hydronic d5wz 25_2216 td 06 2003 je
TRANSCRIPT
J. EberspächerGmbH & Co. KGEberspächerstr. 24D - 73730 Esslingen
Telefon (zentral)(0711) 939 - 00Telefax(0711) 939 - 0500
www.eberspaecher.com
Eberspächer
25 2216 90 95 89 06.2003 Subject to changes Printed in Germany © J. Eberspächer GmbH & Co. KG
Technical descriptionInstallation instructionsOperating instructionsMaintenance instructions
Heater (additional heater) for vehicles withpetrol engine
Order no.
HYDRONIC B 5 W Z – 12 Volt 20 1818 05 00 00
Heater (additional heater) for vehicles withdiesel engine
Order no.
HYDRONIC D 5 W Z – 12 Volt 25 2216 05 00 00
Please give this manual to the customerafter installation of the heater.
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Introduction1
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Contents
Chapter Title Contents Page
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 .............................. 6, 7• Accident prevention .............................................................................. 7
Product information • Scope of supply ................................................................................. 8, 9• Technical data petrol heaters .............................................................. 10• Technical data diesel heaters .............................................................. 11• Main dimensions .................................................................................. 12
Installation • Installation and location ...................................................................... 13• Possible installation positions ............................................................. 14• Mounting and fastening ....................................................................... 14• Nameplate ........................................................................................... 15• Connection to the cooling water circuit ......................................... 16, 17• Exhaust system ................................................................................... 18• Combustion air system ........................................................................ 19• Fuel supply .................................................................................. 20 – 24
Operation and • Operating instructions / important information for operation ............... 25function • Initial commissioning ........................................................................... 25
• Description of functions ...................................................................... 25• Control and safety devices ................................................................. 26
Electrical system • Heater wiring ........................................................................................ 27• Circuit diagram ..................................................................................... 28
Troubleshooting • Troubleshooting procedure .................................................................. 29Maintenance • Maintenance instructions .................................................................... 29Service • Service ................................................................................................ 29
Environment • Certification ......................................................................................... 30• Disposal ............................................................................................... 30• EU Declaration of Conformity ............................................................... 30
Guarantee conditions • Guarantee ........................................................................................... 31• Liability ................................................................................................ 31• Place of jurisdiction ............................................................................. 31
Lists • List of key words ........................................................................... 32, 33• List of abbreviations ............................................................................ 33
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Introduction1
Concept of this manual
This manual aims to support the service companyinstalling the heater and to provide the user with allimportant information about the heater.The manual has been divided into 9 chapters to makeit easier to find the corresponding information quickly.
IntroductionHere you will find important introductoryinformation about installation of the heaterand about the structure of the manual.
Product informationHere you will find information about the scopeof supply, the technical data and thedimensions of the heater.
InstallationHere you will find important information andinstructions referring to installation of theheater.
Operation and functionHere you will find information about theoperation and function of the heater.
Electric systemHere you will find information about theelectronic system and electronic componentsof the heater.
Troubleshooting / maintenance / serviceHere you will find information about anynecessary troubleshooting procedures,maintenance and the service hotline.
EnvironmentHere you will find information about certificationand disposal of the heater together with the EUDeclaration of Conformity.
Guarantee conditionsHere you will find the guarantee, the liabilityand the place of jurisdiction.
ListsHere you will find the key word list andabbreviations list.
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Introduction1
Special text structure, presentation andpicture symbols
This manual uses special text structures and picturesymbols to emphasise different contents.Please refer to the examples below for thecorresponding meanings and associated actions.
Special structure and presentations
A dot (•) indicates a list which is started by aheading. If an indented dash (–) follows a dot, this listis subordinate to the dot.
Picture symbols
Regulation!
This picture symbol with the remark “Regulation”refers to a statutory regulation. Failure to comply withthis regulation results in expiry of the type permit forthe heater and preclusion of any guarantee andliability claims on J. Eberspächer GmbH & Co. KG.
Danger!
This picture symbol with the remark “Danger!” refersto the risk of a fatal danger to life and limb. Failure tocomply with these instructions can result in severeinjuries under certain circumstances.
Caution!
This picture symbol with the remark “Caution!” refersto a dangerous situation for a person and/or theproduct.Failure to comply with these instructions can result ininjuries to people and/or damage to machinery.
These remarks contain application recommendationsand useful tips for installation of the heater.
Important information beforestarting work
Range of application of the heater
The heater operating independently of an engine isintended for installation in the following vehicles,depending on its heating output:• Vehicles of all kinds• Construction machinery• Agricultural machinery• Boats, ships and yachts
The heater must not be installed in motor vehiclesused to transport dangerous goods according toADR / ADR 99.
Purpose of the heater(using the vehicle heat exchanger)
• Heat up the vehicle's water circuit together with thevehicle engine for adequate heating of:– Driver and working cabs– Freight compartments– Ship’s cabins– Passenger and crew compartments– Vehicle engines and units
On account of its functional purpose, the heater is notpermitted for the following applications:• Long-term continuous operation, e.g. for pre-heating
and heating of:– Residential rooms– Garages– Work huts, weekend homes and hunting huts– House boots, etc.
Caution!
Safety instructions for application andproper purpose
• The heater must only be used and operated for therange of application stated by the manufacturer incompliance with the “Operating instructions”included with every heater.
Please note!
Please note!
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Introduction1
Statutory regulations
The Federal Vehicle Office has awarded an “EU TypePermit” with an official test symbol for installation ofthe heater in motorised vehicles, shown on the heaternameplate.
HYDRONIC e1 00 0023
Regulation!
Directive 2001 / 56 / EU of the EuropeanParliament and the Council
• Arrangement of the heater– Parts of the structure and other components near
the heater must be protected from excess heatexposure and possible contamination from fuel oroil.
