Escolar Documentos
Profissional Documentos
Cultura Documentos
20 1944 90 00 01
06.2014
1 Introduction
Contents
1 Introduction • Contents..................................................................................................2
• Concept of this manual.............................................................................3
• Special text structure, presentation and picture symbols...........................4
• Important information before starting work................................................4
• Statutory regulations.............................................................................5, 6
• Safety instructions for installation and operation....................................... 7
• Accident prevention..................................................................................7
3 Installation • Nameplate..............................................................................................16
• Installation and location..........................................................................16
• Installation location...........................................................................16, 17
• Possible installation positions..................................................................18
• Cable harness connection, right or left....................................................18
• Mounting and fastening..........................................................................19
• Hot air system........................................................................................20
• Installation of pipe connection sockets and air outlets . ..........................21
• Exhaust system......................................................................................22
• Combustion air system...........................................................................23
• Fuel supply..................................................................................... 24 – 28
2
1 Introduction
Concept of this manual
1 Introduction
Here you will find important introductory
5 Electric system
Here you will find information about the elec-
information about installation of the heater and tronic system and electronic components of the
about the structure of the manual. heater.
2 Product information
Here you will find information about the scope
6 Troubleshooting / maintenance / service
This section contains information on possible
of supply, the technical data and the dimensions faults and malfunctions, troubleshooting, mainte-
of the heater. nance and the service hotline.
3 Installation
Here you will find important information and
7 Environment
Here you will find information about certification
instructions referring to installation of the heater. and disposal of the heater together with the EU
Declaration of Conformity.
4 Operation and function
Here you will find information about the opera-
8 Lists
Here you will find the key word list and abbrevia-
tion and function of the heater. tions list.
3
1 Introduction
Special text structure, presentation and Important information before
picture symbols starting work
This manual uses special text structures and picture Range of application of the heater
symbols to emphasise different contents. The air heater operating independently of an engine
Please refer to the examples below for the corre- is intended for installation in the following vehicles,
sponding meanings and associated actions. depending on its heating output:
• All types of vehicles (max. 8 seats + driver’s seat)
and their trailers
Special structure and presentations • Construction machinery
• Agricultural machinery
A dot (•) indicates a list which is started by a head- • Boats, ships and yachts (only diesel heaters)
ing. If an indented dash (–) follows a dot, this list is • Camper vans
subordinate to the dot.
Please note!
Picture symbols • The heaters (only diesel heaters, 24 volt) can be in-
stalled in vehicles used for the transport of dangerous
goods as per ADR.
Regulation! • The current controller is to be replaced by a special
This picture symbol with the remark “Regulation” controller when the heater is to be used to heat the
refers to a statutory regulation. Failure to comply with freight compartment / cargo (order no. see heater
this regulation results in expiry of the type permit for price list or spare parts list).
the heater and preclusion of any guarantee and liabil- • The „Plus“ installation kits are intended for installa-
ity claims on Eberspächer Climate Control Systems tion in a camper van.
GmbH & Co. KG. and its associated companies.
Purpose of the heater
• Pre-heating, de-misting windows
Danger! • Heating and keeping the following warm:
This picture symbol with the remark “Danger!” refers – Driver and working cabs, Ship’s cabins
to the risk of a fatal danger to life and limb. Under cer- – Freight compartments
tain circumstances, failure to comply with these instruc- – Passenger and crew compartments
tions can result in severe or lifethreatening injuries. – Camper vans
Caution!
Safety instructions for application and proper
purpose
• The heater must only be used and operated for the
range of application stated by the manufacturer in
compliance with the “Operating instructions” included
with every heater.
4
1 Introduction
Statutory regulations
The Federal Motor Transport Authority has issued an – All appropriate precautions must be taken when
approval for a component according to ECE R122 and arranging the heater to minimise the risk of injuries
ECE-R10 for the heater for installation in motor vehicles, to persons or damage to other property.
with the following official type-approval markings noted
on the heater’s nameplate. • Fuel supply
– The fuel intake connection must not be located in
Heater type: ECE type approval mark: the passenger compartment and must be sealed
with a properly closing lid to prevent any fuel leaks.
Airtronic 122 R – 000025 – In heaters for liquid fuel where the heater fuel is
10 R – 041516 separate from the vehicle fuel, the type of fuel and
intake connection must be clearly identified.
Airtronic M 122 R – 000026 – A warning sign is to be fixed to the intake connec-
10 R – 041653 tion indicating that the heater must be switched off
before refuelling.
• Exhaust system
Regulation! – The exhaust outlet must be arranged so as to
Excerpt from ECE regulation No. 122 of the Euro- prevent any penetration of exhaust fumes into the
pean Parliament and the Council vehicle interior through the ventilation system, warm
air intakes or open windows.
General regulations
• Operating state display • Combustion air intake
– A clearly visible operating display in the user’s field of – The air for the heater’s combustion chamber must
vision must indicate when the heater is switched on not be sucked in from the vehicle’s passenger com-
and off. partment.
– The air intake must be arranged or protected in such
Regulations concerning installation in the vehicle a way that it cannot be blocked by other objects.
• Scope
– Subject to differing stipulations in the following • Hot air intake
section, combustion heaters must be installed ac- – The heater’s air supply must consist of fresh air or
cording to the regulations 5.3 of ECE-R122. circulated air and must be sucked in from a clean
– It is assumed that Class O vehicles with heaters for area, which cannot be contaminated by exhaust
liquid fuel conform to the regulations 5.3 of ECE- fumes from the engine, the combustion heater or
R122. any other source in the vehicle.
