Truma 4 E Caravan Motorhome Water Boiler Space Heater Instruction Manual

Truma 4 E Caravan Motorhome Water Boiler Space Heater

Installation example

1. Control panel
2. Room temperature sensor
3. Circulated air intake (min. 150 cm²)
4. Warm air ducts
5. Warm air outlets
6. Wall cowl

Symbols used

The unit must only be installed and repaired by an expert.

**** Symbol indicates possible hazards.

Note containing information and tips.

Observe the ESD regulations! Electrostatic charging can cause destruction of the electronics. Ensure that potential compensation is present before touching the electronics.

Read the installation instructions carefully before commencing the work, and then comply with them.

Disregarding installation instructions or erroneous installation can put people in danger and cause damage to property.

Observe the ESD regulations.

Intended use

The liquid gas heater Combi is a warm-air heater with integrated hot water boiler (10 litre volume). This unit was designed for installation in motor homes and caravans. The equipment must not be installed in buses or in vehicles for transporting hazardous goods (vehicle classes M2 and M3).

If the equipment is installed in special vehicles, the applicable regulations must be followed.

The Combi E has additional electric heating elements for operation with a mains voltage of 230 V ~.

Approval

Directive UN ECE R 122 stipulates that a safety shut-off device is required if motor homes and caravans are heated while driving. The Truma MonoControl CS gas pressure regulation system satisfies this requirement. Throughout Europe, a type tested liquefied gas heating system may be used while driving (according to the directive UN ECE R 122) if the system includes a gas pressure regulator with an appropriately configured gas installation. National regulations and rules must be followed.

The heater is approved for installation in passenger vehicles (class M1 motor homes) with a maximum of 8 seats excluding the driver’s seat, and for trailers (class O caravans).

The year when the equipment was first put into operation must be indicated with a cross on the type plate.

Regulations

Guarantee claims, warranty claims and acceptance of liability

will be ruled out in the event of the following:

• Modifications to the appliance (including accessories),
• Modifications to the exhaust duct and the cowl,
• Use of replacement and accessory parts other than original Truma parts,
• Failure to follow the installation and operating instructions.

The appliances’ operating permit, and consequently also the vehicle’s operating permit in some countries, are also rendered void.

Installation instructions for vehicles

The installation of the device in vehicles must comply with the technical and administrative regulations of the respective country of use (e.g. EN 1949). The national legislation and regulations (e.g. DVGW Work Sheet G 607 for vehicles in Germany) must be observed.

The relevant employer’s liability insurance association accident prevention regulations must be observed in Germany for vehicles used for commercial purposes (DGUV regulation 79 – formerly BGV D 34).

In other countries, the relevant regulations must be observed.
More information about the regulations in the relevant destination countries can be requested from our foreign representatives (see www.truma.com).

Selecting a location

The unit and its exhaust duct must always be installed so that they are easy to access at all times for service work (e.g. gas and water connection via a service flap, furniture doors etc.) and are easy to remove and install.

The distance between the unit and surrounding furniture items or vehicle components must be at least 10 mm at all sides.

The scope of delivery includes a second type plate (duplicate) with removable bar code.

If the type plate on the heater is not visible after the heater has been installed, the second type plate (duplicate) must be affixed to the unit in a clearly visible location.

The duplicate must only be used in conjunction with the original.

In order to heat the vehicle evenly throughout, the heater must be installed in a location in the vehicle that is as central as possible in a wardrobe, stowage compartment or the like with an adequate height, so that the air distribution ducts can be routed with equal lengths. Appropriate openings must be present in the installation compartment so that air can be drawn in – see relevant sections concerning circulated air intake and warm air distribution.

In order to reduce the potential danger caused by a heater becoming loose in the event of an accident, the upper covering plate (17) of the installation cabinet can be screwed to other pieces of furniture in a position that makes it flush with the heater. Depending on the installation situation, it may be necessary (especially with rear-mounted fixtures) to install a stable furniture console (18) in front of (next to) the heater, perpendicular to the direction of travel. For this purpose, a solid spacer (minimum cross section 30 x 50 mm) can be attached at a height of approx. 180 mm above the floor, or a board (18a) for sliding in on a stable furniture console.

There must not be any heat-sensitive materials beneath the unit (e.g. floor coverings such as PVC, cables etc.), since high temperatures can occur at the base of the unit.

In order to prevent damage to components inside the equipment, no cables or water lines of any kind may be attached to the equipment’s insulation.

The operation of important vehicle components must not be adversely affected.

