E-Guardian 5, 8 10 and 12Espar Heater Systems

08.2008 Subject to Change WEB Edition

HYDRONIC D5 25 2823 25 0500

HYDRONIC MII 8 25 2824 70 0800

HYDRONIC MII 10 25 2824 34 1000

HYDRONIC MII 12 25 2824 72 1200P/N 221000 30 36 00 (Coolant heater 12/24 volt)

Installation InstructionsOperating Instructions

Espar Products, Inc.6099A Vipond DriveMississauga, OntarioCanada L5T 2B2

(905) 670-0960(800) 387-4800 Canada & U.S.A.(905) 670-0728 Fax

www.espar.com

2

Table of contents

Introduction 3........................................................sgninraW retaeH

4........................................................5 naidrauG-E

4........................................................21 dna 01 ,8 naidrauG-E

Mounting theE-Guardian Diagram ........................................................ 5

Installation 6........................................................retaeH eht gnitnuoM

Integrating into the coolant system ........................................................ 6

7........................................................metsyS leuF

7........................................................snoitcennoC gniriW

7........................................................snoitarepO laitinI

8........................................................tiK pmuP tnalooC

8........................................................snoitpO lortnoC

8........................................................hctiwS lluP/hsuP

8........................................................noitcnufitluM

9........................................................tloV 21 remiT elbammargorP

9........................................................serutaeF

9........................................................emiT eht gnitteS

9........................................................semiT gnihctiwS fo gnimmargorP

9........................................................edirrevO launaM

Switchover Summertime/Wintertime, Time zone change ........................................................ 9

9........................................................nottuB teseR

Diagnostics, Troubleshooting, Wiring Programable timer......................................................... 10

Heater Components

Hydronic D5W SC, 12 volt, Diesel ........................................................ 5

Hydronic D5W SC, FMP OUT, 12 volt, Diesel ........................................................ 5

6........................................................snoisnemiD lapicnirP

Installation 7........................................................noitacoL retaeH

Procedures Heater Mounting ........................................................ 7

Special Notes

Note: Highlight areas requiring special attention or clarification.

Caution: Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed.

Warning: Indicates that serious or fatal injury may result if specific guidelines are not followed.

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Introduction

• Correct installation of this heater is necessar y to ensuresafe and proper operation.Read and understand this manual before attempting toinstall the heater. Failure to follow all these instructionscould cause serious or fatal injury.

• Heater must be turned off while re-fueling.

• Do not install heater in enclosed areas where com-bustible fumes may be present.

• Do not install heaters in engine compar tments of gaso-line powered boats.

• Install the exhaust system so it will maintain a minim umdistance of 50mm (2”) from any flammable or heat sensi-tive material.

• Ensure that the fuel system is intact and there are no leaks .

• Route the heater exhaust so that exhaust fumes cannotenter any passenger compartments.

• If running exhaust components through an enclosedcompartment, ensure that it is vented to the outside.

• The use of Espar coolant heaters requires that thecoolant in the system to be heated contain a proper mix -ture of water and antifreeze to prevent coolant fromfreezing or slushing.

• If the coolant becomes slushy or frozen, the heater’scoolant pump cannot move the coolant causing a b lock-age of the circulating system. Once this occurs, pressurewill build up rapidly in the heater and the coolant hosewill either burst or blow off at the connection point to theheater.

• This situation could cause engine damage and/or per-sonal injury. Extreme care should be taken to ensure aproper mixture of water and antifreeze is used in thecoolant system.

• Refer to the engine manufacturer’s or coolant manufac-turer’s recommendations for your specific requirements.

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Caution: During electrical welding work on the vehi-cle disconnect the power to the heater in order to protect the control unit.

NNoottee:: All measurements contained in this manualcontain metric and approximate SAE equiva-lents in brackets eg 25mm (1”).

Direct questions to Espar Heater Systems:

CCaannaaddaa && UU..SS..AA.. 11--880000--338877--44880000

This publication was correct at the time of pr int.However, Espar has a policy of contin uous improve-ment and reserves the right to amend any specifica-tions without prior notice.

4

EE--GGuuaarrddiiaann 55

The Hydronic 5 Coolant Heater preheats bus engines, elimi-nating cold starts and the need to idle before and during nor-mal bus routes.

• Eliminates the need for an electrical block heater.• Stops white smoke and reduces emissions on star t up.• Supplemental interior heating.• Strong heat output of 17,000 BTU/h.• Compact design.• Frame rail or engine mount.• Diagnostic capabilities.

