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13. Electrical system

43

13. Electrical system

The electrical system of the heater consists of the heater unit, main wire
harness, individual cables for fuel pump and temperature sensor.

The cables can be routed as one or in separate directions depending on the
installation of the heater and the location of the battery, fuel supply and the
selection of the controller location.

The wire harness of the heater unit is connected to the left side of the
heater by default. It can be repositioned to the right side of the heater if
needed. Instructions for this operation are included in the Heater
installation position chapter.

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Summary of Contents for Calaer 2 kW

Page 1: ...Installation manual 2kW Calaer air heater 4kW Calaer air heater...

Page 2: ......

Page 3: ...s of the installation In the end of the manual you will find instructions on troubleshooting and maintenance Before installing the heater please read through the entire manual This manual is divided i...

Page 4: ...2...

Page 5: ...or death The Calaer heater is designed to minimize the risks as much as possible Nevertheless there is a risk of Carbon monoxide poisoning that may cause serious consequences to health if the heating...

Page 6: ...artment that is well ventilated to the atmosphere Make sure that the exhaust gases are led straight to the atmosphere with leak tight pipes avoid passing through passenger compartments Attention Alway...

Page 7: ...uring the warranty period does not prolong the original warranty period of the component or product Calaer excludes and limits from warranty the following Normal wear fuel filters and fuses are not co...

Page 8: ...6...

Page 9: ...ze the risk of injury and damage to personal property Combustion air intake The air for the combustion chamber of the heater must not be drawn from the passenger compartment Combustion air must be tak...

Page 10: ...the heater must be shut down before refueling must be affixed to the fueling point Exhaust system The exhaust outlet must be located so as to prevent emissions from entering the compartment through ve...

Page 11: ...accessible for inspection and the fuel terminus shall not be positioned within 20 inches 508 mm of a refueling fitting or fuel tank vent and shall be positioned to minimize exhaust re entry into the c...

Page 12: ...10...

Page 13: ...Volts 24 V 19 32 Volts 24 V 19 32 Volts Rated electric power consumption 19 41 Watts 19 48 Watts CO2 content in exhaust gas min to max power 7 5 10 9 8 3 11 8 Weight heater only 3 1 kg 5 1 kg 6 8 lbs...

Page 14: ...12...

Page 15: ...6 Heaterdimensions 13 6 Heater dimensions Calaer 2 kW heater All measurements are given in millimeters mm...

Page 16: ...6Heaterdimensions 14 Calaer 4 kW heater All measurements are given in millimeter mm...

Page 17: ...6 Heaterdimensions 15...

Page 18: ...16...

Page 19: ...bracket 1 Piece 9 Nylon Fuel line 5 x 1 5 Meter 10 Rubber fuel line 4 5 x 11 x 50mm 4 Piece 11 Exhaust pipe 25 mm 1 Meter 12 Combustion air pipe 25 mm 1 Meter 13 Air duct 60 90 mm 1 Meter 14 Air outl...

Page 20: ...18...

Page 21: ...nch Fuel connections and duct clamps 10 mm wrench Heater mounting 13 mm wrench Exhaust clamp In case you need to install lines through bulkheads the following drill heads may be needed 6 mm Fuel lines...

Page 22: ...20...

Page 23: ...faces refer to the fuel system chapter for further requirements Exhaust lines Consider the maximum length of the exhaust line and the outlet position The surface temperature of the exhaust line will b...

Page 24: ...ning them 1 8 of a turn 2 Repeat the previous on the heating air output ring 3 Push down on the fastening clips 4 Lift the cover up 5 Re route the cables to the other side and place the sealing plug r...

Page 25: ...ould be on a strong bulkhead thin bulkheads may require additional supports to ensure safe mounting For fastening the heater in place use the pre drilled mounting bracket which is provided with the he...

Page 26: ...ng from vehicle boat movements It may be necessary to add reinforcements After the bracket has been fastened to the bulkhead make sure that the rubber casket is in place under the heater unit and secu...

Page 27: ...ith information about the heater should be placed in a clearly visible position where it cannot be damaged The clearly readable label is necessary for warranty claims Heater warranty will be void if t...

Page 28: ...26...

Page 29: ...recommended or from a well ventilated internal source When drawing the combustion air from an internal source the line should be mounted on a slanting angle away from the heater to avoid condensation...

Page 30: ...haust gases can reach temperatures up to 300 C 570 F therefore extreme caution needs to be taken to ensure that the exhaust lines are well insulated and at safe distance from any heat sensitive materi...

Page 31: ...s inside the heater produces high temperature toxic gases therefore the exhaust tube must be installed according to the instructions given Do not perform any maintenance or work on the unit or exhaust...