– The heater must not pose a fire hazard even whenit overheats.This requirement is deemed to be fulfilled whenadequate clearance to all parts is observed duringinstallation, sufficient ventilation is provided andfire-proof materials or heat plates are used.
– The heater must not be located in the passengercompartment in vehicles of class M1, M2, M3 and N.A unit may however be used in a hermetically sealedhousing which also corresponds to the conditionsstated above.
– The factory nameplate or duplicate must be affixedso that it can still be easily read when the heateris installed in the vehicle.
– All appropriate precautions must be taken whenarranging the heater to minimise the risk of injuriesto persons or damage to other property.
• Fuel supply– The fuel intake connection must not be located in
the passenger compartment and must be sealedwith a properly closing lid to prevent any fuel leaks.
– In heaters for liquid fuel where the heater fuel isseparate from the vehicle fuel, the type of fuel andintake connection must be clearly identified.
– A warning sign is to be fixed to the intakeconnection indicating that the heater must beswitched off before refuelling.
• Exhaust system– The exhaust outlet must be arranged so as to
prevent any penetration of exhaust fumes into thevehicle interior through the ventilation system,warm air intakes or open windows.
• Combustion air intake– The air for the heater combustion chamber must
not be sucked in from the passenger compartmentof the vehicle.
– The air intake must be arranged or protected insuch a way that it cannot be blocked by otherobjects.
• Operating status display– A clearly visible operating display in the user’s
field of vision must indicate when the heater isswitched on and off.
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Introduction1
Statutory regulations
• Compliance with the statutory regulations andsafety instructions is prerequisite for guaranteeand liability claims.Failure to comply with the statutory regulations andsafety instructions and incorrect repairs even whenusing original spare parts make the guarantee nulland void and preclude any liability forJ. Eberspächer GmbH & Co. KG.
• Subsequent installation of this heater must complywith these installation instructions.
• The statutory regulations are binding and must alsobe observed in countries which do not have anyspecial regulations.
• Installation of the heater in special vehicles mustcomply with the regulations applying to suchvehicles.
• Other installation requirements are contained in thecorresponding sections of this manual.
Safety instructions for installationand operation
Danger!
Risk of injury, fire and poisoning!• Disconnect the vehicle battery before starting any
kind of work.
• Before working on the heater, switch the heater offand let all hot components cool down.
• The heater must not be used in closed rooms, e.g.in the garage or in a multi-storey car park (do notleave the engine running when the vehicle is at astandstill).
Caution!
Safety instructions for installation and operation!• The heater must only be installed by a JE partner
authorised by the manufacturer according to theinstructions in this manual and possibly according tospecial installation recommendations; the sameapplies to any repairs to be carried out in the caseor repairs or guarantee claims.
• Repairs by non-authorised third-parties or with notoriginal spare parts are dangerous and therefore notallowed. They result in expiry of the type permit ofthe heater; consequently, when installed in motorvehicles they can cause expiry of the vehicleoperating licence.
• The following measures are not allowed:– Changes to components relevant to the heater– Use of third-party components not approved by
Eberspächer– Nonconformities in installation or operation from
the statutory regulations, safety instructions orspecifications relevant to safe operation as statedin the installation instructions and operatinginstructions. This applies in particular to theelectrical wiring, fuel supply, combustion airsystem and exhaust system.
Please note!
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Introduction1
Accident prevention
General accident prevention regulations and thecorresponding workshop and operation safetyinstructions are to be observed.
Safety instructions for installationand operation
Caution!
Safety instructions for installation and operation
• Only the controls approved by Eberspächer may beused to operate the heater.The use of other controls can result in malfunctions.
• Only when upgrading the additional heater:Before the heater is installed again in anothervehicle, rinse the heater parts carrying water withclear water.
• When carrying out electric welding on the vehicle,the plus pole cable at the battery should bedisconnected and placed at ground to protect thecontroller.
• The heater must not be operated where there is arisk of an accumulation of flammable vapours ordust, for example close to– fuel depot– coal depot– wood depot– grain depots etc.
• The heater must be switched off when refuelling(vehicle engine).
• When the heater is mounted in a safety housingetc., the installation compartment of the heater isnot a stowage compartment and must be kept clear.In particular fuel canisters, oil cans, spray cans,gas cartridges, fire extinguishers, cleaning rags,items of clothing, paper etc. must not be stored ortransported on or next to the heater.
• Defect fuses must only be replaced by fuses withthe prescribed rating.
• If fuel leaks from the heater fuel system, arrangefor the damage to be repaired immediately by aJE service partner.
• When topping up the coolant, only use the coolantpermitted by the vehicle manufacturer, see thevehicle operating manual. Any blending withunpermitted coolant can cause damage to theengine and heater.
• After-running of the heater must not be interruptedprematurely e.g. by pressing the batterydisconnecting switch, apart from in the case of anemergency stop.
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• Please consult the additional parts catalogue forany other parts required for installation, e.g. hoseclips.
• The heater can be upgraded from additional heaterto pre-heater with a mod kit. Please consult thesales documents for the order number for vehicle-specific mod kits.
Recommendation:Starting the heater can be limited with an outsidetemperature switch, i.e. the heater switches on at atemperature < 5°C or <10°C.In addition, an ON/OFF switch should be fitted forvehicles frequently used for short distances.This allows for the heater to be switched off with theON/OFF switch when used for short distances andduring the summer months.The ON/OFF switch can be bought from a good partsdealer.
Order number:Outside temperature switch < 05°C 201 00 121Outside temperature switch < 10°C 201 00 122ON / OFF switch, 12 volt 201 00 123
Product information2
Please note!
