hydronic l-ii...heater order no. order no. – compact version hydronic l16 25 2486 02 00 00 – –...

Heater OrderNo. OrderNo.–compactversion

HydronicL16 252486020000 –––

HydronicL24 252487020000 252487050000

HydronicL30 252599020000 252599050000

HydronicL35 252600020000 252600050000

HYDRONIC L-II Technical Description, Installation, Operating and Maintenance Instructions.

Engine-independent water heater for diesel.

25.2599.90.0001.0A02.2019

2

1 •Contents...................................................................................................... 2•Conceptofthismanual................................................................................ 3•Specialtextstructure,presentationandpicturesymbols.............................. 4•Importantinformationbeforestartingwork................................................... 4•Statutoryregulations................................................................................ 5,6•Safetyinstructionsforinstallationandoperation........................................... 7•Accidentprevention.................................................................................... 7

•Scopeofsupply/additionalparts............................................................ 8,9•Technicaldata,heaters.............................................................................. 10•Technicaldataforthewaterpump..................................................... 11–13•Maindimensions....................................................................................... 14•Maindimensions,compactversion............................................................ 14

•Permissiblemountingpositionandfasteningoftheheater......................... 15•Mainwaterpumpdimensions............................................................ 16–18•Permissibleinstallationpositionandfixingofthewaterpump............ 16–18•Installationlocation.................................................................................... 19•Installingtheheaterinabox...................................................................... 20•Nameplate/NameplatewithEBANo........................................................ 21•Exhaustsystem(pipes)........................................................................ 22,23•Combustionairsystem.............................................................................. 24•Connectiontothecoolingwatercircuit...................................................... 25•Watercircuit.............................................................................................. 25•Fuelsupply....................................................................................... 26–28

•Structureoftheheater............................................................................... 29•Operationinstructions/importantinformationforoperation....................... 29•Initialcommissioningoftheheater............................................................. 29•Functionaldescription/Functionaldiagram............................................... 30•Controlandsafetydevices/EMERGENCYOFF........................................ 31

•Heaterwiring............................................................................................. 32•Partslistforcircuitdiagram,heaterandcableharness.............................. 32•Heatercircuitdiagram................................................................................ 33•Cableharnesscircuitdiagram.................................................................... 34•Controlunitscircuitdiagrams............................................................. 35–39

•Ifanyfaultsoccur,pleasecheckthefollowingitems................................... 40•Troubleshooting......................................................................................... 40•Maintenanceinstructions........................................................................... 40•Changingcomponents.............................................................................. 40•Service...................................................................................................... 40

•Certifications.............................................................................................. 41•Disposal.................................................................................................... 41•EUDeclarationofConformity..................................................................... 41

•Listofabbreviations.................................................................................. 42

•Maintenancescheduleandmeasurementsrecord............................. 43–45

Introduction1

Chapter Title Contents Page

Contents

Introduction

Product information

Installation

Operation and function

Electrical system

FaultsMaintenanceService

Environment

List

Maintenance schedule

6

5

4

3

2

7

8

9

3

Concept of this manual

Thismanualaimstosupporttheservicecompanyinstallingtheheaterandtoprovidetheuserwithallimportantinformationabouttheheater.Themanualhasbeendividedinto9chapterstomakeiteasiertofindthecorrespondinginformationquickly.

IntroductionHereyoufindimportantintroductoryinformationaboutinstallationoftheheaterandaboutthestructureofthemanual.

Product informationHereyouwillfindinformationaboutthescopeofsupply,thetechnicaldataandthedimensionsoftheheater.

InstallationHereyouwillfindimportantinformationandinstructionsreferringtoinstallationoftheheater.

Operation and functionHereyouwillfindinformationabouttheoperationandfunctionoftheheater.

Electrical systemHereyouwillfindinformationabouttheheater'selectricsandelectroniccomponents.

Troubleshooting / maintenance / serviceHereyouwillfindinformationonpossiblefaults,maintenanceandtechnicalsupport.

EnvironmentHereyouwillfindinformationaboutcertificationanddisposaloftheheatertogetherwiththeEUDeclarationofConformity.

ListHereyouwillfindthelistofabbreviations.

Maintenance schedule and measurements recordHereyouwillfindthemaintenancescheduleandthemeasurementrecordforheaters.

4

Introduction1

5

61

2

3

7

8

9

4

Introduction1

Special text structure, presentation and picture symbols

Thismanualusesspecialtextstructuresandpicturesymbolstoemphasizedifferentcontents.Pleaserefertothefollowingexamplesfortheirmean-ingsandappropriateaction.

Special text formats and presentations

Adot(•)indicatesalistwhichisstartedbyaheading.Ifanindenteddash(–)followsadot,thislistissubordi-natetothedot.

Picture symbols

Regulation!

Thispicturesymbolwiththeremark"Regulation!"referstoastatutoryregulation.Failuretocomplywiththisregulationresultsinexpiryofthetype-approvalfortheheaterandpreclusionofanyguaranteeandliabilityclaimsonEberspächerClimateControlSystemsGmbH&Co.KG.

Danger!

Thispicturesymbolwiththeremark"Danger!"referstotheriskofafataldangertolifeandlimb.Undercertaincircumstances,failuretocomplywiththeseinstructionscanresultinsevereorlife-threateninginjuries.

Important!

Thispicturesymbolwiththeremark"Caution!"referstoadangeroussituationforapersonand/ortheproduct.Ignoringthisinformationcanresultininjuriestopeopleand/ordamagetomachinery.

Theseremarkscontainrecommendationsforuseandusefultipsforinstallationoftheheater.

Important information before starting work

Range of application of the heater

Thewaterheateroperatingindependentlyofanengineisintendedforinstallationinthefollowingvehicles:

•Alltypesofmotorvehicles,especiallybusesandcoaches

•Constructionmachinery

•Agriculturalmachinery

•Boats,shipsandyachts

•Railvehicles

•Installationoftheheaterinvehiclesusedforthetrans-portofdangerousgoodsaccordingtoADRisnotpermitted.

•Theheaterisprimarilyintendedforinstallationinbusesandisdesignedfortheirspecialrequirements.Hereitmustbenotedthatinstallationisnotallowedinvehiclespacesusedbypersons(morethan8pas-sengerspaces).

Exception:seepage5.Statutoryregulations,locationoftheheater.

Intended purpose of the heater (via the vehicle's own heat exchanger)

•Pre-heating,de-mistingwindows

•Heatingandkeepingthefollowingwarm:–Driverandworkingcabs–Freightcompartments–Ship'scabins–Passengerandcrewcompartments–Vehicleenginesandunits

Onaccountofitsfunctionalpurpose,theheaterisnotapprovedforthefollowingapplications:

•Long-termcontinuousoperation,e.g.forpre-heatingandheatingof:–Residentialrooms–Garages–Workhuts,weekendhomesandhuntinglodges–Houseboats,etc.

Important!Safety instructions for the range of application and proper, intended use!

Theheatermustonlybeusedandoperatedfortherangeofapplicationstatedbythemanufacturerandincompliancewiththeoperationinstructionsincludedwitheveryheater.

Please note!

Please note!

5

Statutory regulations

TheFederalMotorTransportAuthorityhasissuedanapprovalforacomponentaccordingtoECER122andECE-R10fortheheaterforinstallationinmotorvehicles,withthefollowingofficialtype-approvalmarkingsnotedontheheater’snameplate.

Heater type: ECE type approval mark:

HydronicL-II 122R–00023310R–045282

TheFederalRailwayOfficehasissueda“typeapprovaltoArt33EBO”forinstallationoftheheaterinrailvehi-cles;thevehiclehasthefollowingofficialtypeapproval:

HydronicL-II EBA32AZ3/0097/08

RegulationsExcerpt from ECE regulation No. 122 of the Euro-pean Parliament and the Council

General regulations

• Operating state display–Aclearlyvisibleoperatingdisplayintheuser's

fieldofvisionmustindicatewhentheheaterisswitchedonandoff.

Regulations concerning installation in the vehicle

• Scope–Subjecttodifferingstipulationsinthefollowing

section,combustionheatersmustbeinstalledaccordingtotheregulations5.3ofECE-R122.

–ItisassumedthatClassOvehicleswithheatersforliquidfuelconformtotheregulations5.3ofECE-R122.

• Arrangement of the heater–Partsofthestructureandothercomponentsnear

theheatermustbeprotectedfromexcessiveheatexposureandpossiblefueloroilcontamination.

–Theheatermustnotposeafirehazardevenwhenitoverheats.Thisrequirementisdeemedtobeful-filledifadequateclearanceisensuredforallpartsduringinstallation,sufficientventilationisprovidedandfireproofmaterialsorheatshieldsareused.

–TheheatermustnotbemountedinthepassengercompartmentofvehiclesinclassM2andM3.How-ever,aheaterinahermeticallysealedenclosurewhichalsocomplieswiththeaforementionedconditionsmaybeused.

Introduction1

–Thefactorynameplateorduplicatemustbeaffixedsothatitcanstillbeeasilyreadwhentheheaterisinstalledinthevehicle.

–Allappropriateprecautionsmustbetakenwhenarrangingtheheatertominimisetheriskofinjuriestopersonsordamagetootherproperty.

