Snugger SS4200 User manual

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TTechnical echnical descriptiondescription
Installation instructionsInstallation instructions
Operating instructionsOperating instructions
Maintenance Maintenance InstructioInstructionsns
WATER-HEATER FOR VEHICLES
WATER-HEATER FOR VEHICLES

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ContentsContents
P01 P01 Operating Operating Principle and Principle and Use Use of Sof SS4200 S4200 and Sand SS5000 S5000 WWater Heatersater Heaters
P01 P01 Main Main parts parts of of SS4200 SS4200 and and SS5000 SS5000 water water heatersheaters
P02 P02 Installation Installation Instructions Instructions and and RegulationsRegulations
P02 P02 Safety Safety Instructions Instructions and and OperationOperation
P04 P04 TTechnical echnical data data and and specificationsspecifications
P05 P05 Heater Heater Installation Installation Location Location and and PositionPosition
P05 P05 Engine Engine cooling cooling system system and and heater heater hose hose connectionconnection
P06 P06 Combustion Combustion Air Air SystemSystem
P06 P06 Exhaust Exhaust SystemSystem
P07 P07 Fuel Fuel SupplySupply
P09 P09 Operating Operating InstructionsInstructions
P09 P09 Description Description of of FunctionsFunctions
P10 P10 Controls Controls and and Safety Safety DeviceDevice
P10 P10 Electrical Electrical SystemSystem
P11 P11 TroubleshootingTroubleshooting, , Malfunctions Malfunctions and and MaintenanceMaintenance
P14 P14 Heater Heater Assembly Assembly Drawing Drawing SS4200 SS4200 and and SS5000SS5000
P16 P16 Installation Installation Components Components Diagram Diagram SS4200 SS4200 and and SS5000SS5000

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Operating Principle and Use of Operating Principle and Use of SS4200 and SS5000 Water HeatersSS4200 and SS5000 Water Heaters
The SS4200 and SS5000 water heaters are designed to be used as auxiliary engine heaters forThe SS4200 and SS5000 water heaters are designed to be used as auxiliary engine heaters for
trucks, RVs, boats, construction and farm equipment. In extreme cold temperatures, the heaterstrucks, RVs, boats, construction and farm equipment. In extreme cold temperatures, the heaters
will keep the engine warm and also eliminate cold engine starting problems without the necessitywill keep the engine warm and also eliminate cold engine starting problems without the necessity
of engines idling or frequent startups.of engines idling or frequent startups.
In addition, the heater will provide heat to keep the operator cabin or sleeper berth warm andIn addition, the heater will provide heat to keep the operator cabin or sleeper berth warm and
comfortable for a fraction of the cost in comparison to engine idling.comfortable for a fraction of the cost in comparison to engine idling.
Automatic controls keep the temperature of circulating water between 75Automatic controls keep the temperature of circulating water between 75℃－℃－8080℃℃, (167 F, (167 F－－176176
F).F).
Compact design, low volume, easy maintenance, safety protection, auto self diagnosis, optionalCompact design, low volume, easy maintenance, safety protection, auto self diagnosis, optional
timing, wireless remote control, low exhaust emission low operating cost make the heaters ideal totiming, wireless remote control, low exhaust emission low operating cost make the heaters ideal to
use in trucks, boats, farm and construction equipment.use in trucks, boats, farm and construction equipment.
Main parts of SS4200 and SS5000 water heatersMain parts of SS4200 and SS5000 water heaters
(1) Housing(1) Housing
(2) Heat exchanger(2) Heat exchanger
(3) Inner housing(3) Inner housing
(4) Water circulation(4) Water circulation
pumppump
(5) Outer, upper cover(5) Outer, upper cover
(6) Burner assembly(6) Burner assembly
(7) Combustion air(7) Combustion air
blowerblower
(8) Intake and exhaust air(8) Intake and exhaust air
systemsystem
(9) Outer, lower shell(9) Outer, lower shell
(10) Combustion air(10) Combustion air
blower mblower motorotor
(11) Glow pin(11) Glow pin
◆◆ OperationOperation
The fuel pump delivers fuel to the heater atomizer. The glow pin ignites the fuel-air mixture.The fuel pump delivers fuel to the heater atomizer. The glow pin ignites the fuel-air mixture.
Burning fuel heats up the heat exchanger. The heat is transferred into circulating water (coolant)Burning fuel heats up the heat exchanger. The heat is transferred into circulating water (coolant)
through the heat exchanger, and the warm water (coolant) circulates through the engine block andthrough the heat exchanger, and the warm water (coolant) circulates through the engine block and
the cabin heater core, keeping them warm.the cabin heater core, keeping them warm.