• Arrangement of the heater – The intake pipe must be protected by a grid or other
– Parts of the structure and other components near suitable means.
the heater must be protected from excessive heat
exposure and possible fuel or oil contamination. • Hot air outlet
– The heater must not pose a fire hazard even when it – The hot air pipes within the vehicle must be ar-
overheats. This requirement is deemed to be fulfilled ranged or protected in such a way that there is no
if adequate clearance is ensured for all parts during risk of injury or damage if they are touched.
installation, sufficient ventilation is provided and
fireproof materials or heat shields are used. – The air outlet must be arranged or protected in such
– The heater must not be mounted in the passen- a way that it cannot be blocked by any objects.
ger compartment of vehicles in class M2 and M3.
However, a heater in a hermetically sealed enclosure • Automatic control of the heating system
which also complies with the aforementioned condi- – If the engine fails, the heating system must be auto-
tions may be used. matically switched off and the fuel supply stopped
– The factory nameplate or duplicate must be affixed within 5 seconds. The heater may remain in opera-
so that it can still be easily read when the heater is tion if a manual device has already been activated.
installed in the vehicle.
5
1 Introduction
Statutory Regulations!
Additional regulations for certain vehicles named
in Directive 94 / 55 / EC of the ADR Agreement
6
1 Introduction
Safety instructions for installation and
operation
Danger!
Risk of injury, fire and poisoning!
• The heater must only be started up when the mainte- • The following measures are not allowed:
nance flap is closed and the outlet hood is mounted in – Changes to components relevant to the heater.
position. – Use of thirdparty components not approved by
• The maintenance flap must not be opened during Eberspächer.
operation. – Nonconformities in installation or operation from the
• Disconnect the vehicle battery before commencing statutory regulations, safety instructions or specifica-
any kind of work. tions relevant to safe operation as stated in the
• Before working on the heater, switch the heater off installation instructions and operating instructions.
and let all hot parts cool down. This applies in particular to the electrical wiring, fuel
• The heater must not be operated in closed rooms, supply, combustion air system and exhaust system.
e.g. in the garage or in a multistorey car park. • Only original accessories and original spare parts must
• Adjustable hot air outlets must always be adjusted so be used during installation or repairs.
that they cannot blow hot air directly at living creatures • When carrying out electric welding on the vehicle, the
(people, animals) or objects sensitive to temperature plus pole cable at the battery should be disconnected
(loose and / or fastened). and placed at ground to protect the controller.
• Do not operate the heater anywhere where there are
readily flammable materials (e.g. dry grass, leaves,
paper, etc.) in the area of the exhaust system or where
Caution! ignitable fumes and dust can form, e.g. near a
Safety instructions for installation and operation! – fuel depot
• The year of initial commissioning must be marked on – coal depot
the nameplate. – wood depot
• The heat exchanger of air heaters is a component – grain depots, etc.
subject to high thermal loads which must be replaced • The heater must be switched off when refuelling.
10 years after initial commissioning of the heater. In • When the heater is mounted in a safety housing etc.,
addition, the installation date must be entered on the installation compartment of the heater is not a
the plate “original spare part” enclosed with the heat stowage compartment and must be kept clear. In
exchanger must. Then affix the plate next to the particular fuel canisters, oil cans, spray cans, gas
nameplate on the heater. cartridges, fire extinguishers, cleaning rags, items of
• The heater must only be installed by a JE partner clothing, paper etc. must not be stored or transported
authorised by the manufacturer according to the on or next to the heater.
instructions in this manual and possibly according • Defect fuses must only be replaced by fuses with the
to special installation recommendations; the same prescribed rating.
applies to any repairs to be carried out in the case or • If fuel leaks from the heater fuel system, arrange
repairs or guarantee claims. for the damage to be repaired immediately by a JE
• Only the control elements approved by Eberspächer service partner.
Climate Control Systems GmbH & Co. KG. must be • Afterrunning of the heater must not be interrupted
used to operate the heater. The use of other control prematurely e.g. by pressing the battery disconnecting
elements can cause malfunctions. switch, apart from in the case of an emergency stop.
• Repairs by unauthorised thirdparties or with not
original spare parts are dangerous and therefore not
allowed. They result in expiry of the type permit of the Please note!
heater; consequently, when installed in motor vehicles
Following installation, attach the „Switch off heater
they can cause expiry of the vehicle operating licence.
before refuelling!“ sticker near the tank filler neck.
Accident prevention
7
2 Product information
Heater scope of supply, complete packages Using the universal installation kits
and universal installation kit Order No.
Heater Order No. Universal installation kit 25 2069 80 00 00
• with outlet hood Ø 60 mm,
Airtronic D2, 12 V 25 2069 05 00 00 heater guide number 6, usable with:
Airtronic D2, 24 V 25 2070 05 00 00 – Airtronic D2, 12 V 25 2069 05 00 00
Airtronic B3 Plus, 12 V 20 1944 05 00 00 – Airtronic D2, 24 V 25 2070 05 00 00
Airtronic D3, 12 V 25 2317 05 00 00
Airtronic B4, 12 V 20 1812 05 00 00 Universal installation kit 25 2113 80 00 00
Airtronic D4, 12 V 25 2113 05 00 00 • with outlet hood Ø 90 mm,
Airtronic D4, 24 V 25 2114 05 00 00 heater guide number 10, usable with:
Airtronic D4 Plus, 12 V 25 2484 05 00 00
Airtronic D4 Plus, 24 V 25 2498 05 00 00 – Airtronic D3, 12 V 25 2317 05 00 00
8
2 Product information
Scope of supply: Heater, universal installation kit and complete packages
9
2 Product information
Scope of supply Please note!
