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Hydronic 10 Manual 2007-2.qxd
Hydronic 10/ Hydronic M (Water Heater)
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Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts List
Espar Heater Systems
Espar Products, Inc.
6099A Vipond Drive
Mississauga, Ontario
Canada L5T 2B2
(905) 670-0960
(800) 387-4800 Canada & U.S.A.
(905) 670-0728 Fax
www.espar.com
Hydronic 10
Hydronic M
25 2081 05 - 12 Volt
25 2160 05 - 12 Volt
25 2044 05 - 24 Volt
25 2161 05 - 24 Volt
25 2227 05 - 24 Volt
P/N 20 2900 81 01 24 0B
02.2007 Subject to Change
Printed in Canada
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Table of Contents
Page
Introduction
Heater Warnings
........................................................
3
Introduction
........................................................
4
Specifications
........................................................
4
Heater Components
........................................................
5
Principal Dimensions
........................................................
6
Installation Procedures
Heater Location
........................................................
7
Heater Mounting
........................................................
7
Heater Plumbing
........................................................
8
Fuel System
........................................................
9
Electrical Connections
........................................................
11
Exhaust/Intake Connections
........................................................
12
Operating Switches
........................................................
13
Heater Operation
Pre-Start Procedures
........................................................
17
1
S
t
.
R
Switching Off
.
1
........................................................
17
Safety Equipment
........................................................
17
Operational Flow Chart
........................................................
18
Wiring Diagram (12V-24V boxed) .......................................................
19
Wiring Diagram (12V-24V boxed-Universal) ........................................................
20
Wiring Diagram (Engine heat only) ........................................................
21
Wiring Diagram Universal
........................................................
22
Maintenance,
Periodic Maintenance
........................................................
23
Troubleshooting &
Basic Troubleshooting
........................................................
23
Repairs
Self Diagnostic Troubleshooting .......................................................
23
Fault codes/Description/Repair ........................................................
24
Fuel Quantity Test
........................................................
28
Repair Steps
........................................................
28
Resistance Values
........................................................
28
Heater Components
Parts Diagram
........................................................
32
Description & Part #’s
........................................................
33
Parts Diagram - Boxed units
........................................................
36
Description & Part #’s
........................................................
37
Parts Diagram - Universal
........................................................
40
Description & Part #’s
........................................................
41
Parts - Accesories
........................................................
42
Description & Part #’s
........................................................
43
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 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.
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Introduction
Heater Warnings
Warning To Installer
Caution: During electrical welding work on the vehicle
disconnect the power to the heater in order to
protect the control unit.
• Correct installation of this heater is necessary to ensure
safe and proper operation.
Read and understand this manual before attempting to
install the heater. Failure to follow all these instructions
could cause serious or fatal injury.
Note: All measurements contained in this manual con-
tain metric and approximate SAE equivalents in
brackets eg 25mm (1”).
Direct questions to Espar Heater Systems:
Warning - Explosion Hazard
Canada & U.S.A.
1-800-387-4800
• Heater must be turned off while re-fueling.
• Do not install heater in enclosed areas where com-
bustible fumes may be present.
• Do not install heaters in engine compartments of gaso-
line powered boats.
Warning - Fire Hazard
• Install the exhaust system so it will maintain a minimum
distance of 50mm (2”) from any flammable or heat sensi-
tive material.
•
Ensure that the fuel system is intact and there are no leaks.
Warning - Asphyxiation Hazard
• Route the heater exhaust so that exhaust fumes cannot
enter any passenger compartments.
• If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
Warning - Safety Hazard on Coolant Heaters
Used With Improper Antifreeze Mixtures
• The use of Espar coolant heaters requires that the
coolant in the system to be heated contains a proper
mixture of water and antifreeze to prevent coolant from
freezing or slushing.
• If the coolant becomes slushy or frozen, the heater’s
coolant pump cannot move the coolant causing a block-
age of the circulating system. Once this occurs, pressure
will build up rapidly in the heater and the coolant hose
will either burst or blow off at the connection point to the
heater.
