Safire 2400Di Instruction Manual

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 1
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF - Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh./Fax [phone]
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A heater kit contains:
• Heater, mounting bracket
• Fuel hose (3 meters), pump, a fuel tank connection to a standard tank (30 litres)
• Power supply cable (4 meters), control panel cable (10 meters)
• Mounting screws, clamps
• Accessories indicated on the package: Control panel or GENIUS control panel, temperature sensor for the
thermostat, exhaust outlet through the hull.
PLACING THE HEATER
Place the heater so that at least a part of the air to be warmed can be taken outside. This will allow good
ventilation and drying effect.
When choosing a place for the heater remember that warm air hoses placed outside the heated space will
lose plenty of heat. Minimize their length and isolate them carefully. It is more economic to place the heater
close to the space to be heated and use a separate fresh air inlet. You don’t have to isolate the warm air
hoses inside (f. ex. under the bed); the hoses function as “radiators” for they dry the space and balance the
temperature differences.
Remember also that as the heater blows warm air inside, an equivalent amount of air must be let out f. ex.
through a ventilator or return to the heater as circulating air.
Maintenance is usually easiest to perform when the heater is removed from its bracket. If the heater is
examined on its place, place the heater so that the led indicators near the fresh air inlet and the control
display are in sight.
Place the heater so that the heater is above the tank’s fuel level. The heater will however not be damaged if
the filler hole of the tank and thereby the fuel level temporarily rises above the heater.
The fuel hose can be lengthened between the pump and the tank.

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 2
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF_ Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
INSTALLATION
Mounting bracket
Screw the heater’s mounting bracket to its place so that the heater is set in a horizontal position.
Pump and fuel hose
Attach the fuel pump in an upright position close to the fuel tank but above the fuel level, the
suction downwards. Max high between tank and heater 2m. If you need to pass the fuel hose
and the pump’s power supply cable through narrow gaps, disconnect the hose connector
above the pump and unplug the power supply cable from the pump’s connection terminal (the
polarity is insignificant). Attach the fuel hose carefully so that it won’t vibrate or rub against
anything. Don’t attach the pump too tight; this may cause disturbing noise.
Fuel tank connection
The fuel is conducted with a suction hose either from a separate tank (15, 22 or 30 litres) using a suitable
tank connection, or from a diesel tank by using a tank connection kit. Install a shut-off to the tank connection
if the fuel level in the tank or in the fuel hose can rise above the pump. Attach the fuel hoses carefully and
protect them from heat or mechanical strain.
Exhaust outlet
Exhaust is led out and combustion air taken in through hull with a coaxial
exhaust outlet.
For installing the outlet you need to make one Ø 50 mm hole and four 5,5 mm
holes (use the outlet end as a model). Cut the inner pipe a bit too long, so that
it can’t slip from its place. Bend the exhaust outlet hose as shown in the picture
and make a little hole on the outer hose, on the lowest part.
This way the condensation water can trip away.
Max. length of exhaust tube is 2m fir 2400Di, 2600Di and 3200Di and 1,5m for 3600Di.
Thermostat
Place the thermostat’s sensor to a place where it can measure the temperature
in the room in the best way. If you are using a GENIUS control panel, you can
connect two thermostats to the heater; one to be used during the night in the
sleeping cabin and one for the daytime to be used in the front cabin.
Controll panels
SAFIRE 3000
Place the control panel so that the display is easy to see and use, and that there’s no danger of starting the
heater by accident. The basic control panel can be either surface or flush mounted. The GENIUS control
panel is designed to surface mounting only. Attach the control panel to the heater with an included cable.
SAFIRE
BACK OK
Hallinta
Ajastin
Asetukset
Termostaattinytt
Made in Finland by
SF-Lmmitin Oy
genius

SAFIRE 2400Di, 2600Di 3200Di and 3600Di Diesel / fuel oil heaters 3
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF - Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax[phone]
3
Electric wiring
See the wiring diagram below.
The heater’s power supply cables should be connected straight to the battery (red +, blue -). If you need
longer cables, you should change also the original cables to thicker ones so that the area of the wires (mm
2
)
corresponds their length (m); f. ex. 6 meter long wires should be entirely at least 6 mm
2
thick.
