SERVICE MANUAL FOR ALDE ELECTRICAL HEATER
Contents
1. SERVICE 2737 MANUAL FORALDE 2 02 ELECTRICAL HEATER 2 63 MAKE MAKE Contents Page Chap Title 1 0 Flowchart 2 0 About the electrical heater 2 1 Technical data 3 0 General faultfinding 4 0 Faultfinding 4 1 The electrical heater does not function 4 2 The electrical heater does not heat up 4 3 The electrical heater boils Overheating protection trips AA Fuse earth fault circuit breaker trips 4 5 The circulation pump does not start No circulation of glycol mixture Noise in the circulation pump 5 0 Replacing components 5 1 Replacing the circuit board 5 2 Replacing the operating thermostat 5 3 Replacing the overheating protection 5 4 Replacing the circulation pump 5 5 Replacing the impeller 5 6 Fitting the pump ring 5 7 Replacing the electrical heater tube 10 6 0 Spare parts for electrical heaters type 2737 2762 and 2763 11 7 0 Circuit diagram 230 V for electrical heater type 2737 11 7 1 Circuit diagram 230 V for electrical heater type 2762 11 7 2 Circuit diagram 230 V for electrical heater type 2763 11 8 0 Terminal block cables 11 9 0 Output diagram Rw oO oO AJ zd OO OO oo bb P A Foreword This service manual is intended to assist with servicing and fault finding in caravans motor caravans and sheds equipped with Alde s Electrical Heaters types 2737 2762 and 2763 The manual may also be of assistance in ordering spare parts in understanding how the heaters operate and how they are ins2. If the electrical heater is fitted to the rear on an Alde Comfort Boiler the pump motor must not be started until all the air has been bled Run using the 12 volt pump until the air is gone Fig 15 19mm Fig 16 5 7 Replacing the electrical heater tube 1 Pull the pin plug for the electrical heater out of the wall socketor ifthe electrical heater is permanently connected cut off the electrical supply and unscrew the cables 2 Drain the liquid from the heating system see the caravan or boiler instruction book for the location of the drain cock 3 Detach the electrical heater and remove all compo nents as shown in sections 5 1 5 4 With the type 2763 electrical heater remove the circuit breaker with its holder fig 17 A and the connection block instead of the circuit board 4 Detach the cable de tensioner in the connection box to the pump motor by compressing it using multi purpose pliers and then pull it straight out see fig 18 5 Then remove the cable de tensioner on the connection cable by inserting a screwdriver between the de tensioner and the connection box and levering outwards until the cable de tensioner comes free see fig 19 A 6 Remove the earth plate and the cables fig 19 B On older models the earth connections are attached to the electrical heater tube with screws and washers 7 Lift the pump ring out of the pump housing and move it over to the new electrical heater tub
3. for the location of the drain cock Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket 2 Unscrew the four screws fig 12 A in the retaining plate Lift off the pump motor fig 12 B from the electrical heater and remove the impeller and the o ring fig 14 B 3 Remove the casing from the pump motor by unscrewing the screws fig 13 A on both sides 4 Release the cables from the connection block on the pump motor fig 13 B as well as the earth cable fig 13 C Remove the cable de tensioner fig 13 D on the motor and pull out the cable 5 Remove the retaining plate fig 12 C and move it over to the new pump motor 6 Then connect the cables phase and zero as shown in fig 13 B and earth yellow green as shown in 13 C to the new pump motor and then replace the cable de tensioner Fit the casing on the motor 7 Fit a new o ring in the groove and insert the impeller in the centre of the pump housing 8 Fit the pump motor and fasten it through the retaining plate Tighten the screws alternately 9 Refill the heating system with liquid see the caravan or boiler instruction book for the location of the filling point Close the main circuit breaker or insert the pin plug and test run Bleed the heating system before operation NOTE Neverrun the pump motor without liquid If the electrical heater is fitted to the rear on an Alde Comfort Boiler the pump motor
4. B and then push the casing down and tighten the screw fig 3 B Check that the plastic bush for the overheating protection fig 4 C is not jammed is loosely fitted in the casing 8 Close the main circuit breaker or push in the pin plug and test run the electrical heater Fig 5 MAKE 5 2 Replacing the operating thermostat 5 3 Replacing the overheating protection 1 Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket 2 Pull out the connection block fig 3 A and remove the screw fig 3 B 3 Remove the casing fig 4 A by lifting up the rear edge and then pulling it backwards and upwards at an angle 4 Pull out the cables fig 8 A from the flat pin terminals 5 Unscrew the screws fig 8 B and remove the operating thermostat fig 8 C Angle it slightly during removal to prevent the mounting flange catching the overheating protection 6 Check that there is thermal conduction paste left on the contact surface with the electrical heater fig 9 A If there is not it can be ordered from Alde s Service Department Fit the new operating thermostat and replace the screws 7 Fit the cables in the flat pin terminals 8 Replace the casing first placing the tab in the hole fig 4B and then push the casing down and tighten the screw fig 3 B Check that the plastic bush for the overheating protection fig 4 C is not jammed is loosely