Scope of supply for petrol heaters
Picture No.Quantity / Designation Order number
- 1 HYDRONICB 5 W Z – 12 V 20 1818 05 00 00
- 1 HYDRONICD 5 W Z – 12 V 25 2216 05 00 00
as complete package:
1 1 Heater ---- 2 1 Dosing pum ----
to be ordered separately:
3 1 Heater bracket 25 2220 80 00 01 4 1 Central screw 100 10 258 5 4 Metal-rubber puffer 20 1185 00 00 01 6 1 Water hose Ø 20 25 1917 80 00 01 7 2 Connector Ø 20 mm 20 1534 88 00 01 8 p.m. Pipe 3,5x3 360 75 300 9 p.m. Pipe 4x1,25 090 31 11810 1 Pipe clip 22 1000 50 05 0011 1 Hose clip 10 2064 01 60 2512 1 Flexible exhaust pipe 25 1774 80 02 0013 1 Combustion air hose 360 00 09914 1 End sleeve 25 1688 80 12 0115 1 Plug 22 1000 30 10 2116 1 Receptacle housing 22 1000 31 87 0017 1 Bracket 22 1000 50 03 0018 1 T-piece 8-6-8 262 31 15119 2 Support sleeve 22 1000 20 02 0020 p.m. Hose 7,5x2,5 360 31 07021 p.m. Hose 5x3 360 75 35022 p.m. Pipe 6x2 090 31 12523 1 Safety holder 22 1000 31 06 00
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Scope of supply
Product information2
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Technical data for petrol heaters
Heater B 5 W Z
Heating medium Water, cooling fluid
Control of the heat flow Large Small
Heat flow (watt) 5000 1500
Fuel consumption (l/h) 0,69 0,2
Mean electr. power (watt) in operation 37 10
at start 110
after-running 8
Electr. power of water pump 16 watt
Rated voltage 12 volt
Operating range• Lower voltage limit: an undervoltage protection 10,2 volt
in the controller switches the heater off onreaching approx 10 volt.
• Upper voltage limit: an overvoltage protection 16 voltin the controller switches the heater off onreaching approx 10 volt.
Tolerable operating pressure up to 2,5 bar overpressure
Flow rate of the water pump at 0.1 bar 800 l/h
Minimum water flow rate of the heater 250 l/h
Fuel commercially available petrol(see also fuel supply, page 29) (DIN EN 228)
Tolerable operating temperature operation heater –40 °C bis +80 °C
operating, dosing pump –40 °C bis +20 °C
storage –40 °C bis +105 °C
Interference suppression class 5 for VHF, SW, MW, 2 for LW
Weight• without controller and cooling fluid ca. 2,3 kg• with dosing pump and water pump, ca. 2,5 kg
Product information2
All technical data + 10%
Caution!Safety instructions for technical data!Failure to comply with the technical datacan result in malfunctions.
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Technical data for diesel heaters
Heater D 5 W Z
Heating medium Water, cooling fluid
Control of the heat flow Large Small
Heat flow (watt) 5000 2400
Fuel consumption (l/h) 0,62 0,27
Mean electr. power (watt) in operation 37 10
at start 110
after-running 8
Electr. power of water pump 16 watt 16 watt 12 watt
Rated voltage 12 volt 12 volt 24 volt
Operating range• Lower voltage limit: an undervoltage protection in the 10,2 volt 10,2 volt 20,4 volt
controller switches the heater off on reaching approx 10 v.
• Upper voltage limit: an overvoltage protection in the 16 volt 16 volt 32 voltcontroller switches the heater off on reaching approx 10 v.
Tolerable operating pressure up to 2,5 bar overpressure
Flow rate of the water pump at 0.1 bar 800 l/h 800 l/h 950 l/h
Minimum water flow rate of the heater 250 l/h
Fuel commercially available diesel(see also fuel supply, page 29) (DIN EN 590)
PME (DIN V 51606) only for D 5 W S, 24 Volt
Tolerable operating temperature operation heater –40 °C bis +80 °C
operating, dosing pump –40 °C bis +80 °C
storage –40 °C bis +105 °C
Interference suppression class 5 for VHF, SW, MW, 2 for LW
Weight• without controller and cooling fluid ca. 2,3 kg• with dosing pump and water pump, ca. 2,5 kg
Product information2
All technical data + 10%
Caution!Safety instructions for technical data!Failure to comply with the technical datacan result in malfunctions.
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Main dimensions
Product information2
Fuelinlet
Water: inlet / outlet
Combustionair inlet
Exhaust outlet
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Installation exampleDiesel heater in a truck and in a delivery van
� Heater� Exhaust silencer� Combustion air hose� Fuse holder� Dosing pump� Rising pipe� T-piece
Installation location
The installation location for the heater is the enginecompartment. The heater must be mounted below themin. cooling water level (compensation tank, cooler,vehicle heat exchanger) for automatic venting of theheat exchanger of the heater.
• In a truck, the water heater is preferably fastenedunderneath the driver’s cab in the longitudinal beamnear the vehicle engine.
• The regulations and safety instructions to beobserved for this chapter are stated on page 4 – 7.
• The installation suggestions made in theinstallation instructions are examples. Otherinstallation locations are possible if theycorrespond to the installation requirements statedin these installation instructions.
• Other installation information (e.g. for boats and ships)is available from the manufacturer on request.
Installation3
� heater� exhaust pipe� combustion air intake silencer� fuse bracket� dosing pump� rising pipe
Installation examplePetrol heater / diesel heater in a car
Please note!
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Installation3
Mounting and fastening
Position the heater in the holding clips of the heaterbracket and fasten with fastening screw, M6x97(torque 60.5Nm). Mount the heater bracket in a suitableposition in the engine compartment, possibly usinganti-vibration pads if necessary.
Depending on the installation space available, theheater can be moved sideways in the bracket andscrewed in one of the two fastening threads.
Possible installation positions
The heater should preferably be installed in the normalposition, horizontal with the exhaust connection downto the bottom. Depending on the installationconditions, the heater can also be mounted in thepermitted swivel range, see diagram.
