Caltech Calaer 2 kW User manual

Installation manual
2kW Calaer air heater
4kW Calaer air heater

1. Introduction and scope
1
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.
The purpose of this manual is to give an overview of the heater and notify
the user of all aspects of the installation. In the end of the manual you will
find instructions on troubleshooting and maintenance. Before installing the
heater, please read through the entire manual.
This manual is divided into several chapters to give you a better overview
and make it easy to find the necessary information.
1
Introduction and scope
8
Needed tools
2
Safety instructions
9
Positioning of the heater
3
Warranty
10
Combustion air and
exhaust system
4
Statutory regulations
11
Heating air system
5
Technical data
12
Fuel systems
6
Dimensions
13
Electrical system
7
List of parts
14
Operating instructions
15
Trouble shooting

2

2. Safety information
3
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. Nevertheless, there is a risk of
Carbon monoxide poisoning that may cause serious consequences to
health if the heating system is installed improperly. Therefore, it is
extremely important that you read the installation manual thoroughly
before planning installing the heater.
If you have any questions or concerns about the installation or the
operation of the heater do not hesitate to contact our customer service.

2.Safety information
4
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:
oFuel stations
oCoal depo
oWood depo
oGrain deposits etc.
Do not install the heater in an unventilated passenger compartments
or confined cargo holds.
Always make sure that the combustion air intake is located in
ambient environment or in a compartment that is well ventilated to
the atmosphere.
Make sure that the exhaust gases are led straight to the atmosphere
with leak tight pipes, avoid passing through passenger
compartments.
Attention:
Always follow the instructions in the installation manual and heed all
warnings.
It is the installers responsibility to ensure that the installation of the
heater, combustion air and exhaust system, fuel system and air
ducting is performed according to all country specific regulations.
To repair the heater systems, you need to have completed a CTH
Technologies AB training course and have the appropriate technical
documentation, special tools and equipment. Only genuine Calaer
parts may be used.

3. Warranty
5
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.
The warranty is provided to the end user and is to be administrated and
serviced by Calaer or Calaer Authorized Dealer according to the warranty
policy.
When the heater is self-installed by the end user the diagnosis and repare
must be performed by a Calaer or Calaer Authorized Service partner in order
to receive compensation under the terms of this warranty.
3.1 Warranty limitations and exclusions
The replacement of components, whether under warranty or not, during the
warranty period does not prolong the original warranty period of the
component or product.
Calaer excludes and limits from warranty the following:
Normal wear (fuel filters and fuses are not covered).
Faults caused by incorrect installation or maintenance, incorrect voltage
or connection, lightning, external damage, accidents, moisture or any
other conditions beyond our control.
Faults caused by unauthorized repair or other measures carried out and
undertaken by any party who is not authorized by Calaer.
Transport damages: all claims must be filed with carrier.
If the heater label and serial number is illegible or missing.
Modification of product by alteration, use of non-genuine parts.
Costs or inconvenience the product may have caused as a consequence
of a defect on the product.
3.2 Owners responsibility
Install and perform maintenance activities according to Calaer
instructions.
In case of warranty claims, proof of purchase is required.

6

4.Statuatory regulations
7
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
Body sections and any other components in the vicinity of the heater
must be protected from excessive heat and the possibility of fuel or oil
contamination.
Every reasonable precaution should be taken in positioning the heater
to minimize the risk of injury and damage to personal property.
Combustion air intake
The air for the combustion chamber of the heater must not be drawn
from the passenger compartment. Combustion air must be taken from
the atmosphere or from a well ventilated compartment to guarantee
the safety of the passengers.
The combustion air inlet must be so positioned or guarded that blocking
by rubbish or luggage is unlikely.
Heating air intake
The heating air supply may be fresh or recirculated air and must be
drawn from a clean area not likely to be contaminated by exhaust
fumes emitted either by the propulsion engine, the combustion heater
or any other source.
The inlet duct must be protected by the mesh which is delivered with
the heater unit to prevent damage to the combustion fan.

