E-Guardian Manual
Contents
1. 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 the heat exchangers While the engine is running check e Hose connections for leaks e Coolant level in the expansion tank and add coolant as needed 5 Switch on heater Installation Instructions 6 Shut off engine Control Wiring Push Pull Switch Installations with long fuel lines may reguire a second or Brown 31 Power from battery third attempt to prime the fuel system The heater will Red K 15 Power from battery make 2 start attempts and run through a cool down Yellow 15 K Switch control to the heater cycle before shutting down Cycle the timer switch off Blue White Diagnostic from heater disregard tape end and tie off to the side and on to reset the control unit and restart the heater You should be able to hear the fuel pump ticking as it is Note Wired as above the switch light glows when trying to prime the line pulled out and is off when pushed in 7 Switch heater off 7 Day Timer 8 Install any panels and access covers removed during The 7 Day Timer is capable of multiple start functions within a installation 7 day period Other functions include current time display and AM automatic heater numeric fault code Display refer to Coolant Pump Kit instructions provided with timer for setting options e Mount timer and2. To reset the unit including the time and programmed ON OFF settings press the RESET button using a ballpoint pen Yellow Signal to Heater 5670100 12 Volt Programmable Timer Installation Instructions Schematic Hydronic 5 Harness Adaptor MAIN NL 280 GROMMET Main Harness Connector Yellow A C a E rown D Green E IMPACT SWITCH OZ lt z gt Z LI OO 20 Zw U Z lt Z j a lt I EH v IL N LU LL c Ko LO LD 5 j U Z 75 o c Dd G O Sa N U 5 10 Lo o un U 10 G N o a dl poh Yellow Heater Connector Wi Installation Instructions Schematic Hydronic 5 Harness Adaptor BILL OF MATERIAL io P SOD QTY EA ary FT ATY mm A se _ o J o n ms a o s sa o a eee e r TT T T onen Oe rodne O em TT T a sa TT Tone Te PCC nee MES E m A ra e Tom Oe Tone Oe O a gt a aaa f L TL a eee P TL eee mmm so menene L T E HE zam rose S L L HEIM EEE remeras 1 L L a ECO nn _ 2 _ S a ECC C 1 _ NEZ marne 2 _ ap Y S e op me L L Le s EC samme iP E EC NEC L L L HEIM K pren To 011 NECIO OTT T T AT L P PL 11 Installation Instructions Schematic Hydronic M II 8 10 12 Harness Adaptor z S al z I LO LO a
3. days and then set the hour and minutes using the HOUR and MIN buttons When you have completed setting the required ON time press on the TIMER button to validate the entry and move onto the first OFF time you will see OFF and the number 1 appear on the left of the LCD display This indicates that you can now enter the first OFF time by using the DAY HOUR and MIN buttons as above Press the TIMER button to validate this entry Repeat the same steps for the remaining 7 ON and OFF settings as desired When you have set the required ON OFF settings press the CLOCK button to return the display to the clock The timer will now be ready to operate Note that you can check the settings you have programmed by pressing the TIMER button repeatedly each setting will appear on the screen Manual Override You can choose permanent Manual ON permanent Manual OFF Auto mode ON and Auto OFF by pressing the MANUAL button When you choose Auto mode ON the timer turns on until the OFF time is programmed The program settings will only work in Auto mode When Auto mode OFF is chosen the timer is OFF until the next program is activated Switchover Summertime Wintertime Time Zone Change To change from wintertime to summer time press the HOUR and MIN buttons simultaneously The clock will be set forward one hour and an S will appear on the display Repeat the same procedure in order to select wintertime Reset Button
4. guidelines are followed 2 Indicates that serious or fatal injury may result if specific guidelines are not followed O A O oO O O O O DON NN O O 2 1 1 O OVO R O M Introduction Heater Warnings Correct installation of this heater is necessary to ensure safe and proper operation Read and understand this manual before attempting to install the heater Failure to follow all these instructions could 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 compartments of gaso line powered boats Install the exhaust system so it will maintain a minimum distance 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 cannot enter any passenger compartments If running exhaust components through an enclosed compartment ensure that it is vented to the outside The use of Espar coolant heaters requires that the coolant in the system to be heated contain a proper mix ture of water and antifreeze to prevent coolant from freezing or slushing If the coolant becomes slushy or frozen the heater s coolant pump cannot move the coolant causing a block age of the circulating system Once this occurs pressure will build up rapi