• Minimum dimensions – additional space must be provided for the gas connection, water connections and the safety/ drain valve depending on the installation situation. All dimensions in mm.

Cowls must be positioned such that exhaust cannot be drawn into the interior.

The cowl must be in the form of a wall or roof cowl.

The wall or roof cowl must be attached such that there is no fuel tank filler neck or fuel tank breather opening within 500 mm (R). There must also be no living area ventilation openings or window openings within 300 mm.

If the cowl is being installed directly underneath a window that will be opened, an electric window switch (part no. 34000-85800) must be installed.

Securing the appliance

Check whether the vehicle has a load-bearing floor, double floor or false floor for securing the heater. If the floor is unsuitable, create a load- bearing surface beforehand by gluing a plywood board to the floor, for example.

Screw heater to vehicle floor, double floor or false floor using four B 5.5 x 25 screws (included in scope of delivery). Depending on the installation situation, it may also be possible to secure the heater with three screws. In this case, always screw the aluminium feet (a) and optionally one of the plastic feet (b) to the vehicle floor.

The heater must be screwed to the floor, double floor or false floor of the vehicle in order to prevent the gas system from becoming damaged because of movement while driving!

Exhaust duct

Only the Truma exhaust duct AA 3 (part no. 39320-00), combustion air intake duct ZR 80 (part no. 39580-00) and the supplied clamps (part no. 34020-14200) may be used. The appliance is only tested and approved with these components.

Do not crush or kink ducts during installation.

The roof cowl is available as an accessory to the heater the roof cowl comes with installation instructions.

The roof cowl is available as an accessory to the heater the roof cowl comes with installation instructions.

Installing the wall cowl

Permissible duct lengths

The length information relates to the combustion air intake duct.

Ducts with a length of at least 60 cm to a maximum of 100 cm can be routed with any amount of rising for the wall cowl, or with a maximum fall of 20 cm.

Duct lengths from 100 cm to max. 200 cm may only be installed rising.

The ducts must be cut to length so that they protrude from the hole for the cowl after installation. The exhaust duct (1) must be 10 % longer than the combustion air intake duct (5). This avoids exhaust duct expansion and tensile load.

Installing the wall cowl

Install wall cowl (arrow pointing up) on an even surface around which wind can flow from all sides. Drill opening with a diameter of 83 mm (duct hole must be lined with wood in cavities). Seal with provided rubber seal (8). Use flexible body sealant on textured surfaces – do not use silicone!

Before pushing the exhaust double duct through the hole, slide clamp (7) over duct.

Slide rubber seal (8 – smooth side towards cowl, sealing lips towards wall) onto inner part of cowl (9).

Compress the beginning of the exhaust duct (1) (approx. 2 cm) so that the coils are lying against each other.

Slide clamp (2 – claws facing cowl) over exhaust duct (1).

Slide exhaust duct (1) onto connection as far as it will go (11 – bend facing upwards).

Slide clamp (2) as far as it will go (end position must be between claws of clamp) and screw in place.

Slide combustion air intake duct (5) onto toothed connecting piece (12).

Attach cowl inner part (9) with six screws (13), fit outer part of cowl (14) and screw on with two screws (15) (screws B 3.5 x 25, included with delivery).

Use clamp (7) to attach combustion air intake duct to connection (12) from inside and (if length greater than 60 cm) attach to wall with at least one clamp ZRS (16 – part no. 39590-00).

Connecting the exhaust double duct to the device

Compress exhaust duct (1) at its beginning so that the coils lie next to each other. Slide clamp (4 – claws toward unit) over exhaust duct (1). Slide clamp (7) onto combustion air intake duct (5). Slide exhaust duct (1) all the way onto connection (3). Slide clamp (4) as far as it will go (end position must be between claws of clamp) and screw in place. Slide combustion air intake duct (5) onto connection (6) and secure with clamp (7).

Circulated air intake

The circulated air is drawn in by the unit. This must have one large or several small openings with a total area of at least 150 cm² between the living compartment (not the rear storage space) and the installation compartment.

If a grid (not included) is installed (figure 10), the same requirements must be complied with for drawing in air in terms of the cross sectional area through which flow occurs (150 cm²).

The circulated air inlets must be arranged such that exhaust from the vehicle engine or the heater cannot be drawn in under normal operating conditions. Structural measures must be taken in order to ensure that the heating air that is led into the interior of the vehicle cannot be contaminated.

Warm air distribution

Most of the warm air is led into the floor area of the living compartment via flexible ducts.

