Timberline Binar-5B-Compact User manual

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Hydronic Heating System by Elwell Corp.
Binar-5B-Compact
Binar-5D-Compact
Service manual

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1. Main Technical Characteristics 3
2. Safety Measures 4
3. Construction and Description of the Main Units of the Heater 4
4. Possible Heater Faults, their Root Causes & Troubleshooting Methods 4
Possible Faults & Replacement of Parts in the Timberline Heating System Components 5
5. Repair, and Replacement of Pre-heater Units 8
5.1 Replacement of the Glow Plug 9
5.2 Replacement of the Plug Screen 10
5.3 Replacement of the Flame Detector 11
5.4 Replacement of the Air Blower 13
5.5 Replacement of the Control Unit 14
5.6 Replacement of Temperature Sensors 15
5.7 Replacement of the Combustion Chamber 16
5.8 Replacement of the Fuel Pump 17
5.9 Replacement of the Pump 19
6. Domestic Water Heat Exchanger 20
7. Air Sensor 20
8. Water Solenoid Valve 21
9. Heating Fans 21
10. Timberline Tank 22
11. Pinout and Replacement of the Control Box 23
12. Touch Panel 24
13. Purging the System 24
14. Pre-heater Check after Installation 25
15. Manufacturer’s Warranty 25
Warranty Part Replacement Labor Time 26
Contents

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Introduction
This Service Manual (“SM”) is intended for use by the
maintenance personnel servicing Binar-5B-Compact and
Binar-5D-Compact hydronic pre-heaters (“pre-heaters”).
This manual contains techniques for troubleshooting, as well as
for determining whether various units and parts are in good con-
dition or need to be replaced. It also contains general technical
specications and descriptions of the units and their purpose as
parts of the pre-heater, as well as tips for their maintenance and
particular features of the various models.
The operating manual and the catalogue of parts and assemblies
must be used alongside this manual during the repair of
the pre-heater.
This Service Manual may not include information about minor
design alterations made by the manufacturer after the
publication date of this SM.
Binar-5B-Compact, Binar-5D-Compact
Service Manual

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1. Main Technical Characteristics
See Table 1 for the main technical characteristics of the pre-heater.
The technical characteristics include a ±10% tolerance and are specied for
operation at the rated power supply voltage and air temperature
of 68°F.
Table 1.
Parameter description Model
Binar-5B-Compact Binar-5D-Compact
Heat capacity, BTU 17,060
Rated power voltage, V 12
Operating power voltage
range, V 9.5 - 16
Fuel type Gasoline Diesel
Fuel consumption (max.), GPH 0.18 0.21
Heat transfer agent DEX-Cool Antifreeze
Electric power consumed,
pump included, (max.), W 45 45
Power consumed at startup
(100 s), W 65 65
Maximum liquid heating tem-
perature, °F +194
Ignition mode Manual or Automatic
Preheater weight in full con-
guration, lbs, max. 19.8

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2. Safety Measures
2.1 Relevant workforce safety rules
must be observed during the
repair.
2.2 Failure to observe pre-heater
operation instructions may
cause re.
2.3 A workplace must be equipped
with re-ghting means.
2.4 Do not refuel an operating
pre-heater.
2.4 Do not operate the pre-heater
with the fuel system poorly
sealed.
2.6 Do not use the pre-heater with
in conned spaces and in
poorly ventilated rooms.
2.7 Do not switch off power to the
pre-heater before the purging
cycle ends.
2.8 Where ame appears at the
exhaust nozzle, turn the heater
off and repair the fault after
it stops.
3. Construction & Description of the Main Units of the Heater
3.1 The construction, main units
and parts of the pre-heater are
shown in the CPA (catalogue of
parts and assemblies).
3.2 The electric circuit diagram is
shown in the operating manual.
4. Possible Heater Faults, their Root Causes and Trouble-
shooting Methods
A fault may occur during operation of
the pre- heater. A fault may be diag-
nosed by a malfunction code indicated
on the control panel, as described in
Table 2.
There may be faults that are not identi-
able via the control unit, such as loss
of sealing in the heat exchanger (burn-
ing out) or loss of heat capacity due to
fouling of the inner surface of the heat
exchanger. The above faults may be
diagnosed by visual inspection.
Caution: Do not operate the pre-heater
with a poorly sealed heat exchanger.
During pre-heater operation, its sep-
arate units may fail to operate, and
some of them may be replaced without
removing the entire pre-heater from
the vehicle. Such units include, for
example, the fuel pump or the
control panel.
A PC (laptop) with a USB socket may be
used for diagnosing the condition of
the pre-heater units. To do so, connect
the PC to the pre-heater in place of the
control panel using the USB adapter
(supplied separately).