Caltech Calaer 2 kW User manual

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Installation and operating
instructions
2 kW Calaer Air Heater
4 kW Calaer Air Heater

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WARNING ................................................................................................... 4 
STATUTOR INSTALLATION REGULATIONS ................................................. 5 
USE OF THE HEATER (SCOPE) ...................................................................... 7 
INSTALLATION .......................................................................................... 10 
   
   
   
   
     
   
OPERATING INSTRUCTIONS ...................................................................... 25 
     
   
   
   
   
   
DIAGNOSTICS AND FAULT LOCK-OUTS ...................................................... 28 
 !    

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  
TECHNICAL DATA ...................................................................................... 30 
WARRANT .............................................................................................. 34 
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
Improper installation or repair of the air heater
systems may cause leakage of poisonous carbon
monoxide (CO) causing serious injury or death or
cause fire.
To install the heater systems you need to have
necessary technical skills, the appropriate technical
documentation, special tools and equipment to
ensure that you can complete the installation work
properly.
Do not insert foreign objects into the heater and
moving parts of the heater
To repair the heater systems you need to have
completed a CalTech Heating Technologies AB
training course and you need to have the appropriate
technical documentation, special tools and
equipment. Only genuine CalTech Heating
Technologies AB parts may be used. See the heater
system accessory catalog.
Always follow the installation and repair
instructions and pay attention to all warnings.
CalTech Heating Technologies AB rejects any
liability problems and damage caused by the system
being installed or repaired by untrained personnel.
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
"#$%&'$%(%#)%*)"#%+#),"%-#.##&+/0#+#,+#'%&'%00)1-#'
*&%221)'%&2#+1+"#'*)#2+*-#,345%&'4#%+*&657*+"
+"#81((17*&60#)9*+&:9.#),;
%(%#)$*)#%+#)
•33<
•33<3
%(%#)$*)#%+#)
•33<
•33<3
#=:*)#9#&+,%&'*&,+%((%+*1&%)#61-#)&#'./+"#0)1-*,*1&,*&&&#>?18
+"#*)#2+*-#33@@A%&'%)+%&'&&#> 18+"#'*)#2+*-#
B
0#)%+*&6%&'9%*&+#&%&2#*&,+):2+*1&,,"%((.#,:00(*#'7*+"#-#)/"#%+#)
%&'A*&+"#2%,#18"#%+#),*&+#&'#'81)+"#%8+#)9%)$#+A*&,+%((%+*1&
*&,+):2+*1&,"%((%(,1.#,:00(*#'4#=:*)#9#&+8)1933@@&&#>?A
%&'&&#> A5
2(#%)(/-*,*.(#+#((+%(#*&+"#10#)%+1)C,8*#('18-*#7,"%((*&81)97"#&+"#
219.:,+*1&"#%+#)*,,7*+2"#'1&1)1884#=:*)#9#&+8)1933@@
&&#>?A %&'&&#> A 5
1)*&,+%((%+*1&,##2"%0+#)18+"#'*)#2+*-#,33@@&&#>?%&'
%)+%&'&&#> 
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NOTE:
%*(:)#+181((17+"#,+%+:+1)/)#6:(%+*1&,A*&,+%((%+*1&,*&,+):2+*1&,%&'+"#
&1+#,21&+%*&#'+"#)#*&7*(((#%'+1%(((*%.*(*+/2(%*9,+1.#)#8:,#'./
%(#2"#%+*&6#2"&1(16*#,"#,%9#%00(*#,*8)#0%*),%)#2%))*#'1:+
*&21))#2+(/1)7*+"+"#:,#180%)+,1+"#)+"%&6#&:*&#,0%)#0%)+,"*,7*((
)#,:(+*&+"#*&-%(*'%+*1&18+"#+/0#%00)1-%(81)+"#"#%+#)%&'+"#)#81)#18
*+,"191(16%+*1&@+/0#(*2#&,#
;?

&%''*+*1&+1+"*,*&,+%((%+*1&*&,+):2+*1&A-#"*2(#,0#2*8*2+#2"&*2%(
'12:9#&+%+*1&9%/.#)#=:*)#'+1,:22##'7*+"+"#*&,+%((%+*1&18+"#
"#%+#)#8#)+1+"#-#"*2(#9%&:8%2+:)#)81),:2"'12:9#&+%+*1&
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45
"#%(#2"#%+*&6#2"&1(16*#,%*)"#%+#)*,'#,*6&#'+1;
•#%+2%.*&,A.1%+,A+):2$,A9*&*.:,#,A-%&,%&'91+1)"19#,%,
7#((%,+1"#%+2%)611&.1%)'-#"*2(#,
•#8)1,+-#"*2(#7*&'17,
((1+"#)%00(*2%+*1&,%)#&1+%((17#'A:&(#,,#>0(*2*+(/%00)1-#'*&%'-%&2#
./%(#2"#%+*&6#2"&1(16*#,
"#%*)"#%+#)10#)%+#,*&'#0#&'#&+(/18+"#-#"*2(##&6*&#%&'*,
*&+#6)%+#'*&+1+"#-#"*2(#D,#(#2+)*2%(%&'8:#(,/,+#9,
"#"#%+#),%)#&1+'#,*6&#'81)"#%+*&6"%E%)'1:,,:.,+%&2#,"#"#%+#)
9:,+&1+.#*&,+%((#',1+"%+*+*,21&+*&:1:,(/#>01,#'+17%+#)