The 4 connections on the unit are designed for the 65 mm diameter ÜR duct (part no. 40230-00). Use only pressuresafe ducts in compliance with Truma quality requirements. Other ducts that do not meet our quality standard (particularly crown pressure resistance, duct diameter and number of grooves) must not be used.

If the warm air duct has to be subjected to a considerable amount of bending immediately behind the warm air outlet of the unit in confined spaces, we recommend the use of the BGC 90° elbow (part no. 34091-01). This elbow makes it possible to connect a ÜR warm air duct with a diameter of 65 mm or a VR warm air duct with a diameter of 72 mm.

With a duct length of less than 2 m the air outlet must not be installed higher than the warm air duct connection. With a duct length of less than 50 cm, the duct must create a siphon between the connection and the outlet.

These measures prevent undesirable heating of the vehicle due to convection (cowl effect) during operation in summer.

The ducts for warm air distribution must be firmly inserted into the connections. A clip is attached to each connection to provide a more secure grip.

For optimum warm air distribution, Truma always recommends using the 4 warm air outlets of the heater. If only three warm air outlets are needed, one of the lower warm air outlets must be sealed with a blank cover VD-Combi (part no. 34310-01). The blank cover must be firmly pushed into the moulded part of the heater until it audibly engages and is firmly seated. Check for firm seating.

If four warm air outlets are being used, a closable end outlet EN may be installed in one warm air branch. If only three warm air outlets are being used, it must be ensured that if a closable end outlet is being used (in a bathroom, for example), a second non-closable nozzle is installed in the warm air branch.

In order to prevent heat accumulation when using the Combi D 6(E), all 4 warm air connections must be attached. The cross-section of the warm air ducts must not be reduced by duct connections or the like. If a closable EN end outlet is installed in a warm air branch of the Combi D 6(E) (e.g. in the bathroom), a second non-closable nozzle should be installed in this warm air branch.

The warm air system is designed individually for each vehicle type using the modular design principle. A wide range of accessories is available for this purpose.

Gas connection

The 30 mbar operating pressure of the gas supply must correspond to the device’s operating pressure (see type plate).

The ducts must be routed in such a way that the device is easy to remove for service work.

The gas supply line (Ø 8 mm) must be attached to the gas connection muff (20) with an olive screw fitting (19 – included with delivery depending on version). Carefully counterhold with another wrench when tightening.

The gas connection muff (20) on the device may not be shortened or bent.

Before connecting to the device, please ensure that the gas ducts are free of dirt, shavings and the like.

The number of separation points in the gas supply line in rooms used by persons must be limited to the technical minimum.

The gas system must comply with the technical and administrative regulations of the respective country of use (e.g. EN 1949 in Europe).

The national legislation and regulations (e.g. DVGW Work Sheet G 607 for vehicles in Germany) must be observed.

Water connection

Any pressure or immersion pump up to 2.8 bar can be used to operate the boiler, as can any mixing battery with or without an electric switch.

If the boiler is connected to a central water supply (rural or urban connection) or if powerful pumps are being used, a pressure reducer must be used, which will prevent pressures higher than 2.8 bar from occurring.

Before the pressure relief valve triggers, warming of the water and its resulting expansion may cause pressure of up to 4.5 bar to occur (also possible with immersion pumps). The water lines for connecting to the boiler and the safety/ drain valve must be drinking water safe, pressure resistant (up to 4.5 bar) and hot water resistant up to +80 °C.

If using immersion pumps, a non-return valve (21 – not included in delivery) must be installed between the pump and the first branch. Observe the direction of flow when installing the non-return valve. (See figure 14 – Example of an installation with flexible hoses Ø 10 mm.)

When using pressure pumps with a high switching hysteresis, hot water can flow back via the cold water valve. We recommend installing a non-return valve (22 – not included in delivery) between the outlet to the cold-water valve and the safety/drain valve as a return flow inhibitor. Observe the direction of flow when installing the non-return valve. (See figure 15 – Example of an installation with flexible hoses Ø 10 mm.)

Installation with flexible hoses (Ø 10 mm)

The elbow fittings (27 + 28) and the safety/drain valve (24) have a connection with Ø 10 mm. All hose rubber connections must be secured with hose clamps (including the cold water connection).

Installation with fixed duct routing (Ø 12 mm)

The elbow fittings (27 + 28) and the safety/drain valve (24) have an inner connection of Ø 12 mm. We recommend the use of John Guest ducts, insertion sleeves and locking rings. Appropriate adapters are available for connecting ducts with different diameters (not included in scope of delivery).

