of continuous improvement and reserves the right to amend any specifications without prior notice.

Introduction

H ea err W arrn s

W arrn g T o IIn

Correct installation of this heater is necessary to ensure safe and proper operation.

Read and understand this manual before attempting to install a heater.

A TT TIIO N

O pe

AIIR TR C D 2 // D

AIRTRONIC D2 is not certified for use with bio-diesel.

Admixtures of bio-diesel up to a magnitude of approx. 5%, as in some countries, are allowed.

W arrn

3.

g -- E xp siio Ha za

1.

Heater must be turned off while re-fueling.

2.

Do not install heater in enclosed areas where combustible fumes may be present.

Do not install heaters in engine compartments of gasoline powered boats.

W arrn g -- F e H az

1.

Install heater so it will maintain a minimum distance of

2” from any flammable or heat sensitive material.

2.

Install the exhaust system so it will maintain a minimum distance of 2” from any flammable or heat sensitive material.

3.

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

A TT TIIO N attiin g a ud s

Up to 1500 meters - unrestricted heating operation is possible

Above 1500 meters - heating operation is in principle possible for short periods, e.g. when crossing a mountain pass of during a brief stop. In cases of extended stays , the fuel supply at the fuel metering pump has to be adapted to high altitude conditions. Please call for special circumstances.

C an da 1--8 00 7--4 80

Failure to follow these instructions could cause fire resulting in serious or fatal injury.

W arrn g -- A sp yx attiio n H za

1.

Route the heater exhaust so that exhaust fumes can not enter any passenger compartments.

2.

Ensure an air tight seal will be maintained between the heater and mounting surface and at any exhaust connection points.

3.

Ensure that heating air supply is taken from an area where poisonous gases will not be present.

4.

If running exhaust components through an enclosed compartment, ensure that it is vented to the outside.

Failure to follow these instructions could cause oxygen depletion resulting in serious or fatal injury.

Direct questions to Espar Heater Systems

C an da 1--8 00 7--4 80

3

Introduction

Es pa A TR C b un k h ea

The AIRTRONIC D2 is a compact diesel-fired 7,500 BTU/hr air heater, quality engineered to provide a dependable means of space heating.

This heater is uniquely designed for inside mounting and ease of installation. The AIRTRONIC D4 is a 13,650 BTU/hr air heater for larger bunks.

These heaters provide hot air to the interior of vehicles for passenger comfort. Since the heater runs on diesel fuel and 12 or

24 volt power, it is able to provide space heat completely independently of the vehicle engine.

The heater is operated by a rheostat switch or room thermostat. It cycles through four temperature settings (boost-high-medium-low) in order to maintain the desired temperature.

If, in special cases, less heating capacity is required than the heater supplies in the “Low” setting, the heater switches to a

“stand-by” setting. Temperature and overheat sensors, and a specially designed heat exchanger are among the safety features which make this heater a safe and dependable unit.

4

For illustration purposes only

Product Information

T ec niic

Heater

Version

Heat Output (±10%)

Current at 12v (±10%)

AIIR TR C

D2

7,500 BTU/hr Boost (2.2 kW)

6,150 BTU/hr High (1.8 kW)

4,100 BTU/hr Medium (1.2 kW)

2,900 BTU/hr Low (0.85 kW)

8.3 amps - Start

2.8 amps - Boost

1.9 amps - High

1.0 amps - Medium

0.7 amps - Low

Current at 24v (±10%)

Fuel Consumption (±10%)

Air Flow (±10%)

Operating Voltage Range

4.2 amps/hr - Start

1.4 amps/hr - Boost

1.0 amps/hr - High

0.5 amps/hr - Medium

0.3 amps/hr - Low

U.S.

Gal/hr

Litre/hr

Boost

High

0.07

0.06

Medium 0.04

Low 0.03

48 cfm Boost

40 cfm High

27 cfm Medium

19 cfm Low

10.5 - 16 vdc at 12 vdc

21 - 32 vdc at 24 vdc

240°F (115°C)

0.28

0.23

0.14

0.10

Overheat Temperature

Shutdown (±10%)

Ambient Operating

Temperature

Weight

-40°F to 158°F (-40°C to 70°C)

6.0 lbs. (2.7 kg)

AIIR TR NIIC

D4

13,650 BTU/hr Boost (4.0 kW)

10,200 BTU/hr High (3.0 kW)

6,800 BTU/hr Medium (2.0 kW)

3,400 BTU/hr Low (1.0 kW)

8.3 amps - Start

3.3 amps - Boost

2.0 amps - High

1.1 amps - Medium

0.6 amps - Low

4.2 amps/hr - Start

1.7 amps/hr - Boost

1.0 amps/hr - High

0.5 amps/hr - Medium

0.3 amps/hr - Low

U.S.

Gal/hr

Litre/hr

Boost

High

0.13

0.10

Medium 0.07

Low 0.03

85 cfm Boost

69 cfm High

50 cfm Medium

30 cfm Low

10.5 - 16 vdc at 12 vdc

21 - 32 vdc at 24 vdc

240°F (116°C)

0.51

0.38

0.25

0.13

-40°F to 158°F (-40°C to 70°C)

9.9 lbs. (4.5 kg) voltage cutout to prevent vehicle battery drain and a high voltage cutout to protect heater electrical parts.

5

Product Information ciip all D en siio ns A RT RO C D 2

(12.2 inches)

* 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.

(4.5 inches)

Prriin ciip me ns ns A RT RO B // D 4

(14.8 inches)

6

(5.5 inches)

Product Information

H ea err C om on en

1

11

8

2 3 4 5 6 7

9

10

22

20

12

17

13

21

14 15 16

18

19

1 Hot Air Blower Wheel

2 Control Unit

3 Combustion Air Blower Wheel

4 Glow Pin

5 Cover

6 Heat Exchanger

7 Overheat/Flame sensor

8 7 Day Timer with Thermostat (optional)

9 Operating Unit (Thermostat)

10 Operating Unit (Rheostat)

11 Mini Controller

12 Blower Motor

13 Fuel Connection

14 Flange Seal

15 Combustion Chamber

16 Hot Air Outlet Hood

17 Combustion Air Intake Hose

18 Fuel Metering Pump

19 Fuel Filter built into FMP

20 Hot Air Output Deflector

21 Flexible Exhaust Pipe

22 Main Fuse: -

AIRTRONIC D2 - 20 A - 12V

AIRTRONIC D4 - 20 A - 12V

= C om bu sttiio

= F ue ntta ke m T

= E xh au stt

Frre sh ntta e

= H ott A uttp

7

Installation

H ea err L oc H ea ou nttiin e IIn stta attiio n n

Depending on the type of vehicle, the best location for mounting the heater will vary. Typically, air heaters are mounted inside tool or luggage compartments. However, the heater may be mounted anywhere inside the vehicle provided you adhere to the following conditions:

• Combustion air intake, exhaust and fuel inlet must be located outside of the vehicle.

• Heater must be mounted on flat horizontal surface providing an air tight seal between heater and vehicle.

• Do not mount the heater outside the vehicle, unless care is taken to protect the heater from the weather. When selecting the location, consider the following:

• Combustion air and exhaust connections.

• Ducting.

• Fuel line connections.

• Electrical connections.

