How To Remove Carbon buildup on Airtronic D2 and D4 Burners
To help identify when a burner has excessive carbon build up, Click here and follow the recommendations.
In the event that the burner / flame tube and combustion chamber of the Airtronic D2 or D4 becomes restricted and the heater fails due to carbon/soot build up it may be possible to clean the burner without disassembling the heater by running the heater in high using Kerosene instead of Diesel.
Since the replacement of a burner with carbon build up is not covered by warranty unless the carbon was caused by a defective heater or component this bulletin will assist in reducing the cost and time of cleaning a burner that has caused the heater to fail due to excessive carbon build up.
The excessive build‐up of carbon in the heater is not a result of normal operation of the heater. The build‐up of excessive carbon or soot in the burner / combustion chamber and flame tube as well as the inside of the heat exchanger is in most a symptom of an underlying problem which is the root cause. Therefore, it is very important to identify and correct the root cause so that the burner does not become restricted again. Please refer to the troubleshooting guide and fault code list to identify the problem. Also refer to the installation instructions to make sure the heater and accessories are installed according to the installation guidelines using the correct parts.
In some cases the carbon build up in the burner may be too severe and the burner would need to be replaced. Unless the root cause of the carbon build up is corrected the replacement or cleaning of the burner will not result in a permanent solution but only a temporary fix.
One way to identify if the burner in your Espar Heaters may have excessive carbon build up is to look into the exhaust outlet of the heater with the flexible exhaust pipe removed.
This may be difficult while the heater is installed due to its location but with the assistance of a mirror and a flashlight it can be accomplished.
Another way to find out if the burner has excessive carbon build up, is to inspect the glow pin screen chamber and look into the burner as much as possible.
If the bottom of the glow pin screen chamber is blocked or partially restricted it may be an indication that the burner could have carbon build up.
When Espar heaters have failed to start due to excessive carbon build‐up in the burner, the heater may produce a Fault Code 52 which is Safety Time Exceeded.
This indicates that the heater was not able to start within its allowed start up time. This may also be accompanied by excessive white smoke.
During the cleaning process of the heater it is likely that hot pieces of carbon will come out of the exhaust pipe of the heater. Make sure that there is nothing on or around the exhaust that could be ignited by these particles. For example, oily rags, fuel spills, the kerosene container or any other flammable material or substance.
Do not look into exhaust pipe or expose unprotected part of your body to the exhaust outlet.
It is the responsibility of the technician who is performing this method of carbon removal to ensure all safety regulations for working with fuel, are met during the procedure.
Below is a picture of a burner that was cleaned using Kerosene.
Alternate method of cleaning Espar Heaters
- Remove the glow pin using the glow pin removal tool, Espar part number 25 2069 01 03 03 and replace the glow pin screen, Espar part number 25 2069 01 03 00. Make sure the ventilation hole on the side of glow pin chamber is completely clear and not restricted or plugged. Clean the glow pin screen chamber with a brush before inserting the new glow pin screen.
- Reassemble the heater back to operating condition.
- Make sure all sources of ignition are kept a safe distance away from the fuel lines and the container of kerosene.
- Remove fuel line from inlet side of fuel pump.
- Replace this fuel line with another section of fuel line which is an appropriate length and secure one end to inlet side of fuel pump and other end into a flammable safe container of Kerosene. Espar plastic fuel tank or another approved container may be used.
- Make sure that the fuel lines and fuel container are not near any sources of heat. Make sure the fuel lines do not touch the exhaust systems of the vehicle, or the Heater.
- Ensure end of fuel line is securely fastened to fuel pump as to not allow any air to enter fuel system during operation.
- Ensure Kerosene container is not placed near the air intake or exhaust of heater; this will prevent any fumes to enter combustion chamber and also prevent any sparks or hot particles from igniting the Kerosene.
- Turn on the heater. This may take several attempts to prime fuel lines.
- Adjust Thermostat or Mini Controller to the highest temperature set point. If necessary, open vehicle doors allowing cool air in. This will ensure that the heater runs in boost.
- Some heaters with excessive carbon build up may not start using kerosene and will give a Fault Code 52: Safety Time Exceeded. These heaters may require that they be disassembled and cleaned manually.
- Allow heater to run in boost for approximately 25‐30 minutes.