• Fuel supply–Thefuelintakeconnectionmustnotbelocatedin

thepassengercompartmentandmustbesealedwithaproperlyclosinglidtopreventanyfuelleaks.

–Inheatersforliquidfuelwheretheheaterfuelisseparatefromthevehiclefuel,thetypeoffuelandintakeconnectionmustbeclearlyidentified.

–Awarningsignistobefixedtotheintakeconnec-tionindicatingthattheheatermustbeswitchedoffbeforerefuelling.

• Exhaust system–Theexhaustoutletmustbearrangedsoasto

preventanypenetrationofexhaustfumesintothevehicleinteriorthroughtheventilationsystem,warmairintakesoropenwindows.

• Combustion air intake–Theairfortheheater'scombustionchambermust

notbesuckedinfromthevehicle'spassengercompartment.

–Theairintakemustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyotherobjects.

• Automatic control of the heating system–Iftheenginefails,theheatingsystemmustbe

automaticallyswitchedoffandthefuelsupplystoppedwithin5seconds.Theheatermayremaininoperationifamanualdevicehasalreadybeenactivated.

Please note!

TheheaterisnotapprovedforinstallationintheinteriorofClassM1vehicles(vehiclesforpassengertransport/cars)andNvehicles(vehiclesforthetransportofgoods).

6

Statutory regulations

• Compliancewiththestatutoryregulations,theadditionalregulationsandthesafetyinstructionsisprerequisiteforguaranteeandliabilityclaims.

Failuretocomplywiththestatutoryregulationsandsafetyinstructionsandincorrectrepairs,eveniforigi-nalsparepartsareused,maketheguaranteenullandvoidandprecludeanyliabilityforEberspächerClimateControlSystemsGmbH&Co.KG.

• Subsequentinstallationofthisheatermustcomplywiththeseinstallationinstructions.

• Thestatutoryregulationsarebindingandmustalsobeobservedincountrieswhichdonothaveanyspecialregulations.

• WheninstallingtheheaterinvehiclesnotsubjecttotheGermanRoadTrafficLicensingRegulations(StVZO),forexampleships,therespectivespeciallyvalidregulationsandinstallationinstructionsmustbeobserved.

• Installationoftheheaterinspecialvehiclesmustcom-plywiththeregulationsapplyingtosuchvehicles.

• Otherinstallationrequirementsaregivenintherelevantsectionsofthismanual.

Introduction1

Please note!

7

Safety instructions for installation and operation

Danger!

Risk of injury, fire and poisoning!

•Disconnectthevehiclebatterybeforestartinganykindofwork.

•Beforeworkingontheheater,switchtheheateroffandletallhotpartscooldown.

•Theheatermustnotbeoperatedinclosedrooms,e.g.inthegarageorinamulti-storeycarpark.

Important!Safety instructions for installation and operation!

•TheheatermustonlybeinstalledbyaJEpartnerauthorisedbythemanufactureraccordingtotheinstructionsinthismanualandpossiblyaccordingtospecialinstallationrecommendations;thesameappliestoanyrepairstobecarriedoutinthecaseofrepairsorguaranteeclaims.

•Repairsbynon-authorisedthird-partiesorwithnotoriginalsparepartsaredangerousandthereforenotallowed.Theyresultinexpiryofthetype-approvaloftheheater;consequently,wheninstalledinmotorvehiclestheycancauseexpiryofthevehicleoperatinglicence.

•Thefollowingmeasuresarenotallowed:–Changestocomponentsrelevanttotheheater.–Useofthird-partycomponentsnotapprovedby

EberspächerClimateControlSystemsGmbH&Co.KG.

–Nonconformitiesininstallationoroperationfromthestatutoryregulations,safetyinstructionsorspecifica-tionsrelevanttosafeoperationasstatedintheinstallationinstructionsandoperatinginstructions.Thisappliesinparticulartotheelectricalwiring,fuelsupply,combustionairsystemandexhaustsystem.

•Installationandrepairmaybecarriedoutwithoriginalaccessorypartsandoriginalsparepartsonly.

•OnlycontrolunitsapprovedbyEberspächerClimateControlSystemsGmbH&Co.KGmaybeusedtooperatetheheater.Useofothercontrolunitscancausemalfunctions.

Introduction1

•Beforetheheaterisinstalledagaininanothervehicle,rinsetheheaterpartscarryingwaterwithclearwater.

•Whencarryingoutelectricweldingonthevehicle,thepositivecableatthebatteryshouldbedisconnectedandplacedatgroundtoprotectthecontrolbox.

•Donotoperatetheheateranywherewheretherearereadilyflammablematerials(e.g.drygrass,leaves,paper,etc.)intheareaoftheexhaustsystemorwhereignitablefumesanddustcanform,e.g.neara

–fueldepot–coaldepot–wooddepot–graindepots,etc.

•Theheatermustbeswitchedoffwhenrefuelling.

•Iftheheaterisfittedinasafetycasing,etc.,theheater'sinstallationboxmustnotbeusedasstor-agespaceandmustbekeptclear.Inparticularfuelcanisters,oilcans,spraycans,gascartridges,fireextinguishers,cleaningrags,itemsofclothing,paperetc.mustnotbestoredortransportedonornexttotheheater.

•Defectfusesmustonlybereplacedbyfuseswiththeprescribedrating.

•Iffuelleaksfromtheheaterfuelsystem,arrangeforthedamagetoberepairedimmediatelybyaJEser-vicepartner.

•Whentoppingupthecoolant,onlyusethecoolantpermittedbythevehiclemanufacturer,seethevehicleoperatingmanual.Anyblendingwithunpermittedcoolantcancausedamagetotheengineandheater.

•Theafter-runningoftheheatermustnotbeprema-turelyinterruptede.g.bypressingthebatteryisolatingswitch,exceptforanemergencystop.

Please note!

Followinginstallation,attachthe“Switchoffheaterbeforerefuelling!”stickernearthetankfillerneck.

Accident prevention

Generalaccidentpreventionregulationsandthecor-respondingworkshopandoperatingsafetyinstructionsaretobeobserved.

8

Product information2

Scope of supply

Fig. No. Designation Order No.

1 HydronicL16–24volt 252486020000

1 HydronicL24–24volt 252487020000

2 HydronicL24–24volt 252487050000 Compactversion

1 HydronicL30–24volt 252599020000


1 HydronicL35–24volt 252600020000


Thefollowingadditionalpartsarerequiredtoruntheheater:

•Additionalpartsforconnectiontothewatercircuit

•Additionalpartsforthefuelsupply

•Additionalpartsfortheexhaustsystem

•Controlunit

Additional parts which have to be ordered separately

Fig. No. Designation Order No.

3 Flowtronic5000 252488260000 4 Flowtronic5000S 251818300000 5 Flowtronic6000SC 252488250000 6 Hoseclip,ø40-47mm 15200158 7 Hoseelbow,ø38mm 36000300 8 Connectionpipe,ø38mm 251214890021 9 T-piece,ø38-38-38 25137189040010 Reducer,ø38/28mm 25121489001911 Hoseclip,ø32-39mm 1526109712 Pipeelbow,ø38mm 25121489000313 Waterhose,ø38mm 3607509614 Exhaustpipesocket,ø70mm 22100040040015 Exhaustpipeelbow,ø70mm 22100040030016 Fuelfilter 25248805010017 Banjobolt,M14x1.5 1041004018 Sealingring,A14x18 3231600619 Fuelsuctionline, 252488050400 Ø5x3,800mmlong20 Screwfixing,M14x1.5 2664200421 Sphericalliner 2633508022 Unionnut,M14x1.5 1161004023* Fuelpipe, ––––––

Cu,DIN1786,innerdiameterø624 Fuelhose, 36075350

innerdiameterø5x325 Hoseclip,ø11mm 10206801109826 Screwfixing,M14x1.5 25170605010027 RubberbufferM6x10, 201607650002 height15mm28 Fuelreturnline, 251698050400

Ø5x3,750mmlong29 Ballvalve 25248805020030 Reducingcoupling8/6 2660002631 Shroudwithhoseconnection 22100040060032 1mflexiblehose,ø60mm 10211431000033 Hoseclip 10206405007034 Airhosefixingkit 22100050020035 Plasticgrille 251688800600

* Thefuelpipemustbeboughtfromthetrade.

Forfurtheradditionalparts,seeproductoverview.

Please note!

9


Scope of supply

10


Important!Safety instructions for technical dataFailuretocomplywiththetechnicaldatacanresultinmalfunctions.

Technical data

Heatertype Hydronic L-II

Heater HydronicL16 HydronicL24 HydronicL30 HydronicL35

Version HL2-16 HL2-24 HL2-30 HL2-35

Heatingmedium Mixtureofwaterandantifreeze(Proportionofantifreezeatleast10%upto50%maximum)

Heatflowinwatts(atambienttemperature–10°C)

16000 24000 30000 35000

Temperaturevalues–atwaterinlet ON73°C/OFF78°C

Temperaturevalues–atwateroutlet ON85°C/OFF118°C

Fuel Diesel–commerciallyavailable(DINEN590)HeatingoilEL(DIN51603)

Fuelconsumption(atambienttemperature–10°C)

2.0l/h 2.9l/h 3.65l/h 4.2l/h

Ratedvoltage 24volt

Operatingrange•Lowervoltagelimit: Anundervoltageprotectioninstalledinthe

controlboxswitchesofftheheaterifthevoltagelimitisreached.

