hydronic m-ii m...hydronic m-ii eg- e1 00 0215 emv- – ae1 035075 regulation! directive 2001 / 56 /...

HYDRONIC M-II Technical description, installation, operation and maintenance instructions.

Water heater for diesel, operating independently of the engine.

Heater Order no.

Hydronic M12 12 V 25 2472 05 00 00 24 V 25 2473 05 00 00

Heater Order no.

Hydronic M8 Biodiesel 12 V 25 2470 05 00 00 24 V 25 2471 05 00 00

Hydronic M10 12 V 25 2434 05 00 00 24 V 25 2435 05 00 00

25 2435 90 99 8001.2011

2

Introduction1

Chapter Title Contents

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

2 Product information •Scopeofsupply...................................................................................... 8,9•Technicaldata.................................................................................... 10 – 12•Maindimensions ........................................................................................ 13

3 Installation •Installationlocation .................................................................................... 14•Installingthe24Vheaterinavehicleforthetransportof dangerousgoodsasperADR/ADR99 .................................................... 14

•Possibleinstallationpositions ..................................................................... 15•Mountingandfastening ............................................................................. 15•Nameplate ................................................................................................. 16•Connectiontothecoolingwatercircuit .............................................. 17 – 20•Exhaustsystem ........................................................................................ 21•Combustionairsystem .............................................................................. 22•Fuelsupply ........................................................................................ 23 – 27

4 Operation and func-tion

•Operatinginstructions ............................................................................... 28•Initialcommissioning .................................................................................. 28•Importantinformationforoperation ............................................................ 28•Descriptionoffunctions ............................................................................. 28•Controlandsafetydevices/EMERGENCYOFF ........................................ 29

5 Electrical system •Heaterwiring ............................................................................................. 30•Partslistforthecircuitdiagrams .................................................... 30,33,35•Circuitdiagrams..................................................................... 31,34,36–39

6 TroubleshootingMaintenanceService

•Incaseoffaults,pleasecheckthefollowingpoints ................................... 40•Troubleshooting ......................................................................................... 40•Maintenanceinstructions ........................................................................... 40•Service ...................................................................................................... 40

7 Environment •Certification ............................................................................................... 41•Disposal .................................................................................................... 41•EUDeclarationofConformity ..................................................................... 41

8 Lists •Listofkeywords ................................................................................. 42,43•Listofabbreviations ................................................................................... 43

Contents

3

1 Introduction

Concept of this manual

Thismanualaimstosupporttheservicecompanyinstallingtheheaterandtoprovidetheuserwithallimportantinformationabouttheheater.Themanualhasbeendividedinto8chapterstomakeiteasiertofindthecorrespondinginformationquickly.

Electric systemHereyouwillfindinformationabouttheelectronicsystemandelectroniccomponentsoftheheater.

Troubleshooting / maintenance / serviceThissectioncontainsinformationonpossiblefaultsandmalfunctions,troubleshooting,mainte-nanceandtheservicehotline.

EnvironmentHereyouwillfindinformationaboutcertificationanddisposaloftheheatertogetherwiththeEUDeclarationofConformity.

ListsHereyouwillfindthekeywordlistandabbrevia-tions list.

IntroductionHereyouwillfindimportantintroductoryinforma-tionaboutinstallationoftheheaterandaboutthestructureofthemanual.

Product informationHereyouwillfindinformationaboutthescopeofsupply,thetechnicaldataandthedimensionsoftheheater.

InstallationHereyouwillfindimportantinformationandinstructionsreferringtoinstallationoftheheater.

Operation and functionHereyouwillfindinformationabouttheoperationandfunctionoftheheater.

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4

3

2

1

7

6

8

4

Special text structure, presentation and picture symbols

Thismanualusesspecialtextstructuresandpicturesymbolstoemphasisedifferentcontents.Pleaserefertotheexamplesbelowforthecorrespond-ingmeaningsandassociatedactions.