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◆◆ Use and applicationUse and application
Widely used in water-cooled engines: cars, commercial and industrial equipment, trucks,Widely used in water-cooled engines: cars, commercial and industrial equipment, trucks,
passengpassenger vanser vans, buses, , buses, motor motor and sail and sail boats, anboats, and housed houseboats. In aboats. In additiddition, the on, the heaters heaters are useare used ford for
heating water in RVheating water in RV’’s, travel trailers, cabins, watering carts, food service vehicles, and cleanings, travel trailers, cabins, watering carts, food service vehicles, and cleaning
vehicles.vehicles.
Installation Instructions and RegulationsInstallation Instructions and Regulations
Select the location to place the heater in the engine compartment or truck cabin so that the heaterSelect the location to place the heater in the engine compartment or truck cabin so that the heater
exhaust gases exhaust gases will will exhaust directly exhaust directly to the to the outside of outside of the cabin the cabin or or passengers space, passengers space, through tthrough thehe
floor or wall, and the heater water hoses can be easily attached to the cabin heater core lines. Thefloor or wall, and the heater water hoses can be easily attached to the cabin heater core lines. The
top of the heater must be installed below the minimum engine coolant/water level to allow the airtop of the heater must be installed below the minimum engine coolant/water level to allow the air
to escape and the heater to fill up with water/coolant when the bleed screw is open. Protect theto escape and the heater to fill up with water/coolant when the bleed screw is open. Protect the
heater from excessive heat, exposure, and possible contamination from fuel or oil. Keep heaterheater from excessive heat, exposure, and possible contamination from fuel or oil. Keep heater
exhaust away from electrical wires, fuel lines, water lines, and any other heat sensitive andexhaust away from electrical wires, fuel lines, water lines, and any other heat sensitive and
flammable materials. Provide sufficient ventilation.flammable materials. Provide sufficient ventilation.
All precautions must be taken when arranging the heater placement to minimize the risk of injuryAll precautions must be taken when arranging the heater placement to minimize the risk of injury
or damage to property.or damage to property.
◆◆ Fuel SupplyFuel Supply
The fuel intake connections shall NOT be in the passenger compartment or operator (driver) cabin.The fuel intake connections shall NOT be in the passenger compartment or operator (driver) cabin.
In vehicles where a separate fuel tank is used for the heater, the fuel tank lines and intakeIn vehicles where a separate fuel tank is used for the heater, the fuel tank lines and intake
connection must be clearly identified. A warning sign shall be permanently attached to the intakeconnection must be clearly identified. A warning sign shall be permanently attached to the intake
connection or fuel tank indicating that the heater must be switched OFF before refueling.connection or fuel tank indicating that the heater must be switched OFF before refueling.
◆◆ Exhaust SystemExhaust System
The exhaust outlet must be arranged in a way to prevent penetration of exhaust fumes into theThe exhaust outlet must be arranged in a way to prevent penetration of exhaust fumes into the
vehicle interior through the ventilation system, warm air intakes, or open windows, etc.vehicle interior through the ventilation system, warm air intakes, or open windows, etc.
◆◆ Combustion Air IntakeCombustion Air Intake
The heater combustion air shall NOT be taken from passenger compartment, cargo space orThe heater combustion air shall NOT be taken from passenger compartment, cargo space or
operator (driver) cabin. The air intake shall be protected from possible water intake intooperator (driver) cabin. The air intake shall be protected from possible water intake into
combustion chamber, and cannot be blocked by any object at any time.combustion chamber, and cannot be blocked by any object at any time.
◆◆ Please Note:Please Note:
··Failure to comply with the regulations, safety instructions, repairs done by unauthorized person,Failure to comply with the regulations, safety instructions, repairs done by unauthorized person,
use of aftermarket parts voids warranty and relieves manufacture, distributors, dealers, anduse of aftermarket parts voids warranty and relieves manufacture, distributors, dealers, and
installation technicians from any and all liabilities.installation technicians from any and all liabilities.
Safety Instructions and OperationSafety Instructions and Operation
Disconnect vehicle battery power before commencing repair or performing heater maintenance.Disconnect vehicle battery power before commencing repair or performing heater maintenance.
Before beginning any work on the heater, switch the heater OFF and let all hot parts cool down.Before beginning any work on the heater, switch the heater OFF and let all hot parts cool down.
The heater shall NOT be used in: poor ventilated rooms, garages, shops, multi-storage car park,The heater shall NOT be used in: poor ventilated rooms, garages, shops, multi-storage car park,

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etc. Use heater only in open, well ventilated areas.etc. Use heater only in open, well ventilated areas.
Use of aftermarket parts is strictly prohibited unless authorized by the manufacturer.Use of aftermarket parts is strictly prohibited unless authorized by the manufacturer.
Installation and operation of the heater shall comply with statutory regulations, safety instructionsInstallation and operation of the heater shall comply with statutory regulations, safety instructions
and specifications as stated in the installation and operating instructions. Extreme precaution shalland specifications as stated in the installation and operating instructions. Extreme precaution shall
be takebe taken when in when installnstalling and ming and maintaiaintaining elning electrical wectrical wiring, iring, fuel sufuel supplypply, combus, combustion air tion air andand
exhaust system.exhaust system.
Unauthorized persons are not allowed to do any repairs or maintenance.Unauthorized persons are not allowed to do any repairs or maintenance.
Debris or any other remains shall be removed and cleaned before reinstalling the heater intoDebris or any other remains shall be removed and cleaned before reinstalling the heater into
another vehicle.another vehicle.
The heater shall NOT be used in hazardous places such as but not limited to: fuel depots, carbonThe heater shall NOT be used in hazardous places such as but not limited to: fuel depots, carbon
storage, timber warehouses, granaries and any other places where combustible or flammable vaporstorage, timber warehouses, granaries and any other places where combustible or flammable vapor
or dust may be present.or dust may be present.
Heater must be switched OFF during refueling.Heater must be switched OFF during refueling.
The heater shall be installed in a spacious compartment. Fuel canisters, oil cans, spray cans, gasThe heater shall be installed in a spacious compartment. Fuel canisters, oil cans, spray cans, gas
cartridges, fire extinguisher, cleaning rags, clothing, papers, or any combustible or flammablecartridges, fire extinguisher, cleaning rags, clothing, papers, or any combustible or flammable
materials shall NOT be stored or transported on or next to the heater.materials shall NOT be stored or transported on or next to the heater.
Defective or burned fuses shall be replaced only with same type and same rating fuses.Defective or burned fuses shall be replaced only with same type and same rating fuses.
In the event of a fuel leak; turn OFF the heater immediately, disconnect and cap off fuel line. TheIn the event of a fuel leak; turn OFF the heater immediately, disconnect and cap off fuel line. The
leak shall be repaired by a professional, authorized technician.leak shall be repaired by a professional, authorized technician.
Use only coolant liquids that are permitted by the vehicle manufacturer. Use of other coolantsUse only coolant liquids that are permitted by the vehicle manufacturer. Use of other coolants
might damage the engine or heater.might damage the engine or heater.
◆◆ Please note:Please note:
··Do NOT prematurely shut down the heater by disconnecting the power unless required to do soDo NOT prematurely shut down the heater by disconnecting the power unless required to do so
by an emby an emergenergencycy..
WARNINGWARNING
·Carbon monoxide monitoring sensor with alarm shall be installed in all passenger·Carbon monoxide monitoring sensor with alarm shall be installed in all passenger
compartments, operator or driver cabin, and sleeper berth.compartments, operator or driver cabin, and sleeper berth.