"#(%.#(0)1-*'*&6*&81)9%+*1&%.1:++"#"#%+#)9:,+.#01,*+*1&#',1+"%+
*+2%&.#)#%'#%,*(/7"#&+"#"#%+#)*,*&,+%((#'*&+"#-#"*2(#4#=:*)#9#&+
8)1933@@A00#&'*>?A1*&+%&'A%&'1*&+
5"#91'#(0(%+#9:,+.#01,*+*1&#'*&,:2"7%/+"%+*+2%&&1+.#
'%9%6#'%&'9:,+.#2(#%)(/(#6*.(#7"#&*&,+%((#'*&+"#"#%+#),
+"#)7*,#%':0(*2%+#/0#%.#(9:,+.#:,#'
 

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Figure 1: Labels with information about the system.

<
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 

3
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
?B
:.F#2++10%)%6)%0"@219.:,+*1&"#%+#),,"%((.#*&,+%((#'
%221)'*&6+1+"#)#=:*)#9#&+,18+"*,&&#>4#=:*)#9#&+,8)19
33@@&&#>?%&'%)+5
?#"*2(#,182%+#61)/4*#+)%*(#),*&2(:'*&6,#9*+)%*(#),5"%-*&6(*=:*'8:#(
"#%+#),%)#'##9#'+12190(/7*+"+"#)#=:*)#9#&+,18+"*,&&#>
4#=:*)#9#&+,8)1933@@&&#>?%&'%)+
5

1'/,#2+*1&,%&'%&/1+"#)21901&#&+,*&+"#-*2*&*+/18+"#"#%+#)9:,+
.#0)1+#2+#'8)19#>2#,,*-#"#%+%&'+"#01,,*.*(*+/188:#(1)1*(
21&+%9*&%+*1&4#=:*)#9#&+,8)1933@@&&#>?%&'
%)+5
"#219.:,+*1&"#%+#),"%((&1+21&,+*+:+#%)*,$188*)#A#-#&*&+"#2%,#18
1-#)"#%+*&6"*,)#=:*)#9#&+,"%((.#'##9#'+1.#8:(8*((#'*8+"#
*&,+%((%+*1&#&,:)#,%&%'#=:%+#'*,+%&2#+1%((0%)+,%&',:*+%.(#
-#&+*(%+*1&A./+"#:,#188*)#)#,*,+%&+9%+#)*%(,1)./+"#:,#18"#%+
,"*#(',4#=:*)#9#&+,8)1933@@&&#>?%&'%)+
5
&+"#2%,#18%&'-#"*2(#,4*#017#)')*-#&.:,#,"%-*&6%+(#%,+
81:)7"##(,%&':,#'81)2%))*%6#180%,,#&6#),5A+"#"#%+#)9:,+&1+.#
01,*+*1&#'*&+"#0%,,#&6#)2190%)+9#&+17#-#)A%&*&,+%((%+*1&*&%&
#88#2+*-#(/,#%(#'#&-#(10#9%/.#:,#'4#=:*)#9#&+,8)1933@@
&&#>?%&'%)+5



"#(%.#()#8#))#'+1*&0%)%6)%0"3*&+"#81((17*&6'12:9#&+A1)%
':0(*2%+#A9:,+.#01,*+*1&#',1+"%+*+2%&.##%,*(/)#%'7"#&+"#"#%+#)
*,*&,+%((#'*&+"#-#"*2(#4#=:*)#9#&+,8)1933@@&&#>?
%&'%)+5
-#)/)#%,1&%.(#0)#2%:+*1&,"1:('.#+%$#&*&01,*+*1&*&6+"#"#%+#)+1
9*&*9*E#+"#)*,$18*&F:)/%&''%9%6#+10#),1&%(0)10#)+/4#=:*)#9#&+,
8)1933@@&&#>?%&'%)+5
;
"#"#%+#)9:,+&1+.#*&,+%((#'*&+"#0%,,#&6#)2%.*&182(%,,4*#
017#)')*-#&0#),1&%(2%),"%-*&6%+(#%,+81:)7"##(,%&':,#'81)2%))*%6#
180%,,#&6#),5%&'-#"*2(#,4*#017#)')*-#&-#"*2(#,"%-*&6%+(#%,+81:)
7"##(,%&':,#'81)2%))*%6#18611',517#-#)A%&*&,+%((%+*1&*&%&
#88#2+*-#(/,#%(#'#&-#(10#9%/.#:,#'4#=:*)#9#&+,8)1933@@
&&#>?%&'%)+5

Figure 2a: Dimensions of the 2 kW Calaer Air heater. All dimensions are in mm unless stated
otherwise.