Heater in normal position withpermitted swivel range
Swivel range from the normal positionup to max. 90° swivel upwards.
Swivel range from the normal position tomax. 90° swivel around the longitudinal axis.
When the heater is operating, the shown normal ormaximum installation positions can be varied brieflyby up to +15° in all directions. Such deviationscaused by the inclined position of the vehicle do notimpair the heater functions in any way.
Please note!
� heater� bracket clips� bracket holder
� fastening screw� fastening thread
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Nameplate
The nameplate is fastened to the front of the heater.The second nameplate (duplicate) is included in thescope of supply of the heater.If required, the duplicate nameplate can be adheredin a clearly visible position on the heater or near tothe heater.
The regulations and safety instructions to beobserved for this chapter are stated on page 5.
Installation3
� Original nameplate� 2nd nameplate (duplicate)
Please note!�
�
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Installation3
Connection to the cooling water circuit
The heater is connected to the cooling water circuitin the water feed pipe from the vehicle engine to theheat exchanger. There are four possible alternativeinstallations here.
Danger!
Risk of injuries and burns!It is possible for the coolant and components of thecoolant circuit to get very hot.
• Parts conveying water must be routed and fastenedin such a way that they pose no temperature risk toman, animals or material sensitive to temperaturefrom radiation / direct contact.
• Before working on the coolant circuit, switch theheater off and wait until all components have cooleddown completely, if necessary where safety gloves.
• When installing the heater and the water pump,please note the direction of flow of the coolantcircuit.
• Fill the heater and water hoses with coolant beforeconnecting to the coolant circuit.
• Route the water hoses without any kinks, and in arising position if possible.
• When routing the water pipes, observe a sufficientclearance to hot vehicle parts.
• Protect all water hoses/water pipes from chafing andfrom extreme temperatures.
• Secure all hose connections with hose clips.
• After the vehicle has been operating for 2 hours ortravelled 100 km, tighten the hose clips again.
• The minimum water flow rate is only guaranteed ifthe temperature difference of the heating mediumdoes not exceed 10 K between water inlet and wateroutlet during heating.
• Only overpressure valves with an opening pressureof min. 0.4 – max. 2 bar may be used in the coolantcircuit.
• The coolant liquid must contain at least 10%antifreeze all year round as corrosion protection.
• The cooling liquid must contain sufficient antifreezefor low temperatures.
• Before commissioning the heater or after changingthe cooling liquid, the whole coolant circuit includingheater must be vented free of bubbles according tothe instructions issued by the vehicle manufacturer.
• Only top up with coolant approved by the vehiclemanufacturer.
Please note!
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Installation3
Heating characteristics
The heater starts in the "large" setting.Once the cooling water temperature has reachedapprox. 80°C, depending on the selected fan setting,the heater switches to the "small" setting.If the heating output is inadequate in the "small"setting, the cooling water temperature falls to 75°C:the heater then switches back to the "large"settings.If the heating output is sufficient in the "small"setting, the cooling water temperature increases to85°C: the heater switches to the pause setting.Once the cooling water has cooled down to 75°C inthe pause setting, the cycle starts up again in the"large" setting.
Connection to the cooling water circuit
Integrate the heater in the water feed pipe fromthe vehicle engine to the heat exchanger “inlineconnection”
Disconnect the water feed pipe from the vehicle engineto the vehicle heat exchanger. Connect up the heaterwith connection pieces and water hoses to the waterfeed pipe.Route and connect a water hose from the pressureconnection of the water pump to the water intakeconnection of the heater.Secure both connection parts with hose clips.
� heater� connection piece� heat exchanger� vehicle engine
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Installation3
Exhaust system
(Exhaust diagram see page 19).
Mounting the exhaust system
The scope of supply of the universal installation kitincludes a flexible exhaust pipe, inner Ø 24 mm,1000 mm long and an exhaust silencer.The flexible exhaust pipe can be shortened to 20 cmor lengthened to max. 2 m, depending on theinstallation conditions.Fasten the exhaust silencer to a suitable position inthe vehicle. Route the flexible exhaust pipe from theheater to the exhaust silencer and fasten with pipeclips. If necessary, also fasten the flexible exhaustpipe with pipe clips at suitable positions in the vehicle.Connect the exhaust end pipe to the exhaust silencerwith an end sleeve and fasten with a pipe clip.
Caution!
Safety instructions!The whole exhaust system gets very hot during andimmediately after the heater has been working in theheating mode. This is why the exhaust system mustbe routed according to these installation instructions.• The exhaust outlet must end in the open air.• The exhaust pipe must not protrude beyond the
lateral limits of the vehicle.• Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm atthe lowest point to drain off condensation.
• Important functional parts of the vehicle must not beimpaired (keep sufficient clearance).
• Mount the exhaust pipe with sufficient clearance toheat-sensitive parts. Pay particular attention to fuelpipes (plastic or metal), electrical cables and brakehoses etc.!
• Exhaust pipes must be fastened safely(recommended clearance of 50 cm) to avoid damagefrom vibrations.
• Route the exhaust system so that the emitted fumesare not sucked in with the combustion air.
• The mouth of the exhaust pipe must not get cloggedby dirt and snow.
• The mouth of the exhaust pipe must not point in thedirection of travel.
• Always fasten the exhaust silencer to the vehicle.
Danger!
Risk of injuries and burns!Every type of combustion produces high temperaturesand toxic exhaust fumes. This is the reason why theexhaust system must be installed according to theseinstructions.• Do not perform any work on the exhaust system
while the heater is working.• Before working on the exhaust system, first switch
the heater off and wait until all parts have cooleddown completely, wear safety gloves if necessary.
• Do not inhale exhaust fumes.
• Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.
• If a silencer is fitted, the exhaust end pipe must bemuch shorter than the flexible exhaust pipe bet-ween the heater and the exhaust silencer.
Please note!