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Introduction

The Hydronic “M” Series Coolant Heater is offered in 8, 10and 12 kw versions to meet the needs and requirements of allenviroments.

• Preheats the engine to eliminate cold star ts and extendsengine life.

• Accelerates and maintains window defrosting and defog-ging.

• Provides supplemental heat for increased driver and pas-senger comfort.

• Stops white smoke at engine star t-up and eliminates dieselknock.

• High capacity water pump for increased heat distr ibution.• 1 inch coolant connections.

E-Guardian Coolant Heaters go to work before the driver arrives, preheating the coolant in the engine and eliminating cold star tsas well as offering supplemental heat to the inter ior. The heater is mounted on the dr iverside frame rail and plumbed in ser ies tothe 1” coolant lines.

5

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Introduction

COOLANTPUMP

(Possible Location)

DRIVERʼS HEATERSTANDARD

FRONT HEATER

FRONTAXLE

REARAXLE

Heat Exchanger

Heat Exchanger

Espar(Option #2)

Espar(Option #1)

ENGINE

6

CCAARREEFFUULLLLYY RREEAADD AANNDD UUNNDDEERRSSTTAANNDD TTHHEE FFOOLLLLOOWWIINNGGIINNSSTTRRUUCCTTIIOONNSS BBEEFFOORREE PPRROOCCEEEEDDIINNGG WWIITTHH TTHHEEIINNSSTTAALLLLAATTIIOONN..

11. Find a suitable mounting spot on the frame rail.Note: Make sure there is enough clear ance to remove the lidoff the boxed heater before securing the mounting tray.See page #5.

22. Solidly bolt the mounting tray onto the frame rail.

33. You can then mount the bo xed heater on the mountingbracket/tray. Tighten and secure with the loc k w ashers andnuts.

Installation Instructions

Integrating into the Coolant System:

A series heating system works in this fashion:Heated coolant from the engine travels through the first heatercore in the circuit, then on to the next heater core in the circuit,and on to the ne xt, etc. Each core adds some restr iction,resulting in decreased coolant flo w. Not only is coolant flo wreduced, b ut also coolant temper ature is reduced b y eachsuccessive heater core resulting in the last core receivingwater that is usually to cool to be eff ective. The Espar fueloperated heater is equipped with a high capacity coolant pumpwhich increases flo w and significantly increase the a vailableheat supplied to a ser ies plumbed system.

11. Remove the radiator cap and release system pressure .

22. Close the shut off v alves f or the heating system, if soequipped.

33. Two 90 deg ree elbo ws ha ve been pro vided f or makingconnections into the existing coolant lines. To Install:

• Remove heater hose access co ver(s) running down theleft side of the floor inside the bus at a location over top ofthe heater installation.

• Find and identify heating circuit supply hose . This is thehose you will use to plumb the Espar heater into thesystem.

Try to use existing holes in the frame rail before drilling.

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Check local and state codes to see requirements f or mounting the exhaust. In New York State the exhaust MUST exit out the rear of the b us. We supply 2 meters (6 ft.) of flexible stainless steel exhaust.

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• Locate and mark suitable location on floor where the brass elbows will be installed.

• Once you are satisfied with the location, making certain there are no obstructions, you can now bore 2 holes 32mm (1-1/4”) through the floor.

• From inside the bus, drop the elbows down through the floor and align with the heating circuit supply hose, inlet elbow pointing forward and outlet elbow rear ward.

6. From inside the bus cut the previously identified heatingsupply hose at a point where it can be connected to the inletand outlet elbows! Use hose clamping pliers to secure the hosebefore cutting.

7. Connect the heater supply line running from the engine tothe inlet elbow. Connect the other cut end of the supply line tothe outlet elbow.

8. Secure all hose connections with hose clamps.

9. Remove hose clamping pliers and/or open shut off valves.

10. Top off engine coolant as per engine manufacturersrecommendations and re-install radiator cap.

The fuel pick up pipe and fuel line must be installed accordingto these instructions to ensure proper operation.

1. Locate the cover plate on the floor of the school bus abovethe fuel tank.

Installation Instructions2. Drill holes on the plate of the tank as shown in the instal-lation manual that is included.

3. Cut the fuel pick up pipe to length, approx. one inch off thefuel tank bottom. Cut standpipe end on a 45 degree angle toprevent clogging.