20volt

•Uppervoltagelimit: Anovervoltageprotectioninstalledinthe

controlboxswitchesofftheheaterifthevoltagelimitisreached.

30volt

Electricalpowerconsumption(inoperation) 60watt 80watt 105watt 120watt

Watervolume(intheheater) approx2.4l

Heatingcircuitwatervolume min10l

Minimumthroughput(minimumattheheater)

1400l/h 2000l/h 2600l/h 3000l/h

Permissibleambienttemperature

Heater

inoperation

–40°Cto+85°C

withoutoperation

–40°Cto+100°C

Permissibleoperatingtemperature

Heatingmedium

Combustionair

–40°Cto+90°C/brieflyupto+120°C

<60°C

Operatingpressure(intheheater) 2.5bar

CO2values(%vol) 9–11 9–11 9–11 9,5–11,5

COintheexhaust <0,04

Smokespotno.(Bacherach) <4

Weight approx18kg

Interferencesuppressionclass 4forVHF/SW/LW,5forMW

Protection IP54

Providednolimitvaluesaregiven,thetechnicaldataprovidediswiththeusualheatertolerancesof±10%atratedvoltage,20°CambienttemperatureandreferencealtitudeEsslingen.

Please note!

11



Technical data

Pumptype Flowtronic 5000


Deliveryrate 5200l/h±10%at0.2bardeliverypressure

Operatingpressure,watercircuit max2bar

Weight(withoutbracket,clipandcoolant) 2.04kg

Ratedvoltage 24volt

Operatingrange 20–28volt

Powerconsumptionat5200l/hand0.2bardeliverypressure

104watt±10%

Interferencesuppressionclass Limitclass3InterferencefieldstrengthtoCISPR253rd0.15MHz–1000MHztoDIN57879/Part1VDE0879

Protection IP5K4

Electricalfusingforthirdpartycontrols 15A

Temperatureconditions

–40°Cto+90°C short-term(15min)+115°CHeatingmedium

–40°Cto+90°C short-term(15min)+115°CAmbient,operating

Dryrunning No

Blocking Theengineremainsundamagedwithinaperiodofmax6seconds.

Shaft–impellerconnection Mechanicalseal

Pumping and pressure loss characteristic curves

•Providednolimitvaluesaregiven,thetechnicaldataprovidediswiththeusualwaterpumptolerancesof±10%atratedvoltage,20°CambienttemperatureandreferencealtitudeEsslingen.

•TheFlowtronic5000waterpumpisinstalledincom-pactheaters.

•Thewaterpumpsmustbeassignedtotheheatersdependingontheminimumthroughputandcoolingwatervolume.

Please note!

Volumetricflow(withwaterat20°C)

Flowresistance(whenpumpatastandstill)

p [

bar

]

Q [l/h]

12



Technical data

Pumptype Flowtronic 5000 S





Ratedvoltage 24volt



104watt±10%

Interferencesuppressionclass 1forVHF,5forSW,2forMWandLWtoDIN57879/Part1VDE0879

Protection IP54AtoDIN40050Sheet1


Temperatureconditions –40°Cto+90°C short-term(15min)+115°CHeatingmedium


Dryrunning No

Blocking Theengineremainsundamagedwithinaperiodofmax6seconds.

Shaft–impellerconnection Magneticclutch


Please note!





p [

bar

]

Q [l/h]

13



Technical data

Pumptype Flowtronic 6000 SC





Ratedvoltage 24volt



210watt±10%

Interferencesuppressionclass 5forLW,MW,SW1,SW2,VHFaccordingtoDINEN55025

Protection IP25(encapsulatedelectronics)accordingtoDIN40050,Part9


Temperatureconditions –40°Cto+90°C short-term(15min)+115°CHeatingmedium


Storage –40°Cto+120°C

Dryrunning approx45min.–themotorswitchesitselfoffafterapprox45min.

Anti-blockingprotection Yes–thestartingattemptsarecontinuedwithoutlimit.


Please note!





p [

bar

]

Q [l/h]

14

162

180

38

79

75

Ø8

224

228

Main dimensions

Main dimensions – compact version


min.375forremovingtheheaderpipe

Please note!

Thisfigureshowsthedimensionsdifferingfromthetopversiononly.

15

Permissible mounting positions and fasten-ing of the heater

Theheatershouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesandthethroughholefortheexhaustfittingontothemountingsurface–asshowninthesketch–anddrillaccordingly.Fixtheheaterwith4screwsM8and4bodywashers.

•Thecontactsurfaceforthetwofasteningconsolesmustbeflat.

•Dependingontheinstallationconditions,theheatercanbetiltedatanangleasshowninthediagrams.Inheatingmode,theheatercandeviatefromthenormalpositionbyupto+15°inalldirectionsasaresultoftheslantedpositionofthevehicle.

•Forverticalmountingpositiontheheatermustalwaysbesupportedatthebottomoftheheatexchangerbyastablebearingsurface.Thefixingscrewsaresolelyforfixingtheheater.

Permissible mounting positions and hole pattern for the heater

Mounting position, compact version•Horizontalmountingpositionwiththeallowabledeviations.•Verticalmountingpositionnotallowed.

•Horizontalmountingpositionwiththeallowabledeviations.

•Verticalmountingpositionwith-outdeviations.

Drilling hole pattern

Installation3

Ø4.5forhexagonscrewM4Ø2.9forself-tappingscrewB3.9

Please note!

5°

5°

15° 15°

15° 15°

5°

5°

16

Installation3

Main dimensions, Flowtronic 5000

Permissible mounting positions and fasten-ing of the water pump

Thewaterpumpisinstalledinahorizontalposition.Inthishorizontalposition,thewaterpumpwithitspumphousingcanberotated–asshowninthesketchbelow.Transferthefourfasteningholesontothemountingsurface–asshowninthesketchofthemaindimen-sions–anddrillaccordingly.Ifpossible,fixthewaterpumptothevehiclewith4rub-berbuffersM6x10.

•Thelayingoftheconnectionlinesmustnotcauseanylateralstrainforcestooccurintheinletandoutletcon-nectionsocketsofthewaterpump(theconnectionsocketsandconnectionlinesmustbeinalignment).

•Theinstallationclearancefromadjacentcomponentsmustbeatleast10mm.

•Contactthemanufacturerforinstallationinadifferentposition.

Please note!

a Preferredinstallationposition

b Permissiblemountingpositionb

aa

b

17

Installation3

Main dimensions, Flowtronic 5000 S


Thewaterpumpshouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesontothemountingsurface–asshowninthesketchofthemaindimen-sions–anddrillaccordingly.Ifpossible,fixthewaterpumptothevehiclewith4rub-berbuffersM6x10.


•Theinstallationclearancefromadjacentcomponentsmustbeatleast10mm.

Please note!


b Permissiblemountingposition

b

a

a

b

18

Installation3

Main dimensions, Flowtronic 6000 SC


Thewaterpumpshouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesontothemountingsurface–asshowninthesketchofthemaindimen-sions–anddrillaccordingly.FixthewaterpumptothevehicleusingtheM6rubberbuffersincludedinthescopeofsupply.

•Themountingpositionofthewaterpumpmustbechosentopreventlargequantitiesofwaterorexhaustgasfromenteringtheelectricmotor.


•Thedistancefromadjacentpartsmustbeatleast10mmtoensureventilation.

Please note!


b Permissiblemountingposition

a

b

19

Installation location

Theheaterandthewaterpumpareintegratedinthecoolingwatercircuitofthevehicleorinaseparatewatercircuit.Theheatershouldbeinstalledaslowaspossibleinthevehicle,inasplash-proofposition,e.g.intheenginecompartmentorinastowagecompartment.Thisensuresautomaticventingoftheheaterandthewaterpump.Whenchoosingthemountingposition,spacemustbelefttodismantletheshroud(130mm)andtheheaderpipe(375mm).Breakthroughstotheoutsidemustbesplashproof.Iftheinstallationconditionsaretoocramped,orifthetemperatureisexcessivelyhigh,ahoodwithhosecon-nectionmustbeinstalledforcombustionairintake.Thecombustionairisthendrawninthroughaflexiblehose.Thisenablesthecombustionairtobedrawninfrom

anareawithanallowabletemperaturerangewhichisprotectedfromdirt.Asafetygrilleistobefittedtotheflexiblehose.Afterinstallingahoodwithhoseconnection,thecombustionairmustbeadjustedbymeasuringtheCO2level.Pleaserefertothetroubleshootingsectionandrepairinstruc-tionsforthesetvalues.Otherinstallationlocationsarepossibleiftheycomplywiththeinstallationrequirementsstatedintheseinstalla-tioninstructions.

Additional notes on the location in rail vehicles

Inrailvehiclestheheatermustbefixedintheenginecompartment(e.g.locomotive)orunderfloorintheinstallationboxonthevehiclebody(e.g.railcar).OtherlocationsrequireanacceptanceinspectionbyEberspächerClimateControlSystemsGmbH&Co.KG.