Installing the FrostControl (safety/drain valve)

The FrostControl must be installed in the immediate vicinity of the unit in the heated room in a location that is easily accessible to the user. Make sure that rotary switch (30) and pushbutton (31) can still be operated.

When selecting a location, please ensure that the FrostControl (24) is not installed in the vicinity of external heat sources (e.g. power supplies) or in the immediate proximity of warm air ducts.

Water removal can take place directly to the outside in a splash-protected location (fit splash guards if necessary).

Drill a hole (18 mm diameter) in the floor of the vehicle. Attach the hose (24b) to the drainage socket (24a), insert both through the vehicle floor and route to the outside. Align the drainage socket centrally to the hole. Secure the FrostControl with two B 5.5 x 25 screws (included with delivery) without tension. Screw in the screws vertically. Seal gap between hose and hole with plastic body sealant from below. (See figure 16 – Example of an installation with flexible hoses Ø 10 mm.)

Installing the safety/drain valve

Fit safety/drain valve (24) in easily accessible location in the vicinity of the device. Ensure that the lever can still be operated.

Water removal can take place directly to the outside in a splash-protected location (fit splash guards if necessary).

Drill a hole (18 mm diameter) in the floor of the vehicle. Attach the hose (24b) to the drainage socket (24a), insert both through the floor and route to the outside. Secure the safety/ drain valve in place with 2 screws. (See figure 17 – Example of an installation with fixed duct routing Ø 12 mm.)

Water pipe connection / routing

In order to ensure that the connected components will work, the water pipes must be kept as short as possible, and free of kinks and tension.

Route all water lines so they slope downwards to the safety/drain valve. No claims may be made under the warranty for damage caused by frost.

If a water supply is being installed in the vehicle, it must be ensured that sufficient room is left between the water pipes and the heat source (e.g. heater, warm air duct).

A water pipe may only be routed at a distance of 1.5 m from the heater at the warm air duct. The Truma SC hose clip (part no.: 40712-01) can be used from this distance. With parallel routing (e.g. through a wall) a spacer (e.g. insulation) must be fitted in order to avoid contact.

Ensure that the cold water supply does not come into contact with cold bridges (e.g. the outer wall) in order to prevent freezing.

Connect cold water supply (23) to safety/drain valve (24).

The included elbow fittings (27 + 28) must always be used in order to empty all water and to prevent the water hoses on the unit from leaking in the long term.

Provide a supply line (25) for the cold water supply between the safety/drain valve (24) and the boiler inlet.

Route the hot water supply line (26) from the elbow fitting with integrated aeration valve (28) to the hot water consumption points.

Attach elbow fitting (28 – with aeration valve) to upper connection (hot water outlet) and elbow fitting (27) to lower connection (cold water supply) of heater as far as it will go.

Pull in opposite direction to ensure that the elbow fittings are securely attached.

Slide venting hose with an outer diameter of 11 mm (29) onto the hose nozzle of the aeration valve (32) and route to the outside free of kinks. Radius of arc must not be less than 40 mm.

Cut off the venting hose about 20 mm below the vehicle floor at a 45° angle relative to the direction of travel. (See figure 18 – Example of an installation with flexible hoses Ø 10 mm.)

Room temperature sensor installation

When choosing a location, please note that the room temperature sensor must not be subjected to direct heat radiation. In order to obtain optimum room temperature control, install room temperature sensor over the entrance door.

Please ensure that the sensor is always attached to a vertical wall. There must be a free flow of interior air around the sensor.

Drill a hole with a diameter of 10 mm. Lead the connector cable through the hole from the rear, and connect the end of the cable to the sensor using an insulated connection plug (no need to observe polarity). Slide in the room temperature sensor and route the end of the cable with the two insulated connection plug to the heater electronics (lengthen the cable to a maximum total length of 10 m with 2 x 0.5 mm² cable if necessary).

The provided room temperature sensor must always be connected, otherwise the heater will switch to fault.

Fitting the control panels

Installation of the control panels is described in the installation instructions provided with the control panel.

Electrical connections

Route connector cables in such a way that they cannot chafe. Please also use leadthrough bushings or edge protection profiles where there are sharp edges such as metal panel leadthroughs. The connector cables must not be attached to or come into contact with metal surfaces, the exhaust duct or warm air ducts.

The electrical connections are located beneath the heater connection cover (39). The cover can be removed by pressing and simultaneously sliding it in the direction of the arrow. When removing or installing the connection cover, ensure that the connector cables are not pulled out or become pinched.