Hex Head Tek Screw

Flat washer

N

Nut

Spring Washer

Silicon gasket (flange)

Stainless Steel Plate

Plate seal

Cab Floor e:: Tighten screws sufficiently to ensure positive seal between mounting plate and mounting surface.

Do not over tighten.

H ea ou nttiin

A mounting plate and hardware are provided with the truck heater kit.

• Choose heater location.

• Using template, drill and cut center hole. Cut (1) four and one half inch (4 1/2”) diameter hole or one rectangular hole four (4”) by five (5”) inches to accommodate mounting plate and seal. Secure mounting plate to vehicle floor with “Tek” screws provided.

• Use heater flange as a template if not using mounting plate and seal.

• Mount heater on mounting plate with nuts and spring washers provided.

• For ease of installation make the exhaust, combustion air intake and fuel connections at base of heater before mounting the heater into the vehicle. See following pages for instructions and restrictions on exhaust, combustion and fuel hook-ups.

Wiirriin g h arrn es on ne cttiio n,, rriig

Wiring harness can be converted to the opposite side of the heater if it makes the installation more practical. To do this you must remove the AIRTRONIC cover and then the control unit.

On the control unit (underneath) is a semicircular clip protecting the harness. This must be removed. The harness can be moved to the other side of the control unit then reassembled.

The grommet on the heater casing (side) must also be taken out and secured into the opposite lower side of heater casing.

Wiring Harness

Right or Left

Stainless Steel

Mounting Plate and seal

Combustion

Air intake

Fuel line

Heater

Flange

Exhaust

Tubing

8

Installation

Mo un g P atttte inches

Ø 1.024 (2 HOLES)

0.472

Ø 0.295 (5 HOLES)

Ø 26.0 (2 HOLES)

1.732

12.0

Ø 7.5 (5 HOLES)

44.0

millimeters

0.709

2.165

H ea Aiirr D uc g IIn stta

A 60mm flexible duct 40 inches long, hot air outlet and clamps are provided with the heater kit. In routing and installing the ducting the following criteria must be observed:

• Route ducting with smooth bends. Avoid crushing duct.

• Position hot air outlet so that it cannot be obstructed.

• When not using return ducting. Use a protective air intake grille on air inlet side of heater to prevent objects from being sucked in.

• Ensure provisions are made for proper air return ventilation.

• Use return air ducting for best heating efficiency.

18.0

For illustration purposes only

55.0

R ettu Du cttiin

N o R n D uc g

For illustration purposes only

D uc g C om on s

2 AIRTRONIC D2 - ø60 or75mm

AIRTRONIC D4 - ø75 or 90mm

W arrn

Ducts and outlets must be capable of withstanding a minimum of 300°F operating temperatures.

C au Do not over tighten duct clamps.

Do not position outlet so that it will blow hot air directly at operator or at room thermostat.

9

Installation

F ue ys

The fuel metering pump is the heart of the system and must be installed properly to ensure a successful heater operation.

F ue ys m O viie w

M ax 0’’

M ax

M ax

F ell

T an

F ell

T an

1. Fuel Pick-Up Pipe

2. 5.0 Rubber Connector

3. 11mm Clamp on all

6. 9mm Clamp

F ue Piic k--U e IIn stta attiio n ((S an da Piic k--U

• Choose a protected mounting location close to the fuel pump and heater. A spare fuel sender gauge plate provides an ideal mounting location.

• Drill the mounting holes as shown

• Cut the fuel pick-up pipe to length.

• Mount the fuel pick-up pipe as shown.

• Lower the fuel pick-up pipe (with reinforcing washer) into the tank using the slot created by the two 1/4” holes.

• Lift the assembly into position through the 1” hole.

• Assemble the rubber washer, fuel metering pump bracket, metal cup washer and nut.

N e:: Drill the two 1/4” holes first.

N e:: Butt joints and clamps on all connections.

4. 2.0mm Black Plastic Fuel Line

5. Fuel Metering Pump

7. 3.5mm Rubber Connector

8. 1.5mm White Plastic Fuel Line

9. 5mm Rubber Fuel Line

FMP bracket

Fuel Tank

Fuel Pick-up Pipe

Nut

Sheet Metal Washer

(raised center to top)

Rubber Gasket

Reinforcing Washer

Holding Tabs

Allow 4" from Fuel

Pick-up to tank bottom.

Allow only 1" for flat bottom tanks.

O pttiio

10

Installation

FMP bracket Fuel Pick-up Pipe

Nut

Sheet Metal Washer

(raised center to top)

Rubber Gasket

Reinforcing Washer

Fuel Tank

Holding Tabs

Allow 4" from Fuel

Pick-up to tank bottom.

Allow only 1" for flat bottom tanks.

C us Piic k--U Piip e w h N PT g -- o

• 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.

N e:: Will not be able to use FMP bracket.

to parts section).

F ue ette g P um p

• Choose a protected mounting location close to the fuel pick-up pipe and heater if not using standard assembly as shown on right.

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

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

F ue

• Route fuel lines from the fuel pick-up pipe to the fuel metering pump then to the heater.

• Use fuel lines provided.

• Other sizes or types of fuel lines may inhibit proper fuel flow.

• Make proper butt joints using clamps and connector pieces as shown on previous page.

• Use a sharp utility knife to cut plastic fuel lines to avoid burrs and pinching fuel line shut.

Typical standard assembly, if not using this format please adhere to specifications on pg.10

NPT fitting and pipe pttiio all

11

Installation

Elle cttrriic all C nn cttiio s

M aiin arrn s..............................................................................................................................................

ud s

P ow err H arrn s..............................................................................

F wiittc ue

Diia gn h H arrn erriin c H es g P um p H ne arrn es s................................................................

16 pin connector with 10 terminated wires at 8 terminals.

(green/red, blue/white (2), red, grey/red, grey, brown, brown/white and yellow (2)). Connect to the heater’s 16 pin connector. Connect other harnesses as described below.

2 core harness (red and brown). Route power harness to batteries, cut to length and terminate as described below. Install

20 amp fuse last (10 amp on 24V). Connect red wire to fuse holder near battery. Connect fuse link wire directly to battery positive post using ring terminal. Connect brown wire directly to battery negative post using ring terminal.

7 core harness (red, brown/white, yellow, grey, brown, grey/red and blue/white). Route this harness the length required to reach thermostat installed in bunk compartment. Do not cut this harness, wires have been soldered at ends for convenience of terminating to terminals on thermostat. Coil up excess harness and secure in safe location.

Connect to thermostat or rheostat switch (refer to switch connection section).

2 core harness (green/red and brown).

Route this harness from heater to fuel metering pump. Cut to length and connect to fuel metering pump using single terminals and connector provided with kit.

N e:: No polarity required.

8 pin connector (red, brown, yellow, blue/white). For diagnostic purposes only.

C au connections are complete. 10 amp on 24V.

ed with protective grease, (petroleum gel,

Vaseline, etc.).

Fuel Metering Pump Harness

Fuse and holder

Power Harness

Main Harness

Connector for Diagnostics

Switch Harness

Thermostat

Mini Controller

12

Installation / Operation and Function

Ex ha an d C bu sttiio e C on ec s

A 24mm flexible stainless steel exhaust pipe (51”long) and a

25mm flexible plastic tube (39” long) for combustion air intake are included with the heater kit. Exhaust clamps and holders are also provided.