Installation3

Installation example in a bus and in a rail vehicle

1 Heater2 Waterpump3 Tankconnection

4 Vehicleengine5 Frontheater6 Roofairducts

7 Roofheater8 Floorheater9 Additionalwaterpump

•Complywiththestatutoryregulationsandsafetyinstructionsregardingthecontentsofthischapteronpage4–7.

•Mounttheheaterundertheminimumcoolingwaterlevel(headertank,radiator,vehicleheatexchanger).

•Ifinstallingtheheaterinaseparatelyinstalledwatercircuittheinstallationmustalwaysbesubjectedtoanacceptanceinspectionbytheheatermanufacturer.

Please note!

Ifthisinstallationacceptancedoesnottakeplaceanywarrantyorliabilityclaimswhatsoeverexpire.

•Itisnotpermissibletofixtheheaterinrailvehicleswithmetal-rubberbuffers.

•Installationrequirements(e.g.forboatsandships)areavailablefromthemanufactureronrequest.

20

Installing the heater in a box

Iftheheatercannotbeinstalledintheenginecompart-mentorinastowagecompartmentofthevehicle,itcanalsobeinstalledinabox.Theboxwiththeinstalledheateristhenfixedtothevehicleatasuitablepointe.g.longitudinalframe.Itisnecessarytoinstallahoodwithhoseconnectionforcombustionairintake.Thecombustionairisthendrawninfromoutsidetheboxthroughaflexiblehose.

•Complywiththestatutoryregulationsandsafetyinstructionsregardingthischapteronpage4–7.

•Theboxmustbeadequatelyventilatedfromtheout-sidesothatthepermissibleambienttemperatureisnotexceeded.

•Ventilationopeningsmustbepositionedintheboxinsuchawaythattheycannotbecloggedupbydirtandsnow.

•Anywaterwhichpenetratestheboxmustbeallowedtodrainoff.

Installation3

1 Box2 Heater3 Shroudwithhoseconnection4 Flexiblehosewithsafetygrille5 Waterpump6 Fuellines7 Waterhose8 Waterinlet9 Wateroutlet

Thisenablesthecombustionairtobedrawninfromanareawithanallowabletemperaturerangewhichisprotectedfromdirt.Asafetygrilleistobefittedtotheflexiblehose.Afterinstallingahoodwithhoseconnection,thecombustionairmustbeadjustedbymeasuringtheCO2level.Pleaserefertothetroubleshootingsectionandrepairinstruc-tionsforthesetvalues.

Installation example – heater in a box

Please note!

21

Nameplate

Thenameplatestuckontotheheatermustbeprotectedagainstdamageandmustbeeasytoreadwhentheheaterisinstalled.Ifthisisnotthecasetheinstallercanstickaduplicatenameplateontotheheaterorintheareaoftheheaterinapositioninwhichitiseasytoseeandread.Theduplicatenameplateisgluedontotheshroudoftheheater,andcanbepulledoffifnecessary.


•HeatersapprovedforinstallationinrailvehiclesareidentifiedbyanEBANo.onthenameplate.

1 Originalnameplate2 Duplicatenameplate

Please note!

Installation3

22

Exhaust system (pipes)

Danger!Risk of injuries and burns!

Everytypeofcombustionproduceshightemperaturesandtoxicexhaustfumes.Thisiswhytheexhaustsys-temmustalwaysbelaidaccordingtotheseinstallationinstructions.

•Donotperformanyworkontheexhaustsystemwhiletheheaterisworking.

•Beforeworkingontheexhaustsystem,switchofftheheaterfirstandwaituntilallthepartshavecompletelycooleddown,wearsafetyglovesifnecessary.

•Donotinhaleexhaustfumes.

Important!Safety instructions for the exhaust system!

•Theexhaustpipemustendintheopenair.

•Theexhaustpipemustnotprotrudebeyondthelaterallimitsofthevehicle.

•Installtheexhaustpipeslopingslightlydownwards,ifnecessarydrilladrainholeapproxØ5mmatthelow-estpointasacondensationoutlet.

•Importantfunctionalpartsofthevehiclemustnotbeimpaired(keepsufficientclearance).

•Installtheexhaustpipewithsufficientclearancefromheat-sensitivecomponents.Payparticularattentiontofuellines(madeofplasticormetal),electricalcablesandbrakehoses,etc.!

•Exhaustpipesmustbesafelyfixed(recommendedclearanceof50cm)toavoiddamagefromvibrations.

•Laytheexhaustsystemsothattheoutflowingexhaustgasesarenotsuckedinascombustionair.

•Themouthoftheexhaustpipemustnotbecomecloggedwithdirtandsnow.

•Aligntheoutletoftheexhaustpipesothatthedis-chargeoftheexhaustisnotpreventedbybackpres-sure(wind/airstream).Backpressureincreasesthetemperatureintheheatexchangerandcausescom-ponentdamage.

•Inrailvehiclesitisimportanttoensurethattheexhaustopeningdoesnotpointinoneofthepossibledirectionsoftravel(90°tothedirectionoftravel).

Installation3

Installing the exhaust system

Pushanexhaustpipeelboworanexhaustpipesocketontotheheater'sexhaustconnectionandfixtothefloorofthevehicle.OrderNo.oftheexhaustsystemparts,seepage8.

Arigidorflexibleexhaustpipe,innerØ70mm,canbefixedtotheexhaustbendasanextension.Theexhaustpipecanbeuptoamaximumof4mlong,dependingontheinstallationconditions.

Arigidexhaustpipemadefromunalloyedoralloyedsteeloraflexibleexhaustpipemadefromalloyedsteel,innerø=70mm,iscurrentlynotavailable.Ifneededtheexhaustpipeandthecorrespondingpipeclipsmustbepurchasedfromaspecialiststore;thewallthicknessoftherigidexhaustpipemustbeatleast1mm.

Aftertheexhaustsystemhasbeeninstalled,makeanendsleeve(seepage17)andpushitontotheendoftheexhaustpipe.

•Theexhaustsystemcanbelaidwithmax.3x90°angles,thetotallengthreducesby0.5mwitheach90°-bend.

•Usepipeclipstofixtheexhaustpipetothevehicleflooratsuitableplaces.


Please note!

23

Installation3

Example for the exhaust system

Metal end sleeve with separators for exhaust pipe

Ifnecessaryyoumustmakeametalendsleevewithseparatorsfortheexhaustpipeyourself.Themetalendsleevemustnotplugtheexhaustsothatsootisformed.

Sketch1

1 Heater2 Exhaustconnection3 Exhaustpipeelbow90°4 Exhaustpipe5 Flexibleexhaustpipe6 Pipeclip7 Metalendsleeve

Items4–6mustbepurchasedfromaspecialiststore.YoumustmakeItem7yourself.

Exhaust system (pipes)

Please note!

24

Combustion air system

Important!Safety instructions for the combustion air system!

•Thecombustionairmaynotbedrawninfromroomsinwhichtherearepeople.

•Thecombustionairopeningmustbefreeatalltimes.•Positionthecombustionairintaketobesurethat

exhaustfumescannotbesuckedinwiththecombus-tionair.

•Donotdirectthecombustionairintakeagainstthevehicle'sairstream.

•Thecombustionairintakemustnotbecomecloggedwithdirtandsnow.

•Installthecombustionairsystemslopingslightlydownwards.Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointasacondensationoutlet.

•Iftheheaterisinstallednearthevehicle'stankinajointinstallationspacethecombustionairmustbedrawninfromtheoutsideandtheexhaustmustbedischargedoutsideintotheopenair.Theopeningsmustbemadesplashproof.

•Inrailvehiclesitisimportanttoensurethatthecom-bustionairopeningdoesnotpointinoneofthepos-sibledirectionsoftravel(90°tothedirectionoftravel).

Complywiththestatutoryregulationsandsafetyin-structionsregardingthischapteronpage4–7.

Theventilationopeningforthecombustionairmustbepositionedontheboxsothatitcannotbecomeblockedbydirtandsnowandexhaustgasescannotbesuckedin.

Example for the combustion air system

Installation3

Combustion air intake

Thecombustionairisroutedtotheburnerintheheaterviathehood.Noinstallationworkisnecessary.Iftheheaterisinstalledinaboxortheinstallationconditionsareveryconfinedand/orthetemperatureisunaccept-ablyhigh,werecommendfittingahoodwithhoseconnectionfordrawinginthecombustionair.Thecom-bustionairisthensuckedinthroughaflexiblehose.Thisensuresthatthecombustionairissuckedinfromanareaintherighttemperaturerangewhichisprotectedfromdirt.Asafetygrilleistobefittedtotheflexiblehose.

Ifahoodwithhoseconnectionisnotusedwhentheheaterisinstalledinabox,thecombustionairmustbesuckedinthroughaventilationopeningwithaneffectiveminimumcrosssectionwhichcorrespondstoapipewithØ60mm.

Combustionairintakethroughagillplate.

Combustionairintakewithaflexiblehoseø60mm,max1mlong.

Please note!

