Airtronic D2-D4 Manual
Airtronic D2-D4 Manual
Airtronic D2-D4 Manual
Espar
AIRTRONIC
AIRTRONIC
AIRTRONIC
AIRTRONIC
AIRTRONIC
D2 - 12 volt
D2 - 24 volt
D4 - 12 volt
D4 - 24 volt
Release period
25 2069 05 00 00
25 2070 05 00 00
25 2113 05 00 00
25 2114 05 00 00
November 2001
November 2001
November 2001
November 2001
P/N: 610-103-0901
November 2001
Table of Contents
Page
Introduction
Heater Warnings
Introduction
Specifications
Principal Dimensions
Heater Components
........................................................
........................................................
........................................................
........................................................
........................................................
3
4
5
6
7
Installation Procedures
Heater Location
Heater Mounting
Heater Plate installation
Mounting Pattern
Ducting Components
Heater Air Ducting
Fuel System
Electrical Connections
Exhaust/Intake Connections
Operating Switches
........................................................
........................................................
........................................................
........................................................
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8
8
8
9
9
9
10
12
13
13
Heater Operation
Switch on
Start-Up
Temperature setting
Temperature Control
Switching Off
Controls & Safety Equipment
Operational Flow Chart
Function Diagrams
Schematic AIRTRONIC D2/D4
........................................................
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........................................................
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14
14
14
15
15
15
15
16
17
Maintenance,
Troubleshooting &
Repairs
Periodic Maintenance
Basic Troubleshooting
Self Diagnostic Troubleshooting
Fuel Quantity Test
Overheat/Flame sensor values
Control and Resistance values
Repair Steps
........................................................
........................................................
.......................................................
........................................................
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18
18
18
23
23
24
25
Heater Parts
AIRTRONIC D2/D4
-Service Parts Diagram
AIRTRONIC D2/D4
-Parts List
........................................................
30/32
........................................................
31/33
Special Notes
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.
3
Heater Warnings
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.
Warning - Explosion Hazard
1.
2.
3.
2.
3.
Failure to follow these instructions could cause fire resulting in serious or fatal injury.
ATTENTION
Operation with bio-diesel
AIRTRONIC D2
AIRTRONIC D2 is not certified for use with bio-diesel.
Admixtures of bio-diesel up to a magnitude of approx. 10%, as
in some countries, are allowed.
AIRTRONIC D4
AIRTRONIC D4 is certified for operation with bio-diesel as per
DIN V 51606 in free-flowing state when installed in normal
horizontal position (exhaust pipe downwards); bio-diesel is not
permitted for any other installation positions.
When using 100% bio-diesel, AIRTRONIC D4 should be oper ated with pure diesel fuel twice per year, preferably in the middle and at the end of a winter period, to burn off any possible
PME residues: For this purpose, drain your vehicle tank as far
as possible (caution: do not forget to leave enough fuel in the
tank to get to the next fuel station!) and then fill the tank with
pure diesel fuel without bio-admixture.
While using this tank filling, let AIRTRONIC D4 run at the maxi mum temperatures pre-selection stage at least twice or three
times for 30 minutes at a time. You can use this for example to
pre-heat your vehicle before setting off. After this diesel operation of your AIRTRONIC D4, you can use bio-diesel again as
required.
When using mixtures of diesel / bio-diesel with up to 50% bioshare, it is not necessary to use pure diesel fuel now and then.
2.
3.
4.
ATTENTION
Heating at high altitudes
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
USA
1-800-387-4800
CDA
1-800-668-5676
1-800-387-4800
CDA
1-800-668-5676
4
Introduction
Espar s AIRTRONIC bunk heaters
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
12,000 BTU/hr air heater for larger bunks.
These heater 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-highmedium-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.
Specifications
AIRTRONIC D2
AIRTRONIC D4
Boost
High
Medium
Low
U.S.
Gal/hr
Litre/hr
0.07
0.06
0.04
0.03
0.28
0.23
0.14
0.10
Boost
High
Medium
Low
U.S.
Gal/hr
Litre/hr
0.13
0.10
0.07
0.03
0.51
0.38
0.25
0.13
48 cfm Boost
40 cfm High
27 cfm Medium
19 cfm Low
85 cfm Boost
69 cfm High
50 cfm Medium
30 cfm Low
Overheat Temperature
Shutdown (10%)
240F (115C)
240F (116C)
Ambient Operating
Temperature
Weight
(12.2 inches)
(4.5 inches)
(14.8 inches)
(5.5 inches)
Heater Components
13
14
15
16
17
18
19
20
21
Flange Seal
Combustion Chamber
Hot Air Outlet Hood
Combustion Air Intake Hose
Fuel Metering Pump
Fuel Filter built into FMP
Hot Air Output Deflector
Flexible Exhaust Pipe
Main Fuse: AIRTRONIC D2 - 20 A
AIRTRONIC D4 - 10 A
C = Combustion Air
D = Fuel Intake from tank
E = Exhaust
F = Fresh Air Intake
H = Hot Air Output
8
Installation Procedures
Heater Location
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:
Flat washer
Nut
Cab Floor
Spring Washer
Heater Mounting
A mounting plate and hardware are provided with the truck
heater kit.