Figure 1b: Dimensions of the 4 kW Calaer Air heater. All dimensions are in mm unless stated
otherwise.

Figure 2: Required installation ositions for diesel heaters.
"#&*&,+%((#'*&%-#"*2(#+"#8:#(0:909:,+.#*&,+%((#'%+%9%>*9:9
'*,+%&2#189#+#),8)19+"#8:#(+%&$%&'&191)#+"%&9#+#),8)19+"#
"#%+#):&*+"#8:#(0:909:,+%(,1.#*&,+%((#'*&,:2"%7%/,1+"%+*+*,
&1+01,*+*1&#'91)#+"%&9%.1-#+"#9*&*9:98:#((#-#(%&'9.#(17
+"#9%>*9:98:#((#-#("#"#%+#):&*+,"%((.#0(%2#'&1+91)#+"%&
9#+#),"*6"#)+"%&+"#8:#(0:90


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
Figure 3: Positioning of fuel system.

;+9%/.#)#=:*)#'+121&,:(++"#+#2"&*2%('12:9#&+%+*1&18/1:)
-#"*2(#+1,:22##'7*+"+"#*&,+%((%+*1&18+"#"#%+#)#8#)+1+"#-#"*2(#
9%&:8%2+:)#)81),:2"'12:9#&+%+*1&




Figure 4: Ty ical installation of the heater in a minivan.


"#%*)81)+"#219.:,+*1&2"%9.#)18+"#"#%+#)9:,+&1+.#')%7&8)19
+"#0%,,#&6#)2190%)+9#&+18+"#-#"*2(#19.:,+*1&%*)9:,+.#+%$#&
8)191:+,*'#18+"#-#"*2(#+16:%)%&+##+"#,%8#+/18+"#0%,,#&6#),
4#=:*)#9#&+,8)1933@@&&#>?%&'%)+
5
"#219.:,+*1&%*)*&(#+9:,+.#,101,*+*1&#'1)6:%)'#'+"%+.(12$*&6./
):..*,"1)(:66%6#*,:&(*$#(/4#=:*)#9#&+,8)1933@@&&#>?
%&'%)+5
"#219.:,+*1&%*)*&+%$#,"%((&1+.#91:&+#'7*+"+"#10#&*&6+17%)',
+"#8)1&+18+"#-#"*2(#
"#*&+%$#,*(#&2#)9:,+.#*&,+%((#'1&+"#%*)*&+%$#0*0#*&1)'#)+18*(+#)
1:+.*66#)0%)+*2(#,4,%&'A(#%-#,5A%&')#':2#+"#&1*,#219*&68)19+"#
"#%+#):&*+




"#"#%+*&6%*),:00(/9%/.#8)#,"1))#2*)2:(%+#'%*)%&'9:,+.#')%7&
8)19%2(#%&%)#%&1+(*$#(/+1.#21&+%9*&%+#'./#>"%:,+8:9#,#9*++#'
#*+"#)./+"#0)10:(,*1&#&6*&#A+"#219.:,+*1&"#%+#)1)%&/1+"#)-#"*2(#
,1:)2#4#=:*)#9#&+,8)1933@@&&#>?%&'%)+
5
"#*&(#+':2+9:,+.#0)1+#2+#'./+"#9#,"7"*2"*,'#(*-#)#'7*+"+"#
"#%+#):&*++10)#-#&+'%9%6#+1+"#219.:,+*1&8%&4#=:*)#9#&+,8)19
33@@&&#>?%&'%)+5
"#2%.*&%*)*&(#+9:,+.#,16:%)'#'1)01,*+*1&#'+"%+.(12$*&6./
(:66%6#1)):..*,"*,:&(*$#(/
 



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Figure 5: Fuel filter mounting angles.
Figure 6: Fuel um mounting angles.

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Figure 7: Tank diver installation.
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Figure 9: Example of sticker which must be applied near the filler neck.
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Figure 10: Seal for the mounting bracket.
Figure 11: Mounting angle of exhaust muffler.
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