40 = Input voltage +12 V (spade connector 6.3 mm)
41 = Input voltage earth (spade connector 6.3 mm)
42 = FrostControl heating element (accessory)
43 = Device fuse: 10 A (slow-acting) (T 10 A)
44 = Wire bridge (or window switch – accessory)
45 = Time switch ZUCB (accessory – only in combination with analogue control panel)
46 = Room temperature sensor
47 = Control panel / diagnostic connector
48 = Control panel / diagnostic connector

• Alternative connections

All connections to the unit should be made with sagging connector cables. This will prevent condensation water from running down the connector cables and into the unit.

The connector cables and plugs must not be subjected to force. Bundle connector cables (see figure) and secure each one to housing using a cable binder in order to provide strain relief.

All cables must be securely attached and must not become loose or disconnected due to vibration – risk of fire!

12 V voltage supply

Electrical lines, switching and control equipment for heaters must be in locations that will not cause the operation thereof to be adversely affected under normal operating conditions. The breakthroughs of all lines leading to the outside must be protected from splash water.

Disconnect the appliance from the power supply before starting to work on electrical components. Switching off at the control panel is insufficient!

The equipment must be disconnected from the on-board power supply when electric welding work is being carried out on the body.

The unit has reverse polarity protection. The LED indicator will not work if the unit is connected with incorrect polarity. The unit can be used after establishing proper polarity.

In order to ensure that an optimum power supply is provided, the heater must be connected to the fuse-protected on-board power supply (central electrical system 10 A) with 2 x 2.5 mm² cable (2 x 4 mm² with lengths exceeding 6 m). Voltage drops in the supply line must be taken into consideration if necessary. Connect negative line to main ground connection. If the equipment is connected directly to the battery, the positive and negative lines must be protected. For the connections (40, 41), we recommend 6.3 mm fully insulated flat connectors.

No other consumers must be connected to the supply line!

When power packs or power supply units are being used, note that the regulated output voltage is between 11 V and 15 V and the alternating current ripple is < 1.2 Vpp. We recommend the automatic chargers from Truma for the various applications. Please contact your dealer. Other chargers may only be used in conjunction with a 12 V battery as a buffer.

Room temperature sensor

Attach plug of connector cable to connection (46) (no need to observe polarity).

Control panel / air conditioning system

The following connection combinations are possible.

Analogue control panels

or

1| CP E classic
power selector switch| Combi E (heater with electrical heating elements)
---|---|---

Digital control panels

1| CP plus control panel| Combi (E) (heater with / without electrical heating elements)
---|---|---

and

1| Air conditioning
system| Suitable systems – see CP plus control panel operating instructions
---|---|---

Insert the plug of the connector cable into one of the connections (47 or 48) and engage.

Power supply 230 V~ / 50 Hz

(Combi E – with electrical heating elements)

The 230 V~ / 50 Hz electrical connection must always be made by an expert (in Germany for example in accordance with VDE 0100, part 721 or IEC 60364-7-721).

The 230 V~ / 50 Hz electrical connection must be made on a fused circuit with a rating of at least 10 A (preferably 16 A).

The following must be provided for the Combi E in the circuit of the caravan / motor home:

• A suitable residual current circuit-breaker
• Mains disconnect switch (for maintenance and repair work)

These switches must disconnect at all poles and must have the specified contact spacing (minimum 3.5 mm).

• Cables must be secured using suitable clamps.
• Lay cables / lines of low-voltage systems physically separate from those for extra low-voltage systems.

Function check

The leak tightness of the gas supply line must be tested using the pressure drop method after installation. A test certificate must be issued (e.g. in accordance with DVGW Work Sheet G 607 in Germany).

Then check all functions of the device as described in the operating instructions, particularly the drainage of the water contents. No claims may be made under the warranty for damage caused by frost.

The operating instructions must be handed over to the vehicle owner.

Warnings

The installer or vehicle owner must affix the yellow sticker with the warning information, which is enclosed with the appliance, in a location in the vehicle where it is clearly visible to all users (e.g. the wardrobe door)! Missing stickers can be requested from Truma.

Should problems occur, please contact the Truma Service Centre or one of our authorised service partners (see www.truma.com).

In order to avoid delays, please have the unit model and serial number ready (see type plate).

Customers Support

Service
Telefon +49 (0)89 4617-2020
Telefax +49 (0)89 4617-2159
service@truma.com
www.truma.com

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