Special structure and presentations

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

Picture symbols

Regulation!Thispicturesymbolwiththeremark“Regulation”referstoastatutoryregulation.FailuretocomplywiththisregulationresultsinexpiryofthetypepermitfortheheaterandpreclusionofanyguaranteeandliabilityclaimsonJ.EberspächerGmbH&Co.KG.

Danger!Thispicturesymbolwiththeremark“Danger!”referstotheriskofafataldangertolifeandlimb.Undercertaincircumstances,failuretocomplywiththeseinstructionscanresultinsevereorlife-threateninginjuries.

Caution!Thispicturesymbolwiththeremark“Caution!”referstoadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.

Theseremarkscontainapplicationrecommendationsandusefultipsforinstallationoftheheater.

Please note!

Important information before starting work

Range of application of the heater

Thewaterheateroperatingindependentlyofanengineisintendedforinstallationinthefollowingvehicles,dependingonitsheatingoutput:•Vehiclesofallkinds•Constructionmachinery•Agriculturalmachinery•Boats,shipsandyachts

•InstallationoftheheaterispermittedinvehiclesusedforthetransportofdangerousgoodsasperADR.

•Theheaterisnotapprovedforinstallationinvehiclecompartmentsusedbypersons(morethan8pas-sengerspaces)inClassM2 and M3vehicles(vehiclesforthetransportofpassengers/commercialbuses).

•TheheaterisnotapprovedforinstallationinthedriverorpassengercompartmentsofClassM1vehicles(vehiclesforthetransportofpassengers/cars)andClassNvehicles(vehiclesforthetransportofgoods).

Onaccountofitsfunctionalpurpose,theheaterisnot permittedforthefollowingapplications:•Long-termcontinuousoperation,e.g.forpre-heatingandheatingof:–Residentialrooms–Garages–Workhuts,weekendhomesandhuntinghuts–Houseboats,etc.

Caution!Safety instructions for application and proper purpose

Theheatermustonlybeusedandoperatedfortherangeofapplicationstatedbythemanufacturerincompliancewiththe“Operatinginstructions”includedwitheveryheater.

Introduction1

Please note!

5

Statutory regulations

TheFederalRoadTransportDirectoratehasissuedan“ECtypeapproval“andan“EMCtypeapproval“fortheheaterforinstallationinmotorvehiclesandwiththefol-lowingofficialtypeapprovalmarks,notedontheheaternameplate.

HydronicM-II EG-e1000215

EMV-e1035075

Regulation!Directive 2001 / 56 / EU of the European Parlia-ment and the Council

•Arrangementoftheheater–Partsofthestructureandothercomponentsneartheheatermustbeprotectedfromexcessheatexposureandpossiblecontaminationfromfueloroil.

–Theheatermustnotposeafirehazardevenwhenitoverheats.

Thisrequirementisdeemedtobefulfilledwhenadequateclearancetoallpartsisobservedduringinstallation,sufficientventilationisprovidedandfire-proofmaterialsorheatplatesareused.

–TheheatermaynotbemountedinthepassengercompartmentofClassM2 and M3vehicles.

Aunitmayhoweverbeusedinahermeticallysealedhousingwhichalsocorrespondstotheconditionsstatedabove.

–Thefactorynameplateorduplicatemustbeaffixedsothatitcanstillbeeasilyreadwhentheheaterisinstalledinthevehicle.

–Allappropriateprecautionsmustbetakenwhenarrangingtheheatertominimisetheriskofinjuriestopersonsordamagetootherproperty.

•Fuelsupply–Thefuelintakeconnectionmustnotbelocatedinthepassengercompartmentandmustbesealedwithaproperlyclosinglidtopreventanyfuelleaks.

–Inheatersforliquidfuelwheretheheaterfuelisseparatefromthevehiclefuel,thetypeoffuelandintakeconnectionmustbeclearlyidentified.

–Awarningsignistobefixedtotheintakeconnec-tionindicatingthattheheatermustbeswitchedoffbeforerefuelling.

