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Summary of Contents for Caltech Calaer 2kW
- Page 1 Installation manual 2kW Calaer air heater 4kW Calaer air heater...
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Page 3: Introduction And Scope
1. Introduction and scope 1. Introduction and scope The Calaer series products provide continuous heating, ensuring a pleasant cabin temperature. It is operated via a step-less thermostatic rotary control and delivers heat between 2 and 4 kW. The heater can be upgraded with more sophisticated controllers and ducting kits. -
Page 5: Safety Information
2. Safety information 2. Safety information Please read this chapter carefully before proceeding with the installation! Improper installation or repair of the heater can cause serious accidents including fire and potentially deadly Carbon Monoxide (CO) emissions that may result in serious injury or death. The Calaer heater is designed to minimize the risks as much as possible. - Page 6 2.Safety information Warning! Improper installation voids all warranties for the product. Always turn off the heater when refueling. Do not run the heater when there is a risk of accumulation of flammable vapors or dust. For example, close to: o Fuel stations o Coal depo o Wood depo...
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Page 7: Warranty Limitations And Exclusions
3. Warranty 3. Warranty CTH Technologies AB (herein after referred to as Calaer) warrants Calaer Air Heaters and heater kits against defects in material and workmanship for two (2) Years or 2000 hours of operation, whichever comes first, effective at the time of purchase by the end user. -
Page 9: Statutory Regulations
4.Statuatory regulations 4. Statutory regulations Country specific regulations shall be followed in all installations. 4.1 Directive 2001 / 56 /EU of the European Parliament and the Council The installation must comply with the requirements from Directive 2001 / 56 /EU of the European Parliament and the Council Installation of the heater unit ... - Page 10 4. Statutory regulation Heating air outlet (hot air outlet) The hot air outlet ducting is hot when the heater is operated. Any ducting used to route the hot air must be so positioned or protected that no injury or damage could be caused if it were to be touched. ...
- Page 11 4.Statuatory regulations Exhaust systems The system shall be 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 compartment through any openings into the accommodation spaces.
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Page 13: Technical Data
5. Technical data 5. Technical data Except where the limit values are specified, the technical data below refers to the usual heater tolerance of +/- 10% at an ambient temperature of +20°C and at the rated voltage. Technical data Heater type Calaer 2 kW Calaer 4 kW 1 - 2 kW... -
Page 15: Heater Dimensions
6. Heater dimensions 6. Heater dimensions Calaer 2 kW heater *All measurements are given in millimeters [mm]. - Page 16 6 Heater dimensions Calaer 4 kW heater *All measurements are given in millimeter [mm].
- Page 17 6. Heater dimensions...
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Page 19: List Of Parts
7. List of parts 7. List of parts Name Specification Quantity Unit Heater unit 12/24 V unit Piece Control knob Piece Fuel pump wire harness Piece Main heater wire harness Piece Thermostat sensor Piece Thermostat sensor harness Piece 12/24V Fuel pump and filter versions Piece Mounting bracket... -
Page 21: Needed Tools
8.Needed tools 8. Needed tools The following tools are needed for the installation of the heater: 7 mm wrench – 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: ... -
Page 23: Positioning Of The Heater
9. Positioning of the heater 9. Positioning of the heater The heater should be placed in a dry and protected position. When selecting the best location, first consider all aspects of the installation and the constraints that they place on: ... - Page 24 9. Positioning of the heater Attention: High temperature on the exhaust line and air ducting Do not store flammable materials in the vicinity of the heater unit or the exhaust lines Combustion air supply must not be drawn from the engine compartment ...
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Page 25: Mounting And Fastening
9. Positioning of the heater 9.2 Mounting and fastening The attachment point of the heater should 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 heater or the additional mounting brackets available by Calaer. - Page 26 9. Positioning of the heater Figure: Bracket for 4 kW heater Fasten the bracket securely to the bulkhead. Make sure that the mounting is secure and can withstand vibration and any other “shock” resulting 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 secure the heater to the bracket.
- Page 27 9. Positioning of the heater 9.3 Nameplate The nameplate with 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 the heater label and serial number is illegible or missing.
- Page 29 10. Combustion air and exhaust system 10. Combustion air and exhaust system 10.1 Combustion air intake The combustion air intake is located near the main heating air intake of the heater. The maximum length of the combustion air intake tube is 2 meters (6.4 feet).
- Page 30 10. Combustion air and exhaust system Before securing the air intake tube to the heater with the provided hose clamp, make sure that the fuel connection is already in place or leave room for it when tightening the clamp. Secure the line in place with the support brackets. Warning! ...
- Page 31 10. Combustion air and exhaust system Caution! Risk of injury: The end of the exhaust pipe is extremely sharp and can easily cut through skin. Use gloves when cutting and mounting the exhaust line. When fastening the exhaust line to the heater apply exhaust paste on the end of the tube and around the outside of the exhaust fitting on the heater.
- Page 32 10. Combustion air and exhaust system Caution! Position the exhaust outlet so that neither the combustion air intake or any other inlets would be able to draw in exhaust fumes.
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Page 33: Heating Air System
11. Heating air system 11. Heating air system The unit comes with 1 meter (3.2 foot) of air duct and one heating air vent. The air ducting can be extended with Calaer approved ducting materials and vents. The heating air intake line must not exceed 2 meters. The hot air distribution ducts maximum lengths and number of vents are listed in the table below: Heater type... - Page 34 11. Heating air system 11.1 Planning The air system can be built up in two types of heating circuits Fresh-Air type heating and Recirculation type heating. In case of the Fresh-Air type circuit the heating air is extracted from the outside.