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TTechnical data and echnical data and specificationsspecifications
Model HYDTE
Model HYDTE
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SS4200 HYDTECSS4200 HYDTEC
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SS5000SS5000
Heating Heating medium medium WWater, ater, coolant coolant WWater, ater, coolantcoolant
Heat Heat flow flow control control High High Low Low High High LowLow
Heating Heating output output (kw) (kw) 14,400 14,400 (4.2) (4.2) 7,500 7,500 (2.2) (2.2) 17,060 17,060 (5) (5) 7,500 7,500 (2.2)(2.2)
Fuel Fuel consumption consumption (L/h) (L/h) 0.13 0.13 (0.51) (0.51) 0.06 0.06 (0.25) (0.25) 0.16 0.16 (0.61) (0.61) 0.06 0.06 (0.25)(0.25)
Fuel DieselFuel Diesel
PowerPower
consumption(W)consumption(W)
Operating Operating 53 53 w w 27 27 w w 53 53 w w 27 27 ww
Startup Startup 120 120 w w 120 120 ww
Rated Rated voltage(V) voltage(V) 12 12 or or 24 24 12 12 or or 2424
OperatingOperating
voltage rangevoltage range
MinimumMinimum
voltagevoltage
10.2 V or 21V (under-voltage protection will shutdown the units10.2 V or 21V (under-voltage protection will shutdown the units
when the voltage drops to this value)when the voltage drops to this value)
MaximumMaximum
voltagevoltage
16 V or 32V (over-voltage protection will shutdown the units16 V or 32V (over-voltage protection will shutdown the units
when the voltage riches this value)when the voltage riches this value)
Allowable Allowable operation operation pressure pressure Max. Max. 15PSI 15PSI (1 (1 bar)bar)
WWater ater capacity capacity of of the the heater heater 0.046 0.046 gal. gal. (0.175 (0.175 L)L)
WWater ater through-put through-put capacity capacity 225~265 225~265 US US Gal/h Gal/h 850~1000 850~1000 L/h L/h (approx (approx operational operational pressure pressure 10Kpa 10Kpa ))
Minimum water through-putMinimum water through-put
capacitycapacity 63.50 US Gal/h63.50 US Gal/h (240 L/h)(240 L/h)
Operating Shutdown Operating ShutdownOperating Shutdown Operating Shutdown
AllowableAllowable
ambientambient
temperaturetemperature
HeaterHeater -40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
-40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
Fuel pumpFuel pump -40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
-40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
ControllerController -40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
-40-40℃℃~ 80~ 80℃℃
-40-40℉℉~ 176~ 176℉℉
-40-40℃℃~ 105~ 105℃℃
-40-40℉℉~ 221~ 221℉℉
WWeight (excluding heaeight (excluding heatingting
medium and optional etc)medium and optional etc) Approx. Approx. 3.1 3.1 Kg Kg / / Approx. Approx. 6.8 L6.8 Lbs bs Approx. Approx. 3.1Kg 3.1Kg / / Approx. Approx. 6.8 L6.8 Lbsbs
◆◆ Please note:Please note: ··Listed technical data is subject to the tolerances ofListed technical data is subject to the tolerances of ±±10 %.10 %.
◆◆ Heater DimensionsHeater Dimensions

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Heater Installation Location and PositionHeater Installation Location and Position
The best place to install the water heater is in the engine compartment; the heater must be installedThe best place to install the water heater is in the engine compartment; the heater must be installed
below mbelow minimum inimum engine engine coolancoolant level t level in ordein order to allr to allow the ow the air to escair to escape anape and fill d fill up the hup the heater wieater withth
water or coolant when the bleed screw is open.water or coolant when the bleed screw is open.
◆◆ Tolerable swivel rangeTolerable swivel range
Depending on the installation conditions, swivel angles should be as shown below.Depending on the installation conditions, swivel angles should be as shown below.
Note:Note:
The bleed screwThe bleed screw－－must be upward.must be upward.
◆◆ Please note:Please note:
··In the heating mode, the heater can deviate from the shown normal or maximum installationsIn the heating mode, the heater can deviate from the shown normal or maximum installations
positipositions by ons by up to +1up to +15° in al5° in all directil directions in ons in order to order to accommaccommodate thodate the vehicle vehicle or boat e or boat movemmovement.ent.
Engine cooling system and heater hose Engine cooling system and heater hose connectionconnection
◆◆ Hose Connection DiagramHose Connection Diagram
Connect the heater between the engine and the cabin heater core as shown.Connect the heater between the engine and the cabin heater core as shown.
Cut water hose from the engine to the heater core, hook up the hose from engine to the inlet fittingCut water hose from the engine to the heater core, hook up the hose from engine to the inlet fitting
of the heater (lower) and the other end of the hose (heater core side) into the heater outlet (upper).of the heater (lower) and the other end of the hose (heater core side) into the heater outlet (upper).
Engine cooling systemEngine cooling system