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Installation3
� heater� combustion air pipe� exhaust pipe� end sleeve
Caution!
Safety instructions for the combustion air system• The combustion air opening must be free at all times.
• Position the combustion air intake to be sure thatexhaust fumes cannot be sucked in with thecombustion air.
• The combustion air intake must not get cloggedwith dirt and snow.
• Install the combustion air intake system slopingslightly downwards. If necessary, make a drain holeapprox. Ø 5 mm at the lowest point to drain offcondensation.
Combustion air system
Mounting the combustion air system
The heater is mounted in the engine compartment, asdescribed in these instructions.If the intake connection for combustion air is in aposition where the combustion air can be expected tobe no warmer than 25°C and whether neither splashedwater nor dust/dirt are expected, then no combustionair hose is required.Otherwise a flexible combustion hose must bemounted with an inner Ø 20 mm and up to 1.5 m long,to ensure that the intake of combustion air comesfrom an area which complies with the aboveconditions.After completing all work, push an end sleeve overthe intake silencer/flexible pipe.
Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.
Please note!
max. 1,5 m
min. 20 cm to max. 2 m
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Installation3
� correct connection� incorrect connection – bubble formation.
� �
Fuel supply
Mounting the dosing pump, routing the fuel pipesand mounting the fuel tank
The following safety instructions must be observedwhen mounting the dosing pump, routing the fuel pipesand mounting the fuel tank.Deviations from the instructions stated here are notallowed.Failure to comply can result in malfunctions.
Danger!
Risk of fire, explosion, poisoning and injuries!
Caution when handling fuel.
• Switch off the vehicle engine and heater beforerefuelling and before working on the fuel supply.
• No naked lights when handling fuel.
• Do not smoke.
• Do not inhale petrol fumes.
• Avoid any contact with the skin.
Caution!
Safety instructions for routing the fuel pipes!
• Only use a sharp knife to cut off fuel hoses andpipes.Interfaces must not be crushed and must be freeof burrs.
• The fuel pipe from the dosing pump to the heatershould be routed at a continuous rise.
• Fuel pipes must be fastened safely to avoid anydamage and/or noise production from vibrations(recommended clearance of approx. 50 cm).
• Fuel pipes must be protected from any mechanicaldamage.
• Route the fuel pipes so that any distortion of thevehicle, engine movements etc. cannot have anylasting effect on the service life.
• Parts carrying fuel must be protected frominterfering heat.
• Never route or fasten the fuel pipes to the heater orvehicle exhaust system. When the systems cross,always ensure there is a sufficient heat clearance.If necessary, install heat deflection plates.
• Dripping or evaporating fuel must never be allowedto collect on hot parts or ignite on electric systems.
• When connecting fuel pipes with a fuel hose, alwaysmount the fuel pipes in a butt joint to prevent anybubbles from forming.
Safety instructions for fuel pipes and fuel tanksin buses and coaches
• In buses and coaches, fuel pipes and fuel tanksmust not be routed through the passengercompartment or driver’s cab.
• Fuel tanks in buses and coaches must bepositioned in such a way that the exits are not indirect danger from a possible fire.
Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.
Please note!
21
a
8
b
Installation3
Fuel feed point with T-piece from the fuel supply linefrom the tank fitting to the vehicle engine.
� fuel feed pipe from tank connection – insertT-piece before the fuel pump in the fuel feed pipe
� fuel return pipe to the tank connection� dosing pump� T-piece, 8-6-8� fuel filter – only necessary for contaminated fuel� fuel hose, 5 x 3 (di = Ø 5 mm)� fuel pipe, 6 x 2 (di = Ø 4 mm)� fuel pipe, 4 x 1.25 (di = Ø 2 mm) fuel hose, 5 x 3 (di = Ø 5 mm),
approx. 50 mm long fuel hose, 3.5 x 3 (di = Ø 3.5 mm),
approx. 50 mm long� to the engine, mechanical fuel or injection pump
Possible pipe lengths
Intake side Pressure sidea = max. 2 m b = max. 4 m for petrol
b = max. 6 m for diesel
Fuel supply for petrol heaters
Installation position of the T-piece
Use the installation positions shown in the diagramwhen inserting a T-piece
� direction of flow from the fuel tank� direction of flow to the vehicle engine
� �
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a
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b
Installation3
Fuel feed point with tank connection –ascending pipe, integrated in the vehicle tank
� tank connection for metal tank –di = Ø 2 mm, da = Ø 6 mm
� tank connection for tank fitting –di = Ø mm, da = Ø 4 mm
� dosing pump� fuel filter – only required for contaminated fuel� fuel hose, 5 x 3 (di = Ø 5 mm)� fuel pipe, 6 x 2 (di = Ø 2 mm)� fuel hose, 4 x 1 (di = Ø 2 mm)� fuel hose, 3.5 x 3 (di = Ø 3.5 mm),
approx. 50 mm long fuel hose, 5 x 3 (di = Ø 2 mm),
approx. 50 mm long fuel pipe, 4 x 1.25 (di = Ø 1.5 mm)� connection fitting, da = Ø 4 mm
Possible pipe lengths
Intake side Pressure sidea = max. 2 m b = max. 4 m for petrol
b = max. 6 m for diesel
Items � � � are included in the “tank connection “ kit(order no. 22 1000 20 07 00).
Fuel supply for petrol heaters
Caution!
Safety instructions for the fuel supply!
• The fuel must not be conveyed by gravity oroverpressure in the fuel tank.
• Withdrawal of fuel after the vehicle’s fuel pump isnot allowed.
• When the pressure in the fuel pipe is more than0.2 bar to max. 2 bar, use a pressure reducer(order no. 22 1000 20 09 00) or separate tankconnection.
• When the pressure in the fuel pipe is more than2 bar or there is a non-return valve in the return pipe(in the tank), a separate tank connection must beused.
