Autoterm Air Heaters PLANAR Technical and Service Manual

1. Technical Specifications

• Models:

  PLANAR 2D, 4DM2, 44D, 8DM

• Rated Voltage:

  12 / 24 V (model dependent)

• Fuel:

  Diesel, varies with ambient temperature

• Heating Output (kW):

  Ranges from 2 / 0.8 (min/max) to 7.5 / 3.2 (min/max) depending on the model

• Hot Air Flow (m³/hr):

  Ranges from 75 / 34 (min/max) to 235 / 70 (min/max) depending on the model

• Fuel Consumption (l/hr):

  Ranges from 0.24 / 0.1 (min/max) to 0.9 / 0.42 (min/max) depending on the model

• Power Consumption (W):

  Ranges from 29 / 10 (min/max) to 90 / 9 (min/max) depending on the model

2. Safety Guidelines

• Follow occupational safety instructions.
• Avoid operating the heater in enclosed or poorly ventilated spaces.
• Ensure the heater is not refueled during operation.
• Do not disconnect the heater before the purge cycle completes.
• In case of flame at the exhaust, turn off the heater and troubleshoot after it stops.

3. Troubleshooting

Refer to the fault codes displayed on the controller panel for specific malfunctions. Common issues include overheating, sensor failures, fuel pump issues, and flame failures. Detailed troubleshooting steps include checking air intake and outlet, sensor integrity, fuel supply, and electrical connections.

4. Heater Dismounting and Disassembly

• General Steps:

  • Remove the heater from the vehicle.
  • Dismantle upper and lower casings by removing clips and grids.
  • Disconnect contacts from the control unit.
  • Remove and inspect components such as the glow plug, air blower, combustion chamber, and heat exchanger.

5. Component Repair and Replacement

• Glow Plug:

  Check for proper heating and replace if faulty. Ensure the correct operating voltage.

• Glow Plug Screen:

  Replace if clogged or damaged. Ensure proper installation for fuel supply uniformity.

• Overheat Sensor:

  Replace if the heater shuts down prematurely or if sensor faults are detected.

• Temperature Sensors (PLANAR-8DM):

  Check output voltage and replace if readings are incorrect.

• Flame Indicator:

  Monitor for flame presence in the combustion chamber and replace if continuity is broken.

• Air Blower:

  Ensure cleanliness of contacts and check for operational faults. Replace if necessary.

• Control Unit (CU):

  Replace if malfunctioning after verifying cables, wires, and connectors.

• Combustion Chamber:

  Replace if damaged or if signs of malfunction such as reduced heat output are observed.

• Heat Exchanger:

  Inspect and clean internally. Replace if damaged.

• Fuel Pump:

  Replace if fuel supply issues are detected. Ensure proper operation during heater startup.

6. Maintenance Tools and Equipment

Ensure the availability of specific tools for maintenance and repairs, including screwdrivers, testers, and mandrels for screen installation.

7. Heater Check after Repair

After any repair or component replacement, perform a comprehensive check to ensure the heater operates correctly under all conditions.

This manual is intended for customer service and technical staff to provide detailed information on troubleshooting, maintenance, and repair of Autoterm PLANAR air heaters. Always refer to specific model guidelines for accurate diagnostics and component handling.