- Page 35 11. Heating air system When the air ducting needs to be routed through bulkheads, use pipe sockets that allow you to fasten the line on both sides of the bulkhead. Ducting holes without the pipe sockets are very likely to ware through in time.
- Page 36 11. Heating air system 11.2 Installation of the air intake duct and vent When an air intake duct is used, the air intake protection grid what is mounted on the heater unit must be removed. Do this by turning the cap counterclockwise, then pull it carefully away from the heater.
- Page 37 11. Heating air system Warning! The heating air temperature can reach upwards to 110°C (230°F). Make sure that there are no heat sensitive materials in the vicinity in the air ducts and adequate clearance is given. 11.4 Possible installation examples: The heating air ducting can be divided into several branches.
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Page 39: Fuel System
12. Fuel system 12. Fuel system Specific requirements may apply in different countries for fuel tanks and fuel lines, consult your local authorities. 12.1 Fuel tank For the fuel pick up point, both the engine main fuel tank or a separate fuel tank can be used. - Page 40 12. Fuel system For the installation of the fuel standpipe cut a hole of 25mm (1 inch) for connector fitting. Make sure that no metal threads get into the fuel tank while drilling. Cut the fuel pipe into length and remove any shreds of metal from the end.
- Page 41 12. Fuel system The pump is recommended to be placed at a 45degree angle but angles of 15-90 degrees are allowed. 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.
- Page 42 12. Fuel system Cut the fuel lines to length with a sharp knife, clean the interfaces from burrs and make sure they are not crushed. Caution! The fuel line between the fuel pick-up point, fuel pump and the heater should be on a continuous rise. ...
- Page 43 12. Fuel system Warning! Fuel lines must be placed and fastened to avoid any damage from vibrations. Fuel lines must be protected against any mechanical damage. Make sure that the fuel lines are protected from any excessive heat source.
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Page 45: Electrical System
13. Electrical system 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. - Page 46 13. Electrical system 13.1 Installing the temperature sensor When selecting the location for the temperature sensor (thermostat) avoid areas where it can be affected by sunlight, drafts, cooking devices and other heat emitting or cooling equipment. We suggest to mount the sensor in the mid height of the heated room to ensure the best temperature control.
- Page 47 13. Electrical system The power supply cable can be extended with the following requirements on the wires: For 12 V system the maximum voltage loss over the extension cable cannot exceed 0.5 V. For a 5-meter total length of plus and minus cables, the cross sectional area of the wire needs to be at least 4 mm2 ...
- Page 48 13. Electrical system 13.4 Wiring diagram Figure: Wiring diagram for Calaer 2 and 4 kW air heaters...
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Page 49: Initial Start-Up Procedure
14. Operating instructions 14. Operating instructions The heater is operated by a control unit. This control unit can be the controller knob, timer or a remote controller. 14.1 Initial start-up procedure Install and connect the heater according to this instruction manual. In order to fill the fuel lines, start the heater by turning the control knob to maximum. - Page 50 14. Operating instructions 14.2 Heater control knob The control button is used to set a desired set point in temperature where the temperature sensor is located and also to turn the heater on and off when no other control unit is connected. It features an off-position, a temperature gradient for setting the heater thermostat and a status light for heater operation feedback.
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Page 51: Troubleshooting
15. Troubleshooting 15. Troubleshooting 15.1 Maintenance Diesel fuel will degrade when stored for a long time. Operating the heater with old fuel can affect the operation of the fuel pump. Run the heater once per month for 15 minutes to refresh the fuel in the lines and keep the fuel pump from malfunctioning. - Page 52 15. Troubleshooting Does the fuel pump start to tick? o Check that the cable is connected and fastened. o Check that there is fuel in the tank and in the fuel lines. Heater does not start but the fan is running and the fuel pump is working.
- Page 53 15. Troubleshooting 15.3 Failure codes Failure of the heater operation will be made visible to the user by an error code, consisting of a series of short and long flashes of the light on the control knob. The coding of the error codes are as follows: Long flash ( ▬...
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Page 54: Advanced Troubleshooting
15. Troubleshooting 15.4 Advanced troubleshooting The table below lists the potential causes and remedies for fault codes. Code Trouble Cause Remedy Ignition failure Battery low Check battery voltage Charge or replace battery Empty fuel tank Fill tank Old or wrong fuel Replace fuel Blocked or broken Replace fuel line... - Page 55 15. Troubleshooting System Heating air intake Clear heating air intake overheat blocked Heating air Clear heating air output output blocked lines Heating air Reduce the length or system too long bends of the heating or with too many ducts bends Ignition sensor Broken cable or Replace cable...
- Page 56 15. Troubleshooting Overheating Broken cable or Replace overheating sensor open connector sensor load or shortcut Broken Replace overheating overheating sensor sensor Broken control Replace control unit unit Ignition open Broken cable or Replace glow plug load or shortcut connector Broken glow plug Replace glow plug Broken control Replace control unit...
- Page 57 15. Troubleshooting 15.5 General faults and potential causes with remedies Trouble Cause Remedy Heater does not Battery empty Charge or replace respond – no light battery when switched on Fuse broken Replace fuse Battery cable or Replace cable or contact bad contact to battery Control button cable Replace cable or...
- 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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