5. tested and certified to meet the CE and GS safety requirement e Upto 8 ON and OFF switches a day 56 ON and OFF switches per week e Option to program individual days or 8 different weekday groups Minimum switching period of one minute Summer Winter time changeover Easy to read LCD display Manual Override button Battery Back up Setting the Time Press and hold the CLOCK button Then press on the DAY button to select the correct day then the HOUR button to select the correct hour and the MIN button to select the correct minutes When the MIN button is released the time will be set and the seconds will be starting from 00 Either holding down or repeatedly pressing the appropriate button can advance the days hours and minutes Programming of Switching Times The Auto Time Switch has the capacity for 8 ON OFF switches By using the blocks of days available you can save program capacity The block days are MO T WE TH FR SA SU Individual days of the week MO TU WE TH FR SA SU MO TU WE TH FR SA MO WE FR TU TH SA MO TU WE TH FR SA Wi For each ON time and each OFF time the days hours and minutes must be set Press the TIMER button once to set the first ON time you will see on and the number 1 appears on the left of the LCD display This indicates that you can now enter the first ON time Press the DAY button to choose the required day or block of
6. E Guardian 5 8 10 and 12 Installation Instructions Espar Heater Systems Espar Products Inc 6099A Vipond Drive Mississauga Ontario Canada L5T 2B2 905 670 0960 800 387 4800 Canada 8 U S A 905 670 0728 Fax www espar com HYDRONIC D5 252823 25 0500 HYDRONIC Mil 8 25 2824 70 0800 HYDRONIC Mil 10 25 2824 34 1000 HYDRONIC Mil 12 25 2824 72 1200 ee a S b _ P N 20 2900 80 1000 0B 09 2008 Subject to Change Printed in Canada Table of contents Introduction Installation Heater Warnings E Guardian 5 E Guardian 8 10 and 12 Mounting theE Guardian Diagram Mounting the Heater Integrating into the coolant system Fuel System Wiring Connections Initial Operations Coolant Pump Kit Control Options Push Pull Switch Multifunction Programmable Timer 12 Volt Features Setting the Time Programming of Switching Times Manual Override Switchover Summertime Wintertime Time zone change Reset Button Hydronic 5 Harness Adaptor Bill of material 5 Harness Adaptor Hydronic MII 8 10 12 Harness Adaptor Bill of material Hydronic MII 8 10 12 Harness Adaptor Hydronic 5 and MII 8 10 12 Main Harness Bill of material Hydronic 5 and MII 8 10 12 Main Harness Diagnostics Troubleshooting Wiring Programable timer Special Notes Note Highlight areas requiring special attention or clarification Caution Indicates that personal injury or damage to equipment may occur unless specific
7. bracket in a suitable location e Connect the switch harness to the connector at the heater and run the harness to the control location e Cut harness to length at the control and install terminals e Connect switch harness to timer as shown below e Refer to timer instructions for other wiring options Coolant Out Coolant In Yellow Switch Wire P N 25 2800 60 0000 Control Options Red i A Push Pull switch a 7 Day Timer or a Programmable Timer Yellow Yellow cla are available en Brown re d gt 2 Ci Ta EN Blue cle ice nee Brown a a Power from battery e Mount switch in a location where it is easily accessible A al to the heater c Power from battery Mount using hardware supplied d Diagnostic from heater e Connect the switch harness to the connector at the heater and run the harness to the switch location e Cut harness to length at the switch and install terminals Option 1 Dash lights to timer connect wire between dash lights circuit and timer at terminal 1 e Connect wiring as shown Option 2 Operate heater continuously connect wire from ignition circuit to terminal 10 See also multifunction 7 day timer in instructions Installation Instructions Programmable Timer 12 Volt P N 5670100 Before using your timer please read the following instructions carefully This guality product has been