- Turn heater off
- After the heater has completed its cool down cycle, the fuel line can be removed from fuel pump and container. Container can be removed from the area and safely stored away.
- Reinstall original fuel line back to inlet side of fuel pump.
- The heater can now be operated as usual.
Arctic Traveler Canada is a MSD (Master Distributor) for Eberspaecher products and a technical leader actively involved in projects driving the mobility of tomorrow. Call ATC @ 1-800‐295‐4156 for all your Heater and AC needs
Clogged, dirty filters restrict airflow and reduce a system’s efficiency. When airflow is restricted, the air that bypasses the filter will carry dirt directly into the evaporator coil and reduce the coil’s heat-absorbing abilities. To ensure efficiency, routinely clean or replace filters.
The condenser and evaporator coils collect dirt over time but a clean filter helps to keep the evaporator performing well. Debris reduces air flow, insulates the coil and reduces its ability to absorb heat. Being exposed to the elements, it is easy to see the dirt collecting on the fins. Cleaning the coil fins and removing any debris around the coil will ensure optimal performance.
The aluminum fins on evaporator and condenser coils are easily bent and can block airflow through the coil. Air conditioning wholesalers sell a tool called a “fin comb” that will comb these fins back into their original condition.Remember to always use caution when performing preventative system maintenance, as ambient conditions (heat load) will increase refrigerant hose temperatures and don’t forget, having the right quality parts on hand makes all the difference.
See How To and Which Components to Inspect and watch this video to learn more about Basic A/C Troubleshooting.
Arctic Traveler Canada is a manufacturer and master distributor for a wide range of industry leading mobile heating solutions for every application.
Designed to perform and engineered to improve operator comfort, productivity and reduce maintenance costs, we have a solution to suite your needs.
From 16-65,000 BTU’s, our Cabin, Headliner and Rooftop AC and heaters will supplement your Gas or Diesel needs and provide hours of comfort.
ESPAR Engine, Cabin & Cargo Heaters – Fuel operated air & coolant heaters.
|Airtronic series – From the smallest on the market D2 to the 27,300 BTU’s D8, ESPAR uses innovative heating technology to provide great comfort and warmth for every application, with pleasant temperatures prevailing on cabin entry.
Hydronic series – 7,170-17,755 BTU – Fuel-powered water heater used to heat the cabin and or the engine and to de-ice the windows (defrost). The heater’s compact design, with its integrated water pump and fuel metering pump (in the diesel version), saves time when installing the heater.
RedDOT Heaters. The most Versatile and maintenance free
|R250 series 16-30 BTU’s – Round tube and fin design allows heater mounting in any position, using multi-position leg brackets or flush mount frame. The compact size, simple plumbing and high output are ideal in any application.
R290 & R295- Single or Double Blower – 20-35,000 BTU’s – The big brother of the pair with two high performance three-speed motor blower assemblies, delivers where it’s needed most.
R3500– 49,000 BTU’s – This crew cab heater was designed to be able to heat larger cabs in extreme conditions. Its low profile and heavy duty construction allows for use in various applications.
ATC Heaters – Versatile and maintenance free
|892059 – 27,000 BTU’s , 892041 – 40,000 BTU’s, 892002 – 65,000 BTU’s|
Available in 12V & 24V, these auxiliary heaters are designed to heat larger cabs in extreme conditions. With a high performance 3 speed blower assembly, compact size, simple plumbing, heavy duty construction and high output, these heaters deliver where it counts and are ideal in any application.
Arctic Traveler Canada (ATC) is dedicated to heating, cooling or refrigerating mobile equipment. We’re specialists in mobile climate control and distribute industry leading products as well as design and manufacture custom products for unique applications. Call us today at 1-800-295-4156 to discuss your mobile HVAC needs.
IMPORTANT – CLOSED FOR INVENTORY
Our annual Inventory starts this Thursday Dec. 8th at 3pm to Friday Dec. 9th.
This is an “All Hands On Deck” effort, as such our phones lines will be closed and we’ll be unable to receive or process any orders.
Parts Orders can be emailed to firstname.lastname@example.org and will be processed as soon as we’re able to. We apologize for any inconvenience caused.
Stocking stuffer – Condenser Clearance – We’re overstocked on a select few and have reduced prices to $99-125 on 8 models. Limited Stock. No Reservations, All Sales Final and available as first come, first serve basis and ONLY while quantities last.