4. Install as shown in manual.

5. Route and secure fuel line from heater to fuel tank. Do notroute fuel line over frame rails, always route through or underframe rail.

1. The wiring harness has 40 ft. of control/timer line, 30 ft. ofbattery line and 25 ft of fuel pump line. Cut any excess wireafter running it to the desired location as to avoid coiling extraharness.

2. Route and secure the battery line from the Espar heater tobattery and cut harness to length.

3. Secure the 20 amp fuse to the positive (Red) line and con-nect it to the positive lead.

4. Connect ground lead to ground stud on battery.

5. Route and secure the control/timer line to either the controlpanel on the outside of the bus or the driver’s compartment.

6. Route the fuel pump line along with the clear plastic fuelline to the pump.

1. Check your installation for:

• All fasteners are secure• Exhaust pipe routing and clamp tightness• Loose hose clamps• Routing and securing of wiring and heater hoses• Kinked or pinched hoses• Battery connection and polarity

2. Top off or refill coolant.

3. Open shut-off valves and driver’s heater valve.

4. Start the vehicle engine and run it at a fast idle for 10 min-utes to purge air from the Espar coolant heater and all of theheat exchangers. While the engine is running check.

• Hose connections for leaks.• Coolant level in the expansion tank and add coolant as needed.

5. Switch on heater.

If the bus has silicone coolant lines you must use con

stant torque hose clamps to prevent leaks.

Do not install the previously removed heater hose access

covers at this time. Hose connections will require

inspection and re-tightening of clamps once installation

is complete and tested.

Fuel System

Routing Harness

The installation kit includes 30 ft. of loom for the battery

line.

Initial Operation

8

66. Shut off engine.

77. Switch heater off

88. Install an y panels and access co vers remo ved dur inginstallation.

A Push/Pull s witch, a 7 Da y Timer or a Prog rammable Timerare available.

77 DDaayy TTiimmeerr

• Mount switch in a location where it is easily accessib le.• Mount using hardware supplied.• Connect the switch harness to the connector at the heater

and run the harness to the switch location.• Cut harness to length at the switch and install terminals.• Connect wiring as shown.

Installation Instructions

The 7 Day Timer is capable of multiple start functions within a7 day period. Other functions include current time displa y andAM automatic heater n umeric f ault code . Display ref er toinstructions provided with timer for setting options.

• Mount timer and bracket in a suitable location.• Connect the switch harness to the connector at the

heater and run the harness to the control location.• Cut harness to length at the control and install ter minals.• Connect switch harness to timer as shown below.• Refer to timer instructions for other wiring options.

Installations with long fuel lines may require a second orthird attempt to pr ime the fuel system. The heater will make 2 start attempts and run through a cool down cycle before shutting down. Cycle the timer switch off and on to reset the control unit and restar t the heater.You should be able to hear the fuel pump ticking as it istrying to prime the line.

12 VoltRelay

TimerYellow Switch Wire

P/N: 25 2800 60 0000PowerSource

Pump Coolant In

Coolant Out

OOppttiioonn ##11:: Dash lights to timer - connect wire betw een dash lights circuit and timer at ter minal #1.

OOppttiioonn ##22:: Operate heater continuously - connect wire from ignition circuit to terminal #10.See also multifunction (7 day) timer in instructions.

77 DDaayy TTiimmeerr

PPuusshh//PPuullll SSwwiittcchh

YellowReda)

b)c)d)

BrownBlue

DIAG

TRS

Yellow

Red

Blue

Brown 1211

109

87

65

43

21

MO123

P

aa)) Power from battery “+”.bb)) Switch control to the heater.cc)) Power from battery “-”.dd)) Diagnostic from heater.

AUTO MANUAL

RESET

CLOCK TIMER DAY HOUR MINMANUAL

PP//NN:: 2200 22990000 7700 0022 3300

PP//NN:: 55667700000077

14.5mm9/16”

K (15)

15 (K)

31

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Brown- 31 Power from battery “-”Red- K(15) Power from battery “+”Yellow-15(K) Switch control to the heaterBlue/White Diagnostic from heater (disregard - tape

end and tie off to the side)

NNoottee:: Wired as above the switch light glows whenpulled out and is off when pushed in.

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Before using your timer, please read the following instructionscarefully.This quality product has been tested and cer tified to meet theCE and GS safety requirement.

