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HYDRONIC D5S/SC

DIAGNOSTIC AND REPAIR MANUAL

A WORLD OF COMFORT

Summary of content (25 pages)

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H YDRONI C D5S/SC D IAG NOSTIC AND REPAIR MANU A L A WORLD OF COMFORT
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Table of Contents REVISION LEVEL A - 12/09/13 Chapter 1 2 3 4 5 6 7 8 9 Content Page System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diagnostic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 System Overview REVISION LEVEL A - 12/09/13 SYSTEM OVERVIEW The Espar Hydronic D5 heater is designed to lower idling by providing an alternative for engine pre-heat and or cab heat. The Espar Hydronic D5 is also designed to maintain engine temperature and or cabin temperature. In the instance cabin temperature is to be maintained, precondition the cab to the desired temperature is recommended. SYSTEM OPERATION 1.
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2 Diagnostic Devices REVISION LEVEL A - 12/09/13 MULTIPLE DIAGNOSTIC DEVICES ARE AVAILABLE AS OUTLINED BELOW: This manual is designed to be used with the Hydronic D5 S and SC. The Hydronic II D5E diagnostics can only be accessed by using an Easy Start fault reader or Edith. Please reference the data tag on your heater to verify which heater model you have. The Hydronic I D5 S or Hydronic I D5 SC can utilize any of the fault readers. 1.
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2 Diagnostic Devices REVISION LEVEL A - 12/09/13 EDITH PC DIAGNOSTICS (PREFERENCE) Figure 2 5
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2 Diagnostic Devices REVISION LEVEL A - 12/09/13 2 . DIGI-DIAGNOSTIC TOOL / FAULT CODE READER Both of these units will provide quick access to the checking and clearing of fault codes but only Edith will provide true diagnostics capability. As such these units are shown for reference only. Figure 3 SPECIAL TOOLS AND ADAPTORS 1. Depending on the heater model and application, diagnostic adapters may be required to interface with the heater harness and perform functions. 2.
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2 Diagnostic Devices REVISION LEVEL A - 12/09/13 PLEASE NOTE! Adapter connection on Park Smart.
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3 Visual Inspection REVISION LEVEL A - 12/09/13 THE 60 SECOND VISUAL INSPECTION 1. Before starting any repairs always perform a complete a visual installation inspection. Problems resulting from an improper installation are not warrantable issues: a. Fuel Pump angle: Between 15 and 35 degrees- Inlet is low side, outlet is high side. i. Yes ______ ii. No ______ iii.If not it will need to be reset to proper angle before completing repairs (pg.
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4 Typical non-warrantable repairs REVISION LEVEL A - 12/09/13 TYPICAL NON-WARANTABLE REPAIRS: 1. FUEL FILTER a. The fuel filter can be found on the inlet side of the fuel pump, see page 24. If this filter is plugged or partially plugged it can cause a no-start to your heater. The filter can be serviced by using a backing wrench and turning the inlet cap off the pump. Then use a small pick to pull the filter out to be replaced. b.
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5 Fault Code / Troubleshooting REVISION LEVEL A - 12/09/13 IF THERE IS NO COMMUNICATION Fault reader displaying - - - (dash dash dash) or non-functional Espar unit without fault codes 1. Check units open circuit voltage at the batteries. 2. If the voltage is below 12.6 (Flooded cell) or below 12.8 (AGM) charge the batteries following your company’s standard practices and restart troubleshooting. a. Otherwise continue below. 3. Connect Diagnostic Interface adapter (Figure 10). 4.
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5 Fault Code / Troubleshooting REVISION LEVEL A - 12/09/13 FAULT CODE / TROUBLESHOOTING PLEASE NOTE! Warranty Process - perform an Edith extraction printout to record codes before proceeding. Carefully document the Complaint – Cause and Correction. 000 - NORMAL OPERATION 1. No Repairs needed. 010 – OVER-VOLTAGE 1. System maximum voltage is 16 volts. 2. The only possible cause of this code is either. a. A battery charger in boost mode. b. Alternator overcharging. 3. Clear the code repair as needed.
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5 Fault Code / Troubleshooting REVISION LEVEL A - 12/09/13 4. Check for debris in heat exchanger and coolant pump. i. Listen to see if coolant pump is operating. If pump is not operating and the existing fault is for overheat, the likely issue is a plugged coolant pump. 1. Remove the magnet from pump (found on page 17) and clean. If magnet is plugged the coolant system must be flushed because it is contaminated.
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5 Fault Code / Troubleshooting REVISION LEVEL A - 12/09/13 051 - FAULTY FLAME RECOGNITION 1. Common cause is restarting of the heater after a failed start attempt. i. Refer to Code 52 for no-start situations. 052 - NO START SAFETY TIME EXCEEDED 1. No flame detected on start attempt but unit diagnostics are unable to detect a fault. 050 - TOO MANY NO START ATTEMPTS - (LOCKOUT) . 10 CONSECUTIVE CODE 52 CODES WILL RESULT IN AN ECU LOCKOUT SITUATION This is normally not a warrantable failure 1.