NB! The housing of the heater is galvanic connected to the minus-pole of the battery.
You can connect a separate main switch to the heater and a 20A time delay fuse near the battery (there is a
20A main time delay fuse F1 on the circuit board).
Be careful not to connect the wires wrong. This would melt the 7,5A fuse F2, which protects the electronics.
Connect the thermostat’s sensor to the connector X10.
The system detects automatically the installed thermostat and changes the Power control on the control
panel to Temperature control.
Connect the pump’s power supply cables to the connector X10 .
Fix the cables so that water does not get into the heater among them.
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SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 4
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF_ Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
USAGE
BEFORE USING THE HEATER
Before using the heater make sure that
• the tank and the fuel hose are properly installed
• the heater is properly attached to the mounting bracket
• the combustion air, circulation air and exhaust can flow freely
• there aren’t any foreign objects inside or near the heater or in its exhaust outlet, or substances which are
flammable or can produce smells.
Fuel
The best fuel is winter grade light fuel oil, or off-road gas oil. If you can’t find winter grade fuel during the summer,
you can use summer grade light fuel oil or paraffin oil. To remove condensation water, add about 2% isopropanol-
based antifreeze for gasoline engines (not antifreeze for diesel engines!) to the fuel.
If you don’t use the heater in the winter and store it in a cold place, use paraffin oil the last time you use the
heater, and leave the fuel hoses full (paraffin oil has a low cloud point). Paraffin oil will protect the hose from
freeze.
CONTROLLING THE HEATER AND INDICATOR LEDS
Basic control panel
Start: turn the switch to position “HEAT/ON”.
Ventilation: turn the switch to position “VENT”.
Turn off: turn the switch to position “OFF”.
Adjust heating power, temperature (heaters with thermostat)
or ventilation power (if the ventilating mode is active) with the
adjustment knob. To obtain the normal room temperature,
turn the adjustment knob to point upwards.
GENIUS control panel
Turn the heater on or off according to the instructions on the display.
Return to the main menu with “BACK”-button. Scroll the main menu with
arrow keys, choose an item with “OK”-button.
NB!: After a power failure the time must be set again.
SAFIRE 3000
SAFIRE
BACK OK
Hallinta
Ajastin
Asetukset
Termostaattinytt
Made in Finland by
SF-Lmmitin Oy
genius

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 5
USAGE, INSTALLATION AND MAINTENANCE
January 2011
SF- Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
INDICATOR LEDS
Indicator LEDs on the control panel:
Green LED above the switch of the basic control
panel: the heater is on. If the LED is not on when
starting the heater, the heater’s power supply is
probably disconnected.
Green LED (flame) on the control
panel: the flame sensor has detected
a flame and combustion is in process.
Indicator LEDs on the end of the heater:
Green LED D10: the flame sensor
has detected a flame and
combustion is in process.
Yellow LED D2: the voltage is low, under
10,8V (or under 9V during the ignition).
The battery voltage may be too low, the power supply
cables too thin or some connection in the wiring loose.
During the start the voltage can be lower, because the
voltage drop caused by the filament current in the power
supply cables can be up to 0,5V. If the voltage drops
below the limits mentioned above, the aftercooling
mode activates and the heater turns off.
Red LED D9: malfunction detected, the
combustion stops.
On the end of the heater is a display which indicates the
type of malfunction (see Malfunctions; NB: the display is
upside down). If you have turned the heater off, you can
see the latest malfunction type on the display again by
turning the switch to “VENT”: the latest error code
shows on the display.
GENIUS CONTROL PANEL
Control the heater according to the instructions
indicated on the GENIUS control panel. The normal
start: Push BACK, the text HEATER CONTROL
appears on the display; push OK, the text START
appears on the display, push OK and the heater starts.
The menu ADJUST POWER allows you to adjust either
the power or the temperature. Choose menu items with
arrow keys, accept with OK.
If you desire extra strong ventilation, choose DRYING
VENTILATE. On this mode the heater takes more fresh
air; this improves the drying effect while the heating
power is low (practical f. ex. in the summer when the air
is damp but not very cold).
Return to the main menu with BACK. NB! All selections
are not allowed in every mode.
STARTING THE HEATER
Start the heater with ON/HEAT-OFF-VENT-switch.