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◆◆ Please note:Please note:
··Heaters hoses and the hot air outlet shall be routed and fastened in such a way that they pose noHeaters hoses and the hot air outlet shall be routed and fastened in such a way that they pose no
risk to people or temperature sensitive materials.risk to people or temperature sensitive materials.
··Before working on the coolant circuit, turn OFF the heater and wait until all components haveBefore working on the coolant circuit, turn OFF the heater and wait until all components have
cooled down completely; always wear safety gloves and eye protection.cooled down completely; always wear safety gloves and eye protection.
··Please take note of the direction of flow of coolant or water.Please take note of the direction of flow of coolant or water.
··Fill the heater and water hoses with coolant before connecting to the coolant circuit. Route theFill the heater and water hoses with coolant before connecting to the coolant circuit. Route the
hoses in such a way as to avoid kinks, rubbing hoses against sharp corners, etc. Provide sufficienthoses in such a way as to avoid kinks, rubbing hoses against sharp corners, etc. Provide sufficient
clearance to hot vehicle parts, and protect hoses from chafing and rubbing against vehicle body.clearance to hot vehicle parts, and protect hoses from chafing and rubbing against vehicle body.
Use protective heat shields if necessary.Use protective heat shields if necessary.
··Secure all hoses with hose clips. After operating the heater for few hours check for leaks andSecure all hoses with hose clips. After operating the heater for few hours check for leaks and
tight clamps as necessary.tight clamps as necessary.
··Maximum cooling circuit pressure shall not exceed 15 PSI (1 bar).Maximum cooling circuit pressure shall not exceed 15 PSI (1 bar).
··The coolant liquid must contain at least 10% antifreeze all year round as a corrosion protection.The coolant liquid must contain at least 10% antifreeze all year round as a corrosion protection.
··Before commissioning the heater or after changing the cooling liquid, the whole coolant circuitBefore commissioning the heater or after changing the cooling liquid, the whole coolant circuit
including heater must be free of air bubbles according to the installation instructions. To top offincluding heater must be free of air bubbles according to the installation instructions. To top off
cooling system, use only coolants approved by vehicle manufacturer.cooling system, use only coolants approved by vehicle manufacturer.
Combustion air systemCombustion air system
Install the tube of the combustion air intake in such a way that the air intake is protected fromInstall the tube of the combustion air intake in such a way that the air intake is protected from
sucking water, dust, hot air, exhaust fumes or any other debris into the combustion chamber.sucking water, dust, hot air, exhaust fumes or any other debris into the combustion chamber.
Inner hose diameterInner hose diameter φφ3/43/4 ””(20 mm); max. Length 55(20 mm); max. Length 55””(1.5 m), depending on the installation(1.5 m), depending on the installation
conditions.conditions.
Exhaust SystemExhaust System
The flexible exhaust pipe inner diameter ofThe flexible exhaust pipe inner diameter of
φφ15/1615/16””(24mm) can be shortened to no less than(24mm) can be shortened to no less than
88””(0.2m) from the heater to the silencer (muffler) but not longer than a total of 78(0.2m) from the heater to the silencer (muffler) but not longer than a total of 78””(2m) including(2m) including
muffler; fasten the exhaust silencer (muffler) at suitable position to the vehicle frame, route themuffler; fasten the exhaust silencer (muffler) at suitable position to the vehicle frame, route the
flexible exhaust pipe from the heater to the exhaust silencer and fasten with hose clamps. Use hoseflexible exhaust pipe from the heater to the exhaust silencer and fasten with hose clamps. Use hose
clips to attach the exhaust flex pipe to the vehicle body.clips to attach the exhaust flex pipe to the vehicle body.
◆◆ Safety InstructionSafety Instruction
WARNINGWARNING
·The entire exhaust system gets very hot during operation and immediately after the·The entire exhaust system gets very hot during operation and immediately after the
heater has been working. Keep the exhaust system parts away from any flammable materials;heater has been working. Keep the exhaust system parts away from any flammable materials;
wires, hoses, fuel lines, carpets, plastics, brake lines, etc.wires, hoses, fuel lines, carpets, plastics, brake lines, etc.