•Exhaustsystem–Theexhaustoutletmustbearrangedsoastopreventanypenetrationofexhaustfumesintothevehicleinteriorthroughtheventilationsystem,warmairintakesoropenwindows.

•Combustionairintake–Theairfortheheatercombustionchambermustnotbesuckedinfromthepassengercompartmentofthevehicle.

–Theairintakemustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyotherobjects.

•Operatingstatusdisplay–Aclearlyvisibleoperatingdisplayintheuser’sfieldofvisionmustindicatewhentheheaterisswitchedonandoff.

1 Introduction

6

•Compliancewiththestatutoryregulations,theaddi-tionalregulationsandsafetyinstructionsisprerequisiteforguaranteeandliabilityclaims.

FailuretocomplywiththestatutoryregulationsandsafetyinstructionsandincorrectrepairsevenwhenusingoriginalsparepartsmaketheguaranteenullandvoidandprecludeanyliabilityforJ.EberspächerGmbH&Co.KG.

•Subsequentinstallationofthisheatermustcomplywiththeseinstallationinstructions.

•Thestatutoryregulationsarebindingandmustalsobeobservedincountrieswhichdonothaveanyspecialregulations.

•WhentheheateristobeinstalledinvehiclesnotsubjecttotheGermanOrdinancefortheRegistra-tionofMotorVehicles(StVZO),forexampleships,thespeciallyvalidregulationsandinstallationinstructionsforthesespecialapplicationsmustbeobserved.

•Installationoftheheaterinspecialvehiclesmustcomplywiththeregulationsapplyingtosuchvehicles.

•Otherinstallationrequirementsarecontainedinthecorrespondingsectionsofthismanual.

RegulationsAdditionalregulationsforcertainvehiclesnamedinDirective94/55/EC(ADRFrame-work Directive)

ScopeThisappendixappliestovehiclesforwhichthespecialprovisionsofDirective94/55/ECapplytocombustionheatersandtheirinstallation.

Definition of terms usedForthepurposesofthisappendix,thevehicledesigna-tions„EX/II“,„EX/III“,„AT“,„FL“and„OX“accordingtoChapter9.1ofAnnexBofDirective94/55/ECareused.

Technical regulations

Generalprovisions(EX/II,EX/III,AT,FLandOXvehicles)

AvoidheatingandignitionThecombustionheatersandtheirexhaustgasroutingshallbedesigned,located,protectedorcoveredsoastopreventanyunacceptableriskofheatingorignitionoftheload.Thisrequirementshallbeconsideredasfulfilledifthefueltankandtheexhaustsystemoftheapplianceconformtoprovisionsin3.1.1.1and3.1.1.2.Compliancewiththeseregulationsshallbecheckedinthecompletevehicle.

FueltanksFueltanksforsupplyingtheheatershallconformtothefollowingregulations:•Intheeventofanyleakage,thefuelshalldraintothegroundwithoutcomingintocontactwithhotpartsofthevehicleortheload;

•fueltankscontainingpetrolshallbeequippedwithaneffectiveflametrapatthefilleropeningorwithaclosureenablingtheopeningtobekepthermeticallysealed.

Exhaust system and exhaust pipe layoutTheexhaustsystemaswellastheexhaustpipesshalllaidoutorprotectedtoavoidanydangertotheloadthroughheatingorignition.Partsoftheexhaustsystemsituateddirectlybelowthefueltank(diesel)shallhaveaclearanceofatleast100mmorbeprotectedbyathermalshield.

Switching on the combustion heaterThecombustionheatermayonlybeswitchedonmanu-ally.Automaticswitchingonviaaprogrammableswitchisnotpermitted.

EX / II and EX / III vehiclesCombustionheatersforgaseousfuelsarenotpermit-ted.

FLvehiclesCombustionheatersmustbeabletobetakenoutofservice/disabledatleastbythemethodsdescribedinthefollowing:a) Switchingoffmanuallyinthedriver‘scabinb) Switchingoffthevehicle‘sengine;inthiscasethe

heatermaybemanuallyswitchedbackonbythevehicledriver;

c) Startingupofafeedpumpinstalledinthevehicleforthedangerousgoodscarried.