Caution: Route exhaust and combustion air intakes so they cannot be plugged by dirt, water or snow.Ensure the outlets do not face into the vehicle slip stream.

Keep exhaust and combustion air intake a minimum of 12” apart.

Drill 1/8” holes in exhaust pipe if necessary to allow water drainage.

Combustion air intake and exhaust lengths can be shortened to a minimum of 8”.

• Attach the exhaust pipe to the exhaust outlet of the heat exchanger.

• Route exhaust pipe to an open area to the rear or side of the vehicle so that fumes cannot build up and enter the cab or the combustion air inlet to the heater.

• Install protective cap.

• Attach the combustion air intake tube to the combustion air inlet of the heater.

• Once secure to the heater inlet, the intake pipe must be routed to the underside of the vehicle where it will pick up clean, fresh, moisture free air.

O pe g S wiittc s

The heater can be controlled using a Mini Controller,

Thermostat or Rheostat type switch. It can also be controlled by a 7 day timer with thermostat. See schematic pg. 19.

nii C on

• Stick the drilling template to the required place of installation. N e:: The drilling template (removable and selfadhesive) is attached to the front. Do not press the control field during installation.

• Drill 2.5 and 7.5 mm holes.

• Remove the control knob from the mini controller.

• Fit the mini controller with the elastic base.

• Screw in fixing screw up to the end stop.

• Put the control knob on the mini controller. The arresting device in the control knob must be inserted in the keyway in the mini controller.

• Connect the mini controller in accordance with the circuit diagram.

1

2

Drilling template

Elastic base for uneven installation area a)

S2

Red

Yellow

Grey

White/red

Brown

Bue/White

Grey/Red

Brown/White

B2

B2 S2

Red

Yellow

Brown

Grey

Red

Blue

Combustion Air Intake

( min. 8” - max. 6.5’ ).

End Cap

Exhaust ( min. 8” - max. 6.5’ ).

W arrn g::

W arrn g::

End Cap

The exhaust is hot, keep a minimum of 2” clearance from any heat sensitive material

Route exhaust so that the exhaust fumes cannot enter the passenger compartment.

a) Connection of control elements on the heater: red battery plus yellow grey brown switch on signal S+ optional external sensor battery minus blue / white grey / red diagnostics set temperature value brown / white sensor reference ground

Insulate any cable ends not used.

The connectors and socket housing are shown from the cable entry side.

T he mo att

• Select a mounting location which will be representative of the average temperature of the area being heated. Avoid mounting near heater outlets, windows, doors, electrical appliances or in areas receiving direct sunlight.

• Route the switch harness from the heater to the thermostat mounting location.

• Mount the thermostat as shown using proper mounting hardware and the slots provided on the thermostat base.

Pull the switch harness through the thermostat base access hole.

• Connect the six core switch harness to the thermostat as shown.

13

Operation and Function

Mounting slots

Red

Yellow

6

5

9

4

Grey - not used

Blue/White - not used

3

10

2

Brown/White

Grey/Red

Brown

H ea err O pe attiio n

1

Switch Harness

Thermostat base access hole

1 2 3 4 5 6 T

Blue/White - not used

Brown/White

Grey/Red

Brown - not used

Red

Yellow

Grey

1

RED

0

GREEN

This wire is “optional”

Grre y w

• It is recommended that when using return ducting, not to use this wire. See illustration on pg. 9 for ducting.

• Not using the grey wire defaults the heater to use the temperature sensor on the control unit of the heater.

• Use of the grey wire defaults the heater to use the sensor on the thermostat.

• The sensor on the control unit provides a more accurate reading of the overall air temperature, whereas the sensor in the thermostat gives more of a spot reading of the air surrounding the thermostat.

Temperature sensor on

AIIR TR C control unit.

he os

N att S otte wiittc cttiin g method must be used as shown on page 9. This

AIIR TR C heater’s internal sensor to properly monitor cab temperature.

Warning: To prevent fire, the heater must be switched off while filling fuel tanks.

To prevent asphyxiation, the heater must not be operated in enclosed areas unless heat exhaust is routed to the outside.

1 S wiittc h O

• Switch the heater on using the mini controller’s heat button or the room thermostat’s, On/Off switch (1=On, 0=Off ) or the rheostat switch.

2 S arrtt U p

On start up the indicator light illuminates and the following sequences take place:

• Control unit does a systems check of the glow pin, flame sensor/temperature sensor, fuel metering pump and control unit.

• Glow pin is energized and starts preheating the combustion chamber.

• Blower starts slowly and begins to accelerate.

• After a delay (approx. 20 seconds) the fuel pump delivers fuel.

• Ignition will take place as the fuel/air mixture begins to burn.

• Blower speed and fuel delivery are slowly increased.

• Once flame sensor has detected a flame the glow pin will switch off, after approx. 15 secs.

• After another 120 secs., heater will have reached maximum power.

• Mount the rheostat switch in a location where it is easily accessible.

• Route the switch harness from the heater to the Rheostat mounting location.

• Connect the six core switch harness as shown.

14

Operation and Function

3 T mp e S ettttiin nii C on

The mini controller enables you to set the heater installed in the vehicle to the temperature you require.

You can control the desired temperature range by turning the dial clockwise to increase temperature.

• Lowest Setting - approx. 47°F (8.5°C)

Highest Setting - approx. 97°F (36°C)

Use the “Heater” button to start the heater in heating mode

(continuous operation). You can adjust the required temperature with the temperature control knob. If the heater is in heating mode, the red LED lights up as a check.

Use the “Fan” button to start the heater in fan mode (continuous operation). This feature circulates the air through out the cabin area. The temperature control knob has no function in fan mode. If the heater is in fan mode, the blue LED lights up as a check.

4 T mp e S ettttiin orr T he os att a nd Rh eo

Using the adjusting dial, set the desired temperature range.

Lowest Setting - approx. 10°C (50°F)

Mid - Setting - approx. 20°C (68°F)

Highest Setting - approx. 30°C (86°F)

O n//O wiittc g lliig htt

On OEM installs the “red” & “green” indicator lights illuminate.

On aftermarket installs only the “red” light illuminates.

O pe diic attiin g lliig htt

R ed D operation check for heater

H ea

Offff s wiittc e L D operation check for fan

F n

T em erra e c on kn b

• Counter-clockwise end stop approx. 47°F (8.5°C) - small amount of heat

• Clockwise end stop approx. 97°F (36°C) - large amount of heat

15

Operation and Function

5 T mp

• The temperature is monitored constantly at the heater’s process air inlet or external sensor.

This temperature is compared to the set temperature on the adjusting dial (Mini controller/Thermostat).

The heater cycles through Boost, High, Medium and

Low heat modes to maintain the desired temperature.

If the desired temperature is exceeded while the heater is operating in low heat mode the heater will switch into

“standby” mode. This is a comfort feature.

The heater will re-start once heat is required again.

6 S wiittc Offff

Once switched off manually, the heater begins a controlled cool down cycle.

• Indicating light(s) on switch will go off.

• Fuel pump stops delivering fuel.

• The glow pin is re-energized for a 40 second after-glow to burn off any combustion residue.

• The blower continues to run for 4 minutes and automatically switches off.