8. dly in the heater and the coolant hose will either burst or blow off at the connection point to the heater This situation could cause engine damage and or per sonal injury Extreme care should be taken to ensure a proper mixture of water and antifreeze is used in the coolant system Refer to the engine manufacturer s or coolant manufac turers recommendations for your specific requirements Wi Caution During electrical welding work on the vehi cle disconnect the power to the heater in order to protect the control unit Note All measurements contained in this manual contain metric and approximate SAE equiva lents in brackets eg 25mm 1 Direct questions to Espar Heater Systems Canada amp U S A 1 800 387 4800 This publication was correct at the time of print However Espar has a policy of continuous improve ment and reserves the right to amend any specifica tions without prior notice Introduction The Hyaronic 5 Coolant Heater preheats bus engines elimi nating cold starts and the need to idle before and during nor mal bus routes e Eliminates the need for an electrical block heater e Stops white smoke and reduces emissions on start up e Supplemental interior heating e Strong heat output of 17 000 BTU h e Compact design e Frame rail or engine mount e Diagnostic capabilities E Guardian 8 10 and 12 The Hydronic M Series Coolant Heater is offered in 8 10 and 12 kw versions to
9. ignal to Heater Blue White Diagnostics Pin 6 15 2nd Printing Sept 2008 Printed in Canada P N 20 2900 80 1000 OB Espar Products Inc 6099A Vipond Drive Mississauga Ontario Canada L5T 2B2 905 670 0960 Canada 905 670 0728 Fax 800 387 4800 Canada 8 U S A www espar com A member of the Worldwide Ebersp cher Group of Companies
10. k YM 2 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 the fuel tank bottom Cut standpipe end on a 45 degree angle to prevent clogging 4 Install as shown in manual 5 Route and secure fuel line from heater to fuel tank Do not route fuel line over frame rails always route through or under frame rail Routing Harness 1 The wiring harness has 40 ft of control timer line 30 ft of battery line and 25 ft of fuel pump line Cut any excess wire after running it to the desired location as to avoid coiling extra harness h The installation kit includes 30 ft of loom for the battery line 2 Route and secure the battery line from the Espar heater to battery 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 control panel on the outside of the bus or the drivers compartment 6 Route the fuel pump line along with the clear plastic fuel line to the pump Initial Operation 1 Check your installation for e All fasteners are secure e Exhaust pipe routing and clamp tightness e Loose hose clamps e Routing and securing of wiring and heater hoses e Kinked or pinched hoses e Battery connection and polarity 2 Top off or refill coolant
11. m U q E a r D E z ae c gt vw 6 Q Za E N N U lt c T lt O Qui lt pa LL ET c OO 5 i n ZE cal O lt Q E 0 O Z O lt O CONNECTION Bg i u 95 183 Diagnostic Connector L a AA Mm 20 20 20 20 Su NE llo 6 22 al La L LL LLL BLES N ei JA Heater Connector Wi Installation Instructions Schematic Hydronic N II 8 10 12 Harness Adaptor BILL OF MATERIAL m Re 1 A m 1011 Tone Oe a JJ a rra nice CE O L L A ra e I r Oe AAA O YA O e SAA us e YA e HR ne ACI L A ca 1 L L Te cone OVO A si IONES L T Le ENE L L asm KON y o NEZ ECO emma NE L MEA ECC oeeo MEA EKO IET 2 Ap RA AY AR A T Poem L TL L AY usss C L T Le ss TL TL L e o TO 202900 70 5917 Insulating PVC Tube A 13 Installation Instructions Harness A rn r co T LO ic Hydron Schematic HSO HS0Ot 1406 3NI 4A4MOd YOLOANNOOD 44 0 ANI 14N4 190 4 0 JNA AF TIOALNOD Boq peayobyo ul pajddns X E ECT MOJE 10 o0UuUu09 dund any Boq PEUDDIJO ul pajddns sy CD ines A E pou OU 1911e9 Mc U A P U UMOJE njg NOJ A 2 u 217S0UBPLII J2VUI 19 041u03 lt a aA
12. meet the needs and requirements of all enviroments e Preheats the engine to eliminate cold starts and extends engine life e Accelerates and maintains window defrosting and defog ging e Provides supplemental heat for increased driver and pas senger comfort e Stops white smoke at engine start up and eliminates diesel knock e High capacity water pump for increased heat distribution e 1 inch coolant connections E Guardian Coolant Heaters go to work before the driver arrives preheating the coolant in the engine and eliminating cold starts as well as offering supplemental heat to the interior The heater is mounted on the driverside frame rail and plumbed in series to the 1 coolant lines Introduction Wi Mounting the E Guardian STANDARD DRIVER S HEATER FRONT HEATER COOLANT PUMP ENGINE Possible Location FRONT AXLE REAR AXLE Installation Instructions CAREFULLY READ AND UNDERSTAND THE FOLLOWING INSTRUCTIONS BEFORE PROCEEDING WITH THE INSTALLATION Mounting the Heater 1 Find a suitable mounting spot on the frame rail Note Make sure there is enough clearance to remove the lid off the boxed heater before securing the mounting tray See page 5 A Try to use existing holes in the frame rail before drilling 2 Solidly bolt the mounting tray onto the frame rail 3 You can then mount the boxed heater on the mounting bracket tray Tighten and secure with the lock washers a