Heater and “Plus” installation kit
• Parts without a figure no. are small parts and packed
Heater Order No. in a bag.
• If other parts are required for the installation, see
Airtronic D2, 12 V 25 2069 05 00 00 product information.
Airtronic D2, 24 V 25 2070 05 00 00 • For notes on the unit ratings, refer to product informa-
tion.
The scope of supply includes: • The “Plus” installation kits are particularly suitable for
Figure No. Name installations in camper vans and boats.
1 Heater
2 Metering pump
10
2 Product information
Scope of supply: Heater and “Plus” installation kit
11
2 Product information
Technichal data
Please note!
Caution! Provided no limit values are given, the technical data
Safety instructions for technical data! listed is subject to the tolerances usually applicable to
Failure to comply with the technical data can result in heaters of ±10% for nominal voltage, ambient tempera-
malfunctions. ture 20 °C and reference altitude Esslingen.
12
2 Product information
Technichal data
Please note!
13
2 Product information
Technichal data
Heatertyp Airtronic M
Heater Airtronic B3 Plus / Airtronic B4
Version B3 Plus / B4
Heating medium Air
Control of the heat flow Stage
Power Large Medium Small Off
Heat flow (watt) B3 Plus 3000 2300 1700 1200 –
B4 3800 3200 2100 1300 –
Heater air flow rate without counterpressure (kg/h)
B3 Plus with hood Ø 90 mm 175 143 115 85 24
B4 with hood Ø 90 mm 185 160 120 85 24
Fuel consumption (l/h) B3 Plus 0,43 0,33 0,24 0,16 –
B4 0,54 0,46 0,29 0,18 –
Elektr. power consumption (watt) B3 Plus 33 20 13 8 5
in operation B4 40 29 15 9 5
at start 100
Rated voltage 12 volt
Operating range
• Lower voltage limit:
approx. 10.5 volt
An undervoltage protection in the controller
Undervoltage protection trigger time: 20 seconds
switches off the heater when the voltage
limit is reached.
• Upper voltage limit:
An uppervoltage protection in the controller approx. 16 volt
switches off the heater when the voltage Undervoltage protection trigger time: 20 seconds
limit is reached.
Fuel
“Fuel quality“ and “Fuel at low temperatures“ Commercially available petrol fuel (DIN EN 228)
see page 28.
Tolarable ambiet temperature Operation Not running
Heater – 40 °C to +50 °C –40 °C to +85 °C
Dosing pump – 40 °C to +20 °C – 40 °C to +125 °C
Maximum air intake temperature +40 °C
Interference suppression Interference suppression class 5 to DIN EN 55 025
Weight approx. 4,5 kg
Ventilation mode possible
Please note!
Caution! Provided no limit values are given, the technical data
Safety instructions for technical data! listed is subject to the tolerances usually applicable to
Failure to comply with the technical data can result in heaters of ±10% for nominal voltage, ambient tempera-
malfunctions. ture 20 °C and reference altitude Esslingen.
14
2 Product information
Main dimensions Airtronic
1 Minimum installation clearance (space) for opening the lid and for A = Exhaust
dismantling the glow plug and the controller. B = Fuel
2 Minimum installation clearance (space) for intake of heater air. V = Combustion air
15
3 Installation
Nameplate
Please note!
The heater is suitable and approved for installation in In a camper van, the heater is preferably installed in
vehicle interiors used by people. the inner compartment or luggage compartment.
The heater, together with its heater flange and the If it is not possible to install the heater in the pas-
mounted flange seal, is fixed directly onto the floor of senger compartment or boot, the heater can also be
the vehicle or in a suitable position in the rear panel of mounted, protected against splashing water, under
the vehicle. the vehicle floor.
Please note!
Please note!
• If installed inside the vehicle, detachable connections
of exhaust gas, combustion air and fuel lines are not The „Plus“ installation kits are intended for installation
allowed. in a camper van.
• The flange seal must be mounted on the heater, in
order to seal off the openings for the exhaust gas,
combustion air and fuel lines.
• Installation in the driver’s cab or passenger compart-
ment of commercial buses with more than 9 seats (8
seats + driver’s seat) is not allowed.
• The ADR regulations must also be complied with for
installation of the heater in vehicles used to transport
dangerous goods.
For information on the ADR regulations, see page 6,
31 and in the information sheet with Print No. 25 2161
95 15 80.
• When installing the heater, ensure sufficient open
space is allowed for intake of the heating air and for
the dismantling of glow plugs and control box (see
page 15 “main dimensions”).
1 Heater in front of the passenger seat
• Observe the regulations and safety instructions for this
2 Heater between the driver’s seat and the passenger
chapter, given on pages 4 – 7.
seat
3 Heater under the vehicle floor
4 Heater in living space
5 Heater in the boot
16
3 Installation
Installation
In a car or people carrier, the heater is preferably In a truck, the heater is preferably installed inside the
installed in the passenger compartment or boot. driver’s cab. If it is not possible to install the heater
If it is not possible to install the heater in the pas- inside the driver’s cab, it can also be mounted in the
senger compartment or boot, the heater can also be tool box or in a storage box.
mounted, protected against splashing water, under
the vehicle floor.
Please note!
17
3 Installation
Possible installation positions
18
3 Installation
Mounting and fastening
Make the necessary breakthroughs for exhaust, If the sheet metal of the support surface is <1.5 mm
combustion air and fuel as shown in the hole diagram. thick, an additional reinforcement must be installed.
