Summary of Contents for Timberline Binar-5B-Compact
- Page 1 Hydronic Heating System by Elwell Corp. Binar-5B-Compact Binar-5D-Compact Service manual...
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Page 2: Table Of Contents
3. Construction and Description of the Main Units of the Heater 4. Possible Heater Faults, their Root Causes & Troubleshooting Methods Possible Faults & Replacement of Parts in the Timberline Heating System Components 5. Repair, and Replacement of Pre-heater Units 5.1 Replacement of the Glow Plug... - Page 3 Service Manual Introduction This Service Manual (“SM”) is intended for use by the maintenance personnel servicing Binar-5B-Compact and Binar-5D-Compact hydronic pre-heaters (“pre-heaters”). This manual contains techniques for troubleshooting, as well as for determining whether various units and parts are in good con- dition or need to be replaced.
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Page 4: Main Technical Characteristics
The technical characteristics include a ±10% tolerance and are specified for operation at the rated power supply voltage and air temperature of 68°F. Table 1. Model Parameter description Binar-5B-Compact Binar-5D-Compact Heat capacity, BTU 17,060 Rated power voltage, V Operating power voltage 9.5 - 16... -
Page 5: Safety Measures
2. Safety Measures Relevant workforce safety rules Do not use the pre-heater with must be observed during the in confined spaces and in repair. poorly ventilated rooms. Failure to observe pre-heater Do not switch off power to the operation instructions may pre-heater before the purging cause fire. -
Page 6: Possible Faults & Replacement Of Parts In The Timberline Heating System Components
Possible Faults and Replacement of Parts in the Timberline Heating System Components Table 2. Malfunction Malfunction Recommended Trouble- Codes Description Root Cause shooting Methods Overheating Heat exchanger tem- 1. Perform complete test (upper tem- perature near the tem- of the... - Page 7 Check the electric wiring. Foreign particles Air blower fault. Check the AB for dirt. obstruct spinner move- Speed lower Correct the fault; replace ment, or the spinner hits than rated the air blower if neces- the air blower cover. sary (see section 5.4). 1.
- Page 8 Test voltage at connector ХS2 on the heater. Test Shutdown due to Power supply voltage < the battery, the vehicle undervoltage 9.5 V voltage regulator, and power supply wiring. Check the air intake and The flame sensor is not Ventilation time the gas exhaust pipe.
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Page 9: Repair, And Replacement Of Pre-Heater Units
5. Purpose, Repair, and Replacement of Pre-heater Units The main units of the heater are shown in the CPA (catalogue of parts and assem- blies). Binar-5B-Compact and Binar-5D-Compact pre-heaters differ in terms of con- trol units, fuel pumps, and combustion chambers. Partial disassembly of the heater is required to check the condition of heater units or to replace them. -
Page 10: Replacement Of The Glow Plug
5.1 Purpose, Check, and Replacement of the Glow Plug The glow plug ensures ignition of the If the heating element works fault- air-fuel mixture as the pre-heater starts. lessly after the replacement of the To check the operation of the plug and control unit, the one removed must replace the plug: be deemed faulty and should... -
Page 11: Replacement Of The Plug Screen
Ø2.8 mm opening Fig. 2a and screw it into the located on the lateral cylindrical combustion chamber. Fig. 3а. Binar-5B-Compact Screen Fig. 3. Installing the screen into combustion chamber nozzle Fig. 3b. A burr on the screen... -
Page 12: Replacement Of The Flame Detector
5.3 Purpose, Dismounting, and Replacement of the Flame Detector Fig. 5. Flame detector The flame detector (Fig. 5) is used If an error appears during the heating to detect flame in the combustion element operation, there is either a chamber. It is comprised of a pipe crack in the weld of the FD thermo- with a thermocouple with two couple (i.e. - Page 13 5.3 Purpose, Dismounting, and Replacement of the Flame Detector Continued Method 2. Remove the FD from the housing and measure the voltage at outputs of the FD that is being heated up. When the FD housing is heated up to +100°С (boiling water temperature), its outputs must provide voltage at about 3 mV.