7 C nttrro an d S Eq uiip ntt

• If the heater fails to ignite within two 90 second start attempts, a "no start" shut down occurs.

• If a flame out occurs after the heater has started, the heater will attempt one restart.

• If repeated flame outs occur within 10 minutes the heater will not restart.

• Overheat shut down will occur if there is a restriction of the heating air flow (i.e. blocked inlet or outlet). The overheat sensor will automatically reset once the heater has cooled down.

• Once the air flow restriction is removed, the heater can be re-started by switching the heater off then back on.

• If the voltage drops below 10.5 volts or rises above

16 volts the heater will shut down (21 volts and 28 volts for 24 volt systems).

• If the glow pin circuit or fuel metering pump circuit are interrupted the heater will not start.

• The blower motor is checked continuously during operation. Shut down will occur if the blower does not start or maintain proper speed.

O pe attiio na Fllo w C arrtt

Operating

Mode

System

Check

Pre-heat

STARTING PHASE

Ignition

Attempt

Pre-heat

2nd. attempt

Ignition

Attempt

2nd. attempt

RUNNING PHASE

Boost

Controlled

Heating

SHUT DOWN PHASE

After

Glow

Cool

Down

Stand by

Off

On On On On On On On On On

Blower

Off

On On On On

Off Off

On

Off Off

Glow Pin

Off Off

On

Off

On On On

Off Off Off

Fuel Pump

1- 3 sec.

60 sec.

Up to

90 sec.

60 sec.

Up to 90 sec.

If Required

Time dependent on heat exchanger temperature

Continual

Operation until switched off by operator

or temperature control

40 sec.

4 min.

Note: During controlled heating cycle, if desired heat level is exceeded the heater will switch into standby mode.

Heater will automatically restart once heat is again required

16

Operation and Function

AIIR TR C D 2

AIIR TR C D 4

17

Operation and Function

S ch ma A RO NIIC 2 // AIIR TR C D 4

1.5

Flame sensor

Green

2 1

2 1

1.1

Overheat sensor

Blue

Blue

2 1

2 1 2 1 2 1

1.2

Black

2 1

Natural/Clear

1 2

2.1

2.2

S1

1

9

2 3 4 5 6 7 8

10 11 12 13 14 15 16

9 10 11 12 13 14 15 16

B1

1 2 3 4 5 6 7 8

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

Green/Red

Brown

6.2

Red

Yellow

Grey

Brown

Blue/White

Grey/Red

Brown/White

6.1

Red

Yellow

Brown

Blue/White 2.7

Red

1.1

1.2

1.5

2.1

2.2

2.7

Blower Motor

Glow Pin

Overheat and Flame sensor

Control Unit

Fuel Metering Pump

Main Fuse 12Volt - 20 amp / 24 volt - 10 amp

3.1.17

Mini Controller

3.1.11 Rheostat

3.2.8

7 Day Timer

3.5

Thermostat

5.1

6.1

6.2

Battery

Diagnostic Pigtail (for connection to Fault code retrieval device)

5 amp switch fuse - on certain models only

Brown

18

5.1

a) e c ollo y orr s wiittc s

D es na yellow= switch brown = ground (-) grey = temperature sensor on thermostat

**vehicle dimmer switch for light display on

7-day timer grey/red = temperature setting blue = diagnostic from heater blue/white = diagnostic from heater brown/white = ground black = to vehicle ignition accessories for continuous operation of heater on

7 day timer

Operation and Function

Yellow

Brown

Blue/White

Brown/White

Grey/Red

Optional

Red

Yellow

Brown

Brown

Blue/White

Brown/White

Red

Brown

TRS

DIAG a)

Red

Yellow

Grey

White/red

Brown

Bue/White

Grey/Red

Brown/White

S2 B2

1 4 7 10

2 5 8 11

3 6 9 12

3.2.8

B2 S2

Red

Yellow

Brown

Grey

Red

Blue

3.1.17

a)

Red

Yellow

1 2 3 4 5 6 T

1 0

RED GREEN

Brown/White

3.5

B3

Red

Yellow a)

Brown

Bue/White

Brown/White

3.1.11

19

Maintenance / Troubleshooting / Repair

M aiin na nc

R ec mm en d P erriio c M aiin na nc e

• Remove the g

Clean or replace.

• Remove the g up. Clean or replace.

n s crre

• Make sure v of non-detergent 100% volatile carburetor cleaner, an air gun will also help. Remove loose carbon from the glow pin chamber.

• Inspect the d restriction or blockage.

• Inspect c mb us ntta ke nd xh au

• Operate your heater for a minimum of 20 minutes each month.

• M n y ou erriie s 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 ffu ell s uiitta orr tth e c e (see engine manufacturers recommendations). Blending used engine oil with diesel fuel is not permitted.

B as

C he k L es ho ottiin g

What happens when the heater is switched on and ....

H ea err d oe s n ott iig

C he ck shuts off

- Fuse in power harness.

- Power to control unit.

- Power to and from switch.

- Electrical connections.

C he ck - Ensure voltage at control unit remains above 10 volts during start up with glow pin circuit on.

shuts down after two start up attempts

C he ck - Fuel lines and fuel filter.

- Fuel quantity. Pg. 25

- Combustion air or exhaust tube blockage.

C he ck - For electrical pulses at fuel metering pump.

- If pump is frozen.

- Blocked fuel line.

H ea err iig niitte

C he ck - Fuel metering pump quantity. Pg. 26

- Possible overheat.

- Control unit input voltage.

C he ck - Exhaust pipe blocked.

- Combustion air intake blocked.

- Exhaust entering combustion air intake pipe.

- Short cycling, rapid on/off operation.

- Fuel system.

- Fuel metering pump quantity.

- Motor rpm.

20

Maintenance / Troubleshooting / Repair

S ellff D gn sttiic s

The heater is equipped with self diagnostic capability. To retrieve information on the heater’s last 5 faults, a retrieval device is required (P/N: CA1 05 020). There is a pig tail to accommodate the connector on the main harness from heater. If wire pigtail is not present, a wiring adapter (P/N: 22 1000 31 86 00) must be used.

Connect the fault code retrieval device as shown. This device enables these five functions to be performed.

1.

Access the current fault which is affecting the heater.

2.

Access the five previous faults which affected the heater.

3.

Clear the fault memory to erase previous fault history.

4.

Unlock “lockout features” which exist for some control units.

5.

Start heater.

E qu me ntt F ac e a nd on

Symbols that are seen on the display face are as follows:

AF

F1-F5

Actual fault.

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.

DIAG

000

The word (DIA) ‘gnostic will come on when the unit is connected.

Three digit diagnostic fault code number.

R ettrriie De viic

1. delete fault memory

2. delete fault memory

3. switch heater on / off, request diagnostic fault codes

4. backwards, fault F5 - F1, AF

5. forward AF, F1 - F5

6. display

• 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).

• Consult the fault code chart for code number descriptions.

• To erase the faults that are in memory press both "L" keys at the same time for 5 seconds. This will also unlock the control unit in the case of an operational lockout.

N e: If there are no heater faults, the heater will go through a normal start cycle and regulate based on thermostat setting.

