Airtronic 2-4.pdf

AIRTRONIC / AIRTRONIC M

Technical Description

Installation Instructions

Operating Instructions

Maintenance Instructions

Troubleshooting and Repair Instructions

Parts List

Espar Heater Systems

Espar Products, Inc.

(800) 387-4800

(905) 670-0960

www.espar.com

AIRTRONIC D2

25 2069 05 - 12 Volt

25 2070 05 - 24 Volt

AIRTRONIC M D4

25 2113 05 - 12 Volt

25 2114 05 - 24 Volt

AIRTRONIC M B4

20 1812 05 - 12 Volt

AIRTRONIC D2 Camper

25 2326 05 - 12 Volt

AIRTRONIC M D4S

25 2144 05 - 12 Volt

AIRTRONIC M D4 Camper Plus

25 2327 05 - 12 Volt

P/N: 20 2900 81 01 03

10.2010 Subject to Change

Web Edition

Table of Contents

Page

Introduction

Heater Warnings

........................................................ 3

Introduction

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

Technical Data

........................................................ 5

Dimensions

........................................................ 6

Heater Components

........................................................ 7

Installation Procedures

Heater Location ........................................................ 8

Heater Mounting ........................................................ 8

Heater Plate installation ........................................................ 8

Mounting Pattern ........................................................ 9

Heater Air Ducting ........................................................ 9

Ducting Components ........................................................ 9

Fuel System ........................................................ 10

Electrical Connections ........................................................ 12

Exhaust/Intake Connections ........................................................ 13

Operating Switches

........................................................ 13

Heater Operation

Switch on ........................................................ 14

StartUp ........................................................ 14

Temperature setting ........................................................ 15

Temperature Control ........................................................ 16

Switching Off ........................................................ 16

Controls & Safety Equipment ........................................................ 16

Operational Flow Chart ....................................................... 16

Function Diagrams ........................................................ 17

Schematic AIRTRONIC D2/D4 ........................................................ 18

Maintenance,

Periodic Maintenance

........................................................ 21

Troubleshooting &

Basic Troubleshooting

........................................................ 21

Repairs

Self Diagnostic Troubleshooting ........................................................ 22

Fault Codes ........................................................ 23

Fuel Quantity Test ........................................................ 29

Overheat/Flame sensor values ........................................................ 29

Control and Resistance values ........................................................ 30

Repair Steps

........................................................ 31

Heater Parts

AIRTRONIC D2/D4

Service Parts Diagram ........................................................ 36

Service Parts List

........................................................ 37

Parts List Diagram

........................................................ 38

Parts List

........................................................ 39

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.

This document aims to support service technicians and end users in North America. This does not replace documenta

tion produced by J. Eberspächer.

The installation instructions and standards described in this document are NOT APPLICABLE TO MARINE INSTALLA

TIONS. Please consult a certified Espar Marine dealer for marine installation.

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

Heater Warnings

ATTENTION

Operation with biodiesel

Warning To Installer:

Correct installation of this heater is necessary to ensure

safe and proper operation.

Read and understand this manual before attempting to

install a heater.

AIRTRONIC D2

The diesel heater IS NOT approved for 100% BioDiesel. Mixtures

up to 10% bio fuel (FAME) may be used.

Airtronic M (D4)

The diesel heater is approved for up to 100% BioDiesel accord

ing to the following conditions:

BioDiesel (FAME) according to Standard CAS NO. 6778480

9 (or similar) in free flowing state (reduced at tempera

tures below 0°C (32°F);

Operation of heater with mixtures greater then 10% is restric

ed during periods of temperatures below 0°C (32°F)

Maintenance schedule for BioDiesel mixtures greater then

10%

Warning Explosion Hazard

1. Heater must be turned off while refueling.

2. Do not install heater in enclosed areas where combusti

ble fumes may be present.

3. Do not install heaters in engine compartments of

marine vessels.

Warning Fire Hazard

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.

Heater must be run for 30min on high heat with regular

diesel fuel once every 500h if mixtures above 20% are

used;

Vent hole must be cleaned every 500h (twice a heating

season assuming 1000h of operation annually);

Atomizing Screen must be replaced every 500h (twice a

heating season assuming 1000h of operation annually).

All maintenance procedures may be performed without remov

ing heater from vehicle.

Failure to follow these instructions could cause fire resulting

in serious or fatal injury.

ATTENTION

Heating at high altitudes

Up to 1500 meters (4920) unrestricted heating operation is

possible.

Warning Asphyxiation Hazard

1. Route the heater exhaust so that exhaust fumes can

not enter any passenger compartments.