Please note!

25

Connection to the cooling water circuit

Theheaterisintegratedinthevehicle'scoolingwatercircuit.Analternativeinstallationoptionistoinstalltheheaterwithitsowncoolingwatercircuitwithaheadertank.

Danger!Risk of injuries and burns!

Thecoolingwaterandcomponentsofthecoolingwatercircuitcangetveryhot.•Partsconveyingwatermustberoutedandfastened

insuchawaythattheyposenotemperaturerisktoman,animalsormaterialsensitivetotemperaturefromradiation/directcontact.

•Beforeworkingonthecoolingwatercircuit,switchtheheateroffandwaituntilallthecomponentshavecooleddowncompletely,ifnecessarywearsafetygloves.

•Wheninstallingtheheater,pleasenotethedirectionofflowofthecoolingwatercircuit.

•ThewaterhosesincludedintheEberspächerClimateControlSystemsGmbH&Co.KGscopeofsupplymustbeused.Ifnot,thehosesusedmustatleastconformtoDIN73411.

•Filltheheaterandwaterhoseswithcoolingwaterbeforeconnectingtothecoolingwatercircuit.

•Routethewaterhoseswithoutanykinks,andinaris-ingpositionifpossible.

•Whenroutingthewaterpipes,observeasufficientclearancetohotvehicleparts.

•Protectallwaterhoses/waterpipesfromchafingandfromextremetemperatures.

•Secureallhoseconnectionswithhoseclips.•Afterthevehiclehasbeenoperatingfor2hoursor

travelled100km,tightenthehoseclipsagain.•Theminimumwaterflowrateisonlyguaranteedifthe

temperaturedifferenceoftheheatingmediumdoesnotexceed10Kbetweenwaterinletandwateroutletduringheating.

•Onlyoverpressurevalveswithanopeningpressureofmin.0.4–max.2barmaybeusedinthecoolingwatercircuit.

•Ascorrosionprotectionthecoolingwatermustcon-tainatleast10%antifreezethewholeyearround.

•Duringcoldperiodsthecoolantwatermustcontainsufficientcoolant(antifreeze).

•Beforecommissioningtheheaterforthefirsttimeorafterchangingthecoolingwater,thewholecoolingwatercircuitincludingtheheatermustbeventedwith-outbubblesaccordingtothevehiclemanufacturer'sinstructions.

•Correctventilationisidentifiablebyawaterpumpwhichoperatesvirtuallynoise-free.Poorventilationcanresultinoverheatingoftheresettablethermalcut-outinheatingmode.

•Onlytopupwithcoolantapprovedbythevehiclemanufacturer.

•Insertthewaterpumppreferablyinthewaterinletlinetotheheater.

•Matchtheheaterandthecoolingwatercircuitsothatacoolingwatertemperatureofatleast60°Ccanbereachedwithinhalfanhour,asotherwisetheheatexchangerproducestoomuchcondensationandthereforereducestheefficiency.

Water circuitInthisinstallationexample,theheaterisshownintegratedinthecoolingwatercircuitofacoach/railvehicle.

Installation3

1 Heater 2 Flowtronicwaterpump 3 Shutoffvalve 4 Electricalshutoffvalve 5 Non-returnvalve 6 Fromvehicleengineorheader

tank 7 Tothevehicleengineorheader

tank 8 Frontheater/driver’scab 9 Spaceheater10 Convectionheater

Please note!

Installation example

26

•Neverlayorfixthefuelpipesimmediatelynexttotheheater'sexhaustsystempipesoralongthevehicle'sexhaustsystem.Ifthesystemscross,alwaysensurethereissufficientheatclearance.Ifnecessary,installheatdeflectionplates.

•Drippingorevaporatingfuelmustneverbeallowedtocollectonhotpartsorigniteonelectricequipment.

•Whenconnectingfuelpipeswithafuelhose,alwaysmountthefuelpipesinabuttjointtopreventanybub-blesfromforming.

Safety instructions for fuel pipes and fuel tanks in buses and coaches

•Inbusesandcoaches,fuelpipesandfueltanksmustnotberoutedthroughthepassengercompartmentordriver'scab.

•Fueltanksinbusesandcoachesmustbepositionedinsuchawaythattheexitsarenotinimmediatedan-gerifafireoccurs.

Complywiththestatutoryregulationsandsafetyinstruc-tionsregardingthischapteronpage4–7.

Important!Safety instructions for laying the fuel pipes!

•Useasharpknifeonlytotrimthefuelhosesandpipes.Interfacesmustnotbecrushedandmustbefreeofburrs.

•Theintakeandreturnlinemustbefilledwithfuelwhenputtingintoservice.Theheateronlyworkswithventedpipesandfilter.

•Fuelpipesmustbesecurelyfixedtoavoidanydam-ageand/ornoiseduetovibrations(recommendedguidelinevalue:atspacingsofapprox.50cm).

•Fuelpipesmustbeprotectedagainstmechanicaldamage.

•Laythefuelpipessothatanydistortionorshakingofthevehicle,enginemovements,etc.donothaveadisadvantageouseffectontheservicelife.

•Partscarryingfuelmustbeprotectedfromdisruptiveheat.

Fuel supply

Thefuelistakenfromthevehicle'sfueltankorasepa-ratefueltank.Thefollowingsafetyinstructionsmustalwaysbeobservedwhenlayingthefuellinesandinstallingafueltank.Deviationsfromtheinstructionsstatedherearenotallowed.Failuretocomplycanresultinmalfunctions.

Danger!Risk of fire, explosion, poisoning and injuries!

Cautionwhenhandlingfuel.•Switchoffthevehicleengineandtheheaterbefore

refuellingandbeforeworkingonthefuelsupply.

•Avoidnakedflameswhenhandlingfuel.

•Donotsmoke

•Donotinhalepetrolfumes.

•Avoidanycontactwiththeskin.

Installation3

Please note!

27

Operation with biodiesel (FAME)

Theheatersarenotapprovedforoperationwithbio-dieselfuel(FAMEaccordingtoDINEN14214).

Installation3

Please note!

Fuel supply

Fuel quality

•Theheaterrunsproblem-freeonstandardcommercialgradedieselfuelaccordingtoDINEN590.

Duringthewintermonthsthedieselfuelisadaptedtothelowtemperaturesof0°Cto–20°C.Problemscanthereforeonlyariseatextremelylowoutdoortempera-tures–asisthecasewiththevehicleengine–pleaserefertothevehiclemanufacturer'sinstructions.

•Inspecialcasesandatoutdoortemperaturesabove0CtheheatercanalsoberunonELheatingoilaccordingtoDIN51603.

•Iftheheaterisrunfromaseparatetank,pleasecom-plywiththefollowingrules:

–atoutdoortemperaturesover0°C: UsedieselfuelaccordingtoDINEN590.

–atoutdoortemperaturesof0°Cto–20°C: usewinterdieselfuelaccordingtoDIN590.

–atoutdoortemperatures–20°Cto–40°C: UseArcticdieselorPolardiesel.

•Additionsofusedoilarenotallowed!

•Afterrefuellingwithwinterorcoldweatherdieselthefuellinesmustbefilledwiththenewfuelbylettingtheheaterrunfor15minutes!

28

Installation3

Fuel supply

Connection of the intake and return pipe to the heater

Iffuelhosesareused,thehosesofferedintheEberspächerClimateControlSystemsGmbH&Co.KGproductrangeshouldalwaysbeused.Ifnot,thefuelhosesmustatleastconformtoDIN73379-1,Type3.Fire-resistantfuelhosestoENISO7840mustbeusedformarinevessels.Ifusingmetalfuelpipes,theusualmaterialsforvehicleconstructionsuchascopperorsteelmustbeused,togetherwiththerespectiveappropriatesealingandconnectiontechnique.Ifusingplasticpipes,theymustconformtoDIN73378(madefromsoft,lightandtemperaturestabilisedPA11orPA12)andmustbeinstalledtogetherwiththerespectiveappropriateconnectiontechnique

Permissible dimensions of the fuel linesInnerdiameterofthesuctionandreturnline:•forconnectiontotheringhosenippleø6mm:

minø5mm/maxø6mm,•Special case–forconnectiontotheringhosenipple

ø8mm:minø7mm/maxø8mm.

Important!Installationforashut-offdeviceinthereturnlineisnotallowed!

•Fuelhosesandfuelpipesareavailableasadditionalparts,seeproductoverview.

•Fuellineswithinnerdiameterø7mm/ø8mmaswellasringhosenipplewithø8mmmustbepur-chasedfromthetrade.

1 Connectionofthesuctionlinetotheringhosenippleø6mm

2 Connectionofthereturnlinetotheringhosenippleø6mm

Functional performance of the heater depending on the underpressure in the fuel system

Inordertoensurethefuelpumpworksproperly,itisnecessarytoensurethattheunderpressureinthefuelsystemisnottoohigh(seetable).