• When using a T-piece in a plastic pipe, always usesupport sleeves in the plastic. Connect the T-pieceand the plastic pipe with corresponding fuel hosesand secure with hose clips.
Please note!
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Possible suction and pressure heightof the dosing pump
Pressure height from vehicle tank to dosing pump:a = max. 3000 mm
Intake height in pressure-less vehicle tank:b = max. 500 mm for petrolb = max. 1000 mm for diesel
Intake height in vehicle tanks with withdrawal bynegative pressure (valve with 0.03 bar in tank cap):b = max. 150 mm for petrolb = max. 400 mm for diesel
Pressure height of the dosing pump to the heater:c = max. 2000 mm
Check tank venting. � connection to heater� max. fuel level� min. fuel level
Installation3
Fuel supply
Installation position of the dosing pump
Always mount the dosing pump with the pressure siderising upwards. Every installation position over 15° isallowed, although an installation position between 15°and 35° is preferable.
� installation position between 0° and 15°is not allowed.
� preferred installation position in range 15° to 35°� installation position in range 35° to 90° is allowed
Caution!
Safety instructions for installingthe dosing pump• Always mount the dosing pipe with the pressure
side rising upwards – minimum incline 15°.
• Protect the dosing pump and filter from intolerableheat, do not mount near to the silencers andexhaust pipes.
Please note!
�
�
�
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Installation3
Fuel supply
Fuel quality for petrol heaters
The heater can run on commercially available fuelas per DIN EN 228, as used in the vehicle tank.
Fuel quality for diesel heaters
In special cases (above 0°C), the heater can alsorun on fuel oil EL or paraffin.
Fuel for low temperaturesRefineries and fuel service stations automaticallyadjust the fuel to normal winter temperatures (winterdiesel). This means that difficulties are only to beexpected for extreme drops in temperature, as alsoapply to the vehicle engine. Please also refer to thevehicle manual.
If the heater is run from a separate tank, pleasecomply with the following rules:For temperatures above 0°C, any kind of diesel fuelas per DIN EN 590 can be used.
If no special diesel fuel is available for lowtemperatures, then paraffin or petrol should be mixedwith the fuel according to the following table:
Temperature Winterdiesel Addition 0 °C bis –25 °C 100 % ––––25 °C bis –40 °C 50 %* 50 % paraffin
or petrol
* or 100% special cold diesel fuel (Arctic diesel)
Please note!
• Mixtures with used oil are not allowed!
• After refuelling with winter or cold diesel or the listedblends, the fuel pipes and the dosing pump must befilled with the new fuel by letting the heater run for15 mins.!
Operation with biodiesel (PME)The heater is not certified for operation with biodiesel.
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Operation and function4
Operating instructions
If the vehicle engine is not providing enough heat inthe warming-up phase, in city traffic or in trafficcongestion, the heater switches on automatically andsupports the vehicle's own heating system.
Important instructions for operation
Safety checks before the startAfter a longer interval in operations (after the summermonths) the fuse must be put in position and/or theheater connected up to the battery. Check that allparts fit firmly (tighten screws where necessary).Check the fuel system visually for any leaks.
Heating at high altitudesWhen using the heater at high altitudes, please note:
• Heating at altitudes up to 1500 m:– Unlimited heating possible
• Heating at altitudes over 1500 mm:– Heating is possible for short periods at this
altitude (e.g. driving over a mountain pass ortaking a break in a journey)
– Heating is not possible for longer periods at thisaltitude (e.g. winter camping).
Initial commissioning
• After installation of the heater, the coolant circuitand the whole fuel supply system must be ventedcarefully. Comply with the instructions issued by thevehicle manufacturer.
• Open the coolant circuit before the trial run (se thetemperature control to “open”).
• During the trial run of the heater, check all water andfuel connections for leaks and firm fitting.
• If the heater shows a fault during operation, findand eliminate the cause of the fault using adiagnosis unit.
Description of functions
Switching on (additional heating mode)After a certain program sequence, the heater startsthe combustion air fan, glow plug and fuel dosingpump. Once a stable flame has formed in thecombustion chamber, the glow plug switches offagain under time control.
Heating modeDepending on heating requirements, the heater isadjusted in the following stages:LARGE – SMALL – OFF (pause).The temperature limits are permanently programmed inthe electronic controller.If the heating requirements in the “SMALL” stage areso small that the cooling water temperature reaches85°C, the heater goes into the pause mode.The heater continues to run on for approx. 130seconds, then it switches off (pause mode).The control lamp lights up and the water pumpcontinues to run, even in the pause mode.
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Operation and function4
Control and safety devices
• If the heater does not ignite within 90 secondsafter starting the fuel pump, the start is repeated.If the heater still does not ignite after another90 seconds, the heater is switched off. After anunacceptable number of failed start attempts, thecontroller is locked.*
• If the flame goes off by itself during operation, theheater is restarted.If the heater does not ignite within 90 secondsafter the fuel pump has started again, the heater isswitched off.The fault shutdown can be cancelled by switchingoff and on again briefly (ignition ON / OFF).
• In the case of overheating (e.g. lack of water, poorlyvented coolant circuit), the overheating sensortriggers, the fuel supply is interrupted and the heaterswitched off.Once the cause of overheating has been eliminated,the heater can be started by switching off and onagain (ignition ON / OFF), on condition that theheater has cooled down again sufficiently, coolingwater temperature <70°C.After the heater has been switched off foroverheating an unacceptable number of times,the controller is locked.*
• The heater is switched off if the upper or lowervoltage limit is reached.
• The heater does not start up when the glow plug isdefect or when the electric lead to the dosing pumpis interrupted.
• The speed of the fan motor is monitored continuously.If the fan motor does not start up, if it is blocked or ifthe speed falls below 40% of the nominal speed, theheater is switched off after 60 sec.