The support surface for the heater foot must be
flat. An appropriate tool can be purchased from the Order no: reinforcement plate 20 1577 89 00 03
manufacturer for drilling the breakthroughs and also Order no: special tool 99 1201 46 53 29
smoothing the support surface.
The hole Ø 10.5 mm for the cable harness “dosing
pump” is not included in the picture drawing and
must be drilled after installation.
Fastening the unit on the vehicle floor Fastening the heater horizontally
to the vehicle wall
1 There must be sufficient clearance between the 4 The vehicle wall must be flat and smooth.
heater and the vehicle floor – also check that 5 Reinforcement plate (if required, for Order No. see
the fan wheel runs freely. above)
2 The mounting surface must be flat and smooth. 6 Spring washer
3 The flange seal must be mounted. 7 Hexagon nut M6 (torque 5+1 Nm)
19
3 Installation
Heater air system
The parts for the hot air system are included in the Please note!
scope of supply of the „Universal“ and „Plus“ instal-
lation kits. • Installation of spherical reduction hood is not permit-
The „Plus“ installation kit does not contain any flexible ted in the Airtronic D4 Plus.
pipes, these must be ordered separately. Refer to the • The regulations and safety instructions to be observed
product information for the Order No. for this chapter are on page 4 – 7.
• If air duct parts are connected the heater code
number in “Using Universal Installation Kits”, page 8
and “Using Plus Installation Kits”, page 10 must be
Danger! observed.
Risk of burning and injuries!
• The hoses of the heater air system and the hot air
outlet are to be routed and fastened in such a way
that they pose no temperature risk to people, animals Caution!
or materials sensitive to temperature from radiation / • The heater air intake openings must be arranged in
contact or blowing directly. If necessary, a cover is to such a way that under normal circumstances, it is
be fitted to the heater air system or hot air outlet. not possible for exhaust from the vehicle engine and
• The outflow hood must be fitted on the hot air outflow heater to be sucked into the system, or for the heating
side. air to be contaminated with dust, salt spray,etc.
• A safety grid must be fitted to the heater air intake • For circulating air, position the circulating air intake
side and outflow side if no air hoses are mounted, to in such a way that the outflowing hot air cannot be
prevent any injuries from the heater air fan or burns directly sucked in again.
from the heat exchanger. • In the event of possible overheating, it is possible for
• High temperatures occur in the heater air system dur- local lot air temperatures of up to max. 150 °C or
ing and after the heater has been working. This is why surface temperatures of up to max. 90 °C to occur
it is important to avoid working in the vicinity of the immediately before the defect shutdown. Therefore
heater air system while the heater is working. In such only temperature-resistant hot air hoses approved by
cases, switch the heater off beforehand and wait until us must be used for the heater air system!
all parts have cooled down completely. If necessary, • When checking the functions, the mean outflow tem-
wear safety gloves. perature measured after the heater has been running
about 10 minutes at approx. 30 cm from the outlet
should not exceed 110 °C (at an intake temperature of
approx. 20 °C).
• If there is a risk of the driver and passengers touching
the heater when the vehicle is being driven normally, a
contact protection device must be fitted.
Hot air system (example)
Some of the parts for the hot air system are included in the scope of supply of the universal installation kit, see page 8.
Please note!
• Observe the regulations and safety instructions for this chapter, given on page 4 to 7.
• When connecting air system parts, note the heater rating, see page 10.
• For important information on the air system, the heater guide numbers and the guide numbers for the air system
parts, refer to the “Product information” document.
20
3 Installation
Installation of pipe connection sockets and Installing the air blocking element
air outlets
Caution!
Cutting out the opening for the connection sockets
Risk of overheating!
Use a keyhole saw to cut out an opening for the Blocking the hot air can cause overheating of the
connection socket at the planned place of installation heater; the heater is switched off by the protection
(vehicle floor or wall). against overheating.
−− Pipe connection socket Ø 60 mm – keyhole saw −− The air blocking element may only be used in
Ø 68 mm multi-duct air systems.
−− Pipe connection socket Ø 75 mm – keyhole saw
Ø 92 mm The air blocking element is clipped into the pipe con-
nection socket, discharge side. This reduces the cross-
Fixing the pipe connection socket section of the pipe connection socket and reduces the
quantity of air flow.
Insert the pipe connection socket in the drillhole. Mark
and drill three fixing holes Ø 2 mm. The air blocking element consists of two rings; the inner
Use 3 self-tapping screws DIN 7981 3.9×13 to fix the ring can be broken out.
connection sockets. 1 ring = low degree of air blocking / 2 rings = high
degree of air blocking
Fix air outlet onto the pipe connection socket
The air blocking element is available in sizes Ø 75 mm
Clip the corresponding air outlet onto the pipe connec- and Ø 90 mm (Order No. see product information).
tion socket.
Please note!
• In case of critical installation conditions, we recom- 1 Connection sockets, discharge side
mend securing the flexible tubing with an additional 2 Air blocking element
hose clip at the pipe connection socket.
• Plastic sheathed hot air hoses with wire inlay must be
fixed onto the pipe connection socket with a hose clip.
• Tightening torque for hose clip = 3 Nm.
1 2 3 4
1 Air outlet
2 Self-tapping screw
3 Pipe connection socket
4 Flexible tubing
21
3 Installation
Exhaust system
Please note!
• Comply with the regulations and safety instructions
for this chapter on page 4 – 7.