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Page 14: Replacement Of The Air Blower
5.4 Purpose, Dismounting, and Replacement of the Air Blower The air blower (Fig. 7) consists of an Visually inspect the spinner for for- electric motor with a scroll housing eign particles, clean if necessary. If the attached. A spinner is installed on the foreign particles are hard to clear away, motor shaft. -
Page 15: Replacement Of The Control Unit
5.5 Purpose, Dismounting, and Replacement of the Control Unit The CU (Fig. 8) performs the • Disconnect the plug wires from the following functions: control unit 1. Initial diagnostics (functional check) • Disconnect the FD wires from the of pre-heater units at startup. control unit 2. -
Page 16: Replacement Of Temperature Sensors
5.6 Purpose, Dismounting, and Replacement of Temperature Sensors The overheating and temperature sensors (Fig. 8 and 9) monitor the temperatures of the heat exchanger. If the temperature exceeds 110°С, the control unit shuts the pre-heater down with malfunction code 01; if the coolant circulation is insufficient, overheating may be caused by a large temperature gradient between the... -
Page 17: Replacement Of The Combustion Chamber
5.7 Purpose, Dismounting, and Replacement of the Combustion Chamber The evaporative type combustion chamber is used for creating and burning the air-fuel mixture Symptoms of combustion chamber faults are: a failure to start the heater (provided other parts are fault-free), a burnt out housing or inner parts of the chamber. -
Page 18: Replacement Of The Fuel Pump
5.8 Purpose, Troubleshooting, Dismounting, and Replacement of the Fuel Pump 5.8.1 5.8.2 The fuel pump (Fig. 11) is used To repair faults and determine the for metered fuel supply to the capacity of the fuel pump: combustion chamber. • Before troubleshooting, first check Main characteristics of the fuel pump: the presence and quality of fuel in the tank... - Page 19 5.8 Purpose, Troubleshooting, Dismounting, and Replacement of the Fuel Pump Continued The pre-heaters are supplied with two If all of the above faults are repaired, pump types: check the capacity of the fuel pump. The fuel pump capacity must be •...
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Page 20: Replacement Of The Pump
5.9 Purpose, Troubleshooting, Dismounting, & Replacement of the Pump The electric motor and the pump To clean the pump, partially disassem- (Fig. 12) are used to circulate coolant ble it in the following order: across the vehicle engine/cabin heat- • Remove the pump from ing systems. -
Page 21: Domestic Water Heat Exchanger
6. Domestic Water Heat Exchanger damage, apply new thread sealant and reinstall the fitting. If the leaking persists, you may need to replace the heat exchanger. To replace the heat exchanger, drain the domestic water in the system before removal. Pinch off the coolant lines in front of the unit and remove. -
Page 22: Water Solenoid Valve
The air, check the voltage at the red and fans should be blowing hot air if the Timberline system is on and the ther- black wire on the solenoid valve. mostat is not satisfied. If there is no air... -
Page 23: Timberline Tank
To replace the tank first unplug the unit. Then you will need to remove the plug in the left side of the tank and drain the Fig. 17. Timberline Tank coolant into a container. Pinch off and remove the coolant lines on the bottom Caution: High risk of electrical shock! of the tank. -
Page 24: Pinout And Replacement Of The Control Box
Black/ Heat Exchanger White Black/ Tank Sensor White Air Sensor Blue Heater Data Green Fig. 18. Timberline Control Board Tank Relay 12 V Black Solenoid Valve Black Touch Screen Data Green Heater Data 2 White Touch Screen Data 2 White... -
Page 25: Touch Panel
1. Make sure the radiator is on top on the • Binar Heater timberline tank before you turn the • Timberline Tank pump on to purge. Turn the pump on and let it purge for 10 minutes. After 10 •... -
Page 26: Pre-Heater Check After Installation
During the replacement operation ing manual. Repair the fault and repeat marked with ** (Timberline tank the test. replacement) 2 gallons of the coolant will need to be drained so that the tank will be empty during removal and installation. -
Page 27: Warranty Part Replacement Labor Time
0.3* Combusting Chamber Cleaning with Heater Removed 0.5 10 Heater Removal and Reinstallation 0.6* 11 Touch Panel Replacement 0.15 12 Timberline Control Box Replacement 0.15 13 Tank Sensor Replacement 0.15 14 High Limit Aquastat 0.25 15 120 V Relay Replacement 0.25... - Page 28 360-608-0916 info@elwellcorp.com 680-C South 28th St. Washougal, WA 98671...
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