IIMMPPOORRTTAANNTT: This electronic timer has a maxim um loadingprinted on the rating label and under no circumstances should this be exceeded.

• Up to 8 ON and OFF switches a day/56 ON and OFFswitches per week

• Option to program individual days or 8 diff erent weekdaygroups

• Minimum switching period of one minute• Summer/Winter time changeover• Easy to read LCD display• Manual Override button• Battery Back-up

IIMMPPOORRTTAANNTT: As soon as you have connected 12 volts you will have to push down the RESETbutton to activate the timer.

Press and hold the CLOCK b utton. Then press on the D AYbutton to select the correct da y, then the HOUR b utton toselect the correct hour and the MIN button to select the correctminutes.When the MIN button is released, the time will be set and theseconds will be star ting from 00.Either holding do wn or repeatedly pressing the appropr iatebutton can advance the days, hours and minutes.

The A uto Time Switch has the capacity f or 8 ON/OFFswitches. By using the b locks of days available, you can saveprogram capacity. The block days are:

MO, TU, WE, TH, FR, SA, SU – Individual days of the weekMO, TU, WE, TH, FRSA, SUMO, TU, WE, TH, FR, SAMO, WE, FRTU, TH, SAMO, TU, WETH, FR, SA

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Installation Instructions

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For each ON time and each OFF time , the da ys, hours andminutes must be set.Press the TIMER button once to set the first ON time – you willsee “on” and the number “1” appears on the left of the LCDdisplay. This indicates that you can now enter the first ON time.Press the D AY button to choose the required da y or b lock ofdays, and then set the hour and minutes using the HOUR andMIN buttons.When you have completed setting the required ON time, presson the TIMER button to validate the entr y and move onto thefirst OFF time y ou will see “OFF” and the n umber “1” appearon the left of the LCD displa y. This indicates that y ou cannow enter the first OFF time by using the DAY, HOUR and MINbuttons as above.Press the TIMER button to validate this entry.Repeat the same steps f or the remaining 7 ON and OFFsettings as desired.When you have set the required ON/OFF settings , press theCLOCK button to return the display to the clock. The timer willnow be ready to operate.Note that you can check the settings you have programmed bypressing the TIMER b utton repeatedly – each setting willappear on the screen.

You can choose per manent Manual ON, per manent ManualOFF, Auto mode ON and Auto OFF by pressing the MANUALbutton. When you choose A uto mode ON, the timer tur ns onuntil the OFF time is prog rammed. The program settings willonly work in Auto mode. When Auto mode OFF is chosen thetimer is OFF until the next program is activated.

To change from winter time to summer time press the HOURand MIN buttons simultaneously.The clock will be set f orward one hour and an “S” will appearon the display. Repeat the same procedure in order to selectwintertime.

To reset the unit including the time and prog rammed ON/OFFsettings, press the RESET buttonusing a ballpoint pen.

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Yellow (Signal to Heater) 5

4 5670100 - 12 Volt

ProgrammableTimer

3

2

1

Brown (-)

Red (+)

1122 VVoolltt PP//NN:: 55667700110000

10

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There is a diagnostics connector located on the wir ing har-ness inside the boxed Hydronic unit. If the heater experi-ences any difficultly starting or shuts down during operationthe mechanic can plug in their diagnostics unit and read thefault codes off the control unit of the heater . Instructions areincluded with the diagnostics unit and the f ault codes are list-ed in your Hydronic M service manual. The diagnostics unit issold separately. PN 20.2900.7050.20

Installation Instructions

5670100-12 Volt

Controller Line

Red (+)

Brown (-)

Yellow (Switch Signal to Heater)

Blue/White (Diagnostics

Pin 1

Pin 5

Pin 2

Pin 6

Diagnostics Connector

ProgrammableTimer

1 2 3 4 5

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series

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Espar has also included the added con venience of wiring anadditional diagnostics connector close to the controller/timerduring installation. The installer will need to cut off appro xi-mately 1 ft. of the control line and use that to connect thecontroller/timer to the diagnostics connector. The terminalsand connector have been provided in the bag par ts.

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Notes:

A member of the Worldwide Eberspächer Group of Companies

2nd Printing - Aug 2008Printed in Canada

Espar Products, Inc.6099A Vipond DriveMississauga, Ontario

Canada L5T 2B2

(905) 670-0960 Canada

(905) 670-0728 Fax

(800) 387-4800 Canada & U.S.A.

www.espar.com