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Maintain at least 1/2Maintain at least 1/2””air gap between the exhaust pipe and sheet metal walls in order to preventair gap between the exhaust pipe and sheet metal walls in order to prevent
the heat transferring through the metal and damaging materials on the other side of the wall. Usethe heat transferring through the metal and damaging materials on the other side of the wall. Use
heat shields if necessary. Point the heater exhaust tail pipe slightly downward, in open air, awayheat shields if necessary. Point the heater exhaust tail pipe slightly downward, in open air, away
from travel direction and at least 12from travel direction and at least 12””away from any combustible or flammable materials.away from any combustible or flammable materials.
Tail pipe cannot protrude beyond the lateral limits of the vehicle. Route the exhaust pipe in such aTail pipe cannot protrude beyond the lateral limits of the vehicle. Route the exhaust pipe in such a
way so the exhaust fumes cannot be sucked into the vehicle.way so the exhaust fumes cannot be sucked into the vehicle.
Do not perform any work on the exhaust system while the heater is working. Before working onDo not perform any work on the exhaust system while the heater is working. Before working on
the exhaust system, first turn the OFF heater and wait until all parts have cooled down completely,the exhaust system, first turn the OFF heater and wait until all parts have cooled down completely,
always wear safety gloves and eye protection.always wear safety gloves and eye protection.
Fuel SupplyFuel Supply
◆◆ The following safety instructions must be observed when mounting the fuel pump,The following safety instructions must be observed when mounting the fuel pump,
routinrouting fuel lg fuel lines and installing fuel tank pick-up tubeines and installing fuel tank pick-up tube
Turn OFF vehicle engine and heater before working on the fuel supply or before refueling. Do notTurn OFF vehicle engine and heater before working on the fuel supply or before refueling. Do not
useuse ““nakednaked “lights“lights, open flames, do not smoke, do not inhale fuel vapors and avoid fuel contact, open flames, do not smoke, do not inhale fuel vapors and avoid fuel contact
with skin. Work only in well ventilated area.with skin. Work only in well ventilated area.
When installing fuel lines, use only a sharp knife to cut fuel hoses and pipes. Interfaces shall notWhen installing fuel lines, use only a sharp knife to cut fuel hoses and pipes. Interfaces shall not
be crusbe crushed and mhed and must be fust be free of bree of burrs.urrs.
The fuel line from the pump to the heater should be installed at a continuous rise.The fuel line from the pump to the heater should be installed at a continuous rise.
Fuel lines must be fastened to avoid damage and / or noise from vibrations.Fuel lines must be fastened to avoid damage and / or noise from vibrations.
Route the fuel lines in a way that they are protected from vehicle distortion, movement, etc. NeverRoute the fuel lines in a way that they are protected from vehicle distortion, movement, etc. Never
route or fasten fuel lines to the heater or vehicle exhaust system. When the fuel line crosses a hotroute or fasten fuel lines to the heater or vehicle exhaust system. When the fuel line crosses a hot
element, always ensure there is sufficient clearance. If necessary, install heat deflection plates.element, always ensure there is sufficient clearance. If necessary, install heat deflection plates.
◆◆ Safety InstructionSafety Instructions for s for fuel pipes and ffuel pipes and fuel tanks in pasuel tanks in passenger compsenger compartmentartment
In a passenger busIn a passenger bus，，fuel pipes and fuel tanks shall NOT be routed through the passengerfuel pipes and fuel tanks shall NOT be routed through the passenger
compartment or operator or drivercompartment or operator or driver’’s cab.s cab.
Fuel tanks in passenger vehicles must be positioned in such a way that the exits are not in directFuel tanks in passenger vehicles must be positioned in such a way that the exits are not in direct
danger from a possible fire.danger from a possible fire.
◆◆ Fuel supply for diesel Fuel supply for diesel heaterheater
Mode 1: Fuel line installation using T connectorMode 1: Fuel line installation using T connector
(1) Fuel return pipe(1) Fuel return pipe
(2) Fuel feed pipe(2) Fuel feed pipe
from tankfrom tank
(3) T fitting(3) T fitting
(4) Fuel pipe(4) Fuel pipe
connecting hoseconnecting hose
(5) Fuel line max.(5) Fuel line max.
length (5m) 15"length (5m) 15"
(6) To engine(6) To engine
(7) Fuel pump(7) Fuel pump
(8) Fuel filter(8) Fuel filter

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◆◆ T fitting T fitting SettinSetting Angleg Angle
Use the installation positions shown in the diagram when inserting a T fitting.Use the installation positions shown in the diagram when inserting a T fitting.
(1) Direction of flow from the fuel tank(1) Direction of flow from the fuel tank
(2) Direction of flow to vehicle engine(2) Direction of flow to vehicle engine
Mode 2: Fuel line installation with tank pick-up tubeMode 2: Fuel line installation with tank pick-up tube
(1) Tank pick-up tube(1) Tank pick-up tube
(2) Fuel connector hose(2) Fuel connector hose
(3) Fuel line max. length 15" (5 m)(3) Fuel line max. length 15" (5 m)
(4) Fuel filter(4) Fuel filter
(5) Fuel pump(5) Fuel pump
◆◆ Max. suction and pressure heightMax. suction and pressure height
Max. height from fuel tank to heaterMax. height from fuel tank to heater －－a= 12" (3000 mm)a= 12" (3000 mm)
Max. suction height from bottom of tankMax. suction height from bottom of tank －－b= 3.9" b= 3.9" (2000 m(2000 mm)m)

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◆◆ MountinMounting of g of fuel intake systemfuel intake system
··Install methodInstall method
Drill 31/32" (24mm) hole in appropriate location In top of fuel tank, as shown figure 1:Drill 31/32" (24mm) hole in appropriate location In top of fuel tank, as shown figure 1:
Mount the fuel intake system and fuel pump, as shownMount the fuel intake system and fuel pump, as shown
figure 2, 3figure 2, 3
◆◆ Please note:Please note:
··When drilling into the fuel tank, take precautions to prevent possible sparks from electric toolsWhen drilling into the fuel tank, take precautions to prevent possible sparks from electric tools
(ground all tools).(ground all tools).
Prevent shavings and any other debris to fall into the fuel tank.Prevent shavings and any other debris to fall into the fuel tank.
Operating InstructionsOperating Instructions
Before starting the heater, perform a safety check: all components must be firmly fastened, checkBefore starting the heater, perform a safety check: all components must be firmly fastened, check
for fuel leaks, make sure the heater is filled with water or coolant (all air shall be bleed out). Bleedfor fuel leaks, make sure the heater is filled with water or coolant (all air shall be bleed out). Bleed
fuel line and prime fuel pump.fuel line and prime fuel pump.
To start the heater; turn the thermostat toTo start the heater; turn the thermostat to ““highhigh””(turn the knob clockwise), push heat bottom, the(turn the knob clockwise), push heat bottom, the
blower mblower motor wilotor will start l start runningrunning. A. After abofter about 45 sut 45 sec. the fuec. the fuel pumel pump will p will start pumstart pumping. Iping. If the fuel f the fuel isis
not ignited in about 90 sec. (possible air in fuel line) the glow pin will shut down for about 1 min.not ignited in about 90 sec. (possible air in fuel line) the glow pin will shut down for about 1 min.
and then it will start the process again. The process will repeat until there is no more air in fueland then it will start the process again. The process will repeat until there is no more air in fuel
line.line.
Heater at high altitudes:Heater at high altitudes:
1. Heating at altitudes below 5,000" (1,500m), -unlimited heating possible.1. Heating at altitudes below 5,000" (1,500m), -unlimited heating possible.
2. Using heater at altitudes higher than 5,000" (1,500m) requires installing an altitude pressure2. Using heater at altitudes higher than 5,000" (1,500m) requires installing an altitude pressure
sensor.sensor.
Description of functionsDescription of functions
◆◆ OperationOperation