* The controller can be enabled again and the faultsread off:• by connecting up a diagnosis unit• the customer service program KD2000.
Or operation and fault list, please refer to theenclosed operating instructions or the troubleshootingand repair instructions for the heater.
Do not switch the heater off and on again more thantwice.
Emergency shutdown – EMERGENCY OFFIf an emergency shutdown – EMERGENCY OFF –is necessary during operation, proceed as follows:• Switch heater off (ignition OFF).• Pull the fuse out or• Disconnect the heater from the battery.
Please note!
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Electrical system5
Heater wiring
Caution!
Safety instructions for wiring the heater!The heater is to be connected up electricallyaccording to the EMC directives.EMC can be affected if the heater is not connected upcorrectly. For this reason, comply with the followinginstructions:
• Ensure that the insulation of electrical cables is notdamaged. Avoid: chafing, kinking, jamming orexposure to heat.
• In waterproof connectors, seal any connectorchambers not in use with filler plugs to ensure theyare dirt-proof and water-proof.
• Electrical connections and ground connections mustbe free of corrosion and firmly connected.
• Lubricate connections and ground connectionsoutside the heater interior with contact grease.
Comply with the following when wiring the heater and thecontrol element:• Electrical leads, switchgear and controllers must be
arranged in the vehicle so that they can functionperfectly under normal operating conditions(e.g.heat exposure, moisture etc.).
• The following cable cross sections are to be usedbetween the battery and heater. This ensures thatthe max. tolerable voltage loss in the cables doesnot exceed 0.5 V for 12 V or 1 V for 24 V ratedvoltage.
Cable cross sections for a cable length of– up to 5 m (plus cable + minus cable) = cable cross section 4 mm²– from 5 to 8 m (plus cable + minus cable) = cable cross section 6 mm²
• If the plus cable is to be connected to the fuse box(e.g. terminal 30), the vehicle cable from the batteryto the fuse box must be included in rating the overallcable length and possibly re-dimensioned ifnecessary.
• Insulate unused cable ends.
Please note!
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Electrical system5
Parts list
1.1 Burner engine1.2 Glow plug1.5 Overheating sensor1.12 Flame sensor1.13 Temperature sensor
2.1 Controller2.2 Dosing pump2.7 Main fuse 25 A
5.1 Battery
a) Diagnosisb) +15
Option: a temperature switch and / or anON / OFF switch can be fitted in this line
c) D+ dynamo
Connectors and bush housings are shownfrom the cable inlet side.
Cable colours
rt = redbl = bluews = whitesw = blackgn = greengr = greyge = yellowvi = violetbr = brownli = purple
Circuit diagram
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Troubleshooting / Maintenance / Service6
When faults occur, please check thefollowing:
• If the heater does not start after being switched on:– Switch the heater off and on again.
• If the heater still does not start, check whether:– there is fuel in the tank?– the fuses are OK?– the electrical cables, connections etc. are OK?– anything is clogging the combustion air supply or exhaust system?
Maintenance instructions
• Before the heating period starts, the heater shouldundergo a trial run.If persistent extreme smoke develops, unusualburning noises or a clear fuel smell can be perceivedor if electric/electronic parts heat up, the heatermust be switched off and put out of service byremoving the fuse.In this case, the heater should not be started upagain until it has been checked by qualified staffwho have been trained on Eberspächer heaters.
• Check the openings of the combustion air supplyand exhaust system after longer standstill periods,clean if necessary!
Service
If you have any technical queries or problemswith your pre-heater, dial the following servicephone number:
HotlinePhone. 0800 / 12 34 300
Fax hotlineFax 01805 / 26 26 24
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Environment7
EU Declaration of Conformity
With regard to the following products
heater type HYDRONIC
we herewith confirm that it conforms with the primesafety requirements stipulated in the directives of theEU Council for harmonisation of the legal regulationsof the member states with regard to electromagneticcompatibility (89 / 336 / EEC).This declaration applies to all heaters producedaccording to the production drawings HYDRONICwhich are an integral part of this declaration.
The following standards/directives have been used toassess the product with regard to electromagneticcompatibility:• EN 50081 – 1 Basic form interference emission• EN 50082 – 1 Basic form interference resistance• 2 / 245 / EEC – Modification status 95 / 54 / EU
interference suppression in motor vehicles
Certification
The high quality of Eberspächer’s products is the keyto our success.To guarantee this quality, we have organised all workprocesses in the company along the lines of qualitymanagement (QM).Even so, we still pursue a large number of activitiesfor continuous improvement of product quality in orderto keep pace with the similarly constantly growingrequirements made by our customers.All the steps necessary for quality assurance arestipulated in international standards.This quality is to be considered in a total sense.It affects products, procedures and customer/supplierrelationships.Officially approved public experts assess the systemand the corresponding certification company awardsa certificate.
Eberspächer has already qualified for the followingstandards:
Quality management as perDIN EN ISO 9001:2000 and ISO/TS 16949:1999
Environment management system as perDIN EN ISO 14001:1996
Disposal
Disposal of materialsOld devices, defect components and packagingmaterial can all be separated and sorted into pure-grade factions so that all parts can be disposed of asrequired in an environment-friendly manner or recycledwhere applicable.Electric motors, controllers and sensors (e.g.temperature sensors) are deemed to be “electronicscrap”.
Dismantling the heaterThe heater is dismantled according to the repairstages in the current troubleshooting/repairinstructions.
PackagingThe packaging of the heater can be kept in caseit has to be sent back.
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Guarantee conditions8
Guarantee
We guarantee the assured characteristics and free-dom from faults in conformity with the current state ofthe art. Changes in design which we execute infulfilment of an order are not an entitlement for com-plaint.
The guarantee covers a period of 24 months; forretrofitting the period commences with the date whenthe heater was installed; for serial installation theperiod commences with the date of acceptance of thevehicle with the heater. This presupposes that thecompleted guarantee card is immediately returnedafter the heater has been installed.