• This situation could cause engine damage and/or per-
sonal injury. Extreme care should be taken to ensure a
proper mixture of water and antifreeze is used in the
coolant system.
• Refer to the engine manufacturer’s or coolant manufac-
turer’s recommendations for your specific requirements.
This publication was correct at the time of print.
However, Espar has a policy of continuous improve-
ment and reserves the right to amend any specifica-
tions without prior notice.
3
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Introduction
Espar’s Hydronic 10 Coolant Heater
Quality engineered to provide a dependable means of heating,
the Espar Hydronic 10 is a diesel fired coolant heater capable of
between 1.5 kW to 9.5 kW/hr (5,100 to 32,400 BTU/hr). The
heater can be purchased either in a weather resistant box to pro-
tect it from the elements and provide for ease of installation or in
the universal form.
This light weight and compact coolant heater offers an affordable
heating solution to many applications. The Hydronic 10 is ideal
for pre-heating the engines of class 7 and 8 trucks, off-road
equipment, buses, boats and in Fuel + Hydraulics in conjunction
with appropriate heat exchangers.
The heater pumps coolant from the engine, heats it and returns it
to the engine. It features automatic heat regulation while being
fuel and power efficient. Since the heater runs on diesel fuel and
12 or 24 volt power, it is able to perform this completely indepen-
dently of the vehicle engine. A temperature regulating switch in
the unit regulates the coolant temperature between a low of 68°C
(154°F) and a high of 85°C (185°F) by automatically cycling the
heater.
The Hydronic 10 can be operated from the vehicle cab by an
on/off switch, a pre-select timer or a combination of both.
A flame sensor, temperature regulating sensor and overheat
sensor are among the safety features which makes the Hydronic
10 a safe and dependable heating system.
Hydronic 10 Specifications
Heat output (±10%)
9.5 kW (32,400 BTU/hr) - Boost
7.5 kW (25,600 BTU/hr) - High
3.2 kW (10,900 BTU/hr) - Medium
1.5 kW (5,100 BTU/hr) - Low
Current draw (±10%)
12Volt
24Volt
10.4
- Boost -
5.2 amps
6.3
- High -
3.2 amps
3.5
- Medium -
1.8 amps
2.9
- Low -
1.5 amps
Fuel consumption (±10%)
1.2 l/hr (0.32 USgal/hr) Boost
0.9 l/hr (0.24 USgal/hr) High
0.40 l/hr (0.11 USgal/hr) Medium
0.18 l/hr (0.05 USgal/hr) Low
Operating Voltage Range
Minimum Voltage
10 V (20V on 24 volt systems)
Maximum Voltage
15 V (30 V on 24 volt systems)
Coolant pump flow (±10%)
1400 Litre/hr
370 U.S. Gal/hr
Coolant Temperature Range (±5%)
68-85°C (154-185°F)
Overheat coolant temperature shutdown (±5%)
115°C (240°F)
Weight
6.5 kg. (14.3 lbs.)
Controls available
On/Off switch, 99hr. timer or 7 day timer.
Note: The heater is equipped with a high voltage
cutout as well a low voltage cutout.
4
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Introduction
Heater Components
17
18
16
we
09:20
P
+
4
5
15
–
V
67
9 8
14
B
WE
1
2
10
V
A
12
13
11
WE = Water inlet
WA = Water outlet
V
= Combustion air
B
= Fuel
A
= Fumes
1 Combustion motor
2 Flame sensor
3 Combustion chamber
4 Control unit
5 Heater plug
6 Temperature sensor
7 Flame tube
8 Heat exchanger
9 Overheating switch
10 Water pump
11 Exhaust silencer
12 Combustion air silencer
13 Fuel feeder pump
14 Fuel branch piece
15 Cable tree
16 Fuse bracket
17 Relay for switching on the vehicle’s fan
18 Automatic switch
5
3
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