Just in time for the heating season. As an authorized master distributor, ATC recently hosted a Certified Technician Training course with Eberspacher’s Training Manager on the newly released Hydronic S3. Attended by our Ontario dealers, It was an informative day for all and we had the chance to put faces to names and share stories. To see more click here
Preventative Maintenance tips for Airtronic or Hydronic heaters?
Visit the Espar category at ATCNEWS for these and other heating tips.
Need a fluid warming solution?
Arctic Fox and Thermex Fluid Warming Systems provide protection against cold weather fluid clouding and gelling with In-Tank or In-Line Heat Exchangers. These proven and cost effective products warm contents so they can properly flow or be easily pumped, eliminating costly and time consuming downtime as well as expensive component damage that frequently occur from cold-thickened fluids.
• Single probe heats up reservoirs from 1 to 80 gals (300 liters) capacity
• Multiple probes can be installed on large bulk tanks
• Eliminate idle equipment and wasted man-hours waiting for products to warm up
• Protect against hydraulic pump cavitation and burst hose lines
For more information, call us today at 1-800-295-4156
Need more heat and comfort? To view some of our Air, Coolant & Auxiliary heating solutions, click here. From 7- 65,000 BTU’s, we carry a variety of mobile heating solutions to supplement your Gas or Diesel needs.
Advanced Temperature Control a division of Arctic Traveler Canada, has specialized in the engineering and manufacture of durable, vehicle engine powered mobile refrigeration and heating systems for safe delivery of your fresh and frozen products. Our line of Truck Refrigeration products has been continuously updated and improved to meet the requirements of today’s competitive markets. Watch video here.
ATC Connect – Parts Lookup and Cross Reference made easy
We know having the right part is paramount to getting the job done right and to help you through this process we present ATC CONNECT. Click here to get access or speak with our Customer Service Reps to start utilizing this exciting and very useful tool.
ATC.CA is your gateway to so much. The Product Line page provides catalog downloads for the industry leading products we carry. Our blog ATCNEWS is where you’ll find best practices, technical tips and product knowledge. Missed a previous Newsletter? Not to worry, there’s a category for newsletters and ATCNEWS is searchable.
Ordering Parts? Use email@example.com or call us toll free at 1-800-295-4156.
Our Customer Service Representatives will be happy to assist you.
If you haven’t already read it, MACS (Mobile Air Conditioning Society) member profile for September/October is ATC. This worldwide blog has been consistently honoured as one the best B2B automotive aftermarket blogs. Read the full interview with our company president for further insights into our world.
As the heating season approaches, the big news is the launch of the Eberspaecher Hydronic S3 heater. Thanks to its compact dimensions and flexible installation options, this state of the art heater impresses! Read the full details here to see how this little wonder works and watch the video on our youtube channel ATCTV While there check out the Airtronic Intro & Basics and the Hydronic Purpose and Function videos.
ATC.ca is your gateway to so much. The Product Line page provides catalog downloads with pictures, overviews and specs. Our blog ATCNEWS is where you’ll find best practices, technical tips and product knowledge. This months feature is ESPAR Pre-season Maintenance tips for Airtronic & Hydronic Heaters and a Red Dot tech tip on Why you should do wintertime Preventative Maintenance on your A/C system? Find out more here.
ATCNEWS has categories like A/C 101, Did you know, Heating, Tech Tips or vendor specific like Espar & RedDot. Missed something from a previous Newsletter? Not to worry, ATCNEWS is searchable.
From 16-65,000 BTU’s, we carry a variety of mobile heating solutions to supplement your Gas or Diesel needs and provide you hours of comfort. To view some of our heating solutions, click here.
We want to take this opportunity to remind you of our Parts ordering email firstname.lastname@example.org or call us toll free at 1-800-295-4156, our Customer Service Representatives will be happy to assist you.
The opinions expressed in this newsletter, do not necessarily reflect those of Arctic Traveler Canada.
Take these steps to inspect an A/C compressor to ensure it really needs replacing before you pull it from a heavy-duty vehicle:
1. Is The Compressor Rotation Smooth?
With the vehicle off, turn the compressor shaft with a 14-mm socket. If you feel grinding or hanging as you rotate the shaft, it’s probably due to broken components within the compressor. If the rotation is smooth, move on to Step 2.