We are entitled to choose within the guaranteewhether an objected product is to be repaired orreplaced. Replaced parts become our property andmust be forwarded to us, together with the guaranteeapplication, by way of the servicing workshop.With heaters the objected part must be immediatelybrought in the installed state to the servicing work-shop so that the fault can be remedied and a writtenguarantee claim can be submitted. If visiting theservicing workshop involves unjustifiable expenses(e.g. with building machinery), then the nearest servic-ing workshop must be informed, and the objected partmust be kept in readiness for assessment.
Furthermore, we bear the dismantling and installingcosts for parts that are built into vehicles or station-ary equipment. However, this presupposes that thework is completed by us or a workshop authorised byus. In the event of unusual dismantling and installingconditions, e.g. due to the peculiarities of the givenvehicle, we will only bear the expenses to acommensurate extent. If the repair work is completedat the ordering party, then the ordering party mustbear the cost of travel time and travel expenses.There is no right to claim rescission or a reduction,except if we are unable to remedy the fault. Theguarantee obligation becomes null and void if thedelivered object is changed by a third party or byincorporating parts of alien origin, except if the fault isnot in a causal connection with the change. It alsobecomes null and void if mounting and operating ruleshave not been observed. Natural wear and damageresulting from improper treatment or overloading areexempted from the guarantee. Moreover, we cannotbe held liable for the changed state or manner ofoperation of our products due to improper storage aswell as climatic or other influences. The guaranteedoes not cover faults resulting from constructionalpeculiarities or the selection of unsuitable materialsor inappropriate installation in a vehicle which theordering party has stipulated contrary to our previousinformation. The guarantee obligation is not extendedor renewed as a result of the repair or replacement.
Liability
In so far as there are no alternative provisions inthese conditions, claims for compensation, particularlyas a result of a positive contract violation andviolation of mutual confidence in the preparation ofa contract, are excluded to the legally permissibleextent. If action based on law that is not modifiable istaken against the ordering party on account of faultliability vis-à-vis a third party, then we will support theordering party to the same extent as the orderingparty would be directly liable.The principles of § 254 BGB (German Civil Code) areapplicable to compensation for damage between theordering party and us. This also appliesin the event that we directly assert a claim.
Place of jurisdiction
The place of jurisdiction is the competent court forEsslingen or, according to our choice, the competentcourt for the domicile of the workshop that executedthe order, provided that:– The customer is a merchant who has been entered
as such in the Commercial Register;– The customer does not have a general inland place
of jurisdiction, or– after the contract was concluded, the customer
moves his domicile or customary whereabouts awayabroad, or if the customer's domicile or customarywhereabouts is unknown when a suitis filed.
We are also entitled to file a suit with the court thatis competent for the seat or branch of the orderingparty.
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Lists9
List of key words A – Z
Keyword Page
AAccident prevention ................................................... 7Arrangement of the heater ......................................... 5
BBiodiesel (PME) ......................................................... 24Bubble formation ...................................................... 24
CCable colours ........................................................... 28Certification .............................................................. 30Circuit diagram .......................................................... 28Combustion air system ............................................. 19Concept of this manual .............................................. 3Connection cooling water circuit ........................ 16, 17Control and safety devices ...................................... 26
DDescription of functions ........................................... 25Disposal .................................................................... 30Dosing pump ............................................................. 23
EElectrical system .............................................. 27 – 28Electronic components ...................................... 33, 34Emergency shutdown ................................................ 26Environment .............................................................. 30EU Decleration .......................................................... 30EU Type Permit ............................................................ 5Exhaust system ........................................................ 18
FFastening .................................................................. 16Fuel supply ....................................................... 20 – 24Fuel quality ............................................................... 24
GGuarantee ................................................................ 31
HHeater wiring ............................................................. 27Heating operation ..................................................... 31Heating mode ........................................................... 25
IInitial commissioning ................................................ 25Installation ........................................................ 13 – 24Installation example ................................................. 13Installation location .................................................. 13Introduction ......................................................... 2 – 7
Keyword Page
LLiability ..................................................................... 31List of abbrevations ................................................. 33List of key words ............................................... 32, 33
MMain dimensions ....................................................... 12Maintenance instructions ......................................... 29Mounting and fastening ............................................ 14Mounting the exhaust system .................................. 18
NNameplate ................................................................ 15
OOperating instructions .............................................. 25Operation and function ..................................... 25 – 26Operating status display ............................................ 5
PParts list ................................................................... 28Picture symbols .......................................................... 4Place of jurisdiction .................................................. 31Possible pipe lengths ......................................... 21, 22Power consumption ............................................ 10, 11Presentations ............................................................. 4Product information ............................................ 8 – 12Proper use .................................................................. 4Protection .......................................................... 10, 11Purpose ...................................................................... 4
RRated voltage .................................................... 12, 13Regulation ............................................................. 5, 6
SSafety checks .......................................................... 25Safety instructions ................................................ 6, 7Scope of supply ..................................................... 8, 9Service ..................................................................... 29Special text structure ................................................. 4Statutory regulations ............................................. 5, 6Storage temperature .......................................... 10, 11Switching on ............................................................. 25
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Lists9
List of key words A – Z
Keyword Page
TTechnical data ................................................... 10, 11Text structure ............................................................. 4T-piece ...................................................................... 21Troubleshooting ........................................................ 29
VVoltage .............................................................. 10, 11Voltage limit ....................................................... 10, 11
WWhen faults occur .................................................... 29
List of abbreviations
EU Type PermitPermit awarded by the Federal Vehicle Office for theproduction of a heater for installation in motorisedvehicles.
EMC directiveElectromagnetic compatibility.
JE partnerJ. Eberspächer partner.
PMEBiodiesel as per DIN V 51606.
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