Clarke XR60DV Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
GC08/23 -Rev 1
ORIGINAL INSTRUCTIONS
DUAL VOLTAGE DIESEL/PARAFFIN HEATERS
MODEL NO: XR60DV, XR80DV, XR110DV, XR160DV, &
XR210DV
PART NO: 6931015, 6931019, 6931023, 6931027 & 6931032

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INTRODUCTION
Thank you for purchasing this CLARKE product. Before attempting to use this
product, please read this manual thoroughly and follow the instructions
carefully.
SPECIFICATIONS
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
Model XR60DV XR80DV XR110DV XR160DV XR210DV
Part No 6931015 6931019 6931023 6931027 6931032
Burn Rate: (Btu/hr) 50,000 70,000 100,000 160,000 210,000
Fuel consumption 1.6 L/hr 1.9 L/hr 2.8 L/hr 3.91 L/hr 4.16 L/hr
Approx Running Time 9.4 hr 11.9 hr 11.4 hr 13.5 hr 12.7 hr
Electrical input 110v/230V ~ 50Hz
Power 175 W 185 W 195 W 310 W 350 W
Max.Outlet Temp 1300°F (704°C)
Fuel Tank Capacity 15 L 22.7 L 32 L 53 L 53 L
Ignition system Electric Ignition
Primary Safety Control Flame failure device
Weight (kg) 15.2 15.5 18.3 24.6 24.6
Dims (D x W x H) mm 830 x 410
x 628
830 x 410
x 648
905 x 413
x 700
1045 x 528
x 692
1045 x 528
x 692
Minimum Fuel Level 5L 6L 6L 10L 10L

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GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
FUNCTION AND OPERATING PARAMETERS
This is a multi-fuel (Diesel or Paraffin), forced air heater. It’s intended use is for
drying and the warming of commercial/industrial buildings where adequate
ventilation is provided.
This is a forced air unit, where a fan pushes the air through the heater body.
Proper combustion depends upon this air flow; therefore, the heater must not
be, modified or operated with parts removed or missing. Likewise, safety
systems must not be circumvented or modified in order to operate the heater.
• It must be operated as prescribed in the operating manual.
• Is not intended to be used for domestic use or for the heating of
habitable areas.
• Is not intended to be used to reach and maintain a certain level of
human thermal comfort within an enclosed space in which the heater is
situated.
• Is not intended to be used in enclosed areas with restricted ventilation.
• Is not for use in areas with high levels of fluctuating drafts.
• The heater must be placed on a flat, level, non combustible surface
during operation.
• Is not intended for warming animals or live stock.

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SAFETY WARNINGS
Your safety is important to you and to others, so please read these instructions
before you operate this heater.
1. Failure to comply with the precautions and instructions provided with this
heater can result in death, serious bodily injury and property loss or
damage from the hazards of fire, explosion, burns, asphyxiation, carbon
monoxide poisoning, and/or electric shock.
2. Only persons who understand and follow the instructions should use or
service this heater.
3. When used, the heater should rest on a suitable insulating material
extending beyond the heater in all directions
4. This heater is not for home or recreational vehicle use.
5. DO NOT use petrol or volatile fuels.
6. Disconnect the heater from the power supply before adding fuel.
7. ALWAYS re-fuel outdoors away from any open flame or other sources of
ignition.
8. DO NOT use an external fuel source.
9. DO NOT use the heater where flammable liquids or vapours may be
present.
10. DO NOT start the heater when the combustion chamber is hot.
11. Plug the electrical cable into a properly earthed power supply.
12. DO NOT leave the heater unattended when in use.
13. DO NOT start or use the heater if there is unburnt fuel in the combustion
chamber.
14. The heater must be placed on flat, level, non combustible surface during
operation.
SAFETY SYMBOLS
The following symbols appear on the unit.
Hot Surface, do not
touch
High Voltage

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SAFETY PRECAUTIONS
1. Check the heater thoroughly for damage. Never operate a damaged
heater.
2. This heater is for indoor use only. Make sure that the heater is not directly
exposed to rain or water spray.
3. Use in well ventilated spaces and provide at least 2 sq. ft. (0.19 sq.m.) of air
opening near the floor and 2 sq. ft. (0.19 sq. m.) near the ceiling directly to
outdoors. Increase air openings for each additional heater.
4. ALWAYS keep combustibles, like paper and wood at least 8 ft. (2.4 m) from
the front of the heater and 3 ft. (1 m) from the top, sides and rear.
5. Locate the heater 3 m from canvas or plastic coverings and secure them
to prevent movement.
6. NEVER use in living spaces and/or where children may be present.
7. DO NOT use with ductwork. DO NOT restrict air inlet or exit.
8. DO NOT move or attempt to service the heater while hot or in operation.
9. Use only in accordance with local regulations and relevant building codes.
10. The heater is not to be used by children or persons with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge.
11. If the supply cable is damaged it must be replaced by the manufacturer,
its service agent, or similarly qualified persons in order to avoid a hazard.
12. Locate the heater at a safe distance from combustible materials.
13. When used, the heater should stand on suitable insulating material
extending beyond the heater in all directions.
14. Only operate on a flat level and stable surface.
CAUTION: DUE TO THE HIGH SURFACE AND EXHAUST TEMPERATURES,
ADULTS AND CHILDREN MUST KEEP CLEAR OF THE UNIT TO AVOID BURNS
OR CLOTHING IGNITION.