5. ate 2 2761 212 O ring 5 2761 212 O ring 3 2762 258 Impeller 6 5810 046 Screw 4 2762 221 Pump ring 9 mm 5 2762 222 Pump ring 19 mm 10 MAKE 7 0 Circuit diagram 230 V 9 0 Output diagram mod 2737 Operating relay 12V DC la Temperature 1050 W El water thermostat limiter _ 1050 W 230 V LI t 7 1 Circuit diagram 230 V mod 2762 Operating relay 12 V DC Water thermostat 7 2 Circuit diagram 230 V mod 2763 Temperature f limiter 8 0 Terminal block cables Not on type 2763 electrical heater 4 Grey 1000W 2 Black Minus ny 1 Blue Circ pump Nominal output W 2000 1500 205 210 215 220 225 230 235 V Voltage 25 W for electrical heaters 2762 and 2763 Nominal amperage Amp 10 i 205 210 215 220 225 230 235 V Voltage 0 1 amp for electrical heaters 2762 and 2763 11 MAKE Alde International Systems AB Wrangels all 90 Box 11066 291 11 F rl v Kristianstad e Sweden Tel 46 0 44 712 70 Fax 46 0 44 718 48 98 05 26 GB
6. d the remedial action which should be carried out are identified The procedure for replacing the parts is given in Chapter 5 1 The electrical heater does no function Cause No electrical supply to the electrical heater Overheating protection tripped faulty Output selection switch not in ONT position Fuse on boiler control panel blown not 2763 Circuit breaker onthe room thermostat in OFF position not 2763 Temperature setting too low the room thermostat has tripped also applies to 2763 if 230 volt room thermostat fitted The relays on the circuit board do not pull not 2763 Remedial action Check that there is electrical power 230 V at the wall socket where the electrical heater is connected Check that the switch for output selection on the control panel or directly on the electrical heater 2763 is set at 1000 or 2000 W Check whether the electrical heater functions when the switch on the boiler control panel is set in the position for warm water When this is done the heater should run continuously as the room thermostat is discon nected not 2763 Check that the circuit breaker on the room thermostat is in the ONT position not 2763 Check that the temperature setting on the room thermo stat is higher than the temperature in the caravan also applies to 2763 if 230 volt room thermostat fitted Check that the fuse in the boiler control panel is intact not 2763 Ch
7. e see section 5 6 8 Then install all components in the new electrical heater tube in accordance with sections 5 1 5 4 NOTE Remove any residual paint on the earth connections and from the holes for the screws which attach the cap fig 19 C 9 Fit the cable de tensioners on each side by pressing them into the holes with multi purpose pliers 10 Attach the contact plate to the electrical heater tube and fit the earth cables 11 Re attach the electrical heater and refill the heating system with liquid Insert the pin plug in the socket or fasten the cables in the junction box and test run the electrical heater Bleed the heating system before opera tion NOTE Neverrun the pump motor without liquid Ifthe electrical heater is fitted to the rear on an Alde Com fort Boiler the pump motor must not be started until all the air has been bled Run using the 12 volt pump until the air is gone Fig 19 iiiz 1 2737 140 Circuit board 2 relay for 2737 1 2737 176 Operating thermostat 2 2762 160 Circuit board 3 relay for 2762 2 2737 185 Overheating protection resetting button on side 3 2737 186 Overheating protection resetting button on top 1 2762 236 Electrical heater tube 2737 921 2762 921 2 2762 276 Electrical heater tube 2762 923 2763 901 1 2762 260 Circulation pump including o ring impel 3 2762 158 Cap ler 4 2762 122 Retaining pl
8. eck whether the overheating protection has been tripped by pushing in the reset button see figure 1 Check that there is electrical current through the overheating protection If not replace the overheating protection Check that the relays on the circuit boards are not burnt If they are replace the circuit board not 2763 Fig 1 Reset button From and including prod no 97895 1997 gt Reset button To and including prod no 97894 lt 1997 4 2 The electrical heater does not heat up Cause Output selection too low Voltage to electrical heater too low Only one element functioning Operating thermostat triggering too early Remedial action Increase the output to max 2000 watt Check that the voltage to the electrical heater is 230 V If the voltage at the electrical heater is low measure it in the electrical supply pillar or the socket from which the current is taken Check that any extension cables are not too long and are of adequate cross sectional area Use a clip on ammeter to check the resistance 50 ohm to check that the elements are undamaged Check that the relays on the circuit board function and the contact surfaces are not burnt not 2763 Ifthey are replace them Replace the operating thermostat 4 3 The electrical heater boils Overheating protection trips Cause Air pocket in the electrical heater The operating thermostattrips too late or is