Choose heater location.
Using template provided, 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.
Heater
Flange
Wiring Harness
Right or Left
Stainless Steel
Mounting Plate
and seal
Exhaust
Tubing
Combustion
Air intake
Fuel line
Mounting Pattern
inches
millimeters
Return Ducting
For illustration
purposes only
No Return Ducting
For illustration
purposes only
Ducting Components
1. Protective Grill
2. Air Outlet Hood AIRTRONIC D2 - 60 or75mm
AIRTRONIC D4 - 75 or 90mm
3. Hose Clamp 2-2 3/4
4. Flex Duct 2 3/8 (60 or 75mm) (90mm on D4)
Warning: Do not use existing vehicle ducting or outlets.
Ducts and outlets must be capable of withstanding a minimum of 300F operating temperatures.
Caution:
10
Fuel System
The fuel metering pump is the heart of the system and must be
installed properly to ensure a successful heater operation.
Fuel System Overview
7
Max. 20
Max. 66
8
6
7
2
5
3
Max. 66
4
Max. 26
Max. 2
3
9
Fuel
Tank
3
Fuel
Tank
1
Optional
Optional
11
Fuel Line
Route fuel lines from the fuel pick-up pipe to the fuel
metering pump then to the heater.
12
Electrical Connections
Main Harness.......................................................................
Power Harness.....................................................................
Switch Harness....................................................................
Diagnostic Harness.............................................................
Main Harness
Fuel Metering Pump Harness
Thermostat
Power Harness
13
Operating Switches
Caution:
Thermostat base
access hole
End Cap
End Cap
Warning:
Warning:
14
Rheostat Switch
Temperature sensor on
AIRTRONIC control unit.
Heater Operation
Switch On
Start Up
Temperature Setting
On/Off switch
Green diagnostic light
Red operating light
Once flame sensor has detected a flame the glow pin will
switch off, after approx. 60 secs.
After another 120 secs., heater will have reached maximum power.
Low
High
15
4.
Temperature Control
Switch Off
The blower continues to run for 4 minutes and automatically switches off.
16
Function diagram AIRTRONIC D2
17
Schematic AIRTRONIC D2 / AIRTRONIC D4
Wire color key
for switches
red
yellow
brown
grey
Designation
=
=
=
=
grey/red =
blue =
blue/white =
brown/white =
black =
1.1
1.2
1.5
2.1
2.2
2.7
3.1.11
3.2.8
3.5
5.1
6.1
Blower Motor
Glow Pin
Overheat and Flame sensor
Control Unit
Fuel Metering Pump
Main Fuse 12Volt - 20 amp / 24 volt - 10 amp
Rheostat
7 Day Timer
Thermostat
Battery
Diagnostic Pigtail (for connection to Fault code retrieval device)
power (+)
switch
ground (-)
temperature sensor
on thermostat
*vehicle dimmer switch
for light display on
7-day timer
temperature setting
diagnostic
from heater
diagnostic
from heater
ground
to vehicle ignition
accessories for continuous
operation of heater
18
Maintenance
Basic Troubleshooting
Check LIst:
Remove the glow pin and inspect for carbon build up.
Clean or replace.
Remove the glow pin screen and inspect for carbon build
up. Clean or replace.
Inspect the ducting, the air intake screen and air outlet for
restriction or blockage.
Use fuel suitable for the climate (see engine manufacturers recommendations). Blending used engine oil with
diesel fuel is not permitted.
Heater ignites
1 Shuts down at random
Check:
19
Self Diagnostics
The heater is equipped with self diagnostic capability. To
retrieve information on the heater s last 5 faults, a retrieval
device is required (part # 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 four functions to be performed.
1.
2.
3.
4.
Actual fault.
F1-F5
On/Off
DIAG
000
Wait 3-5 seconds for the current fault code to appear (AF).
To erase the faults that are in memory press both "L" keys
at the same time for 5 seconds. This will also a unlock the
control unit.
20
See schematic
pg. 17
000
Normal Operation
004
005
009
Switch off due to signal change.Check for change of signal from (+) to
(-) at pin 13 (S1) or a (+) signal at pin 14 (S1).