Green LED above the switch turns on. The pump
operates (you can hear tapping, the dot on the circuit
board display blinks), the fans are operating.
Green LED (flame) on the end of the
heater and on the basic control panel
lights about 1 1/2–3 minutes after the
start when the flame sensor has detected
a sufficient flame.
The ignition process ends in about 6 1/2 minutes. The
heater operates on the power set with the thermostat or
with the adjustment knob; the main fan measures the
temperature of the room and operates on sufficient
power.
HEATING POWER
Make sure that the temperature chosen on the
thermostat or the chosen power settings correspond to
your needs.
ADJUSTING THE HEATING POWER
If your heater has a thermostat, it will adjust the power
automatically. If you want to change the heating power
temporarily, adjust the temperature settings; the power
level will change to correspond to the set limit.
If your heater doesn’t have a thermostat, adjust the
power manually with the adjustment knob. NB! The
main fan doesn’t operate on the new power level until
the temperature of the air requires it.
TURNING OFF THE HEATER
Turn the heater off by turning the switch into OFF
position; the pump stops, the heater goes into
aftercooling mode and after that turns off.
Do not cut the power supply off f. ex. from the main
switch when the aftercooling is on process (about 6
1/2 minutes)!
If the power supply is cut off, the heater starts next time
only after it is set on ventilating mode
(error code A).
+ -

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 6
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF-LÄMMITIN OY Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
6
MALFUNCTION
(To identify the LEDs: see wiring diagram)
NORMAL FUNCTION
Green LED above the switch of the basic
control panel: the heater is on and gets
current.
Green LED (flame) on the control panel and on the end
of the heater: the flame sensor has detected a flame in
the burner.
A blinking dot on the circuit board display: the pump is
operating.
MALFUNCTIONS
The green LED above the switch is not on when
starting the heater: the heater’s power supply is off.
If the LED is not on after the start process (about 6 1/2
min.) the heater goes into aftercooling mode and turns
off. This will happen f. ex. if the fuel system is empty
during the start. If you don’t notice anything unusual,
you may try to restart the heater.
The green LED (flame) turns off when the heater is
operating, the red LED on the end of the heater is on,
and the heater turns off: the fuel tank may be empty or
the fuel inlet is defective. Check the situation.
The yellow LED on the end of the
heater: The voltage is too low (less than
10,8 V or 9 V during the start). During the
start process the voltage can be lower.
Usually undervoltage during the start is caused by too
thin and/or too long power supply cables, oxidation in
some connection or otherwise bad contact. Check the
battery first, then the wires and connections. If the
yellow LED is on during operation and the heater turns
off, the battery is probably about to drain.
The red LED on the end of the heater:
the heater is turned off because of a
malfunction displayed on the circuit
board.
Usually this is caused by lack of fuel, which stops the
combustion; the error code on the circuit board display
is 3.
NB! If you have turned off the heater after some
malfunction, you can see the latest error code on the
display again by turning the switch to the position
“VENT”: the number of the latest malfunction which
caused the heater to turn off shows on the display.
ERROR CODE NUMBERS ON THE CIRCUIT BOARD
DISPLAY
Number 1: Overheating.
Overheating is usually caused by a blockage on the
normal warm air circulation (f. ex. too much restriction
on the warm air grilles or too much fuel. See p. 7,
Examination).
Number 2: The flame sensor electrode is sooty or
defective. Clean the electrode (see p. 8). A short circuit
may have occurred on the housing.
Number 3: The heater has turned off because the
combustion has stopped. Usually this is caused by lack
of fuel or a block in the fuel system.
Number 4: The glow plug is defective, the connection
might be loose, or either the connector or the wire might
be defective.
Number 5: The flame fan or its wires are defective.
Number 6: The main fan or its wires are defective.
Number 7: Undervoltage (see p. 5, Indicator LEDs).
Number 8: The pump’s electric circuit is broken.
Number 9: The temperature sensor of the circulating
air or its wires are defective.
Letter A means that the heater wasn’t turned off
normally. This is caused by either a rapid voltage drop
or because the power supply is cut off with the main
switch before the aftercooling process is finished. Turn
the switch to VENT position for a little while, the heater
will start normally.