Fuel pressure (P)Heater inlet

Fuel pressure (P)Filter inlet

Preferredrange* min–0.3bar min–0.2bar

Allowablerange** –0.45barto–0.3bar –0.35barto–0.2bar

Criticalrange*** –0.55barto–0.45bar –0.45barto–0.35bar

Heatingmodenotpossible <–0.55bar <–0.45bar

*Preferredrangefordesignofthefuelsupply **Overtheoperatingperiodthecounterpressure

inthefuelsupplycanincreaseasaresultofdeposits(filterclogsup).***Heaterbecomessusceptibletofaults(gasbubbleformation/faultcode52,54)

Please note!

Permissible suction height and lengths of the suction line (min. ø 5 mm up to max. ø 8 mm):•Suctionheightupto1.5m—>max.length=25m•Suctionheight1.5mto4.0m—>max.length=15m

Permissible length of the return line (min. ø 5 mm up to max. ø 8 mm):•max.length=18m

29

Operation and function4

Structure of the heater

Theheaterconsistsofaheatexchangerandaremov-ableburner.Theheatexchangercontainsacombustionchamberconsistingofaheaderpipewithintegratedmixer.Theheaderpipecanbepulledoutoftheheatexchangerifnecessary.Thecontrolboxandelectricmotorarefixedtotheburnerflangeundertheshroudoftheburner.Thefuelpumpisintegratedintheburnerhousing.

Thefollowingadditionalpartsarerequiredtoruntheheater:•Waterpump –alreadyinstalledincompactversion

•Additionalpartsforconnectiontothewatercircuit

•Additionalpartsforthefuelsupply

•Additionalpartsfortheexhaustsystem

•Controlunit

FororderNo.oftheadditionalparts,seepage8,forfurtheradditionalparts,seeproductoverview.

Operating instructions

Theheaterisoperatedbyacontrolunit.Detailedoper-atinginstructionsaresuppliedwiththecontrolunit.

Youwillbeissuedtheoperatinginstructionsbytheinstallationworkshop.

Important notes on operation

Perform safety checks before the start

Afteralengthystoppage(summermonths),checkallcomponentsforsecurefit(tightenscrewswhereneces-sary).Carryoutavisualcheckofthefuelsystemforleaks.

Before switching on

Beforeswitchingonorpre-programmingheatingmode,switchthevehicle'sheatingleverto"WARM"(maximumsetting)andtheblowerto"slowlevel"(lowerelectricityconsumption).Invehicleswithautomaticheating,beforeswitchingofftheignition,switchtheheatingleverto"MAX"andtherequireddamperpositionto"OPEN".

Heating at high altitudes

Whenusingtheheaterathighaltitudes,pleasenote:•Heatingataltitudesupto1500m:

–Unlimitedheatingpossible.

•Heatingataltitudesover1500m:–Youcanusetheheateratthisaltitudeforshortperi-

ods(e.g.drivingthroughamountainpassortakingabreakinyourjourney).

–Forlongerstaysitisnecessarytoadjustthelevelofthefuelsupply,pleasecontactaJEpartnerforfurtherdetailsandadvice.

Initial commissioning of the heater

Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.

•Ensureyoureadtheoperatingandmaintenanceinstructionsbeforestartinguptheheater.

•Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

•Openthecoolantcircuitbeforethetrialrun(setthetemperaturecontrolto"WARM").

•Duringtheheatertrialrun,allwaterandfuelconnec-tionsmustbecheckedforleaksandsecure,tightfit.

•Iffaultsoccurwhiletheheaterisrunning,useadiag-nosticunittodetermineandcorrectthecauseofthefault.

Please note!

30


Functional description

Switch on the heater

Whentheheaterisswitchedonacomponenttestisperformed(3seconds),thewaterpumpisthenstartedup.

Note:

Thenozzlepre-heaterisswitchedonthefirsttimetheheaterisswitchedon.•IntheHydronicL16/L24,thenozzlepre-heater

remainsswitchedonuntiltheheaterswitches“OFF”orisswitchedoffbeforehand.

•IntheHydronicL30/L35,theoperatingtimeofthenozzlepre-heaterislimitedto15min.

Burner start

Theelectricmotorstartsanddrivesthecombustionairimpellerandthefuelpump.Afterapprox10secondstheignitionisswitchedonandthenthefuelsolenoidvalveopens.Withinthese10sec-ondsarotarycheckisperformedontheelectricmotor.Thefuelandcombustionairinthecombustionchamberformanignitablemixture.Themixtureisignitedbyahigh-voltageignitionspark.Theflamemonitorrecognisestheflame'sflickerfrequencyandswitchesofftheignitionsparkgenera-tor.Thehotcombustiongasesflowthroughtheheatexchangerandtransfertheheattotheheatdistributionmedium.

•Theheateroperatesdependingontheheatrequire-ments,thismeanstheburner'sswitchingonandswitchingofftimesvary.

•Thewaterpumpremainsinservicethewholetimetheheaterisrunning,evenduringpausemodeandduringafter-running.

Options•Iftemperatureloweringisactivatedthe"ON/OFF"

controltemperaturesareloweredbyapprox8K. ConnectionoftheON/OFF-switchfortemperature

lowering,seecircuitdiagramonpage34.

•Thewaterpumpcanberunindependentlyoftheheaterifappropriatecontrolsareinstalled.Forcon-nectionoftheadditional"ON/OFF"switchforsepa-ratewaterpumpcontrol,seecircuitdiagramonpage34.

•Withcontrolofthevehicle'sblower,thevehicleblowerisswitchedonoroffatthefollowingwatertempera-tures.–Watertemperature>55°C —>Vehicleblower"ON"–Watertemperature<50°C —>Vehicleblower"OFF"

Forcontrolofthevehicle'sblower,seecircuitdiagramonpage34.

Please note!

Nozzlepre-heater(Thenozzlepre-heateris

switchedonthefirsttimetheheaterisswitchedon.)

Waterpump

Operatingdisplay

Solenoidvalve

Flamedetection

Ignitionsparkgenerator

Controltemperaturesensor

Electricalmotor

HeaterON

Componentstest

Heatingmode Pausemode

After-run

StartphaseON

Heatingmode

HeaterOFF

After-run

3se

c

3sec

10s

ec

10s

ec

180sec

10s

ec

10s

ec

180sec

Functional diagram

HydronicL16/L24

HydronicL30/L35

(Operatingtimelimitedtomax.15min.)

31

Switch off the heater

Iftheheaterisswitchedoffthefuelsolenoidvalveclosesandafter-runningsimultaneouslystartsforapprox3minutes.Aftertheafter-runninghasfinishedtheheaterisauto-maticallyswitchedoff.

Untilitisswitchedoff,includingduringtheafter-running,thefueliscirculated.


Control and safety devices

Theheaterisequippedwiththefollowingcontrolandsafetydevices.

•Iftheheaterdoesnotignitethecontrolbox*islockedafteranunpermissiblenumberofunsuccessfulstartattempts.

•Ifthewaterflowistoolowthewaterdischargetem-peratureislimitedbyprematurecompensation.

•Thetimetakenforthetemperatureriseintheheatdistributionmediumismonitored.Ifitrisestoofast(waterflowtoolow)theheaterautomaticallyswitches"OFF"andbeginswiththeafter-running,thecyclethenbeginsagain.

•Constantcomparisonofthetemperaturesensorandoverheatingsensormeasuredvaluesprovidesaddi-tionalheatersafety,becauseifthedifferencebetweenthemeasuredvaluesistoolarge(waterflowtoolow)theheaterisprematurelyswitchedoff(shut-downonfault).

Afteranimpermissiblenumberofshut-downsonfault,thecontrolboxislocked.*

•Iftheloweroruppervoltagelimitisreached,theheaterisautomaticallyswitchedoff.

•Iftheflamesensordetectsaflameduringtheheater'safter-runningtheheaterisautomaticallyswitchedoff.

Afteranimpermissiblenumberofshut-downsonfault,thecontrolboxislocked.*

* Thecontrolboxcanbeunlockedwithtestingequip-ment/acontrolunit.Fortheprocedureanddescrip-tionfortestingequipmentandcontrolunits,see"InstallationInstructionsPlus–EasyStart/AltitudeKit/SpecialFunctionsandDiagnosis"

Emergency stop – EMERGENCY OFFIfanemergencystop–EMERGENCYOFF–isnec-essaryduringoperation,proceedasfollows:•Switchtheheateroffatthecontrolunitor•pullthefuseoutor•disconnecttheheaterfromthebattery.

Please note!

32

Heater wiring

Danger!Danger high voltageBeforeopeningtheheater,disconnecttheplug-incon-nectorwiththevehicle.

Important!Safety instructions!

Theheateristobeconnectedupelectricallyaccord-ingtotheEMCdirectives.ImpropertamperingwiththeheatercanaffecttheEMC.Forthisreason,complywiththefollowinginstructions:

•Ensurethattheinsulationofelectricalcablesisnotdamaged.

Avoid:Chafing,kinking,jammingorexposuretoheat.

•Sealanyconnectionchambersofwaterproofcon-nectorsnotinusewithfillerplugstoensuretheyaredirt-proofandwaterproof.

•Electricalconnectorsandearthconnectionsmustbefreeofcorrosionandsecurelyconnected.

•Lubricateconnectionsandgroundconnectionsout-sidetheheaterinteriorwithcontactgrease.