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When the heater is turned ON, the control lamp comes ON. The combustion air blower startsWhen the heater is turned ON, the control lamp comes ON. The combustion air blower starts
running, glow pin starts heating up, and fuel pump starts pumping fuel. Once the flame is stable,running, glow pin starts heating up, and fuel pump starts pumping fuel. Once the flame is stable,
glow pin will turn off.glow pin will turn off.
◆◆ Heating modeHeating mode
Once the water reaches 175Once the water reaches 175℉℉ (85(85℃℃) the heat will turn OFF, the combustion fan and water pump) the heat will turn OFF, the combustion fan and water pump
will continue to operate on the low speed. The heat light will stay ON. The heater will restart afterwill continue to operate on the low speed. The heat light will stay ON. The heater will restart after
water temperature drop below setting point. After the heater is turned OFF the exhaust fan andwater temperature drop below setting point. After the heater is turned OFF the exhaust fan and
water pump will run for approximate. 2 min. in order to evacuate exhaust fumes and cool off thewater pump will run for approximate. 2 min. in order to evacuate exhaust fumes and cool off the
combustion chamber.combustion chamber.
Controls and Safety DeviceControls and Safety Device
If the heater does not ignite within 90 seconds after starting the fuel pump, the process repeatsIf the heater does not ignite within 90 seconds after starting the fuel pump, the process repeats
several times. After several unsuccessful starting attempts the controller will lock the system inseveral times. After several unsuccessful starting attempts the controller will lock the system in
order to prevent fuel flooding the chamber. You can restart the process by switching the heaterorder to prevent fuel flooding the chamber. You can restart the process by switching the heater
OFF and then ON.OFF and then ON.
If the flame goes off during operation, the heater will restart by itself. If the heater does not igniteIf the flame goes off during operation, the heater will restart by itself. If the heater does not ignite
after several attempts, the heater will lock and it will need to be turned OFF and ON manually.after several attempts, the heater will lock and it will need to be turned OFF and ON manually.
In the case of overheating (for example, lack of water, poorly vented coolant circuit), theIn the case of overheating (for example, lack of water, poorly vented coolant circuit), the
overheating sensor is triggered, the fuel supply is interrupted and the heater turns OFF. Once theoverheating sensor is triggered, the fuel supply is interrupted and the heater turns OFF. Once the
overheating has been eliminated, the heater can be restarted manually by turning OFF and ONoverheating has been eliminated, the heater can be restarted manually by turning OFF and ON
again. The heater will turn ON when the water temperature drops below 158again. The heater will turn ON when the water temperature drops below 158 ℉℉ (70(70℃℃). If the). If the
heater has been switched OFF and ON too many times, the controller will lock, wait for about 15heater has been switched OFF and ON too many times, the controller will lock, wait for about 15
min. and turn the heater ON again.min. and turn the heater ON again.
If the lower or upper voltage limit is reached, the heater will turn OFF.If the lower or upper voltage limit is reached, the heater will turn OFF.
The heater does not start when the glow pin is defective or when the fuel pump power isThe heater does not start when the glow pin is defective or when the fuel pump power is
interrupted.interrupted.
The fan speed is continuously monitored. If the fan motor does not start or if the speed deviates byThe fan speed is continuously monitored. If the fan motor does not start or if the speed deviates by
more than 40%, the heater will turn OFF after 60 sec.more than 40%, the heater will turn OFF after 60 sec.
The controller can be enabled again and it will flash fault code:The controller can be enabled again and it will flash fault code:
Use chart below to read the fault code list.Use chart below to read the fault code list.
Do not switch the heater OFF and ON again more than twice.Do not switch the heater OFF and ON again more than twice.
◆◆ Please note:Please note:
Emergency shut down.Emergency shut down.
In event of an emergency, shut down the heater as follows:In event of an emergency, shut down the heater as follows:
··Try to turn the heater OFF with the control panel.Try to turn the heater OFF with the control panel.
··Pull the fuse out.Pull the fuse out.
··Disconnect battery power.Disconnect battery power.

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Electrical systemElectrical system
Safety Instruction for wiring the heaterSafety Instruction for wiring the heater
·The Heater shall be connected to the power according to the EMC requirements. See·The Heater shall be connected to the power according to the EMC requirements. See
instruction below;instruction below;
··Ensure that the electric cableEnsure that the electric cable’’s insulation is not damaged. Avoid: chafing, kinking, jamming ors insulation is not damaged. Avoid: chafing, kinking, jamming or
exposure to heat.exposure to heat.
··Seal all unused connector chambers with filler plugs to ensure there are not dirt enter into andSeal all unused connector chambers with filler plugs to ensure there are not dirt enter into and
water-proof.water-proof.
··All electrical connection shall be free of corrosion and firmly connected.All electrical connection shall be free of corrosion and firmly connected.
··Lubricate all outside connections with contact grease.Lubricate all outside connections with contact grease.
◆◆ Wire colorsWire colors
Symbol Color Symbol Color Symbol Color
Symbol Color Symbol Color Symbol Color
SW Black SW Black Br Brown Br Brown Ge yellowGe yellow
Or Or Orange Vi Orange Vi Purple Gn GreePurple Gn Greenn
Rt Red Bl BlueRt Red Bl Blue
◆◆ Electrical Circuit DiagramElectrical Circuit Diagram
TTroubleshooting, Malfunctions and roubleshooting, Malfunctions and MaintenanceMaintenance
MalfunMalfunction ction checklistchecklist
Heater does not start after being turned on; switch the heater OFF and ON again.Heater does not start after being turned on; switch the heater OFF and ON again.
If the heater still does not start, check the following:If the heater still does not start, check the following:
··is there fuel in the tank ?is there fuel in the tank ?
··are fuses ok ?are fuses ok ?
··are electrical cables, all connections, etc OK ?are electrical cables, all connections, etc OK ?
··
is anything clogging the combustion air supply or exhaust system ?is anything clogging the combustion air supply or exhaust system ?
··does the control panel flash the fault code ?does the control panel flash the fault code ?