Caution! • If a silencer is fitted, the exhaust end pipe must
Safety instructions! be much shorter than the flexible exhaust pipe be-
The whole exhaust system gets very hot during and tween the heater and the exhaust silencer.
immediately after the heater has been working. This is • Small arrows indicating the direction of flow have
the reason why the exhaust system must be installed been cast into the fittings to differentiate between
according to these instructions. the combustion air and the exhaust fittings at the
• The exhaust outlet must end in the open air. heater (see diagram page 23).
• The exhaust pipe must not protrude beyond the lateral • To prevent contact erosion, the clips used to fix the
limits of the vehicle. exhaust pipe must be made of stainless steel. The
• Install the exhaust pipe sloping slightly downwards. If order No. for the stainless steel fixing clips is given in
necessary, make a drain hole approx. Ø 5 mm at the the product information.
lowest point to drain off condensation.
• Important functional parts of the vehicle must not be
impaired (keep sufficient clearance).
• Mount the exhaust pipe with sufficient clearance to
heat-sensitive parts. Pay particular attention to fuel
pipes (plastic or metal), electrical cables and brake
hoses etc.!
• Exhaust pipes must be fastened safely (recommended
clearance of 50 cm) to avoid damage from vibrations.
• Route the exhaust system so that the emitted fumes
are not sucked in with the combustion air.
• The mouth of the exhaust pipe must not get clogged
by dirt and snow.
• The mouth of the exhaust pipe must not point in the
direction of travel.
• Always fasten the exhaust silencer to the vehicle.
22
3 Installation
Combustion air system
Caution!
Mounting the combustion air system Safety instructions for the combustion
air system!
The universal installation kit includes a flexible combus- • The combustion air opening must be free at all times.
tion air hose, inner Ø 25 mm , 1000 mm long. • Position the combustion air intake to be sure that ex-
If necessary the flexible combustion air hose can be haust fumes cannot be sucked in with the combustion
shortened to 20 cm or lengthened to max. 2 m depend- air.
ing on the installation conditions. • Do not arrange the combustion air intake to pointing
Use a pipe clip (tightening torque 3+0.5 Nm) to fix the against the wind blast.
flexible combustion air hose to the heater and use hose • The combustion air intake must not get clogged with
clips or cable ties to fix in suitable positions. dirt and snow.
Fit an end sleeve after completing the installation. • Install the combustion air intake system sloping slightly
downwards. If necessary, make a drain hole approx.
The „Plus“ installation kit includes a combustion air Ø 5 mm at the lowest point to drain off condensation.
intake silencer with a flexible connection hose (inner
diameter 25 mm).
Use a pipe clip (tightening torque 3+0.5 Nm) to fix the
flexible connection hose to the heater and use hose Please note!
clips or cable ties to fix in suitable positions.
Fit an end sleeve after completing the installation. • For Airtronic and Airtronic M heaters a combustion air
intake silencer can be fitted instead of the combustion
air hose to reduce the noise level. Order No. see spare
parts list or product information.
• Comply with the regulations and safety instructions
for this chapter on page 4 – 7.
min. 0.2 m
min. 0.2 – max. 2 m
max. 2 m
23
3 Installation
Fuel supply
Mounting the dosing pump, routing the fuel pipes • Never route or fasten the fuel pipes to the heater or
and mounting the fuel tank vehicle exhaust system. At crossings, always ensure
adequate heat clearance, if necessary attach heat
The following safety instructions must be observed deflection plates or protective hose (For Order No. of
when mounting the dosing pump, routing the fuel protective hose, see product information).
pipes and mounting the fuel tank.
• Dripping or evaporating fuel must never be allowed to
Deviations from the instructions stated here are not
collect on hot parts or ignite on electric systems.
allowed.
Failure to comply can result in malfunctions. • When connecting fuel pipes with a fuel hose, always
mount the fuel pipes in a butt joint to prevent any bub-
bles from forming.
Danger!
Risk of fire, explosion, poisoning and injuries!
24
3 Installation
Fuel supply
Fuel feed point with T-piece from the fuel supply line
from the tank fitting to the vehicle engine
25
3 Installation
Fuel supply
Caution!
Safety instructions for the fuel supply!
• The fuel must not be conveyed by gravity or • When the pressure in the fuel pipe is more than
overpressure in the fuel tank. 4,0 bar or there is a nonreturn valve in the return
• Withdrawal of fuel after the vehicle’s fuel pump is pipe (in the tank), a separate tank connection must
not allowed. be used.
• When the pressure in the fuel pipe is more than • When using a T-piece in a plastic pipe, always use
0.2 bar to max. 4,0 bar, use a pressure reducer support sleeves in the plastic. Connect the T-piece
(order no. 22 1000 20 08 00) or separate tank and the plastic pipe with corresponding fuel hoses
connection. and secure with hose clips.
26
3 Installation
Fuel supply
Caution!
Safety instructions for installing
the dosing pump
• Always mount the dosing pipe with the pressure side
rising upwards – minimum incline 15°.
27
3 Installation
Fuel supply
• If the heater is run from a separate tank, please com- • When operating with diesel / bio diesel mixtures of up
ply with the following rules: to 50 % bio diesel, intermediate operation with pure
diesel fuel is not necessary.
– if outdoor temperatures over 0 °C,
Use diesel fuel according to DIN EN 590.
Please note!
After refuelling with winter or cold diesel, the fuel pipes
and the metering pump must be filled with the new fuel
by letting the heater run for 15 min!
28
4 Operation and function
Operating instructions Initial commissioning
The heater is operated by a control element. The following points are to be checked by the com-
Detailed operating instructions are enclosed with the pany installing the heater during initial commissioning.
control unit.