The dot on the circuit board display is supposed to blink
same freguency as pump. If this does not happen and
the pump does not make a tapping noise, and there isn’t
any malfunction, the pump doesn’t get current. The
problem is either on the pumps wires, in the spool or on
the circuit board.
If the dot on the display blinks but the pump does not
make a tapping noise and the wires are ok, the problem
is in the pump usually because of clouded fuel.
+ -

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 7
USAGE, INSTALLATION AND MAINTENANCE
January 2011
SF- Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
EXAMINATION, MAINTENANCE AND SERVICE
EXAMINATION
Check regularly especially, if the combustion in the
burner is different, that
1. the heater gets current.
2. the combustion air access is clear; f. ex.
spiders, mosquitoes, snow, water or ice
can block the air flow.
3. the exhaust outlet is clear.
4. the fuel hose does not leak.
5. there aren’t any impurities or water on the
bottom of the fuel tank.
6. the fuel filter is clean.
7. the air hose of the tank is clear.
8. there isn’t any dust inside the heater; it
may cause smells and risk of fire.
If the heater doesn’t seem to get enough fuel (the
power is lower, the combustion is different),
measure the fuel inlet: Remove the fuel filter (it
may cause measurement errors). When the
heater operates normally on maximum power, put
the fuel hose into a measuring glass with a certain
amount of fuel in it. Let the heater operate for 6
minutes. Multiply the amount of fuel consumed by
10, and you will get the fuel inlet/hour.
On maximum power the 3600Di heater consumes
340-380ml/h, 3200Di heater 300–340 ml/h,
2600Di , heater 240-280ml/h and the 2400Di
heater 220–260 ml/h.
If the measured fuel consumption is above these
limits, check the cause: the tank (or the measuring
glass) may be placed above the heater, or the
default settings of the pump have been changed
and the pumps pulsation is too frequent. The
normal pulsation on maximum power with the
3600Di heater is180 pulses/min and 50 pulses/min
on minimum power 3200Di heater is 160
pulses/min and 50 pulses/min on minimum power
2600Di heater is 130 pulses/min and 50
pulses/min on minimum power, with the 2400Di
heater 120 pulses/min on maximum power and 50
pulses/min on minimum power.
If the heater gets too much fuel, the combustion
may be impure and cause risk of overheating. If
the overheating is caused by defective electronics
or pump, always contact your nearest
maintenance service.
If the fuel consumption is too low, there might be a
blockage in the fuel system. If the filter is clean,
check the fuel hose: the fuel in it may be clouded,
if the hose has been in a cold place for a long
time. If the blockage is not thorough, you can
dissolve it rather quickly with isopropanol
(= common anti-freeze for gasoline engines).
You may also force isopropanol into the hose
when the pump operates (during start) f. ex. with
a hypodermic syringe or bicycle pump.
Also a little leak in the suction hose (before the
pump) may cause the low fuel consumption.
Check if there is a significant amount of bubbles in
the hose. With extensive usage also the fuel inlet
pipe near the burner may be blocked. If this
happens, change the pipe or clean it f. ex. by
heating it with a gas flame and blowing by
compressed air it empty.
WINTER
Remove the battery wire for winter.
If the heater is unused in a cold place for a long
time, the fuel in the hoses and in the tank may
become clouded (this may happen also with winter
grade fuel oil). The last time you use the heater
before the winter, use paraffin oil to avoid starting
problems in the spring. Make sure that paraffin oil
fills the fuel hose, the pump and the fuel filter. In
the spring it’s best to acquire new fuel.

SAFIRE 2400Di, 2600Di, 3200Di and 3600Di Diesel / fuel oil heaters 8
USAGE, INSTALLATION AND MAINTENANCE
January 2012
SF_ Lämmitin Oy Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
OPENING AND CLEANING THE COMBUSTION CHAMBER
1. Remove the heater from the mounting bracket; watch out for fuel dripping from the fuel pipe.
Remove the bottom first: Unscrew the two screws on the bottom and tap lightly from the ends with a
suitable block of wood.
2. Remove the thermal barrier from around the combustion chamber. Remove the fuel feed pipe (2).
3. Open the lid of the combustion chamber and remove the spring supporting the burner (3) and its
base plate (11).