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◆◆ Water heater fault codeWater heater fault code
Code flashing
Code flashing
timestimes Description SolutionDescription Solution
1 1 Time Time The The power power supply supply voltage voltage too too highhigh Check the voltage, possible alternator drive beltCheck the voltage, possible alternator drive belt
too loose, check charging systemtoo loose, check charging system
2 2 Times Times The The power power supply supply voltage voltage too too lowlow Check the voltage, charge battery, check chargingCheck the voltage, charge battery, check charging
systemsystem
3 3 Times Times The The burner burner temperature temperature abnormalabnormal Check the temperature sensor connection andCheck the temperature sensor connection and
positiposition whon whether it ether it is correctis correct
Check the temperature sensor wires for possibleCheck the temperature sensor wires for possible
damage or shortdamage or short
4 Times4 Times Inlet Inlet water water temperature temperature sensorsensor
abnormalabnormal
5 Times5 Times Outlet water temperature sensorOutlet water temperature sensor
abnormalabnormal
6 6 Times Times Glow Glow pin pin malfunctionmalfunction
Check the voltage between glow pin terminals itCheck the voltage between glow pin terminals it
should read 9.6 or 21.6 Vshould read 9.6 or 21.6 V
Check for broken wires and loose connection,Check for broken wires and loose connection,
short out wiresshort out wires
Remove and check the glow pin for any visibleRemove and check the glow pin for any visible
damage; replace glow pin if damageddamage; replace glow pin if damaged
7Times 7Times Fuel Fuel pump pump malfunctionmalfunction
Check voltage at fuel pump it should pulsing 12V / 24VCheck voltage at fuel pump it should pulsing 12V / 24V
Check wires for damage, check connections andCheck wires for damage, check connections and
shorted circuitsshorted circuits
Check fuel pump for any damageCheck fuel pump for any damage
8 8 Times Times Blower Blower malfunctionmalfunction
Check blower wires for damage and properCheck blower wires for damage and proper
connectionsconnections
Check blower for any visible damageCheck blower for any visible damage
9 9 Times Times WWater ater pump pump malfunctionmalfunction
Check wiring connectionsCheck wiring connections
Check water pump for debrisCheck water pump for debris
Check for cramped/collapsed hosesCheck for cramped/collapsed hoses
10 Times10 Times Ignite failed or flame extinguishIgnite failed or flame extinguish
protectprotectionion
Check if there is fuel in tankCheck if there is fuel in tank
Check all fuel line connectionsCheck all fuel line connections
Check fuel pump if it is workingCheck fuel pump if it is working
Check the glow pin if it is working normallyCheck the glow pin if it is working normally
Check the air inlet/exhaust if itCheck the air inlet/exhaust if it’’s not blockeds not blocked
Check Atomizer screen (clean it)Check Atomizer screen (clean it)
11 11 Times Times Burner Burner overheating overheating protectionprotection
Check water flowCheck water flow
Bleed water systemBleed water system
Check overheat sensorCheck overheat sensor
12 Times12 Times Outlet warm water temperatureOutlet warm water temperature
overheating protectionoverheating protection
Check water levelCheck water level
Bleed water systemBleed water system
Check water flowCheck water flow
Check warm water temp. sensorCheck warm water temp. sensor
13 Times13 Times
Flame extinguished or burnerFlame extinguished or burner
overheating forbids the systemoverheating forbids the system
operationoperation
Check overheat temp, sensorCheck overheat temp, sensor
Check water flowCheck water flow
Disconnection power and re-connection againDisconnection power and re-connection again

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14 14 Times Times Communication Communication fault fault Check Check all all wire wire connection.connection.
To resets the system press downTo resets the system press down ““OFFOFF””buttonbutton→→waiting for 15 minutes, it should clear the faultwaiting for 15 minutes, it should clear the fault
codes, turn ON the system. If the system does not clear the code, disconnect battery power, waitcodes, turn ON the system. If the system does not clear the code, disconnect battery power, wait
few minutes, hook up the battery power and turn the system ON.few minutes, hook up the battery power and turn the system ON.
◆◆ MaintenanMaintenance ce InstructionInstructionss
Switch the heater ON once a month for about 10 minutes, even if there is no need for heat.Switch the heater ON once a month for about 10 minutes, even if there is no need for heat.
Check the opening of the combustion air supply and the exhaust system after longer standstillCheck the opening of the combustion air supply and the exhaust system after longer standstill
periodsperiods; clean i; clean if necesf necessarysary..
Before the heating period starts the heater should undergo a trial run. If persistent extreme smoke,Before the heating period starts the heater should undergo a trial run. If persistent extreme smoke,
unusual burning noises, or an unburned fuel smell develop or if electric /electronic parts heats up,unusual burning noises, or an unburned fuel smell develop or if electric /electronic parts heats up,
the heater shall be switched OFF immediately. Remove fuse or disconnect battery power.the heater shall be switched OFF immediately. Remove fuse or disconnect battery power.
Have the heater checked by authorized, trained service technician.Have the heater checked by authorized, trained service technician.
At least once a year have the heater checked by authorized, trained service technician. RemoveAt least once a year have the heater checked by authorized, trained service technician. Remove
glow pin and atomizer; clean the screen and the atomizer chamber with wire brush, if notice thatglow pin and atomizer; clean the screen and the atomizer chamber with wire brush, if notice that
there is excessive carbon build up the entire combustion chamber shall be cleaned out.there is excessive carbon build up the entire combustion chamber shall be cleaned out.
◆◆ Please notePlease note
··The warranty claims will become void if the heater is repaired or serviced by an unauthorizedThe warranty claims will become void if the heater is repaired or serviced by an unauthorized
person.person.
◆◆ ExplainExplain
Instruction:Instruction:one time flashing is point to the light on to light out the illustrations show forth timeone time flashing is point to the light on to light out the illustrations show forth time
flashing, it mean there are sensor abnormal from the above form show like that.flashing, it mean there are sensor abnormal from the above form show like that.