9. fitted in the casing 9 Close the main circuit breaker or push in the pin plug and test run the electrical heater 1 Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket 2 Pull out the connection block fig 3 A and remove the screw fig 3 B 3 Remove the casing fig 4 A by lifting up the rear edge and then pulling it backwards and upwards at an angle 4 Pull out the cables fig 10 A from the flat pin terminals 5 Slacken the screws fig 10 B and remove the over heating protection fig 10 C 6 Check that there is thermal conduction paste left on the contact surface with the electrical heater fig 11 A Ifthere is not it can be ordered from Alde s Service Department Fit the new overheating protection and replace the screws 7 Fit the cables in the flat pin terminals 8 Replace the casing first placing the tab in the hole fig 4B and then push the casing down and tighten the screw fig 3 B Check that the plastic bush for the overheating protection fig 4 C is not jammed is loosely fitted in the casing 9 Close the main circuit breaker or push in the pin plug and test run the electrical heater MAKE 5 4 Replacing the circulation pump NOTE When replacing the pump motor on older models which do not have a pump ring one must be fitted See section 5 6 1 Drain the liquid from the heating system see the caravan or boiler instruction book
10. he impeller 1 Drain the liquid from the heating system see the caravan or boiler instruction book for the location of the drain cock Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket 2 Unscrew the four screws fig 12 A in the retaining plate Pull out the pump motor fig 12 B from the electrical heater and take out the impeller fig 14 A and the o ring fig 14 B 3 There are two types of pump housing in the electrical heater depending on the year of manufacture On older models pre 1989 the washer in the pump housing is bent to 45 see fig 15 while on later models itis bent at 90 see fig 16 On older models a pump ring with a height of 19 mm must be used while the later models take a 9 mm high pump ring Place the pump ring with the openings up towards the pump motor and at an angle of 90 to the outlet pipe To prevent the ring turning or rattling it should be squeezed until it is slightly oval 4 Fit a new o ring in the groove and insert the impeller in the centre of the pump housing 5 Fit the pump motor and fasten it through the retaining plate Tighten the screws alternately 6 Refill the heating system with liquid see the caravan or boiler instruction book for the location of the filling point Close the main circuit breaker or insert the pin plug and test run Bleed the heating system before operation NOTE Never run the pump motor without liquid
11. must not be started until all the air has been bled Run using the 12 volt pump until the air is gone Fig 12 5 5 Replacing the impeller 1 Drain the liquid from the heating system see the caravan or boiler instruction book for the location of the drain cock Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket ensuring the power is disconnected 2 Unscrew the four screws fig 12 A in the retaining plate Pull outthe pump motor fig 12 B from the electrical heater and take out the impeller fig 14 A and the o ring fig 14 B 3 Fit a new o ring in the groove and insert the new impeller in the centre of the pump housing 4 Fit the pump motor and fasten it through the retaining plate Tighten the screws alternately 5 Refill the heating system with liquid see the caravan or boiler instruction book for the location of the filling point Close the main circuit breaker or insert the pin plug and test run Bleed the heating system before operation NOTE Neverrun the pump motor without liquid If the electrical heater is fitted to the rear on an Alde Comfort Boiler the pump motor must not be started until all the air has been bled Run using the 12 volt pump until the air is gone Fig 13 MAKE 5 6 Fitting the pump ring NOTE Is fitted as standard on all models since production year 91 92 The pump ring is fitted to stabilise t
12. not working If the switch on the control panel is in the warm water position i e the electrical heater is switched off by the internal operating thermostat it is possible for some boiling noises to be heard just before it trips Check whether moving the switch to the neutral position causes the boiling noise to disappear not 2763 Overheating protection defective Remedial action Bleed the heating system see the caravan instruction book Where the electrical heater has been installed horizontally it may help to raise the electrical heater a few centimetres at the pump motor so that the air automatically escapes through the outlet pipe Replace the operating thermostat If the overheating protection trips without the electrical heater boiling the overheating protection must be replaced 4 4 Fuse earth fault circuit breaker trips Cause Short circuit Poor insulation in the electrical heater Poor insulation in the elements Remedial action Check thatthe cables have not been damaged and that the cable lugs are not in contact with each other MAKE Check the insulation in the electrical heater with a multi meter megger by measuring the resistance between earth and the phase zero in the pin plug It should be gt 2 Mohm If the insulation in the electrical heater was poor check whether the fault is in the elements Remove the casing see fig 4 as well as all the cables on the flat pin te