010
Overvoltage
Start vehicle motor. Check voltage at (B1) between terminals 1 and 10.
This must be less than 16 volts (15.2 volts with glow plug on). Check
vehicle charging system.
AIRTRONIC 24 volt - voltage must be less than 32 volts
011
012
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 23). If O.K. Measure fuel quantity. See page 23.
013
014
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 overheating sensor. If over-heating sensor defective replace
combi-sensor. If over-heating sensor O.K. measure fuel quantity. See
page 23. If fuel quantity O.K. replace control unit.
015
017
The hardware limit value for the overheating 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.
020
021
Caution!
For AIRTRONIC 12 volt, check functions with max. 8 volt
For AIRTRONIC 24 volt, check functions with max. 18 volt.
if voltage values are exceeded the component is destroyed.
Check sort-circuit resistance of mains unit: min. 20 Amp.
21
Fault Code
031
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.
032
Caution!
For AIRTRONIC 12 volt, check functions with max. 8 volt
For AIRTRONIC 24 volt, check functions with max. 18 volt.
if voltage values are exceeded the component is destroyed.
Check sort-circuit resistance of mains unit: min. 20 Amp.
033
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.
047
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
048
050
Control unit is locked after too many unsuccessful start attempts. Check
fuel, glow plug, combustion air and exhaust flow. Use control unit
tester or fault code retrieval device to unlock control unit. Maximum 255
051
052
053
054
055
056
060
061
22
Fault Code
062
063
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 . Normal value: 1740 - 2180 ( 80
).
064
065
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 shot circuit < 486 , see values on following pages.
071
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 .
072
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 , see following
pages for values.
090
091
092
094
096
097
23
Preparation
Measurement
Hold the fuel line in the measuring glass level with the
glow pin while fuel is being delivered.
Temperature (C)
Temperature C
min.
max.
-40
-20
Resistance k
1597.0
458.80
1913.0
533.40
154.70
175.50
20
40
60
59.30
25.02
11.56
65.84
28.04
13.16
80
100
120
5.782
3.095
1.757
6.678
3.623
2.081
140
1.050
1.256
160
180
0.6654
0.4253
0.792
0.5187
200
0.2857
0.3513
Evaluation
Temperature C
-40
0
40
80
120
160
200
240
280
320
360
400
Resistance k
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
24
Control values
Motor speed
Control stage
Power
Fast
Medium
Slow
Adjustment
- in circulation mode with temperature sensor, internal
- In fresh air mode with temperature sensor, external
Ventilation
AIRTRONIC D2
4800 U/min 140 U/min
4000 U/min 120 U/min
2800 U/min 80 U/min
2000 U/min 60 U/min
AIRTRONIC D4
4400 U/min 130 U/min
3600 U/min 100 U/min
2800 U/min 80 U/min
1600 U/min 50 U/min
Resistance values
Component
AIRTRONIC D2 -12V
AIRTRONIC D2 -24V
AIRTRONIC D4 -12V
AIRTRONIC D4 -24V
Blower motor
0.6 0.1
2 0.4
0.4 0.1
1.5 0.3
Glow plug
0.5 0.05
2 0.2
0.5 0.05
2 0.2
10 0.5
36 1.8
10 0.5
36 1.8
1750 - 2080 80
1750 - 2080 80
1750 - 2080 80
1750 - 2080 80
Switching value
Component
AIRTRONIC D2 / D4
Overheating sensor
160C - 170C
measured in the control
stage powerand at a
clearance of 300 mm
from the hot air outlet
Exhaust value
AIRTRONIC D2 / D4
CO2 in exhaust in control stage fast
<6
300 mm
25
Repair Instructions
Removing the cover
Removing and checking the control unit
Removing the glow pin
Removing the lining
Removing and checking the overheating and flame sensor
Installing the overheating and flame sensor
Caution: 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
1.
2.
26
Heater Casing Disassembly
Note:
When the glow pin has been removed, check the lining of the
support in installed state for any contamination. The lining must
be replaced if the surface is covered with dirt.
Glow Pin
Connector of glow pin cable harness
Rubber bushing
Lining
Bore ( 2.7 mm) for glow pin ventilation
illustration 1
27
Connector green
NTC 50 = overheating sensor
PT=flame sensor
Clip
Overheat sensor / flame sensor
Clip
Cable harness -overheat/ flame sensor
Special tool - only necessary for the AIRTRONIC D2
28
Dismantling the heat exchanger
Removing the combustion air blower
29
Combustion chamber
Seal between combustion chamber and heat exchanger must always be replaced.