2. Is The Coil Getting More Than 11.5 Volts?
Take a reading with the engine running and the clutch engaged. If there’s insufficient voltage, get to work on that. Otherwise, move on to Step 3.
3. Is The Coil Resistance Between 2.8 And 4.4 Ohms?
Any resistance outside this range will prevent the clutch from engaging or will cause used circuits to open. If the answer is yes, continue to Step 4.
4. Is The Compressor Able To Produce 350 Psig Or More?
If not, leave the compressor where it is. The system may have a low refrigerant charge because of a leak that needs repair, or a high-side blockage that limits refrigerant flow to the compressor.
Tech Tips from Red Dot
” We see lots of compressors that are returned fully functional and therefore not warrantable.
Get the diagnosis right. Inspect an A/C compressor before you pull the component from the vehicle.”
For expert insight into common failures and causes, watch Examining Compressor Failures on ATCTV
While there, check out How To and Which Components to Inspect and Basic A/C Troubleshooting to further your understanding of A/C Systems.
For more information about AC Compressors or any HVAC component, call the mobile HVAC specialist Arctic Traveler Canada at 800-295-4156.
Tech Tips from Red Dot
1. Inspect Electrical Connections
As you perform a visual inspection under the hood (cab) and/or at the rooftop condenser, take a moment to check all electrical connections both visually and by feel. Make sure all leads and wires are properly supported and securely connected, and that there’s no corrosion or grime on the leads or connectors.
2. Check Electrical Current Flow and Device Functions
Perform the following steps to check the current flow and electrical device functions:
- Turn on the ignition.
- Turn on the A/C system. This will power the thermostat and clutch. If it does not come on, use the A/C mode switch to check the leads to the switch. You should hear a “click” from the thermostat and hear the clutch drive plate “snap” against the clutch pulley.
- Check fuses. If all the connections are clean and tight and there’s still a failure, check the fuses in-cab as well as in-line.
- Check A/C clutch engagement. Since you can’t see and may not hear the clutch engage, get out and look at the clutch. If it’s engaged, you will see that the drive plate is against the pulley and not slightly spaced from it. If you aren’t sure the clutch is engaged, look for the lead wire connector near the clutch. Break and close that connection. The clutch will disengage and engage again.
- Test blower speed operation. Some systems have a common switch that turns on the air conditioner and powers the blower motor. Test blower speed operation by adjusting this or the separate blower control switch. Feeling the air flow from the ducts or note blower sound (speed) changes.
- Inspect roof-mounted condensers. Don’t forget to inspect roof-mounted condensers and A/C units for dirt and debris. Be sure the condenser fan(s) are working properly and all parts and electrical connections are securely fastened. The roof-mounted condenser fans may come on when the system is turned on. Like the thermostat and most clutches, the normal on-off cycling action cannot be observed until the engine is running with the A/C system on.
Quick Heater Service Tip from Reddot
- When the status is “heater fan doesn’t work,” check the ground connection for rust, paint, grime, or some other obstruction at the terminus.
- If the motor doesn’t have a ground wire, its mount serves as a ground connection. Make sure nothing impedes the mount’s ground path.
- Use a multimeter to make sure you’re getting full voltage to the motor. Once you know the voltage is adequate, you can then look for worn brushes, dirty squirrel-cage fans, damaged fan blades, and other more typical motor problems.
Arctic Traveler Canada is an MSD/Master Stocking Distributor and Authorized Technical representative for many industry-leading products. Call us today at 1-800-295-4156 to see what 55 years of excellence can do to achieve your business objectives.
What is a Thermistor?An electrical resistor whose resistance is greatly reduced by heating, used for measurement and control. Thermistors, derived from the term thermally sensitive resistors, are a very accurate and cost-effective sensor for measuring temperature.
Your HVAC Thermistor #2606229-C92 for 2001 International 4000, 7000, 8000 & Prostar series, can be replaced with #1400K for Quicker Installation and Less Hassle!
Our Kit contains “First Fit OE Products” for longer life solutions to today’s A/C problems.
Check out the video courtesy of MEI here.
Arctic Traveler Canada is an authorized distributor of replacement original equipment and aftermarket HVAC Parts & Supplies from industry leading Brands. Call us today at 1-800-295-4156 to hear more information on this replacement Thermistor Kit and other HVAC solutions.