4. Remove the glow plug (1).
5. Remove the burner (8): use a hammer and a suitable block of wood.
6. Open the lock mechanism (4) of the burner cap (5) f. ex. with a screwdriver: push the screwdriver
next to the lock mechanism between the hole cylinder and the lower ring so that the hole cylinder
gives in and the lower ring has room to slide pass the lock mechanism. Rotate the screwdriver and
lift the burner cap simultaneously.
7. Clean the burner f. ex. with an old toothbrush. Remove the carbon deposit from the bottom f. ex. by
first heating it with a gas flame or warm air fan and then scraping it off f. ex. with a screwdriver.
8. If necessary, change the backing (6). The backing stays on its place with a locking spring (7).
9. Assemble in an opposite order. Make sure that the burner is on its place in a right position. Use the
glow plug to align the burner. Check also the position of the casing pipe of the fuel pipe.
CLEANING THE FLAME SENSOR ELECTRODE
Error code number 2 in the circuit board display indicates that the flame sensor electrode is sooty, defective
or that a short circuit has occurred on the housing. A sooty sensor is caused by impure combustion; always
clean the burner too. After you have removed the burner, you can clean the electrode without having to
remove it. If necessary, you can remove the electrode on the end of the heat exchanger: open the locking
spring under the “claws” that keep it steady. Use f. ex. alcohol-based cleaning agent (windshield washer fluid)
for cleaning.
NB! Make sure that the insulation of the electrode is clean to prevent any leakage current which can cause
malfunction. Don’t let the filament of the electrode touch the burner!
Place the flame sensor tip according to the measurements on the picture above. Check the
measurements f. ex. with a cardboard model. If necessary, you can bend the filament of the electrode.
Be careful not to break the insulation. Small fractures however don’t have an impact on the function of the
electrode.
10
8
5
7
4
2
6
1
3

SAFIRE 2400Di, 2600, 3200Di and 3600Di Diesel / fuel oil heaters 9
USAGE, INSTALLATION AND MAINTENANCE
December 2007
SF-LÄMMITIN OY Tilhenkatu 1 20610 Turku Finland Puh/Fax [phone]
CHECKING AND CLEANING THE PUMP
Check the pump by letting an air bubble into the hose. On one pulse the fuel pushes forward about 18–20
mm. If the fuel advances slowly, there might be a blockage. Air bubbles indicate an air leak on the suction or
in the pump.
If the pump doesn’t operate properly although the dot on the error code display blinks, or if you verify by
measuring that the pump’s performance is not sufficient although the pulse frequency is right and there aren’t
any blockages, the problem might be in the pump. The most common malfunctions in the pump are:
1. Blockage in the pump, or restriction or jamming of the piston caused by external impurities or
clouded fuel.
2. Corrosion caused by water during a long period of time.
3. Leakage of the check valve during the suction caused by impurities or corrosion.
CLEANING MINOR IMPURITIES AND CLOUDED FUEL IN THE PUMP
1. Release the hose connectors from the pump.
2. Now you can press isopropanol (a common anti-freeze for gasoline engines and truck air brakes)
through the pump.
OPENING AND CLEANING THE PUMP
1. Release the hose connectors from the pump.
2. Release the wires from the pump.
3. Remove the connector strip (8) so that it rests on the filaments of the spool.
4. Unscrew the iron housing (1) of the pump and remove it.
5. Pull the upper end (3) of the pump out of the spool (4), the piston (9) and the spring (10) are removed
at the same time.
6. Pull also the lower end (5) of the pump out.
7. Wash the inner parts of the pump f. ex. with isopropanol. Check the function of the piston and the
cylinder: there shouldn’t be any “roughness” or stiffness.
8. Test the check valve: connect a hose in the outlet connector (11) and blow air under the fluid level.
The valve should not leak. If necessary, try to clean the valve by squeezing a powerful stream of fluid
forward through the valve.
9. DO NOT OPEN the sealed connection between the pump’s housing (6) and the valve’s housing (7):
the connection specifies the right piston stroke.
10. Assemble in reverse order. Remember to check that the o-rings (12 and 13) and their grooves are
clean.
When you assemble the pump, check the clamps to make sure that the hose connections are tight. Bubbles
after the pump reveal leaks on the suction. NB! If there is air inside the pump, it may take a while before the
pump is completely empty of air.