S ee ch em c p g.. 1

21

Maintenance / Troubleshooting / Repair

F au od F au es pttiio n C au se s // R ep

000

004

Normal Operation

Warning - short circuit in control unit, fresh air-outlet

005 Warning - short circuit at control unit - anti-theft alarm output

009 TRS - shut down

010 Overvoltage

011 Undervoltage shut down

012 Overheat at overheating sensor

013 Overheat at flame sensor

014 Temperature difference between flame sensor and overheat sensor too large

015 Overheat with excessive temperatures

017 Overheat with excessive temperature

019 Glow Pin Resistance

020 Open circuit - glow pin

021 Short circuit - glow pin

C au n!!

For A RT RO NIIC 12 volt, check functions with max. 8 volt

RT RO NIIC 24 volt, check functions with max. 18 volt.

If voltage values are exceeded the component is destroyed.

C he k s ciirrc uiitt rre an ce off m aiin s u niitt:: m n.. 2 0 A p..

Disconnect connection S1/B1 at AIRTRONIC . At connector B1, pin 16 check for short between pin and blower relay. If no short exists replace control unit.

Disconnect connection S1/B1 at AIRTRONIC . At connector B1, pin 16 check the line through to the relay isolating switch or theft warning in line for short circuit to chassis. If no short exists replace control unit.

Switch off due to signal change.Check for change of signal from (+) to

(-) at pin 13 (S1) or a (+) signal at pin 14 (S1).

Start vehicle motor. Check voltage at (B1) between terminals 1 and 10.

This must be less than 16 volts (15.2 volts with glow pin on). Check vehicle charging system.

AIRTRONIC 24 volt - voltage must be less than 32 volts

Start vehicle motor. Check voltage at connector (B1) between terminals

1 and 10. This must be more than 10 volts. Check vehicle charging system. Check batteries and connections.

AIRTRONIC 24 volt - voltage must be more than 21 volts .

Sensor has detected excessive temperatures. Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Re-route if necessary. Check overheat sensor resistance values. (see component value chart pg 25). If O.K. Measure fuel quantity. See page 25.

Flame sensor detects excessive temperature at heat exchanger. Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Re-route if necessary. Measure fuel quantity. See page 25. Check flame sensor resistance. (see component value chart pg 25)

Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Check flame sensor, if O.K., check overheat sensor. If over-heat sensor is defective replace combisensor. If over-heat sensor is O.K. measure fuel quantity. See page 25.

If fuel quantity is O.K. replace control unit.

Fault code 015 is shown when the AIRTRONIC is switched on again after fault code 017. The hardware limit value for the overheat sensor, has been exceeded - control unit is damaged. Check sensor.

Replace control unit.

The hardware limit value for the overheat sensor, has been exceeded, because the control unit has not detected fault code 012, 013.The control unit is locked. If AIRTRONIC is switched on again, fault code 015 is displayed. Replace control unit. Check sensor.

Power consumed by glow pin is too low (glow pin resistance is too high). Replace the glow pin.

Check continuity of glow pin.

AIRTRONIC 12 volt - approx. 0.5

Ω

± 0.05

Ω

AIRTRONIC 24 volt - approx. 2

Ω

± 0.2

Ω

Check functions of glow pin in installed condition, to do so disconnect connector from controller.

AIRTRONIC 12 Volt and 24 Volt. Apply voltage of 8 / 18 volts to glow pin respectively, and measure current intensity after 40 seconds. Glow pin is O.K. for the following values: glow pin 8 volt - current = 9 amps + 1.5 / - 1.2 amps glow pin 18 volt - current = 4 amps ± 0.5 amps

If the values differ, replace glow pin. If the values of the continuity test and function test are O.K., check glow pin cable harness for damage and continuity. If O.K., replace control unit.

22

Maintenance / Troubleshooting / Repair

F au Co e F au es pttiio n C us es Re aiirr

031 Blower motor interrupted

032 Blower motor, short circuit

C au n!!

For A RT RO NIIC 12 volt, check functions with max. 8 volt

RT RO NIIC 24 volt, check functions with max. 18 volt.

If voltage values are exceeded the component is destroyed.

C he k s uiitt rre siis an ce off m aiin s u niitt:: m n.. 2 0 A p..

033 Blower motor does not turn

047 Short circuit - fuel metering pump

048 Open circuit - fuel metering pump

050 Too many no start attempts

051 Faulty flame recognition

052 No start safety time exceeded

053

054

055

056

Flame cutout in boost mode

Flame cutout in high mode

Flame cutout in medium mode

Flame cutout in low mode

060 Open circuit - external temperature

061 Short circuit - external temperature

Check blower motor cable harness for correct routing and damage. If

O.K., disconnect cable harness from control unit and check for continuity, if O.K., replace control unit.

Check functions of blower motor, to do so, disconnect connector from control unit. Apply voltage of 8 volts or 18 volts ± 0.1 to blower motor and measure current intensity after 40 seconds.

Current < 6.5 amp - blower motor O.K., replace controller

Current > 6.5 amp, replace blower.

Motor speed varies from specification by more than 10% for longer than

30 seconds.

If too slow, check for restriction, and check for short in motor circuit or control unit. If none found, replace blower.

If too fast, check for damage or missing magnetic sensor on control unit. Replace blower motor if damaged.

Replace control unit otherwise.

Disconnect connector from fuel metering pump, if fault code 048 (interruption) is displayed then the fuel metering pump is defective, replace

FMP.

If fault code 047 is still displayed, then disconnect connection S1/B1. At connector B1, Pin 5, check line1(green/red) through to FMP for short circuit to pin 10, if O.K. replace control unit.

Disconnect connector from fuel pump and measure resistance value of fuel pump (see values, pg 26). If resistance values O.K., then reconnect cable harness to the fuel pump. Disconnect connection S1/B1, and measure the resistance value between pin 5 and pin 10. If O.K., replace control unit.

Control unit is locked after too many unsuccessful start attempts. Check fuel, glow pin, combustion air and exhaust flow. Use control unit tester or fault code retrieval device to unlock control unit. Maximum 255

If the resistance value of flame sensor is 1274 Ω after switching on (>

70°C), then the blower of the AIRTRONIC runs for approx. 15 minutes to cool down. If resistance does not fall below the above value within 15 mins., this is followed by fault shut down. Check flame sensor, diagrams and values, pg 25. If O.K., replace control unit.

No flame detected on start attempt. Check exhaust and combustion air lines. Check fuel supply/measure fuel quantity, see following pages.

Check glow pin (see fault code 020 and 021). Check flame sensor, diagram and values table on following pages, if O.K., replace control unit.

Heater has started successfully the flame has extinguished.

Check exhaust and combustion air lines. Check fuel supply/measure fuel quantity, see values, pg 25. Check flame sensor, diagram and values table on following pages, if O.K., replace control unit.

Temperature sensor detects a value beyond it's range sensor

Disconnect connection S1/B1 (main harness), measure resistance value at connector B1, pins 6 & 12. Refer to the values table on pg 25.

If there is an open circuit, the ohmic value between the pins is > 7175

Ω

. If the resistance value is O.K., then the control unit is defective.

Replace control unit.

Disconnect connection S1/B1 (main harness), measure resistance value at connector B1, between pins 6 & 12., see values on pg 25. If there is a short circuit, the ohmic value between the pins is < 486 Ω . If fault 061 continues to be displayed, then the control unit is defective.

Replace control unit.