Complywiththefollowingwhenwiringtheheaterandthecontrolunit:

•Thenegativeandpositivepolesoftheheater'scon-trolsaretobedirectlyconnectedtothevehicle'sbat-tery.

•Contacttheheatermanufacturerregardingconnec-torsdifferingfromthestandardversion.

•Electricalleads,switchandcontrolgearmustbeposi-tionedinthevehiclesothattheycanfunctionperfectlyundernormaloperatingconditionswithoutimpairment(e.g.duetoheatexposure,moisture,etc.).

•Thefollowingcablecross-sectionsaretobeusedbetweenthebatteryandheater.Thisensuresthatthemax.permissiblevoltagedropinthecablesdoesnotexceed0.5Vfor12Vor1Vfor24Vratedvoltage.

Cablecross-sectionsforacablelength(pluscable+minuscable)of:–upto5m=cablecross-section4mm2

–from5mto8m(pluscable+minuscable)=cablecrosssection6mm2

•Ifthepositivecableistobeconnectedtothefusebox(e.g.terminal30),thevehicle'scablefromthebatterytothefuseboxmustalsobeincludedinthecalcula-tionforthetotalcablelengthandre-dimensionedifnecessary.

•Insulateunusedcableends.

Electrical system5

Please note!

Parts list for circuit diagram, heater and cable harness

-A10 Controlbox-A Connectorhousingtothecableharness-B Connectorhousing,burnermotor-C Connectorhousing,overheatingsensor-D Connectorhousing,fuelsolenoidvalve-E Connectorhousing,ignitionsparkgenerator-F Connectorhousing,heatingelementforfuel

nozzle-G Connectorhousing,sensor,internalcontrol

temperature-H Relayblock,heatingcartridge-I Relayblock,waterpump-A20 Ignitionsparkgenerator-B1 Sensor,internalcontroltemperature-B2 Overheatingsensor-K6 Relay,waterpump-K10 Relay,heatingcartridge-M1 Burnermotor-R5 Heatingelementforfuelnozzle-Y3 Fuelsolenoidvalve-Z1 Ignitionelectrodesa Interface,heater/cableharness

-A30 Fuseholder,3pin-F1 Fuse,heater-F2 Fuse,controlunit-F4 Fuse,waterpump-K1 Fanrelay-M10 Waterpump-P1 Switchoncontrol-P3 Faultindicatorlamp-P6 Fuelindicatorlamp-S4 Switch,temperaturedrop-S5 Switch,waterpump-XB1 Bushhousing,supply/signals-XB2 Bushhousing,signals-XB3 Bushhousingtotheheater-XB5 Bushhousing,waterpump-XB5/1 Bushhousing,waterpump-XB7 Relayblock,fanrelay-XS1 Connectorhousing,supply/signals-XS2 Connectorhousing,signals-XS5 Connectorhousing,waterpump-XS5/1 Connectorhousing,waterpump-XS8 Connectorhousing,waterpumpfaulta Interface,heater/cableharnessc tothecontrolunitf SwitchcableS+m Optionallyterminal15,terminal30orswitch

cableS+w Waterpumpexternalcontrolx Insulatecableandtieback

33

Electrical system5

Heater circuit diagram

+

-

-Z1

+86

-85

87

87a

-H

30

+86

-85

87

87a

-I

30A

B

CDE

F

G

H I18 2

17 1

12

312

12

12

23

1

21

85 86

87

87a30

86

87a30

85

X:58Light (+)

X:15Ign (+)

X:30Bat (+)

X:31Bat (-)

-A10

Θ

-B1

Θ

-B2

-A

1

2

3

4

5

6

7

8

M

-M1

-Y3

-A20

-R5

1

2

3

4

5

-K10

1

2

3

4

5

-K6

9

10

11

12

13

14

15

16

17

18

2 2

11-B

1,0 RD

1,0 GN

1,0 BN

1,0 BK

1,0 BN

2

1-D

2

1

3 3

2 2

1 1-E

2 2

1-C

3

1

3

2

1-F

2

1

2

1-G

2

1

a

25.1818.00.9601

Partslist,page32

34

Electrical system5

Partslist,page32

Cable harness circuit diagram

+

-

+86

-85

87 87a

-XB730

-XB3

-XB1

-XS1

-XB2

-XS2

-XB5-XB5/1

-XS5-XS5/1

-XS8

-XB8

-XB7

87

87a

30

86 85

X:58Light (+)

X:15Ign (+)

X:30Bat (+)

X:31Bat (-)

-F115A

-A30

-F415A

-F25A

1

2

3

4

5

6

7

89

10

11

12

13

14

15

1617

18 1

3

4

5

6

1

2

3

4

5

6

-XB1

2

1-XB5/1

22

1 1-XB5-XS5

1

2

3

4

5

6

1

2

3

4

5

6

-XB2

8 8

77

2

1-XS8

-M10

M

-XS5/1

2

1

-S4

-S5

2,5 RDBU

2,5 RDWH

1,0 GN

1,0 BK

1,0 GNRD

1,0 YEWH1,0 BUBK

1,0 YE

1,0 YE

1,0 BUWH

1,0 YERD

2,5 RD

2,5 BN

1,0 BUBK

1,0 YE

2,5 BNWH

2,5 BKWH

2,5 BN1,0 BN

1,0

1,0

1,0

1,0

1,0

1,0

1,0

1,0

1,0

4,0

4,0

4,0

1,0

a

-XB3

1 2 3 4 5-K1

2

-XS1

1,0 BN

1,0 YE

1,0 BUWH

c

f

1,0 RD

1,0

-XS2

-P1

-P6

-P3 m

w1,0

x

25.2488.00.9701

Connectorsandbushhousingsareshownfromthecableinletside.

Cable colours

RD red GR grey BK blackBU blue YE yellow GN greenWH white VT violet BN brownOR orange

35

Electrical system5

Circuit diagram – EasyStart Timer

X:58Light (+)

X:15Ign (+)

-E3

0,5* RD

0,5* BUWH

0,5* BN

1

2

3

4

5

6

7

8

-XB10

9

10

1

2

3

4

5

6

7

8

-XS10

9

10

0,35 RD

0,22 GYBK

0,22 BN

0,22 BUWH

0,22 VT

0,35 YE

0,22 BNYE

0,22 WHRD

0,22 BNWH

0,22 GY

0,5 GYBKc

0,22 BNWH

0,22 GYΘ

-B8

-XB10 -XS10

22.1000.34.9701

-B8 Roomtemperaturesensor(optional)-E3 EasyStartTimerc tothecableharness


NoteFurthercircuitdiagramsfortheEasyStartTimerareprintedintheInstallationInstructionsPlus,theseareavailabletoviewanddownloadfromtheServicePortal.

36

Electrical system5

Circuit diagram – EasyStart Remote+

X:58Light (+)

X:15Ign (+)

-E5

1

-XB12

2

12

3

4

5

6

7

8

9

10

11

-H2

0,5* RD

0,22 RDYE

0,5* BUWH

0,22 BNWH

0,22 GY

0,22 BNYE

-W2

0,5* BN

Θ

-B8

0,22 BN

c

-XB12

221000349722

-B8 Roomtemperaturesensor-E5 Stationaryunit,EasyStartRemote+

-H2 Button-W2 Antennac tothecableharness


NoteFurthercircuitdiagramsfortheEasyStartRemote+areprintedintheInstallationInstructionsPlus,theseareavailabletoviewanddownloadfromtheServicePortal.

37

Electrical system5

Circuit diagram – EasyStart Remote

X:58Light (+)

X:15Ign (+)

-E4

1

-XB12

2

12

3

4

5

6

7

8

9

10

11

-H2

0,5* RD

0,22 RDYE

0,5* BUWH

0,22 BNYE

-W2

0,5* BN

0,22 BN

c

-XB12

22.1000.34.9733

-E4 StationaryunitEasyStartRemote-H2 Button-W2 Antennac tothecableharness


NoteFurthercircuitdiagramsfortheEasyStartRemoteareprintedintheInstallationInstructionsPlus,theseareavailabletoviewanddownloadfromtheServicePortal.

38

Electrical system5

Circuit diagram – EasyStart Select

X:58Light (+)

X:15Ign (+)

-E2

0,5* RD

0,5* BUWH

0,5* BN

1

2

3

4

-XB41

2

3

4

-XS40,35 RD

0,35 GYBK

0,35 BN

0,35 BUWH

0,5 GYBKc

-XB4 -XS422.1000.34.9734

-E2 EasyStartSelectc tothecableharness


NoteFurthercircuitdiagramsfortheEasyStartSelectareprintedintheInstallationInstructionsPlus,theseareavailabletoviewanddownloadfromtheServicePortal.

39

Electrical system5

Circuit diagram – EasyStart Web

0,5* RD

0,5* BUWH

0,5* BNc

1

2

3

4

-XB5

-H4

0,22 RDYE

0,22 BNWH

0,22 GY

0,22 BNYE

Θ

-B10

0,22 BN

1

2

3

4

-XS5

0,5 RD

0,5 VT

0,5 BN

0,5 VT

0,5 BUWH

0,5 BUWH

0,5 BN

0,5 RD

-E6

1-XB4/1

2

3

4

1-XB3

2

3

-XB21

2

1-XB4/2

2

3

4

5 5 0,5 YE

0,5 YE

22.1000.34.9719

-B10 Roomtemperaturesensor-E6 EasyStartWeb-H4 Buttonc tothecableharness


NoteFurthercircuitdiagramsfortheEasyStartWebareprintedintheInstallationInstructionsPlus,theseareavailabletoviewanddownloadfromtheServicePortal.