• After installation of the heater, the coolant circuit and
Please note! the whole fuel supply system must be vented carefully.
The workshop / garage installing the heater will issue Comply with the instructions issued by the vehicle
you with the operating instructions. manufacturer.
• During the trial run of the heater, check all water and
fuel connections for leaks and firm fitting.
Important instructions for operation
• If the heater shows a fault during operation, find and
Safety checks before the start
eliminate the cause of the fault using a diagnosis unit.
After a lengthy period of non-use (summer months)
check that all parts fit securely (tighten screws where
necessary).
Check the fuel system visually for any leaks.
Please note!
During the initial startup of the heater, odours can be
Heating at high altitudes produced for a short time. This is fully normal during the
• up to 1500 m altitude, heating mode is possible wit- first few minutes of operation and does not indicate a
hout altitude adjustment. malfunction in the heater.
Please note!
Heaters suitable for high altitudes are labelled with
“HKit” on the side nameplate.
29
4 Operation and function
Description of functions
When the heater is switched on, the control lamp in During the heating mode, the room temperature or the
the control element lights up. temperature of the sucked in heating air is constantly
The glow plug is switched on and the fan starts at measured.
low speed. If the temperature is higher than the temperature
selected on the control element, the heater starts
to regulate its output. There are 4 control stages so
Please note! that the outflow of heat produced by the heater can
be adjusted finely to the heating requirements. Fan
If there is still too much residual heat in the heat speed and fuel quantity correspond to the particular
exchanger from when the heater was last used, firstly control stage.
only the fan starts up (cold blowing). If the set temperature is still exceeded in the smallest
Once the residual heat has been cleared, the heater control stage, the heater goes to the “OFF” stage with
starts. the fan running on for approx. 4 minutes to cool off.
Then the fan continues at minimum speed (circula-
tion mode) or is switched off (fresh air mode) until the
Starting Airtronic heater is started again.
After approx. 60 seconds the fuel supply starts and When the heater is switched off, the control lamp
the fuel / air mixture in the combustion chamber goes off and the fuel supply is switched off.
ignites. The fan runs on for approx. 4 minutes to cool down.
After the flame sensor has detected the flame, the While the fan is running on, the glow plug is switched
glow plug is switched off after approx. 90 sec. The on for approx. 40 seconds to clean.
heater is now in standard operation. Special case:
After another 120 seconds, the heater has reached If no fuel has been supplied or if the heater is in
the “POWER” stage (maximum fuel quantity, maxi- the “OFF” stage until it is switched off, the heater is
mum fan speed). stopped without any after running.
30
4 Operation and function
Control and safety devices Forced shutdown in ADR mode (only for diesel
heaters 24 volt)
• If the heater does not ignite within 90 seconds after
starting the fuel pump, the start is repeated. If the In vehicles for the transport of dangerous goods (e.g.
heater still does not ignite after another 90 seconds of tanker trucks), the heater must be switched off be-
pumping fuel, the heater is switched off, i.e. the fuel fore the truck drives into a danger area (refinery, fuel
supply is off and the fan runs on for approx. 4 min- service station, etc.).
utes. Failure to comply results in the heater switching off
automatically when:
• If the flame goes off by itself during operation, the • The vehicle engine is switched off.
heater is restarted. If the heater does not ignite within • An additional unit is started up (e.g. auxiliary drive for
90 seconds after the fuel pump has started, or ignites unloading pump etc.).
and goes off again within 15 minutes, the heater is The fan then runs on for max. 40 seconds.
switched off, i.e. the fuel supply is off and the fan runs
on for approx. 4 minutes. This status can be remedied
by briefly switching off and on again. Do not repeat
the switching off/on routine more than twice. Emergency shutdown – EMERGENCY OFF
If an emergency shutdown – EMERGENCY OFF –
• In the case of overheating, the combined sensor is necessary during operation, proceed as follows:
(flame sensor / overheating sensor) triggers, the fuel • Switch the heater off with the control or
supply is interrupted and the heater switched off. • pull the fuse out or
Once the cause of the overheating has been elimi- • disconnect the heater from the battery.
nated, the heater can be re-started by switching off
and on again.
Please note!
Do not switch the heater off and on again more
than twice.
31
5 Electrical system
Heater wiring
The electronic control box is integrated in the heater,
which considerably simplifies the wiring required during
installation.
Caution!
Safety instructions for wiring the heater!
The heater is to be connected up electrically accord-
ing to the EMC directives.
EMC can be affected if the heater is not connected
up correctly. For this reason, comply with the following
instructions:
Please note!
Comply with the following when wiring the heater and
the control element:
32
5 Electrical system
Parts list for the circuit diagrams
Please note!
Airtronic / Airtronic M and
Airtronic / Airtronic M – ADR mode Circuit diagram for Airtronic / Airtronic M see Page 34
and 35.
-A1 Airtronic / Airtronic M control box Circuit diagram for Airtronic / Airtronic M in ADR mode ¬
-A30 Fuse holder, 3 pin see also Page 36.
-B1 Control sensor, internal
-B6 Flame and overheating sensor For circuit diagrams for other control units, e.g.
-F1 Fuse 12 V = 20 A / 24 V = 10 A EasyStart T, R and R+, refer to the installation instruc-
-M4 Burner motor tions of the control unit concerned.
-R1 Glow plug
-Y1 Fuel metering pump
Optional
b Activation of vehicle blower and / or separate
fresh air fan
Please note!