Combustion heater after-runAfter-runningoftheswitchedoffcombustionheaterispermitted.Inthecasesnamedinthe„FLvehicles“paragraphunderlettersb)andc)thesupplyofcombus-tionairmustbeinterruptedbysuitablemeansafteramaximumafter-runperiodof40seconds.Onlycombus-tionheaterswhoseheatexchangersareverifiablynotdamagedbythereducedafter-runperiodof40secondsbeyondtheirusualuseperiodmaybeused.

Introduction1

Please note!

7

•Theheatermustnotbeoperatedwherethereisariskofanaccumulationofflammablevapoursordust,forexamplecloseto–fueldepot–coaldepot–wooddepot–graindepotsetc.

•Theheatermustbeswitchedoffwhenrefuelling.

•Whentheheaterismountedinasafetyhousingetc.,theinstallationcompartmentoftheheaterisnotastowagecompartmentandmustbekeptclear.

Inparticularfuelcanisters,oilcans,spraycans,gascartridges,fireextinguishers,cleaningrags,itemsofclothing,paperetc.mustnotbestoredortransportedonornexttotheheater.

•Defectfusesmustonlybereplacedbyfuseswiththeprescribedrating.

•Iffuelleaksfromtheheaterfuelsystem,arrangeforthedamagetoberepairedimmediatelybyaJEserv-icepartner.

•Whentoppingupthecoolant,onlyusethecoolantpermittedbythevehiclemanufacturer,seethevehicleoperatingmanual.Anyblendingwithunpermittedcoolantcancausedamagetotheengineandheater.

•After-runningoftheheatermustnotbeinterruptedprematurelye.g.bypressingthebatterydisconnectingswitch,apartfrominthecaseofanemergencystop.

Accidentprevention

Generalaccidentpreventionregulationsandthecor-respondingworkshopandoperationsafetyinstructionsaretobeobserved.

Safety instructions for installation and operation

Danger!Risk of injury, fire and poisoning

•Disconnectthevehiclebatterybeforestartinganykindofwork.

•Beforeworkingontheheater,switchtheheateroffandletallhotcomponentscooldown.

•Theheatermustnotbeoperatedinenclosedrooms,e.g.inthegarageormulti-storeycarpark.

Caution!Safety instructions for installation and operation

•TheheatermustonlybeinstalledbyaJEpartnerauthorisedbythemanufactureraccordingtotheinstructionsinthismanualandpossiblyaccordingtospecialinstallationrecommendations;thesameappliestoanyrepairstobecarriedoutinthecaseorrepairsorguaranteeclaims.

•Repairsbynon-authorisedthird-partiesorwithnotoriginalsparepartsaredangerousandthereforenotallowed.Theyresultinexpiryofthetypepermitoftheheater;consequently,wheninstalledinmotorvehiclestheycancauseexpiryofthevehicleoperatinglicence.

•Thefollowingmeasuresarenotallowed:–Changestocomponentsrelevanttotheheater.–Useofthird-partycomponentsnotapprovedbyJ.EberspächerGmbH&Co.KG.

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

•Onlyoriginalaccessoriesandoriginalsparepartsmustbeusedduringinstallationorrepairs.

•Onlyoriginalaccessoriesandsparepartsmaybeusedforinstallationorrepairs.

•OnlythecontrolsapprovedbyEberspächermaybeusedtooperatetheheater.Theuseofothercontrolscanresultinmalfunctions.

•Beforetheheaterisinstalledagaininanothervehicle,rinsetheheaterpartscarryingwaterwithclearwater.

•Whencarryingoutelectricweldingonthevehicle,thepluspolecableatthebatteryshouldbedisconnectedandplacedatgroundtoprotectthecontroller.