40

If any faults occur, please check the follow-ing items

•Iftheheaterdoesnotstartafterbeingswitchedon:–Switchtheheateroffandonagain.

•Iftheheaterstilldoesnotstart,checkwhether:–Fuelinthetank?–Thefusesareok?–Theelectricalcables,connections,terminals,are

ok?–Anythingiscloggingthecombustionairsupplyor

exhaustsystem?–Fuelsupplyok?

Troubleshooting

If,aftercheckingtheseitems,theheaterisstillfaultyoranothermalfunctionoccursinyourheater,pleasecontact:

•Iffactory-installed,yourcontractworkshop/garage.

•Ifsubsequentlyinstalled,theworkshop/garagewhichinstalledtheheater.

Pleasenotethatguaranteeclaimscanexpireiftheheaterismodifiedbyathirdpartyorifnon-originalpartsareinstalled.

Maintenance instructions

•Switchtheheaterononceamonthforabout10min-utes,evenoutsidetheheatingperiod.

•Beforetheheatingperiodstarts,atrialrunshouldbecarriedoutfortheheater.Ifthick,persistentsmokedevelops,unusualburningnoisesoraclearfuelsmelloccursorifelectric/electronicpartsoverheat,theheatermustbeswitchedoffandputoutofservicebyremovingthefuse.

Inthiscase,theheatershouldnotbestartedupagainuntilithasbeencheckedbyqualifiedstaffwhohavebeentrainedonEberspächerheaters.

•Checktheopeningsofthecombustionairsupplyandexhaustsystemafterlongerstandstillperiods,cleanifnecessary!

Please note!

Followthemaintenancescheduleonpage43to45.

Initial commissioning

Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.

•Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

•Openthecoolingwatercircuitbeforethetrialrun(setthetemperaturecontrolto"WARM").

•Duringtheheatertrialrun,allwaterandfuelconnec-tionsmustbecheckedforleaksandsecure,tightfit.

•Iffaultsoccurwhiletheheaterisrunning,useadiag-nosticunittodetermineandcorrectthecauseofthefault.

Changing components

Thecomponentslistedbelowmustbeexchangedattheendofthegivenoperatingperiod:

•Heatexchangerafter5000operatinghours,

•Burnerafter3000operatinghours,

•Nozzleafter600operatinghoursoratleastonceperyear.

Service

TechnicalSupportIfyouhaveanytechnicalquestionsorproblemswiththeheater,thecontrolunitortheoperatingsoftware,pleasecontactthefollowingserviceaddress:[email protected].

Troubleshooting / maintenance / service6

Please note!

41

EU Declaration of Conformity

WeherewithdeclarethattheversionoftheheaterplacedonthemarketbyusconformstotheapplicableprovisionsofthefollowingEUDirective.

EUDirective2014/30/EU

ThefullDeclarationofConformitycanbeviewedanddownloadedfromthedownloadcentreunderwww.eberspaecher.com.

Certifications

ThehighqualityofEberspächer'sproductsisthekeytooursuccess.Toguaranteethisquality,wehaveorganisedallworkprocessesinthecompanyalongthelinesofqualitymanagement(QM).Evenso,westillpursuealargenum-berofactivitiesforcontinuousimprovementofproductqualityinordertokeeppacewiththesimilarlyconstantlygrowingrequirementsmadebyourcustomers.Allthestepsnecessaryforqualityassurancearestipulatedininternationalstandards.Thisqualityistobeconsideredinatotalsense.Itaffectsproducts,proceduresandcustomer/supplierrelationships.Officiallyapprovedexpertsassessthesystemandthecorrespondingcertificationcompanyawardsacertificate.

EberspächerClimateControlSystemsGmbH&Co.KGhasalreadyqualifiedforthefollowingstandards:

Quality management in accordance with ISO TS 9001:2015 and IATF 16949:2016

Environmental management system in accordance with ISO 14001:2015

Disposal

Disposal of materials

Olddevices,defectivecomponentsandpackagingma-terialscanallbeseparatedandsortedintopure-gradefactions,ifnecessary,sothatallpartscanbedisposedofinanenvironment-friendlywayorthematerialsrecycled.Electricmotors,controlboxesandsensors(e.g.temperaturesensors)aredeemedtobe"electronicscrap".

Dismantling the heater

Theheaterisdismantledaccordingtotherepairstagesinthecurrenttroubleshooting/repairinstructions.

Packaging

Theheater'spackagingcanbekeptincaseithastobesentback.

Environment7

42

List8

List of abbreviations

ADREuropeanagreementabouttheinternationaltransportofdangerousgoodsontheroad.

ECE regulationInternationallyagreed,uniformtechnicalspecificationsforvehicles,partsandequipmentofmotorvehicles.

EMC DirectivesElectromagneticcompatibility.

JE-partnerEberspächerpartner.

43

Maintenance schedule9

Maintenance schedule and measurement record for JE Hydronic L-II heaters

Theheatermustbecheckedatleastonceayearinaccordancewiththefollowingtable.

Tocarryoutthework,usetherelevanttroubleshootingandrepairinstructions.

Thismaintenancescheduleensuresthatthemainte-nancehasbeencarriedoutproperly.

Inspection / maintenance work(once per year)

Inspection results

Measured values,Repairs carried out

Important Informa-tion

oknotok

1. Electrical connections

• Disconnectplug-inelectricalconnectionswiththeheatercableharness,checkforoxidation.Sprayplug-inconnectionsand,aftercompletingitem5,reconnect.

• Checkelectricalfusesforoxidationandcontactresistances.

Usesuitablecontactspray.

2. Heat exchanger

• Checkforsignsofleaks.

• Ifnecessary,cleanoutsideandinsideofheater.

Renewtheheatex-changerafter5000h.

3. Fuel system

• Checkfuellinesandconnectionsforleaks.

• Replacefuelfilterinsertwithseal

• Ifavailable,openfuelstopcocks

• Checkfuelpumprunningtime

Ensurenoleaksinfuelsupplyandreturnconnection!Re-tightenthreadedconnectionsandhoseclips.

Renewthefuelpumpafter5000horafter5years.

4. Burner head

• Checkcombustionairintakeopeningforfreepassage.

• Removeburnerhead–Checkinsideofhousingforaccumulationsof

fuelduetoleaks.–Cleaninspectionwindowofflamemonitor.–Checkignitionelectrodes.–Replaceatomizingnozzle.

Renewtheburnerheadafter3000h.

Replacebentelec-trodes.

Incaseofcokebuild-up,shortenreplacementintervalforfuelfilter.

Renewtheatomisingnozzleafter600h.

44


Inspection / maintenance work(once per year)

Inspection results

Measured values,Repairs carried out

Important Informa-tion

oknotok

5. Exhaust system

• Checkexhaustpipeforfreepassage,cleanifnecessary.

• Removeflametubefromheatexchanger,checkbothpartsfordamageanddirt,cleanorreplaceifnecessary.

• Insertflametubeandinstallburnerhead. Ensuresecureconnectionwiththeheatex-

changer.

• Re-connectionelectricalplug-inconnection.

• Measurements Thesetpointvaluesandprocedurearelistedin

thetroubleshootingandrepairinstructions.

–Ambienttemperature(°C)

–Exhausttemperature(°C)

–CO2(%vol)

–CO(ppm) limitvalue<1000

–Smokespotnumber(accordingtoBacharach) limitvalue<4

–Fuelpumppressure(bar)

___________ °C

___________ °C

___________ %vol

___________ ppm

___________

___________ bar

Recommendedmeas-uringdevice:MSI150Eurofluegasanalyser5600593

LimitvaluesaccordingtoDirective2001/56/EC

6. Water system

• Ifavailable,cleanwaterfilterinsert.

• Ifavailable,openwaterstopcocks

7. Functional check

• Ifavailable,openstopcockinreturnline.

• Checkfunctionoftheheaterafteratleast10minutes'heating.

• Lookforsmokeduringtheafter-run;ifnecessaryreplacenozzle.

Please note!

Afterfinishingthework,completethedatasheetonthefollowingpage.

45


Data sheet

Details of the operator

Address Dateofmeasurement

Heatertype Yearputintoservice

NominaloutputinkW

Name:_____________________________________

Date: ______________________________________

Place:______________________________________

Dept.:______________________________________ ____________________________________________

Signature

Fuel

Diesel HeatingoilEL

Installedinrailvehicle

Theresultcomplieswiththerequirements

Theresultdoesnotcomplywiththerequire-ments(furtheractionisnecessary).

Heater details

Summary

The check or adjustment has been performed:

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www.eberspaecher.com

EberspächerClimateControlSystemsGmbH&Co.KGEberspä[email protected]

hydronic l-ii...heater order no. order no. – compact version hydronic l16 25 2486 02 00 00 – –...

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