• The plus signal is only applied in „Low“ control stage
(PIN 16, plus signal for relay, Imax = 200 mA)
ADR function
Wiring for ADR mode (dangerous goods in utility or
commercial vehicles, e.g. fuel tanker) - wire yourself
according to vehicle circumstances
Please note!
• It must be ensured that if the battery isolating switch
is pressed due to EMERGENCY STOP, all the heat-
er‘s electric circuits are disconnected from the bat-
tery immediately (without any consideration of the
heater‘s status).
• If the battery isolating switch is pressed to disconnect
the battery from all electric circuits, the heater must
be switched off first and if applicable you must wait
until the heater’s afterrun has finished.
a to the heater
c to the control unit
x Insulate and tie back any cable ends that are not
needed.
33
5 Electrical system
Airtronic / Airtronic M
X:15
Ign (+)
X:58
Light (+)
X:30
Bat (+)
X:31
Bat (-)
-A1
-XS2/1
2,0 WH 1 1
-R1
2,0 BN 2 2
-XS16
1,5 RD 1
-XS2/2 2
-M4 0,75 BN 1 1
0,5 BUWH 3
0,75 BK 2 2
0,5 YE 4
M 1,0 GNRD 5
0,5 BNWH 6
0,5 GYRD 7
0,5 BUYE 8
9 a
-XS2/3 1,5 BN 10
1 1
11
2 2
0,5 GY 12
-B6
0,5 BU 0,5 BU 13
Θ
-XS2/4 0,5 BUBK 14
0,5 GN 1 1
0,5 PK 15
Θ
0,5 BNWH 2 2
0,5 BKGY 16
0,5 YE
-B1
0,5 YE
Θ
34
5 Electrical system
Airtronic / Airtronic M
X:15
Ign (+)
X:58
Light (+)
X:30
Bat (+)
X:31
Bat (-)
/ / /
b x x x
4,0 RD 1,0 RD
-A30 1 1 1
-F1 -F2 -F3
5A
2 2 2
-XB16
1 2,5 RD 0,5 RD
2
3 0,5 BN
4 0,5 YE 0,5 BUWH
5 1,0 GNRD
c
6 0,5 BNWH
7 0,5 GYRD
8 0,5 BUWH 0,5 GYRD
a 9 0,5 BNWH
10 2,5 BN 0,5 YE x
11 0,5 GY x
12 0,5 GY 0,5 WHRD x
13 0,5 BU
14 0,5 BUVT
15 0,5 WHRD
16
-XB2 2 1
-Y1
2 1
35
5 Electrical system
Circuit diagram Airtronic / Airtronic M – ADR mode
X:15
Ign (+)
X:58
Light (+)
X:30
Bat (+)
X:31
Bat (-)
b m n o
4,0 RD 1,0 RD
-A30 1 1 1
-F1 -F2 -F3
5A
2 2 2
-XB16
1 2,5 RD 0,5 RD
2
3 0,5 BN
4 0,5 YE 0,5 BUWH
5 1,0 GNRD
c
6 0,5 BNWH
7 0,5 GYRD 0,5 WHRD
8 0,5 BUWH 0,5 GYRD
a 9 0,5 BNWH
10 2,5 BN 0,5 YE x
11 0,5 GY x
12 0,5 GY
13 0,5 BU
14 0,5 BUVT
15 0,5 WHRD
16
-XB2 2 1
-Y1
2 1
36
5 Electrical system
Circuit diagram EasyStart Timer
X:15
Ign (+)
X:58
Light (+)
0,5 GYRD
g y
0,5 BNWH -E3
-XB10 -XS10
0,5 RD 1 1 0,35 RD
0,5 GYBK 2 2 0,22 GYBK
c 0,5 BN 3 3 0,22 BN
0,5 BUWH 4 4 0,22 BUWH
5 5 0,22 VT
6 6 0,35 YE
7 7 0,22 BNYE
8 8 0,22 WHRD
9 9 0,22 BNWH
10 10 0,22 GY
-XB10 -XS10
22 1000 34 97 20
Cable colours
Please note!
• For heater circuit diagrams see page 34, 35 and 36.
• Further circuit diagrams for the EasyStart Timer are
printed in the Installation Instructions Plus, these are
available to view and download from the Service
Portal.
37
5 Electrical system
Circuit diagram EasyStart Remote+
X:15
Ign (+)
X:58
Light (+)
0,5 GYRD
g y
0,5 BNWH -E5 -W2
-XB12
0,5 RD
1
2
c 0,5 BN
3
0,5 BUWH
4
5
0,22 BN
8
0,22 BNWH
-B8 9
0,22 GY
10
Θ
11
12
-XB12
25 2361 00 97 01 C
Cable colours
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Remote+
are printed in the Installation Instructions Plus, these
are available to view and download from the Ser-
vice Portal.
38
5 Electrical system
Circuit diagram EasyStart Select
X:15
Ign (+)
X:58
Light (+)
0,5 GYRD
g y
0,5 BNWH -E2
-XB4 -XS4
0,5 RD 1 1 0,35 RD
0,5 GYBK 2 2 0,35 GYBK
c 0,5 BN 3 3 0,35 BN
0,5 BUWH 4 4 0,35 BUWH
-XB4 -XS4
25 2361 00 97 05 B
Cable colours
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Select are
printed in the Installation Instructions Plus, these are
available to view and download from the Service Por-
tal.