1 Introduction

8

Product information2

Scope of supply

Quantity / Designation Order number

1 Hydronic M8 Biodiesel 12 Volt 25 2470 05 00 00 24 Volt 25 2471 05 00 00

Tobeorderedseparately: 1 Universalinstallationkit 252435800000 1 Controlunit* –

1 Hydronic M10 12 Volt 25 2434 05 00 00 24 Volt 25 2435 05 00 00


1 Hydronic M12 12 Volt 25 2472 05 00 00 24 Volt 25 2473 05 00 00


* Controlunitsseepricelist/accessoriescatalogue..

Parts list for the „Scope of supply“ figure on page 9

Hydronic M8 Biodiesel heater scope of supply

Picture-No. Designation

1 Heater 2 Meteringpump21 Tube,Ø6x1.length6m22 TransitionpieceØ3.5/5,(2x) – HoseclampØ10,(4x)

Hydronic M10 / M12 heater scope of supply


1 Heater 2 Meteringpump

Universal installation kit scope of supply


3 Relay12V/24V 4 Exhaustsilencer 5 Cabletree,heater 6 Bracket,heater 7 Flexibleexhaustpipe 8 Cableties(10x) 9 Pipe,Ø6x1,length1,5m10 Hose,Ø5x3,length0,5m11 Pipe,Ø4x1,length6m12 Hose,Ø3,5x3,length10cm13 Intakesilencerforcumbustionair14 Waterhose15 Waterhose16 Leadharness,meteringpump17 Leadharness,blower18 Corrugatedtube, InnerØ10mm,length2m19 Grommet20 Bracket – Smallparts

Cable harnesses

A „Controls“leadharnessB „Blowercontrol“leadharnessC PositivecableD NegativecableE Connection,blowerrelaypositivesupplycableat

thefuseholderF Connectionatblowerrelay,terminal85(1-pole,

brown)G Connectionatblowerrelay,terminal86(1-pole,red/

yellow)H Meteringpumpconnection

Please note!

•Thecableharness,OrderNo.252435800600,isalsorequiredforvehiclesusedfortransportingdan-gerousgoods.

•Pleaseconsulttheadditionalpartscatalogueifanyotherpartsarerequiredforinstallation.

9


Scope of supply

* makefromItem12**makefromItem10

10

Caution!Safety instructions for technical dataFailuretocomplywiththetechnicaldatacanresultinmalfunctions.

Technical data

Heatertype Hydronic M-II

Heater Hydronic M8 Biodiesel

Version D8W

Heatingmedium Mixtureofwaterandcoolant(max.50%water,50%coolant)

Controloftheheatflow Power Large Medium Small

Heatflow(watt) Figuresforoperationwithdieselfuel.IfoperatedwithFAME

theheatflowcanreducebyupto15%.8000 5000 3500 1500

Fuelconsumption(l/h) 0.90 0.65 0.40 0.18

Electricalpower(watt) inoperation 55 46 39 35

atstart–after25Sek. 200

inthecontrolphase“OFF” 32

Ratedvoltage 12 Volt 24 Volt

Operatingrange•Lowervoltagelimit:Anundervoltageprotectioninthecontrollerswitchestheheateroffonreachingthevoltagelimit.

10 Volt 20 Volt

•Uppervoltagelimit:Anovervoltageprotectioninthecontrollerswitchestheheateroffonreachingthevoltagelimit.

15 Volt 30 Volt

Tolerableoperatingpressure upto2baroverpressure

Flowrateofthewaterpumpat0.14bar 1400l/h

Minimumwaterflowrateoftheheater 500l/h

Fuel–seealso“Fuelqualitydieselheaters”page27Commerciallyavailablediesel(DINEN590)

FAME–fordieselenginesaccordingtoDINEN14214

Tolerableoperatingtemperature Operation Notrunning

Heater/ControlboxDiesel –40°Cto+80°C –40°Cto+85°C

FAME –8°Cto+80°C –40°Cto+85°C

DosingpumpDiesel –40°Cto+50°C –40°Cto+85°C

FAME –8°Cto+50°C –40°Cto+85°C

Interferencesuppressionclass interferencesuppressionclass5toDINEN55025

Weightwithcontrollerandwaterpump,withoutdosingpump

approx.6.2kg

Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttempera-ture20°CandreferencealtitudeEsslingen.