23

Maintenance / Troubleshooting / Repair

F au Co e

062 Thermostat/Rheostat/Timer, open circuit

063 Switch control - short circuit

Fault recognition only works in heating mode. However, if a short circuit already exists and the AIRTRONIC is subsequently switched on, ventilating mode will be active (no fault code).

064 Open circuit - flame sensor

065 Short circuit - flame sensor

071 Open circuit - overheat sensor

072 Short circuit - overheat sensor

090

091

Control unit defect

External voltage disturbance

092

094

096

097

Control unit defective (ROM fault)

Control unit defective (EEPROM fault)

Internal temperature sensor defect

Control unit defective (power failure)

F au es pttiio n C us es Re aiirr

Potentiometer values outside of range on Thermostat (switch)

Check resistance between pins 6 and 7 at B1.

Resistance value for interruption between pins > 7175 Ω

Normal value: 1740

Ω

- 2180

Ω

(± 80

Ω

)

If resistance value is O.K., replace control unit. If not replace thermostat switch.

If a ventilating switch has been built in, disconnect and check function. If faulty, replace switch. Disconnect wires from thermostat or switch. If fault code 062 is displayed, replace switch. If switch is O.K., check connection lines grey/red and brown/white for short-circuit. If O.K., reconnect wires to thermostat/switch. Disconnect connection B1. If fault 063 is still displayed, replace control unit. Resistance value for short circuit between pins 6 and 7 < 486 Ω . Normal value: 1740 Ω - 2180 Ω (± 80

Ω ).

Sensor is sensing value outside of range. Open Airtronic shell and remove control unit from casing. Disconnect green connector from control unit. At green connector measure resistance value at green wire and brown/white wire. Check flame sensor, diagram and values on pg.

25. If flame sensor is O.K., replace control unit. Resistance value for interruption > 7175

Ω

Open Airtronic shell and remove control unit from casing. Disconnect green connector from control unit. If fault 064 is displayed, replace combination sensor (flame/temperature). If fault 065 is still displayed, replace control unit. Resistance value for short circuit < 486

Ω

, see values on following pages.

Open Airtronic shell and remove control unit from casing. Disconnect blue and green connectors from control unit. Measure the resistance value at blue connector(pin 1- blue wire) and at green connector pin 2

(brown/white wire). See values on following pages. If O.K., replace control unit. Resistance value for interruption > 223 Ω .

Open Airtronic shell and remove control unit from casing. Disconnect blue connector from control unit. If fault 071 displayed, replace combination sensor (flame/temperature). If fault 072 is still displayed, replace control unit. Resistance value for short circuit < 183 Ω , see following pages for values.

Internal failure. Replace control unit.

Check vehicle charging system. Poor battery, battery charger, eliminate fault.

Internal failure. Replace control unit.

Replace control unit.

Replace control unit or use external temperature sensor.

Internal failure. Replace control unit.

24

Maintenance / Troubleshooting / Repair

F ue Qu an y T stt

The fuel quantity should be tested if the heater has difficulty starting or maintaining a flame. Check the following before measuring fuel quantity.

• Check the filter in the fuel pump.

• Check that the fuel lines are correctly routed.

• Check that the fuel lines don’t leak.

• Check and tighten hose connections.

• Does fuel withdrawal comply with the data in the technical description.

attiio n

• Detach the fuel line from the AIRTRONIC.

• Insert the fuel line into a measuring glass (10 cm3) graduated cylinder 10ml.

• Switch the AIRTRONIC on and allow fuel system to bleed out air for approx. 60 seconds.

• Switch the AIRTRONIC off and drain the measuring glass.

ea su me

• Switch the AIRTRONIC on.

• The fuel is pumped approx. 30 seconds after switching on.

• Hold the fuel line in the measuring glass level with the glow pin while fuel is being delivered.

• The pump will stop automatically after delivering fuel for 90 seconds (110 seconds for AIRTRONIC 4).

• Once fuel pump stops, switch off the heater.

Ev allu

• Read out the quantity of fuel in measuring glass.

• Fuel quantity should be between:

3.7 ml and 4.3 ml. on AIRTRONIC 2

5.4 ml and 6.3 ml. on AIRTRONIC 4

• If the fuel quantity is outside this range, check for and remove any restriction in fuel system or replace the fuel metering pump.

N e:: The fuel quantity is not affected by voltage variances.

Espar part # CA0 05 006

Graduated Cylinder 10ml

V Ov errh en orr

Temperature (°C)

Temperature °C (F°) Resistance k

Ω

-40 (-40)

-20 (-4)

0 (32)

20 (68)

40 (104)

60 (140)

80 (176)

100 (212)

120 (248)

140 (284)

160 (320)

180 (356)

200 (392) min.

1597.0

458.80

154.70

59.30

25.02

11.56

5.782

3.095

1.757

1.050

0.6654

0.4253

0.2857

V allu allu Flla me en

Temperature (°C)

Temperature °C (F°) Resistance

Ω

-40 (-40)

0 (32)

40 (104)

80 (176)

120 (248)

160 (320)

200 (392)

240 (464)

280 (536)

320 (608)

360 (680)

400 (752) min.

825.90

980.00

1132.30

1282.80

1431.50

1578.30

1723.40

1866.60

2008.10

2147.70

2285.50

2421.50

max.

859.60

1020.00

1178.50

1335.10

1489.90

1642.80

1793.70

1942.80

2090.00

2235.40

2378.80

2520.30

25 max.

1913.0

533.40

175.50

65.84

28.04

13.16

6.678

3.623

2.081

1.256

0.792

0.5187

0.3513

Maintenance / Troubleshooting / Repair

C on oll v allu s

M otto pe d

C on stta e

• Power

• Fast

• Medium

• Slow

• Adjustment

- in circulation mode with temperature sensor, internal

- In fresh air mode with temperature sensor, external

• Ventilation

R es stta nc e v allu

C om on

Glow plug ntt

Fuel metering pump

Operator control unit set value potentiometer

AIIR TR NIIC 2 --1 V

0.5 Ω ± 0.05 Ω

10

Ω

± 0.5

Ω

1750 - 2080 Ω ± 80 Ω

AIIR TR NIIC 2 --2 V

2 Ω ± 0.2 Ω

36

Ω

± 1.8

Ω

1750 - 2080 Ω ± 80 Ω

AIIR TR C

D 2

4800 U/min ± 140 U/min

4000 U/min ± 120 U/min

2800 U/min ± 80 U/min

2000 U/min ± 60 U/min

600 U/min ± 20 U/min

0 U/min

4800 U/min ± 140 U/min

AIIR TR NIIC

0.5 Ω ± 0.05 Ω

10

Ω

± 0.5

Ω

1750 - 2080 Ω

4 --1

± 80

V

Ω

AIIR

4400 U/min ± 130 U/min

3600 U/min ± 100 U/min

2800 U/min ± 80 U/min

1600 U/min ± 50 U/min

600 U/min ± 20 U/min

0 U/min

3600 U/min ± 100 U/min

AIIR TR

TR

NIIC

2 Ω ± 0.2 Ω

36

Ω

± 1.8

Ω

1750 - 2080

C

Ω

4 --2

± 80

V

Ω

S wiittc hiin g v allu e

C om ne ntt

Overheating sensor

AIIR TR C D 2 // D

160°C - 170°C measured in the control stage “power”and at a clearance of 300 mm from the hot air outlet

300 mm

E xh stt v allu

CO

2 in exhaust in control stage “fast”

Soot number as per Bacharach

AIIR TR C D 2 // D

7.5 -12.5 Vol. %

<4

26

Maintenance / Troubleshooting / Repair ep aiirr IIn cttiio s em ov g tth co err em ov g a em ov g tth em ov d c he kiin e c on em ov g a

IIn stta g tth d c he kiin e o ve ea g tth e o errh att a nd d fflla me en

Diis ma g tth e h att e xc ha ng em ov g tth em ov g tth co mb sttiio bllo err co mb sttiio n c ha mb err am e s ns orr on Remove power from the heater prior to any disassembly by unplugging main connection or removing main fuse.