Heat exchanger
Fastening screws
AIRTRONIC D2 = 3 fastening screws
AIRTRONIC D4 = 4 fastening screws
Combustion chamber
Heat Exchanger
Fastening screws
AIRTRONIC D2 = 3 fastening screws
AIRTRONIC D4 = 4 fastening screws
30
AIRTRONIC D2/D4
Service Parts Diagram
18
12
17
16
19
11
2
10
4
3
1
5
7
14
8
13
15
20
31
Parts List
AIRTRONIC D2/D4
Ref. No.
Description
Part Number
25 2069 99 06 00
25 2113 99 06 00
Heat exchanger
25 2069 06 01 00
25 2113 06 01 00
25 2069 10 01 00
25 2113 10 01 00
25 2069 06 00 01
25 2113 06 00 01
3
4
Burner
Gasket seal
Grommet
Blower motor
Gasket , blower
10
Control unit
11
12
Upper casing
13
14
Lower casing
Grommet
12V
24V
12V
24V
25 2069 06 00 02
103 10 348
25 2069 99 20 00
25 2070 99 20 00
25 2113 99 20 00
25 2114 99 20 00
103 10 462
25 2069 01 00 03
25 2113 01 00 03
22 5101 00 10 01
22 5102 00 10 01
22 5101 00 10 05
22 5102 00 10 03
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
15
Flange seal
25 2069 01 00 02
16
25 2069 01 02 00
17
Clip
25 2069 01 02 02
25 2113 01 02 02
18
25 2069 01 03 00
25 2070 01 03 00
19
20
25 2069 10 01 02
CA0 00 019
32
AIRTRONIC D2/D4
Service Parts Diagram
5
2
3
30
2a
43
42
29
27
22
22
22
21
31
24
9
10
32
20
25
33
26
8
11
6
36
34
7
35
41
19
38a
18
28
37
44
10
38
18
12
16
23
13
17
39
14
15
17
16
40
17
33
Parts List
AIRTRONIC D2/D4
Ref. No.
Description
Part Number
Safety screen
60
75
25 1688 80 06 00
25 1552 05 01 00
2
2a
60
90
20 1577 89 06 00
20 1609 80 09 00
Clamp
50-70
70-90
10 2064 05 00 70
10 2064 07 00 90
60
90
10 2114 31 01 00
10 2114 37 00 50
60
90
22 1000 01 00 16
22 1000 01 00 19
Main harness
short harness
CA1 60 201
CA1 60 205
Cable ties
CA1 00 005
Air intake
25 mm
360 00 006
Flexible exhaust
24 mm
25 1774 80 01 00
10
Fuel hose
3.5 mm
360 75 300
11
1.5 mm
090 31 118
12
12V
24V
22 4519 01 00 00
22 4518 01 00 00
13
14
15
Angle bracket
2 mm
22 1000 50 03 00
090 31 125
CA0 10 105
16
Fuel hose
5 mm
360 75 350
17
Clamp
11 mm
10 2063 01 10 98
18
Clamp
9 mm
10 2063 00 90 98
19
25 1729 89 00 02
20
Grommet
20 1280 09 01 03
21
20-32
10 2064 02 00 32
22
Clamp
26 mm
23
Fuel screen
24
Blade fuse
25
20 amp
10 amp
Plug connector
152 61 102
20 1280 09 01 03
CA1 07 005
CA1 07 006
22 1000 31 80 00
26
Housing
22 1000 31 81 00
*27
Muffler
25 1864 81 01 00
28
22 1000 31 87 00
*29
60
75
90
22 1000 01 00 20
22 1000 01 00 22
22 1000 01 00 23
60
75
25 1688 89 00 01
25 1482 89 00 05
CA1 07 001
*30
90 Bend
31
32
Terminals
CA1 90 043
33
CA1 90 014
*34
12V
24V
CA1 00 210
CA1 00 211
12V
24V
301 00 154
301 00 153
35
Thermostat
34
Ref. No.
*36
37
Description
Part Number
12V
24V
25 1895 71 00 00
25 1896 71 00 00
2 mm
CA0 12 056
* 38
CA0 12 042
* 38a
Compression fittings
1/4 NPT
3/8 NPT
1/2 NPT
CA0 12 044
CA0 00 031
CA0 12 005
*39
Rubber hose
5 mm
CA3 00 103
40
C-clamp
10 mm
152 00 139
41
C-clamp
25 mm
152 10 048
42
C-clamp
28 mm
152 10 051
End-sleeve
24 mm
43
25 1482 80 00 01
CA1 05 020
25 1482 70 01 00
44
Canada (Tel):
Fax:
905-670-0960
800-668-5676
905-670-0728
U.S. (Tel):
800-387-4800