Please note!


11




Please note!

Technical data


Heater Hydronic M10

Version D10W


Controloftheheatflow Power Large Medium Small

Heatflow(watt) 9500 8000 3500 1500

Fuelconsumption(l/h) 1.2 0.9 0.4 0.18

Electricalpower(watt)(l/ inoperation 86 60 39 35





10 Volt 20 Volt


15 Volt 30 Volt




Fuel–seealso“Fuelqualitydieselheaters”page27 Commerciallyavailablediesel(DINEN590)


Heater/Controlbox –40°Cto+80°C –40°Cto+85°C

Dosingpump –40°Cto+50°C –40°Cto+85°C



approx.6.2kg

12

Technical data


Heater Hydronic M12

Version D12W


Controloftheheatflow Power Large Medium1 Medium2 Medium3 Small

Heatflow(watt) 12000 9500 5000 3500 1500 1200

Fuelconsumption(l/h) 1.5 1.2 0.65 0.40 0.18 0.15

Electricalpower(watt)(l/) inoperation 132 86 46 39 35 34





10 Volt 20 Volt


15 Volt 30 Volt




Fuel–seealso“Fuelqualitydieselheaters”page27 Commerciallyavailablediesel(DINEN590)


Heater/Controlbox –40°Cto+80°C –40°Cto+85°C

Dosingpump –40°Cto+50°C –40°Cto+85°C



approx.6.2kg




Please note!

13

Main dimensions

A ExhaustB FuelV CombustionairWA WateroutletWE Waterinlet


14

Installation location

Theinstallationlocationfortheheateristheenginecompartment.Theheatermustbemountedbelowthemin.coolingwaterlevel(compensationtank,cooler,ve-hicleheatexchanger)forautomaticventingoftheheatexchangeroftheheaterandthewaterpump.

•Inatruck,thewaterheaterispreferablyfastenedunderneaththedriver’scabinthelongitudinalbeamnearthevehicleengine.

•Theregulationsandsafetyinstructionstobeobservedforthischapterarestatedonpage4–7.

•Theinstallationsuggestionsmadeintheinstallationinstructionsareexamples.Otherinstallationlocationsarepossibleiftheycorrespondtotheinstallationrequirementsstatedintheseinstallationinstructions.

•Otherinstallationinformation(e.g.forboatsandships)isavailablefromthemanufactureronrequest.

•Pleasetakenoteoftheinstallationlocationstogetherwiththeoperatingandstoragetemperatures.

Installation3

Installation example heater in a truck

1 Heater 2 Exhaustpipewithexhaustsilencer3 Combustionairintakesilencer4 Fanrelay5 Fusebracket6 Controls7 Dosingpump8 Tankconnection

Installing the 24 V heater in a vehicle for the transportofdangerousgoodsasperADR

Forinstallationoftheheaterinvehiclesforthetransportofdangerousgoods,theregulationsof ADR/ADR99mustbeobserved.

WiththeappropriateelectricalwiringtheheaterfulfilstheADRregulations,seethe“AdditionalRegulations”onPage6,the“ControlandSafetyDevices”onPage29andthe“CircuitDiagrams”onPage34and39.

DetailedinformationabouttheADRregulationsiscon-tainedinleafletno.252161951580.

Please note!

15

Installation3

Possible installation positions

Theheatershouldpreferablybeinstalledinthenormalposition,horizontalwiththeexhaustconnectiondowntothebottom.Dependingontheinstallationconditions,theheatercanalsobemountedinthepermittedswivelrange,seediagram.

Whentheheaterisoperating,theshownnormalormaximuminstallationpositionscanbevariedbriefly byupto+15°inalldirections.Suchdeviationscausedbytheinclinedpositionofthevehicledonotimpairtheheaterfunctionsinanyway.