39
5 Electrical system
Circuit diagram EasyStart Call
X:15
Ign (+)
X:58
Light (+)
0,5 GYRD
y
g -E1
0,5 BNWH -W1
-XS9 -XB12
-XB9
0,5 RD 1 1 RD RD
1
2 2
2
0,5 BN 3 3 BN BN
c 3
4 4 VT BUWH
4
0,5 BUWH 5 5 BUWH VT
5
6 6 YE
7 7 -H1 0,22 RDYE
6
8 8 0,22 BNYE
7
9 9
0,22 BN
8
0,22 BNWH
-B8 9
0,22 GY
10
Θ
YE
11
12
25 2361 00 97 02 B
Cable colours
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Call are
printed in the Installation Instructions Plus, these are
available to view and download from the Service
Portal.
40
6 Troubleshooting / Maintenance / Service
In case of faults, please check the following Maintenance instructions
points • Switch the heater on once a month for about 10 min-
utes, even outside the heating period.
• If the heater does not start after being switched on:
– Switch the heater off and on again. • Before the heating period starts, the heater should
undergo a trial run. If persistent extreme smoke devel-
• If the heater still does not start, check whether: ops, unusual burning noises or a clear fuel smell can
– There is fuel in the tank? be perceived or if electric / electronic parts heat up,
– The fuses are OK? the heater must be switched off and put out of service
– The electrical cables, connections etc. are OK? by removing the fuse. In this case, the heater should
– Anything is clogging the combustion air supply not be started up again until it has been checked by
or exhaust system? qualified staff who have been trained on Eberspächer
heaters.
41
7 Environment
Certification EU Declaration of Conformity
The high quality of Eberspächer’s products is the key We herewith declare that the version of the heater
to our success. placed on the market by us conforms to the applicable
To guarantee this quality, we have organised all work provisions of the following EC Directive.
processes in the company along the lines of quality
management (QM). EC Directive 2004/108/EC
Even so, we still pursue a large number of activities
for continuous improvement of product quality in
order to keep pace with the similarly constantly grow-
ing requirements made by our customers.
The full Declaration of Conformity can be viewed and
All the steps necessary for quality assurance are
downloaded from the download centre under
stipulated in international standards.
www.eberspaecher.com.
This quality is to be considered in a total sense.
It affects products, procedures and customer / sup-
plier relationships.
Officially approved public experts assess the system
and the corresponding certification company awards
a certificate.
Disposal
Disposal of materials
Old devices, defect components and packaging
material can all be separated and sorted into pure-
grade factions so that all parts can be disposed of as
required in an environment-friendly manner or recy-
cled where applicable.
Electric motors, controllers and sensors (e.g. temper-
ature sensors) are deemed to be “electronic scrap”.
Packaging
The packaging of the heater can be kept in case
it has to be sent back.
42
8 Lists
List of key words A – Z
A I
Accident prevention.................................................... 7 Introduction............................................................. 4, 5
ADR........................................................................... 16 Installation......................................................... 16 – 28
Altitude...................................................................... 29 Installation area................................................... 16, 17
Ambient temperature......................................... 12 – 14 Interference suppression class......................... 12 – 14
Initial commissioning................................................. 29
C Installation location.............................................. 16, 17
Cable harness connection........................................ 18 Installation position.................................................... 18
Certificates................................................................ 42 Information.................................................................. 4
Circuit diagrams................................................ 34 – 40 Important instructions................................................ 29
Combustion air system.............................................. 23
Control devices......................................................... 31 L
Control in heating mode............................................ 30 List of abbreviations.................................................. 44
Contents...................................................................... 2
M
D Maintenance.............................................................. 41
Dangerous goods................................................ 16, 31 Main dimensions....................................................... 15
Declaration of conformity.......................................... 42
Description of functions............................................. 30 N
Disposal..................................................................... 42 Nameplate................................................................. 20
Dosing pump..................................................... 24 – 27
O
E Operation................................................................... 29
Electronic components........................................ 33, 36 Operating instructions............................................... 29
Emergency off........................................................... 31
Environment management........................................ 42 P
EU Declaration of Conformity.................................... 42 Picture symbols........................................................... 4
Exhaust system......................................................... 22 Power consumption........................................... 12 – 14
Pressure height......................................................... 27
F Pressure side....................................................... 25, 26
Faults......................................................................... 46 Presentation................................................................. 4
Fastening................................................................... 19 Purpose....................................................................... 4
Fan operation............................................................ 30
Forced shut-down..................................................... 31 R
Formation of air bubbles........................................... 24 Rated voltage.................................................... 12 – 14
Fuel supply.................................................... 5, 24 – 28 Regulations.............................................................. 5, 6
Fuel consumption.............................................. 12 – 14
Fuel quality................................................................ 28 S
Safety devices........................................................... 31
H Safety check (before starting)................................... 29
Heat flow............................................................ 12 – 14 Scope of supply.................................................. 8 – 11
Hotline....................................................................... 41 Storage temperature......................................... 12 – 14
Statutory regulations................................................ 5, 6
Start procedure......................................................... 30
Suction height............................................................ 27
Switching on.............................................................. 30
Switching off.............................................................. 30
43
8 Lists
List of key words A – Z List of abbreviations
U JE partner
Use.............................................................................. 4 Eberspächer partner.
V FAME
Voltage............................................................... 12 – 14 Biodiesel according to DIN V 14 214.
Voltage limit....................................................... 12 – 14
CE marking
W With the CE marking, the manufacturer declares in a
Weight............................................................... 12 – 14 declaration of conformity, that the version of the heater
Wiring........................................................................ 32 placed on the market conforms to the relevant provi-
sions of the EU Directive.
44
Subject to changes Printed in Germany © Eberspächer Climate Control Systems GmbH & Co. KG
www.eberspaecher.com