Carefully check all seals and O-rings and replace where necessary.

Clean all parts before reassembly and check for any signs of damage, replace where necessary.

R em viin g tth e c ov err ffrro m tth AIIR RO C

Unlock both seal plates, lift cover and pull to the front.

N e::

The cover must always be removed from the AIRTRONIC for all repair stages. You may have to wait for the device to cool down.

The cable harness can exit from the left or right of heater shell.

Cover

1

Seal Plates

2

R em viin g tth co nttrro

AIIR TR C cover.

Unscrew fastening screw, press retaining brackets together, lift out control unit. Unclip the lines from the holder of the control unit (observe the positions of the lines). Remove the bushing

(lower part) from the outer case. Disconnect the control unit from the controller. The control unit can now be removed.

N e::

When reassembling the control unit, ensure that the lines are correctly clipped in the holder of the control unit, and that the connectors are plugged into the control unit (non-interchangeable).

Fastening screw

1

Retaining brackets

2

Control unit

3

Bushing

4

C he kiin g tth e c on

A test instrument is necessary to check the control unit in a dismantled state. The test instrument is connected up to the

PC and with special software can display run times on certain parts and give a visual of heater in operation.

Part number: 22 1524 89 00 00

Adapter P/N: 22 1000 31 86 00

2 3

N e:: Control unit can only be checked while on heater.

27

Maintenance / Troubleshooting / Repair

H ea err C as ss em

• Remove the AIRTRONIC cover.

• Remove the control unit.

Disconnect the connector of the glow pin cable harness from the control unit.

Remove the rubber grommet and use the special tool (SW 12) to unscrew the glow pin.

The special tool is included with the glow pin.

Tighten torque of the glow pin : 6 +0.5

Nm

N e::

When the glow pin has been removed, check the screen of the support in installed state for any contamination. The screen must be replaced if the surface is covered with carbon.

Glow Pin

1

Connector of glow pin cable harness 2

Rubber bushing

3

R em viin g tth e s

Pull the screen out of the support with pointed pliers. Blow out the support with compressed air.

If necessary, carefully pierce with a wire.

The special tool has to be used to install the new screen. The special tool is included with the screen. Push the screen onto the special tool, watching the position of the recess. The recess must be positioned at right angles (90°) to the axis of the heater.

Push the tool with the screen carefully as far as it will go, ensuring that the bore (ø 2.7 mm) for the glow plug ventilation is free. See illustration 1.

1

Special tool with lining

2

Position of recess

28

Screen

1

Bore (Ø 2.7 mm) for glow pin ventilation

2 illustration 1

Maintenance / Troubleshooting / Repair

R em viin g tth e o errh att s en orr // fflla e s en

Remove the AIRTRONIC cover.

Remove the control unit.

Disconnect both connectors of the overheating / flame sensor cable harness from the control unit.

Unlock clip from sensor.

Remove overheat/flame sensor.

Cable harness for overheat/flame sensor

1 clip 2

C he kiin g tth e o he att // fflla en orr

Observe a maximum temperature of 320° C for checking the sensor.

O ve ea se ns

Check the overheat sensor with a digital multimeter. If the resistance value is outside the set point indicated in the values, on pg.26 then the sensor must be replaced.

Flla me en orr

Check the flame sensor with a digital multimeter. If the resistance value is outside the set point indicated by the values table on pg 26, then the sensor must be replaced.

IIn stta g tth ov errh att // fflla en orr

For AIRTRONIC D2 (Assembly using purpose made tool) mount the special tool on the sensor.

Place the sensor on the heat exchanger using the special tool.

The special tool slides on the heat exchanger until the sensor meets the collar (installation site of the sensor).

Lock the sensor in place and remove the purpose made tool. It is then vital to check that the sensor sits flat on the heat exchanger. If necessary use a mirror and lamp to aid correct assembly.

Route the cable harness sensor along the clip eyelet to the control unit and connect.

1 Special tool - only for AIRTRONIC D2

2

Overheat sensor / flame sensor

Connector blue

1

Special tool - only for AIRTRONIC D2

2

Overheat sensor / flame sensor

Connector green

1 NTC 50 Ω = overheating sensor

2

PT =flame sensor

1

2

Clip

Overheat sensor / flame sensor

1

Clip

2

Cable harness - overheat/ flame sensor

3

Special tool - only necessary for the AIRTRONIC D2

29

Maintenance / Troubleshooting / Repair

Diis ma

R em nttlliin g tth viin g tth e h e c ea om xc ha err sttiio n a bllo err

• Remove the AIRTRONIC cover.

• Remove the control unit.

Remove the flange seal.

Take the AIRTRONIC out of the outer case (lower part).

Unscrew the 4 fastening screws from the combustion air blower.

Remove the combustion air blower and the seal from the heat exchanger.

mp orrtta

When reassembling the combustion air blower, a new seal is always required.

Tighten the 4 fastening screws of the combustion air blower in the series shown in the drawing, with a tightening torque of 4

+0.5

Nm.

1 Combustion Air blower

2

Heat Exchanger

3

Fastening screws

1

-

4

Tighten the fastening screws in this sequence with a tightening torque of 4 +0.5

Nm

5

Always replace the seal between combustion air blower and heat exchanger

30

Maintenance / Troubleshooting / Repair

R em viin e c om sttiio n c am err

• Remove the AIRTRONIC cover.

Remove the flange seal.

Take the AIRTRONIC out of the outer case (lower part).

Remove control unit ( see previous pages).

Remove glow pin ( see previous pages).

Remove combustion air blower ( see previous pages).

Unscrew the fastening screws.

For AIRTRONIC D2 = 3 fastening screws

For AIRTRONIC D4 = 4 fastening screws

Pull the combustion chamber out to the front and remove the seal from the heat exchanger.

N e!!

When reassembling the combustion chamber, the seal, which has been enclosed with the spare part, must always be replaced.

Tighten the fastening screws of the combustion chamber with a torque of 5 +0.5

Nm.

N e::

If the heat exchanger is being replaced, the overheat / flame sensor must be dismantled and mounted to the new heat exchanger (see previous pages).

1

Combustion chamber

2

Heat Exchanger

3 Fastening screws

AIRTRONIC D2 = 3 fastening screws

AIRTRONIC D4 = 4 fastening screws

1

Combustion chamber

2

Seal between combustion chamber and heat exchanger

- must always be replaced.