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FRESH AIR PRECAUTIONS
VENTILATION
Even though this heater operates very close to 100 percent combustion
efficiency, it still produces small amounts of carbon monoxide.
Carbon monoxide (CO) is toxic.
CO can build up in a confined spaces and failure to provide adequate
ventilation can be fatal.
The early symptoms of asphyxiation caused by inadequate ventilation are:
The following groups of people are more likely to be effected by Carbon
Monoxide.
1. Pregnant women,
2. Persons with a heart or lung condition, anaemia
3. People under the influence of alcohol,
4. Those living/working at high altitude
WHAT TO DO IF YOU SUSPECT CO POISONING
• Get fresh air immediately. Open doors and windows, switch off the
heater and leave the area.
• See your doctor immediately or go to hospital - let them know that you
suspect CO poisoning. They can do a blood or breath test to check.
Do not use the heater until it has been serviced.
Be sure to follow all warnings in this manual.
BYSTANDERS
When the heater is to be operated in the presence of other people the user is
responsible for informing those present of the safety precautions and of the
hazards involved.
WE RECOMMEND THE USE OF A CARBON MONOXIDE DETECTOR
• headache • nausea
• dizziness • dry mouth or sore throat

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ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved BS1363/A plug fitted with a BS1362 13 amp fuse.
The heater may also be connected to a 110V supply through a suitably
approved plug. The control module of the heater will determine if the unit is
connected to a 230 or 110V power supply.
If the plug has to be changed because of damage, it must be removed and a
replacement fitted, following the wiring instructions shown below. The old plug
must be discarded safely, as insertion into a power socket could cause an
electrical hazard.
• The BLUE wire must be
connected to the
terminal which is
marked N or coloured
black.
• The BROWN wire must
be connected to the
terminal which is
marked L or coloured
red.
• The YELLOW AND
GREEN wire must be
connected to the terminal which is marked E or or coloured green.
We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD)
If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.
WARNING: WIRES IN THE MAINS LEAD ARE COLOURED IN
ACCORDANCE WITH THE FOLLOWING CODE:
GREEN/YELLOW = EARTH, BLUE = NEUTRAL, BROWN = LIVE.
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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UNPACKING AND ASSEMBLY
Remove the heater from carton and discard all protective material which
may have been applied to the heater for shipment. Recycle packaging
materials responsibly.
1. Pass the axle through the wheel
frame as shown
2. Add a flat washer and secure
everything in place by inserting a
split pin into the small hole at the
end of the axle.
3. Fit the handle into position and
secure using four bolts and nuts
provided (2 each side).
4. Fit the front rail into position and
secure using four bolts and nuts
provided (2 each side).

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PREPARATION
SUITABLE FUELS
Diesel or paraffin are the only fuels that should be used in this heater.
FILLING THE FUEL TANK
IMPORTANT: Before filling the fuel tank the first time or after extended
storage periods, drain the fuel tank of any moisture or condensation.
1. Follow all of the “Safety Precautions”.
2. Remove the fuel cap.
NOTE: If you lose the fuel cap a
replacement must be
obtained before use, this is
available from your local
Clarke dealer.
3. Fill the fuel tank with clean diesel
or paraffin.
• In cold weather, condensation
may develop in the tank if the
tank is empty and it is recommended that a tablespoon of de-icer
be added for each gallon of fuel in the tank.
• When filling the heater, make sure that the heater is level and do not
overfill. Use a funnel or can with a long fill spout.
• Fill with a minimum of 5 litres of fuel for the XR60DV, 6 litres for the
XR80DV & XR110DV, or 10 litres the XR160DV and XR210DV.
POSITIONING THE UNIT
• Locate heater at a safe distance from combustible materials.
• When used, the heater should rest on suitable insulating material
extending beyond the heater in all directions.
• Only operate on a flat level and stable surface.

