Caltech Calaer 2 kW Installation And Operating Instructions Manual Download Page 6 | Manualshive

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NOTE:

Failure to follow the statutory regulations, installations instructions and the

notes contained therein will lead to all liability claims to be refused by

CalTech Heating Technologies AB. The same applies if repairs are carried out

incorrectly or with the use of parts other than genuine spare parts. This will

result in the invalidation of the type approval for the heater and therefore of

its homologation/ECE type license.

ADDITIONAL DOCUMENTATION: VEHICLE SPE CIFIC TECHNICAL

DOCUMENTATION

In addition to this installation instruction, vehicle specific technical

documentation may be required to succeed with the installation of the

heater. Refer to the vehicle manufacturer for such documentation.

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Summary of Contents for Calaer 2 kW

Page 1: ...Installation and operating instructions 2 kW Calaer Air Heater 4 kW Calaer Air Heater...

Page 2: ...PLY 14 HOT CABIN AIR OUTLET 16 FUEL INTEGRATION AND SUPPLY 16 EXHAUST SYSTEM 18 ELECTRICAL SYSTEM 21 OPERATING INSTRUCTIONS 25 INITIAL START UP PROCEDURE 25 NORMAL START AND STOP PROCEDURES 25 EMERGEN...

Page 3: ...3 ERROR CODES 28 TECHNICAL DATA 30 WARRANTY 34...

Page 4: ...n objects into the heater and moving parts of the heater To repair the heater systems you need to have completed a CalTech Heating Technologies AB training course and you need to have the appropriate...

Page 5: ...EC and Part 1 and Annex 7 of the directive ECE R 122 GENERAL REQUIREMENTS Operating and maintenance instructions shall be supplied with every heater and in the case of heaters intended for the afterm...

Page 6: ...r with the use of parts other than genuine spare parts This will result in the invalidation of the type approval for the heater and therefore of its homologation ECE type license ADDITIONAL DOCUMENTAT...

Page 7: ...into the vehicle s electrical and fuel systems The heaters are not designed for heating hazardous substances The heater must not be installed so that it is continuously exposed to water TYPE LABEL The...

Page 8: ...8 Figure 1 Labels with information about the system...

Page 9: ...9...

Page 10: ...d the possibility of fuel or oil contamination Requirements from 2001 56 EG Annex VII 2 2 1 and ECE R122 Part I 5 3 2 1 The combustion heater shall not constitute a risk of fire even in the case of ov...

Page 11: ...y Requirements from 2001 56 EG Annex VII 2 2 5 and ECE R122 Part I 5 3 2 5 NOTE The heater must not be installed in the passenger cabin of class M1 i e power driven personal cars having at least four...

Page 12: ...vehicle the fuel pump must be installed at a maximum distance of 2 meters from the fuel tank and no more than 6 meters from the heater unit The fuel pump must also be installed in such a way so that...

Page 13: ...ng of fuel system INSTALLATION EXAMPLE NOTE It may be required to consult the technical documentation of your vehicle to succeed with the installation of the heater Refer to the vehicle manufacturer f...

Page 14: ...uirements from 2001 56 EG Annex VII 2 5 1 and ECE R122 Part I 5 3 5 1 The combustion air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely Requirements from 2001 5...

Page 15: ...on heater or any other vehicle source Requirements from 2001 56 EG Annex VII 2 6 1 and ECE R122 Part I 5 3 6 1 The inlet duct must be protected by the mesh which is delivered with the heater unit to p...

Page 16: ...cm away from all body parts The heater must not be integrated into the vehicle s air system Only materials that can permanently withstand temperatures of at least 130 C may be used for the hot cabin a...

Page 17: ...efueling must be affixed to the fueling point In addition a suitable instruction must be included in the manufacturer s operating manual Requirements from 2001 56 EG Annex VII 2 3 3 and ECE R122 Part...

Page 18: ...k EXHAUST SYSTEM The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators heated air inlets or opening windows Requirements from 2001 56 EG Annex VII...

Page 19: ...aust pipe bracket must be mounted no further away than 150 mm from the exhaust port The openings for the combustion air inlet port the exhaust outlet port and the fuel pipe must be sealed if the heate...

Page 20: ...20 Figure 10 Seal for the mounting bracket Figure 11 Mounting angle of exhaust muffler...

Page 21: ...onsists of a control button with an off position and a temperature gradient witch sets the thermostat temperature The control unit shall be mounted in a place where it is protected from moist or dust...

Page 22: ...22 WIRING DIAGRAM...

Page 23: ...23 Connector Description Picture X1 AMP282080 1 X2 AMP282104 1 X3 X6 AMP282108 1 X4 X7 AMP282090 1...

Page 24: ...24 X5 DJ7021A 3 5 20 X8 AMP282080 1 X9 AMP282104 1 X10 X11 AMP282105 1 Figure 8 Wiring diagram of the heater and identification of the connectors valid for installation with the rotary control button...

Page 25: ...l button from off to the desired setting The heater responds by starting the fuel pump after 3 seconds and turning on the control button status light The fuel pump will stop after 7 seconds and the he...

Page 26: ...set point in temperature where the temperature sensor is installed and also to turn on and off the heater when no other control unit is connected It features an off position a temperature gradient fo...

Page 27: ...ing switch before it has come to a complete stop apart from in the case of an emergency event The heater must not be operated where there is a risk of an accumulation of flammable vapors or dust for e...

Page 28: ...the control button indicating that maintenance is required In the event that the voltage drops below 10 19 Volts for the 12 Volt 24 Volt system respectively or goes above 15 32 Volts for the 12 Volt 2...

Page 29: ...open load or shortcut 7 long 5 short F08 Fan motor open load or shortcut 8 long 5 short F10 Overheating sensor open load or shortcut 10 long 5 short F11 Ignition open load or shortcut 11 long 5 short...

Page 30: ...olerance of 10 at an ambient temperature of 20 C and at the rated voltage Type test permits E11 122R 00 1689 10R 05 9041 Type Fuel Operated Air Heater Output declared performance 1000 2000 W Fuel Dies...

Page 31: ...31 Weight heater only 3 1 kg Hot air outlet 60 mm CO2 in exhaust gas normal function range 7 5 min power 10 9 max power...

Page 32: ...the usual heater tolerance of 10 at an ambient temperature of 20 C and at the rated voltage Type test permits E11 122R 00 1696 10R 05 9041 Type Fuel Operated Air Heater Output declared performance 200...

Page 33: ...mm Weight heater only 5 1 kg Hot air outlet 90 mm CO2 in exhaust gas normal function range 8 3 min power 11 8 max power VERSION The 2 kW and 4 kW Calaer Air heaters are designed for either 12 or 24 V...

Page 34: ...incorrect voltage or connection lightning external damage accidents moisture or any conditions beyond our control b Faults caused by unauthorized repair or other measures carried out or undertaken by...

Page 35: ...35 CT Heating Technologies AB Skalholtsgatan 2 164 40 Kista Sweden Information in this manual is subject to change without notice updated on line manual is available at www caltechheating se...

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