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Heater assembly SS4200 and SS5000Heater assembly SS4200 and SS5000

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Parts list of the SS4200 and SS5000Parts list of the SS4200 and SS5000
Item
Item # # QTY QTY Part Part # # DescriptionDescription
11 22 ··GB / T701985 5x65GB / T701985 5x65 ··Hex screwHex screw
22 11 ··SS4-016SS4-016 ··Outer Outer cover cover / / control control unitunit
33 22 ··GB / T819 1985 M4x10GB / T819 1985 M4x10 ··Flat head Philips screwFlat head Philips screw
44 11 ··SS4-014SS4-014 ··Intake and exhaust assemblyIntake and exhaust assembly
55 22 ··GB / T701985 5x25GB / T701985 5x25 ··Hex screwHex screw
66 11 ··SS4-007-01SS4-007-01 ··Outer cover and blower fan cover 1Outer cover and blower fan cover 1
77 11 ··SS4-031SS4-031 ··Gasket 1Gasket 1
88 11 ··SS4-022SS4-022 ··O ring 1O ring 1
99 11 ··SS4-030SS4-030 ··Gasket 2Gasket 2
1010 11 ··SS4-008SS4-008 ··Cooling pumpCooling pump
1111 22 ··GB / T70 1985 5x35GB / T70 1985 5x35 ··Hex screwHex screw
1212 11 ··SS4-007-02SS4-007-02 ··Outer cover and blower fan cover 2Outer cover and blower fan cover 2
1313 44 ··M4x20 M4x35M4x20 M4x35 ··Mounting screw, water pumpMounting screw, water pump
1414 11 ··GB / T70 1985 5x12GB / T70 1985 5x12 ··Hex screwHex screw
1515 11 ··SS4-013SS4-013 ··Flat springFlat spring
1616 22 ··SS4-036SS4-036 ··TTemperature emperature sensorsensor
1717 22 ··SS4-026SS4-026 ··O O ring ring temp. temp. SensorSensor
1818 11 ··SS4-009SS4-009 ··CasingCasing
1919 22 ··SS4-024SS4-024 ··O ring 3O ring 3
2020 11 ··SS4-014SS4-014 ··Burners AssemblyBurners Assembly
2121 11 ··SS4-028SS4-028 ··Heat exchangerHeat exchanger
2222 11 ··SS4-010SS4-010 ··AtomizerAtomizer
2323 11 ··SS4-023SS4-023 ··O ring 2O ring 2
2424 11 ··SS4-025SS4-025 ··O ring 4O ring 4
2525 11 ··SS4-027SS4-027 ··Connected socketConnected socket
2626 11 ··SS4-001SS4-001 ··Glow pin assemblyGlow pin assembly
2727 11 ··SS4-034SS4-034 ··Spring washerSpring washer
2828 11 ··SS4-011SS4-011 ··Flame sensorFlame sensor

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Installation components diagram HYDTECInstallation components diagram HYDTEC®®SS4200 / SS5000SS4200 / SS5000

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Components list of Components list of the Water Heathe Water Heaterter
Item
Item Part Part # # DescriptionDescription
11 ··SS4200SS4200 ··HeaterHeater
22 ··SS4-037SS4-037 ··Exhaust silencerExhaust silencer
33 ··SS4-000501SS4-000501 ··Heater wire harnessHeater wire harness
44 ··SS4-040SS4-040 ··Heater bracketHeater bracket
55 ··SS4-052SS4-052 ··WWater ater hosehose
66 ··SS4-059SS4-059 ··Exhaust pipeExhaust pipe
77 ··SS4-057SS4-057 ··Cable tiesCable ties
88 ··SS4-055SS4-055 ··Combustion air inletCombustion air inlet
99 ··SS4-062SS4-062 ··Fuel line, outside ODFuel line, outside OD φφ3/8" (9.5mm), ID3/8" (9.5mm), IDφφ3/16" (3.5mm)3/16" (3.5mm)
1010 ··SS4-056SS4-056 ··Screw M6 x 100Screw M6 x 100
1111 ··SS4-033SS4-033 ··Pick up tube assemblyPick up tube assembly
1212 ··SS4-057SS4-057 ··Fuel pumpFuel pump
1313 ··SS4-000503SS4-000503 ··Fuel pump control wire harnessFuel pump control wire harness
1414 ··SS4-045-01SS4-045-01 ··Vehicle fan controller wire harness negative sideVehicle fan controller wire harness negative side
1515 ··SS4-045-02SS4-045-02 ··Wire harness for sensorWire harness for sensor
1616 ··SS4-046SS4-046 ··Control panelControl panel