4. Statutory regulation
8
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.
The hot air outlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
Fuel supply
The fuel pump and filter must not be situated in the passenger
compartment.
When the heater is installed with its own fuel supply tank, separate
from the main fuel supply tank, the type of fuel and its filler point must
be clearly labeled.
A notice, e.g. by a sticker, indicating that the heater must be shut down
before refueling, must be affixed to the fueling point
Exhaust system
The exhaust outlet must be located so as to prevent emissions from
entering the compartment through ventilators, heated air inlets or
opening windows.
4.2 The American Boat and Yacht Council Standards
The installation must comply with the ABYC Standard A-7.
Air handling systems
Air handling systems, including discharge and return air systems, shall
be so constructed and installed as to prevent harmful gasses from
entering living spaces, and
shall be airtight, with respect to compartments containing engines or
fossil fueled devices where the air handling system shares common
partitions with or passes through those compartments, and
shall neither discharge to, nor return to, any compartments other than
the one(s) intended to be serviced by that equipment.

4.Statuatory regulations
9
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.

10

5. Technical data
11
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
Heating output
1 - 2 kW
2 - 4 kW
3 400 –6 800 BTU
6 800 –13 600 BTU
Fuel
Diesel
Diesel
Fuel consumption
0.13 –0.3 l/h
0.25 –0.48 l/h
0.034 –0.079 US gph
0.066 –0.127 US gph
Rated voltage
12 or 24 Volts
12 or 24 Volts
Operating voltage
range
12 V: 10-15 Volts
12 V: 10-15 Volts
24 V: 19-32 Volts
24 V: 19-32 Volts
Rated electric power
consumption
19-41 Watts
19-48 Watts
CO2content in
exhaust gas (min to
max power)
7.5 –10.9 %
8.3 - 11.8 %
Weight (heater only)
3.1 kg
5.1 kg
6.8 lbs
11.2 lbs
Dimensions
Length: 350 mm (13.9 inch)
Length: 403 mm (15.9 inch)
Width: 124 mm (4.9 inch)
Width: 150 mm (5.9 inch)
Height: 130 mm (5.1 inch)
Height: 160 mm (6.3 inch)
Cold and hot heating
air connection
Ø 60 mm (2.36 inch)
Ø 90 mm (3.54 inch)
Maximum length of
exhaust pipe
2m (6.5 feet)
2m (6.5 feet)
Maximum length of
fuel hose
8.8 m (28 feet)
8.8 m (28 feet)
Maximum length of
hot air outlet duct
6.5 m (21 feet) +
3 outlets with vent
10 m (33 feet) +
5 outlets with vent
Maximum length of
heating air inlet duct
2m (6.5 feet) + vent
2m (6.5 feet) + vent

12

6. Heater dimensions
13
6. Heater dimensions
Calaer 2 kW heater
*All measurements are given in millimeters [mm].

6 Heater dimensions
14
Calaer 4 kW heater
*All measurements are given in millimeter [mm].

6. Heater dimensions
15

16

7. List of parts
17
7. List of parts
Nr.
Name
Specification
Quantity
Unit
1
Heater unit
12/24 V unit
1
Piece
2
Control knob
1
Piece
3
Fuel pump wire
harness
1
Piece
4
Main heater wire
harness
1
Piece
5
Thermostat sensor
1
Piece
6
Thermostat sensor
harness
1
Piece
7
Fuel pump and filter
12/24V
versions
1
Piece
8
Mounting bracket
1
Piece
9
Nylon Fuel line
ɸ5 x 1
5
Meter
10
Rubber fuel line
ɸ4.5 x ɸ11 x
50mm
4
Piece
11
Exhaust pipe
ɸ25 mm
1
Meter
12
Combustion air pipe
ɸ25 mm
1
Meter
13
Air duct
ɸ60/90 mm
1
Meter
14
Air outlet vent
ɸ60/90 mm
1
Piece
15
Fuel standpipe
5 mm
1
Piece
16
Combustion air
silencer
1
Piece
17
Hose clamps
10-12 mm
8
Piece
18
Hose clamps
20-32 mm
2
Piece
19
Exhaust muffler
Not included
in base kit
1
Piece
20
Exhaust clamp
30 mm
1
Piece
21
Air duct clamp
50-70 /
80-100 mm
2
Piece
22
Exhaust pipe holder
32 mm
1
Piece

18