Page 32: ...10 Combustionairandexhaustsystem 30 Caution Position the exhaust outlet so that neither the combustion air intake or any other inlets would be able to draw in exhaust fumes...

Page 33: ...not exceed 2 meters The hot air distribution ducts maximum lengths and number of vents are listed in the table below Adjustable vents are recommended to control the air flow Be aware that at least one...

Page 34: ...cold outside air In the second Recirculation type of installation the heating air is extracted from the heated cabin When using this type of heating circuit make sure that the air intake vent is locat...

Page 35: ...g lines In case the air ducting passes through a wet environment the use of spiral wire reinforced ducting is recommended The use of closable air outlets is only allowed in branch lines Care should be...

Page 36: ...rom the heater unit by turning it counter clockwise then pull it carefully away from the heater Attach the air outlet duct to the heater using one of the supplied clamps The original air outlet ring c...

Page 37: ...stated in the beginning of this chapter Figure 2 kW heater installation example NCV Non Closure vent Figure 4 kW heater installation example NCV Non Closure vent Warning The heating air temperature ca...

Page 38: ...36...

Page 39: ...ny other device Both plastic and metal fuel tanks can be used but make sure that the tanks comply with all legal regulations and standards in your country 12 2 Fuel standpipe The fuel stand pipe is in...

Page 40: ...ositions of the fuel pump are determined by the location of the heater and the fuel tank The pump must be installed with a fuel line maximum length of 1 2meters 78 inch from the fuel tank and no more...

Page 41: ...owed The pump can be turned 360 degrees around its central axes The fuel pump should be mounted to a bulkhead with the provided bracket The fuel filter is preinstalled to the fuel pump When fastening...

Page 42: ...l pump and heater with the rubber tubes and hose clamps provided with the unit When mounting the fuel lines always connect them with a putt joint in order to prevent air pockets in the fuel system Cau...

Page 43: ...m vibrations Fuel lines must be protected against any mechanical damage Make sure that the fuel lines are protected from any excessive heat source Do not fasten or route the fuel line with the exhaust...

Page 44: ...42...

Page 45: ...one or in separate directions depending on the installation of the heater and the location of the battery fuel supply and the selection of the controller location The wire harness of the heater unit...

Page 46: ...he installation of the control knob to a surface pull the turning switch off then screw off the nut and remove the dial plate Make a hole in the mounting location with a diameter of 12 mm Place the un...

Page 47: ...e at least 6 mm2 In case the cables are connected to a fuse box the cables leading to the fuse box shall be included in the calculation for the maximum voltage loss Caution For permanently live connec...

Page 48: ...13 Electricalsystem 46 13 4 Wiring diagram Figure Wiring diagram for Calaer 2 and 4 kW air heaters...

Page 49: ...he battery This will reset the failure mode and the heater can be started again Repeat this procedure until the fuel lines are filled and the heater starts to operate Let the heater run for at least 1...

Page 50: ...e control 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 an...

Page 51: ...vent that two sequential failures are detected the heater will flash the light on the control button to indicate an error In the event that the flame extinguishes during operation the heater will atte...

Page 52: ...locked at any point o Check for a blocked fuel filter o Check that there is not a significant amount of water intruded into the burner Heater stops in the middle of operation Check that there is fuel...

Page 53: ...rt F02 Flame loss 2 long 5 short F03 Under overvoltage 3 long 5 short F04 System overheat 4 long 5 short F05 Ignition sensor open load 5 long 5 short F06 The temperature sensor open load or shortcut 6...

Page 54: ...ne Blocked or broken fuel filter Replace fuel filter Broken or damaged fuel pump Replace fuel pump Broken glow plug Replace glow plug F02 Flame loss Empty fuel tank Fill tank Old or wrong fuel Replace...

Page 55: ...or shortcut Broken cable or connector Replace cable Broken temperature sensor Replace temperature sensor Broken control unit Replace control unit F07 Fuel pump open load or shortcut Broken cable or co...

Page 56: ...erheating sensor Broken control unit Replace control unit F11 Ignition open load or shortcut Broken cable or connector Replace glow plug Broken glow plug Replace glow plug Broken control unit Replace...

Page 57: ...us dense smoke while running Exhaust pipe blocked Clear exhaust pipe Combustion air intake blocked Clear combustion air intake pipe Old or wrong fuel Replace fuel Smell of exhaust fumes in cabin Leaki...

Page 58: ......

Page 59: ...Information in this manual is subject to change without notice the latest updated manual cab be found on our website at www calaer com...

Page 60: ...CTH Technologies AB Skalholtsgatan 2 16440 Kista Sweden www calaer com Product number 100079 to100082 Book 334 000560 001 This product complies with ABYC standards...

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