3

Heat exchanger

4

Fastening screws

AIRTRONIC D2 = 3 fastening screws

AIRTRONIC D4 = 4 fastening screws

31

Parts List

AIIR TR C D 2 // D

S errv e P arrtts Diia grra

B // D 4

1 1

1 6

1 5

1 7

1 8

1 3

1 4

32

Parts List

AIIR TR C D 2 // D B // D 4

R eff.. N D es pttiio n P arrtt N mb

7

8

9

3

4

5

6

1

2

10

11

12

13

14

15

16

17

18

19

20

Heat exchanger

Burner

Gasket seal

Grommet

Fillister head bolt, M 5 x 12 (3 required)

Fillister head bolt, M 5 x 12 (4 required)

Blower motor

Fillister head bolt, M 5 x 25

Gasket, blower

Control unit

25 2069 06 01 00

25 2113 06 01 00

25 2069 10 01 00

25 2113 10 01 00

20 1812 10 01 00

25 2069 06 00 01

25 2113 06 00 01

25 2069 06 00 02

103 10 348

103 10 348

12V 25 2069 99 20 00

24V 25 2070 99 20 00

12V 25 2113 99 20 00

24V 25 2114 99 20 00

12V 25 2144 99 20 00

24V 25 2145 99 20 00

Locally available hardware

25 2069 01 00 03

25 2113 01 00 03

24V 22 5102 00 10 01

12V 22 5101 00 10 05

24V 22 5102 00 10 03

12V 22 5101 00 10 06

24V 22 5102 00 10 06

12V 22 5101 00 10 12

12V 22 5101 00 10 11

12V 22 5101 00 10 13

12V 22 5101 00 10 14

Hella 12V 22 5101 00 30 01

Hella 12V 22 5101 00 30 05

22 5101 00 30 15

Fillister head bolt, M 4 x 10

Upper casing

Lower casing

Grommet

Flange seal

Overheat sensor / Flame sensor with tool

Clip

Glow pin

Glow pin screen with tool

Mounting plate with hardware and seal

Socket wrench

103 10 349

25 2069 01 06 00

25 2113 01 00 01

25 2069 01 01 00

25 2113 01 01 00

25 2069 01 00 01

25 2069 01 00 02

25 2069 01 02 00

25 2069 01 02 02

25 2113 01 02 02

12V 25 2069 01 03 00

24V 25 2070 01 03 00

25 2069 10 01 02

CA0 00 019

25 2069 01 03 03

• • • •

• • • • • • • •

• •

• • • • • • •

• • • •

• • • • • • •

• • • • • • • • • • •

• • • •

• • • • • • •

• • •

• • • • •

• •

• • • • • • • • • • •

• • • •

• • • • • • •

• • • • • • • • • • •

• • • •

• • • • • • •

• • • •

• • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • •

• • • •

• • • • • • •

• • • •

• • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

33

Parts List

AIIR TR C D 2 // D

S errv e P Diia grra

B // D 4

3 0

34

2 2

2 5

1 0

1 8

1 3

1 0

1 2

2 3

1 7

1 9

3 4

2 0

3 7

3 8

3 a

4 4

3 3

3 6

Parts List

AIIR TR C D 2 // D B // D 4

R eff.. N D es pttiio n P arrtt N mb err

5

6

10

11

12

7

8

9

16

17

18

19

20

13

14

15

21

22

23

24

25

26

*27

28

*29

*30

31

32

33

*34

1

2

2a

3

4

Safety screen

Warm air deflector

Clamp

Flexible air hose

Straight outlet hood

Main harness

• short harness

Cable ties

Air intake

Flexible exhaust

Fuel hose - rubber

Plastic fuel line

Fuel metering pump

ø25 mm

ø24 mm

3.5 mm

1.5 mm

12V

24V

Clamp for fuel metering pump

Plastic fuel line - black

Angle bracket

2 mm

Fuel hose - rubber

Clamp

Clamp

End sleeve with cross bar - 25mm plastic

9 mm

Grommet

5 mm

11 mm

ø 60

ø 75

ø 60

ø 90

ø75

ø 50-70

ø 70-90

ø 60

ø 90

ø 75

ø 60

ø 90

ø 75

Intake hose clamp

Clamp

ø 20-32

26 mm

Fuel screen

Blade fuse 20 amp

10 amp

Plug connector - Kit

Housing - Kit female

Muffler

Connectors for fuel metering pump - Kit

90° Air outlet hood

90° Bend

ø 60

ø 75

ø 90

ø 60

ø 75

Fuse holder with terminals

Terminals

3/8’ Ring terminals 10-12 G

7 day timer with thermostat 12V

24V

25 1688 80 06 00

25 1552 05 01 00

20 1577 89 06 00

20 1609 80 09 00

22 1050 89 21 00

CA1 10 047

CA1 10 042

10 2114 31 00 00

10 2114 37 00 00

10 2114 34 00 00

22 1000 01 00 16

22 1000 01 00 19

22 1000 01 00 18

CA1 60 201

CA1 60 205

CA1 00 005

360 00 006

25 1774 80 02 00

360 75 300

090 31 118

22 4519 01 00 00

22 4518 01 00 00

22 1000 50 03 00

090 31 125

CA0 10 105

360 75 350

10 2068 01 10 98

10 2068 00 90 98

25 1729 89 00 02

20 1280 09 01 03

10 2065 02 00 32

152 61 102

20 1312 00 00 06

CA1 07 005

CA1 07 006

22 1000 31 80 00

22 1000 31 81 00

25 1864 81 01 00

22 1000 31 87 00

22 1000 01 00 20

22 1000 01 00 22

22 1000 01 00 23

25 1688 89 00 01

25 1482 89 00 05

CA1 07 001

CA1 90 043

CA1 90 014

22 1000 30 40 00

• • • •

• • • • • • •

• • • • •

• • • • • • •

• • • • • •

• • • •

• • • • • • •

• • • •

• • • • • • •

• • • • • • •

• • • •

• • • • • • •

• • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • •

• • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • •

• • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • •

• • • • • • •

• • • • • • •

• • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • •

• • • • • • • • • • •

35

Parts List

AIIR TR C D 2 // D B // D 4

R eff.. N es crriip P arrtt N

39

40

41

42

43

44

35

*36

37

* 38

* 38a

Thermostat 12V

24V

Operating switch (rotary)

Standard fuel pick up pipe

P-clamp

End-sleeve

Fault code retrieval device

Bezel kit for 7 day timer

Mini Controller

12V

24V

2 mm

Fuel pick up pipe (Compression fitting type)

Compression fittings

P-clamp w/Lining

1/4” NPT

3/8” NPT

1/2” NPT

10 mm

P-clamp 25 mm

28 mm

24 mm

301 00 154

301 00 153

25 1895 71 00 00

25 1896 71 00 00

CA0 12 056

CA0 12 042

CA0 12 044

CA0 00 031

CA0 12 005

152 00 139

152 10 048

152 10 051

25 1482 80 00 01

CA1 05 020

25 1482 70 01 00

22 1000 32 07 00

*indicates optional features

• •

• •

• • • •

• •

• •

• • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

• • • • • • • • • • •

36

3rd Printing - February 2007

Printed in Canada

P/N: 20-2900-81-01-03-0A

Espar Products, Inc.

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

A member of the Worldwide E pä ch Group of Companies

advertisement

Related manuals

Download PDF

advertisement