13. nd nuts A Check local and state codes to see reguirements for mounting the exhaust In New York State the exhaust MUST exit out the rear of the bus We supply 2 meters 6 ft of flexible stainless steel exhaust Integrating into the Coolant System A series heating system works in this fashion Heated coolant from the engine travels through the first heater core in the circuit then on to the next heater core in the circuit and on to the next etc Each core adds some restriction resulting in decreased coolant flow Not only is coolant flow reduced but also coolant temperature is reduced by each successive heater core resulting in the last core receiving water that is usually to cool to be effective The Espar fuel operated heater is eguipped with a high capacity coolant pump which increases flow and significantly increase the available heat supplied to a series plumbed system mt MUTT HH THAT TEL 1 Remove the radiator cap and release system pressure 2 Close the shut off valves for the heating system if so eguipped 3 Two 90 degree elbows have been provided for making connections into the existing coolant lines To Install e Remove heater hose access cover s running down the left side of the floor inside the bus at a location over top of the heater installation e Find and identify heating circuit supply hose This is the hose you will use to plumb the Espar heater into the system Installation Instruc
14. sn4 uren asn4 VOZ 14 Wi Installation Instructions Schematic Hydronic 5 and M ll 8 10 12 Main Harness BILL OF MATERIAL HEINE e L T T gt T jJ MEN EA C L TL L e esters id E s wanna nes EN ono Eins esa O a no O tanna no a gt C JA JL m T T jJ J rr eno HE KC ee 1111 eno gt o JA a wa 110 PT ro OOo Pa sore nan L a e FE E CI YT ro JA L Diagnostics and Troubleshooting Wirin There is a diagnostics connector located on the wiring har Espar has also included the added convenience of wiring an ness inside the boxed Hydronic unit If the heater experi additional diagnostics connector close to the controller timer ences any difficultly starting or shuts down during operation during installation The installer will need to cut off approxi the mechanic can plug in their diagnostics unit and read the mately 1 ft of the control line and use that to connect the fault codes off the control unit of the heater Instructions are controller timer to the diagnostics connector The terminals included with the diagnostics unit and the fault codes are list and connector have been provided in the bag parts ed in your Hydronic M service manual The diagnostics unit is sold separately PN 20 2900 7050 20 5670100 12 Volt Programmable Timer MIES 1 Controller Line Diagnostics Connector Red Pin 1 Yellow Switch S
15. tions e Locate and mark suitable location on floor where the brass elbows will be installed e Once vou are satisfied with the location making certain there are no obstructions you can now bore 2 holes 32mm 1 1 4 through the floor e 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 heating supply hose at a point where it can be connected to the inlet and outlet elbows Use hose clamping pliers to secure the hose before cutting 7 Connect the heater supply line running from the engine to the inlet elbow Connect the other cut end of the supply line to the outlet elbow 8 Secure all hose connections with hose clamps If the bus has silicone coolant lines you must use con stant torque hose clamps to prevent leaks 9 Remove hose clamping pliers and or open shut off valves 10 Top off engine coolant as per engine manufacturers recommendations and re install radiator cap Do not Install the previously removed eater hose access covers at this time Hose connections will reguire insspection and re tightening of clamps once installation is complete and tested The fuel pick up pipe and fuel line must be installed according to these instructions to ensure proper operation 1 Locate the cover plate on the floor of the school bus above the fuel tan
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