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OPERATION
STARTING UP
1. Make sure power switch is in the
OFF position.
2. Turn thermostat to lowest setting.
3. Plug the heater into the power
supply (either 230V or 110V).
NOTE: The voltage setting needs to
match the available power
supply. The onboard circuit
will identify the input.
4. Set the power switch to the ON position.
See Troubleshooting on page 14 if the above error conditions occur.
• The switch will illuminate in the ON position.
5. Adjust the thermostat to the desired heat setting.
• The heater will cycle on/off as heat is required.
SHUTTING DOWN
1. Set the power switch to the OFF position.
2. For extended shutdown, unplug the heater from the power supply.
3. Before storage, Clean the heater as described in the Maintenance section.
WARNING: DO NOT START HEATER WHEN EXCESS FUEL HAS
ACCUMULATED IN THE COMBUSTION CHAMBER.
LED status UNIT OPERATION
Steady light Unit is performing a self-test.
Off Operation OK
2 Flashes No flames detected.
3 Flashes High limit switch failure. Unit has overheated.
4 Flashes Flame sensor failure.

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MAINTENANCE, STORAGE AND SERVICING
GENERAL
1. Make a general visual inspection of the heater for loose or damaged parts.
• Damaged parts should be repaired or replaced before using the
heater again.
2. Check heater operation to be sure it is operating normally as follows:
• The flame is contained within the heater.
• The flame is essentially yellow without smoke or soot.
• There is no disagreeable odor, eye burning or other discomfort.
6-MONTHLY
1. Clean the heater twice a season (more often under dusty conditions).
Remove accumulated dust from the transformer, burner, motor and fan
blades with compressed air.
2. Clean out the fuel tank (every 500 Hours) (during frequently used periods,
clean twice a month). Drain and flush the fuel tank with clean fuel.
The XR160DV and XR210DV have a
rubber drain plug on the bottom of
the tank. Place a suitable container
beneath the drain plug and pull out
the plug, replace the plug before
filling the tank again.
ANNUALLY
Clean the air output filter. Remove
the air output filter and tap the
contaminated side gently on a solid
object to remove contaminates.
Clean the air intake filter when
required (approx 500 hours). Remove
and wash in mild detergent. Dry
thoroughly and refit.
WARNING: TO PREVENT PERSONAL INJURY, UNPLUG THE HEATER FROM
THE MAINS SUPPLY BEFORE SERVICING.

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FILTERS
Dirty air filters will cause an imbalance in the air-fuel mixture. The best
indication that this condition exists is an increase in odour or difficulty getting
your heater to ignite. This heater should never be operated without the filters in
place. If required, clean the filters as follows.
ACCESSING THE FILTERS
1. Make sure that the plug is
removed from the power supply
before carrying out any
maintenance.
2. Remove the six screws shown and
remove the top cover of the
heater.
NOTE: There may be eight screws on
the larger models.
3. Lift out the rear guard.
4. Remove the 3 screws securing the
filter cover.
5. Pull the filter cover away from the
motor.

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AIR INTAKE FILTER CLEANING
6. To clean the air intake filter.
• Remove and wash the filter
element with a mild detergent.
• Dry thoroughly and refit.
• DO NOT oil the filter element. If
your heater is used where there
is considerable dust or dirt.
• Clean as often as necessary (at
least approximately every 500
hrs.).
NOTE: If the filter is damaged or extremely dirty, a replacement filter of the
same type must be fitted, this is available from your local CLARKE
service department.
AIR OUTPUT FILTER CLEANING
7. To clean the air output filter (Annually or as required) remove the air output
filter and tap the contaminated side gently on a solid object to remove
contaminates.
NOTE: Compressed air or liquids should not be used to clean this filter.
NOTE: If the filter appears damaged or extremely dirty replace it with a new
filter of the same type, obtained from your local CLARKE service
department.
8. Reinstall the clean filter into the filter housing.
9. Replace the filter cover and secure using the screws removed in step 4.
NOTE: When replacing the filter cover, make sure that the gasket is firmly in
place and the screws in the filter cover are tight to prevent air leaks. if
the gasket is damaged a replacement must be obtained and fitted
this is available from your local CLARKE service department.
10. Refit the rear guard and replace the top cover.
11. Make sure all screws are replaced before use.
STORAGE
1. Drain any residual fuel / condensate from the fuel tank (see page 10).
2. Store the heater in a dry location free from fumes or dust.

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TROUBLESHOOTING
LED OPERATION TROUBLE SHOOTING
LED gives 2
Flashes
No flame
detected
Heater fails to start.
1. Check fuel level
2. Check the mains plug is correctly fitted and
that the fuse inside it has not blown.
3. Return to Clarke service department for repair.
LED gives 3
Flashes
High limit
switch failure.
(unit has over-
heated)
Make sure heater is cooled down,
1. Make sure that the power switch is set to the
OFF position.
2. Wait 5 minutes
3. Start heater by setting the power switch to the
ON position.
LED gives 4
Flashes
Flame sensor
failure
Return to CLARKE service department for repair.

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WIRING DIAGRAM

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COMPONENT PARTS

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COMPONENT PARTS

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COMPONENT PARTS

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DECLARATIONS OF CONFORMITY