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5 Fault Code / Troubleshooting REVISION LEVEL A - 12/09/13 053 – FLAME LOSS DURING START 1. See Code 52 054 – FLAME CUTOUT IN BOOST MODE 1. Heater has started successfully but the flame has extinguished. 2. Inspect and or replace fuel filter on inlet side of fuel pump, see page 24 (maintenance). 3. Check fuel supply/measure fuel quantity. a. Disconnect the fuel line from the heater. b. Turn the unit on (remember 60 second delay prior to pump activation). c.
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6 Maintenance / Troubleshooting & Repair REVISION LEVEL A - 12/09/13 Repair Steps covered are for the Hydronic 4 & 5 SC versions - other models are similar DISASSEMBLY / ASSEMBLY 1 Cover, metering pump 2 Water pump, assembly 3 Metering pump and bracket 4 Cover, blower 5 Control unit and cover 6 Glow pin 7 Flame sensor 8 Cable harness 9 Electric motor, complete 10 Combustion chamber with flame tube 11 Heat exchanger and jacket 1 Cover, metering pump 4 Cover, blower 2 Water pump assembly.
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6 Maintenance / Troubleshooting & Repair REVISION LEVEL A - 12/09/13 7 Flame sensor, For removal of tab receptacles, use AMP extractor tool 10 Combustion chamber with flame tube 8 Cable Harness 11 Heat exchanger and jacket, Align slot on heat exchanger (arrow) with lug in jacket 34 29 35 30 34 24 8 3 9 Electric motor, complete 27 28 32 18 22 28 14 16 21 15 9 11 10 31 23 20 17 19 26 26 38 2 36 25 16 25 39 37 6
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6 Maintenance / Troubleshooting & Repair REVISION LEVEL A - 12/09/13 It is advised to make this procedure part of an annual pre-season check up for this heater . Remove the four screws holding the coolant pumps two halves together .
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6 Maintenance / Troubleshooting & Repair REVISION LEVEL A - 12/09/13 FUEL QUANTITY TEST The fuel Quantity should be tested if the heater has difficulty starting or maintaining a flame, using graduated cylinder part # 5520004 10ml. PLEASE NOTE! Measure the fuel quantity when the battery is sufficiently charged. At least 11V and at most 13V should be applied at the control unit during measurement. PREPARATION • Remove metering pump cover in the cases of SC versions.
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6 Maintenance / Troubleshooting & Repair REVISION LEVEL A - 12/09/13 TEST VALUES RESISTANCE Metering pump approx. 10 Ω for 12 volt heater; approximately 36 Ω for 24 volt heater Glow Pin approx. 0.
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7 Examples / Causes of Carboning REVISION LEVEL A - 12/09/13 EXAMPLES / CAUSES OF CARBONING Carbon is a term used to classify debris in the burner chamber . What you may visually see may not be carbon but still needs to be addressed properly to resolve the root cause of the issue . This is just a guide to the more common things you may encounter . 1. AIR FUEL MIXTURE a.
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1.12 1.13 1.5 h) 2.2 1.2 2.12 M M B2 Brown Black Brown Violet Brown White Green Green Red Red Blue Blue Brown Blue B2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 8 10 12 1.1 11 13 9 7 5 3 6 4 1 2.1 2 1 4 3 6 5 S1 8 7 8 7 6 5 4 3 B1 2 1 87 B3 Yellow Blue/White Brown Red 30 86 87a 85 8 6 5 Black/White Blue/White 4 7 Green 3 2 Blue Black/Red 1 B1 Yellow Brown S1 Red Red 2.7.1 Brown Red/Yellow a) b) c) d) Red Yellow Brown Blue 1 2 3 4 Red Brown 2.
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1.12 1.13 1.5 h) 2.2 1.2 2.12 M M Brown Black Brown Violet Brown White Green Green Red Red Blue Blue Brown Blue B2 B2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 8 10 12 1.1 11 13 9 7 5 3 6 4 1 2.1 2 1 4 3 6 5 S1 8 7 8 7 6 5 4 3 B1 2 1 87 B3 Yellow Blue/White Black/Red Brown Red 30 86 87a 85 8 Black/White 6 5 7 Blue/White 4 Blue Green 3 2 1 B1 Yellow Brown Black/Red Red S1 2.5.
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2.12 1.12 1.13 1.5 1.2 1.1 M M Red Red Blue Blue Brown Blue Brown Black Brown Violet Brown White B2 B2 2.1 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11 13 9 7 5 8 10 12 6 Black 3 Brown Violet 4 Brown 1 2 1 4 3 6 5 S1 Green 8 7 8 7 6 5 4 3 2 1 87 B3 Yellow Blue/White Green Brown Red 30 86 87a 85 8 B1 7 Yellow 6 5 4 3 2 1 B1 Black/White Blue Black/Red Blue/White Brown S1 Red Red 2.2 2.7.
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9 Fuel Filter / Fuel Pump angle REVISION LEVEL A - 12/09/13 FUEL PUMP MAINTENANCE / PROPER MOUNTING Figure 18 Fuel pump inlet filter Fuel pump inlet filter – clean or replace annually, more frequently if fuel contamination is noticed. Fuel pump should be mounted at a 15-35 degree angle, harness connection / outlet side facing up.
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Espar Products, Inc. (800) 387-4800 (905) 670-0960 www.espar.com HYDRONIC D5S/SC DIAGNOSTICS & REPAIR MANUAL www.espar.com Version 12/2013 Subject to change without notice.