13. ot rotate freely Wear in bearing on impeller Wear in shaft on pump motor Remedial action Remove the pump motor and impeller and check that the pump housing is free from foreign objects Remove the pump motor and replace the impeller Replace the complete pump motor 5 0 Replacing components This Chapter shows the easiest way of replacing components in an electrical heater NOTE All work on the electrical heater may only be carried out by authorised electrical installation per sonnel in accordance with the relevant regulations Always switch 12 VDC and 240 V off before servicing 5 1 Replacing the circuit board 1 Open the main circuit breaker or remove the pin plug for the electrical heater from its wall socket 2 Pull out the connection block fig 3 A and remove the screw fig 3 B 3 Remove the casing fig 4 A by lifting up the rear edge and then pulling it backwards and upwards at an angle 4 Cut off the cable tiers fig 5 A and pull out the cables fig 5 B and 6 B from the flat pin terminals 5 Push in the gills one after the other on the four plastic spacers fig 7 A with pliers or similar to release the circuit board and then pull it straight upwards 6 Push the new circuit board firmly into the plastic spacers and connect the lugs in the flat pin terminals Fit new cable tiers around the cables 7 Replace the casing first placing the tab in the hole fig 4
14. rminals see fig 2 on the elements Then using a multi meter megger check the insulation between the flat pin contacts and earth If the insulation is less than 2 Mohm the electrical heater tube must be replaced If the insulation was satisfactory the fault will be in one of the components in the electrical heater 4 5 The circulation pump does not start No circulation of liquid Cause Switch for circulation pump not switched on Switch on room thermostat not in the ONT position not 2763 Temperature too high the room thermostat has triggered also applies to 2763 if a 230 volt room thermostat has been fitted The relay for the circulation pump on the circuit board is faulty not 2763 Cable not connected to in pump motor Pump motor faulty Remedial action Check that the selection switch for the circulation pump is in the 230 V position not 2763 Check that the switch on the room thermostat is in the ONT position not 2763 Check that the temperature setting on the room thermo stat is higher than the temperature in the caravan also applies to 2763 if a 230 volt room thermostat has been fitted Check that the relay is not burnt If it is replace the circuit board not 2763 Remove the cap on the pump motor and check that the cables are properly attached at the connection block Replace pump motor MAKE 4 6 Noise in circulation pump Cause Impeller in pump housing does n
15. talled We hope that you will find this manual very useful and that it will save you time during service and faultfinding on our electrical heaters Alde International Systems AB Service Department NOTE We reserve the right to make changes after this manual has been printed MAKE 1 0 Flow chart Heat on electrical heaters 2737 and 2762 LPG boiler types 2921 2923 2928 SET board 12V 230 V Over heating protection ON OFF Room thermostat Operating thermostat Element LPG boiler types 2921 2923 2928 SECH board 12V 230 V ON OFF Over Room heating thermostat protection Switch Circulation 12 230 V pump Heat on electrical heater 2763 Over heating protection Operating thermostat Circulation pump on electrical heater 2763 Over heating protection Circulation pump MAKE 2 0 About the electrical heater The construction of the electrical heater The electrical heater is intended for fitting inside a caravan motor caravan or similar It is made from a steel tube with 2 1050 watt stainless elements inside At one end of the tube a 230 V circulation pump is fitted not 2737 A bipolar overheating protection 110 C and an operating thermostat 80 C which regulate the liquid temperature in the electrical heater are fixed to the connection box on
16. the long side of the tube 2 1 Technical data Length 380 mm 315 without motor Height AA d se ties 150 mm Width 85 mm Weight oo eee 3 0 kg 2 2 kg without motor Rated voltage 230 V Element output 2100 W 1050 1050 Motor power 05 25 W Connection pipe 22 mm Liquid volume 1 litre 3 0 General faultfinding This guide to general faultfinding should be useful in rapidly establishing where in the electrical heater the fault may lie This saves time in faultfinding For more detailed faultfinding see sections 4 1 4 6 Fault Possible fault in Electrical heater Electrical supply fuse does not heat up over heating protection temperature settings Electrical heater not warm Output selection operating thermostat Electrical heater warm Circulation pump but no heat in the caravan air inheating system warm water heater Electrical heater boiling Operating thermostat air in the electrical heater Noise in circulation Air in the system pump 230 V foreign object in pump housing pump motor impeller Room thermostat connections Uneven temperature in the caravan Too little warm water System temperatures circulation pump water flow 4 0 Faultfinding on electrical heater This Chapter contains a more detailed faultfinding chart where both the cause of the fault an
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