2. Ensure an air tight seal is 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.

Above 1500 meters (4920) heating operation is in principle

possible for short periods, e.g. when crossing a mountain pass

or during a brief stop. In cases of extended stays , the fuel

supply at the fuel metering pump has to be adapted to high

altitude conditions.

The following high altitude kits are available:

P/N: 24 0222 00 00 00 12V only (Contains high altitude fuel pump)

P/N: 20 2900 70 00 07 12V or 24V (Contains high altitude com

pensator, no extra fuel pump needed)

P/N: 22 1000 33 22 00 12V or 24V (Only works with Airtronic

Heaters that have “HKit” on the factory label)

Failure to follow these instructions could cause oxygen

depletion resulting in serious or fatal injury.

Direct questions to Espar Heater Systems

Note: Only one kit from the listed above is needed.

Canada & U.S.A. 18003874800

Marine conciderations:

Follow marine manual for installation requirements (separete

document)

Gasoline (B4) heaters must not be installed in ingene compart

ment.

Diesel or Gasoline (petrol) heaters must not be installed in

engine compartment of gasoline (petrol) boats.

Introduction

Espar s AIRTRONIC bunk heaters

The AIRTRONIC D2 is a compact dieselfired 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 instal

lation. 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 are available in

12 or 24 volt versions, it is able to provide space heat complete

ly independently of the vehicle engine.

Various control options are available to operate the heater. It cycles

through four heat output modes (boosthighmediumlow) in order to

maintain the desired temperature.

In special cases where the heat output required is less then what the

"low" power mode provides the heater switches to "standby" mode.

Temperature and overheat sensors, and a specially designed heat

exchanger are among the safety features which make this heater a safe

and dependable unit.

For illustration purposes only

Product Information

Technical Data

Heater

AIRTRONIC D2

AIRTRONIC D4

AIRTRONIC B4

Version

Heat Output (±10%) 7,500 BTU/hr Boost (2.2 kW) 13,650 BTU/hr Boost (4.0 kW) 12,950 BTU/hr Boost (3.8 kW)

6,150 BTU/hr High (1.8 kW) 10,200 BTU/hr High (3.0 kW) 10,910 BTU/hr High (3.2 kW)

4,100 BTU/hr Medium (1.2 kW) 6,800 BTU/hr Medium (2.0 kW) 7,160 BTU/hr Medium (2.1 kW)

2,900 BTU/hr Low (0.85 kW) 3,500 BTU/hr Low (1.0 kW) 4,430 BTU/hr Boost (1.3 kW)

Current at 12v (±10%) 8.3 amps Start

8.3 amps Start

2.8 amps Boost

3.3 amps Boost

1.8 amps High

2.0 amps High

2.4 amps High

1.0 amps Medium

1.1 amps Medium

1.3 amps Medium

0.7 amps Low

0.6 amps Low

0.8 amps Low

0.4 amps Stand by

Current at 24v (±10%) 4.2 amps Start

4.2 amps Start

1.4 amps Boost

1.7 amps Boost

0.92 amps High

1.0 amps High

(No 24V version available)

0.5 amps Medium

0.3 amps Low

0.2 amps Stand by

Fuel Consumption (±10%)

U.S. Litre/hr

Gal/hr

Boost 0.07 0.28 Boost 0.13 0.51 Boost 0.14 0.54

High 0.06 0.23 High 0.10 0.38 High 0.12 0.46

Medium 0.04 0.15 Medium 0.07 0.25 Medium 0.08 0.29

Low

0.03 0.10 Low

0.03 0.11 Low 0.05 0.18

Air Flow (±10%)

48 cfm Boost

85 cfm Boost

40 cfm High

69 cfm High

74 cfm High

27 cfm Medium

50 cfm Medium

55 cfm Medium

19 cfm Low

30 cfm Low

43 cfm Low

6 cfm Stand by

11 cfm Stand by

Operating Voltage Range 10.5 16 vdc at 12 vdc

10.5 16 vdc at 12 vdc

21 32 vdc at 24 vdc

Overheat Temperature 240°F (115°C)

240°F (116°C)

Shutdown (±10%)

Ambient Operating

40°F to 158°F (40°C to 70°C) 40°F to 158°F (40°C to 70°C) 40°F to 122°F (40°C to 50°C)

Temperature

Weight

5.9 lbs. (2.7 kg)

9.9 lbs. (4.5 kg)

Note: The heater control unit is equipped with a low

voltage cutout to prevent vehicle battery drain and a

high voltage cutout to protect heater electrical parts.

Note: The terms "Boost" and "Power" are used interchan

geably through out this manual. The terms refer to the

highest level of heat output.

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