Normal position with permitted swivel range

•Swivelrangefromthenormalpositionswivelleduptomax.85°downward–theheater‘swateroutletsocketishorizontal.Thewaterpump‘swaterinletsocketmustfacedownward.

•Swivelrangefromthenormalpositionswivelleduptomax.90°totheleftaboutthelongitudinalaxis–thewateroutletsocketisatthetopoftheheaterandfacestheleft.

Mounting and fastening

Fixtheunitholderfromtheinstallationkittotheheaterusing4hexagonscrewsM8and4springwashers(tighteningtorque12+0.5Nm).Fixtheheaterandthemountedunitholderinasuitable5placeinthevehicleusing5hexagonscrewsM8,5springwashersand5hexagonnutsM8(tighteningtorque12+0.5Nm).

1 Heater2 Heaterbracket

1 Wateroutletsocket,heater2 Waterinletsocket,waterpump

16

Nameplate

Thenameplateisonthefrontandthe2ndnameplate(duplicate)isfixedtothesideofthecontrolbox/fanunit.Ifrequired,theinstallercansticktheduplicatename-plateinaclearlyvisiblepositionelsewhereontheheaterorneartotheheater.

Theregulationsandsafetyinstructionstobeobservedforthischapterarestatedonpage5.

1 Originalnameplate2 2ndnameplate(dupliate)

Please note!

Installation3

17

Connection to the cooling water circuit

Theheaterisconnectedtothecoolingwatercircuit inthewaterfeedpipefromthevehicleenginetotheheatexchanger.Therearethreepossiblealternativeinstallationshere.

Thealternativesaredescribedonpages16–18.

Danger!Risk of injuries and burns!

Itispossibleforthecoolantandcomponentsofthecoolantcircuittogetveryhot.

•Partsconveyingwatermustberoutedandfastenedinsuchawaythattheyposenotemperaturerisktoman,animalsormaterialsensitivetotemperaturefromradiation/directcontact.

•Beforeworkingonthecoolantcircuit,switchtheheateroffandwaituntilallcomponentshavecooleddowncompletely,ifnecessarywheresafetygloves.

•Wheninstallingtheheater,pleasetakenoteofthedirectionofflowofthecoolantcircuit.

•Filltheheaterandwaterhoseswithcoolantbeforeconnectingtothecoolantcircuit.

•Routethewaterhoseswithoutanykinks,andinarisingpositionifpossible.

•Whenroutingthewaterpipes,observeasufficientclearancetohotvehicleparts.

•Protectallwaterhoses/waterpipesfromchafingandfromextremetemperatures.

•Secureallhoseconnectionswithhoseclips. (tighteningtorque=1.5Nm)

•Afterthevehiclehasbeenoperatingfor2hoursortravelled100km,tightenthehoseclipsagain.

•Theminimumwaterflowrateisonlyguaranteedifthetemperaturedifferenceoftheheatingmediumdoesnotexceed15Kbetweenwaterinletandwateroutletduringheating.

•Onlyoverpressurevalveswithanopeningpressureofmin.0.4–max.2barmaybeusedinthecoolantcircuit.

•Thecoolantliquidmustcontainatleast10%anti-freezeallyearroundascorrosionprotection.

•Thecoolingliquidmustcontainsufficientantifreezeforlowtemperatures.

•Beforecommissioningtheheaterorafterchangingthecoolingliquid,thewholecoolantcircuitincludingheatermustbeventedfreeofbubblesaccordingtotheinstructionsissuedbythevehiclemanufacturer.

•Onlytopupwithcoolantapprovedbythevehiclemanufacturer.

Please note!

Installation3

18

Connection to the cooling water circuit

Integrate the heater with non-return valve in the coolant circuit

Disconnectthewaterfeedpipefromthevehicleenginetothevehicleheatexchangerandinsertthenon-returnvalve.Connecttheheaterwithitswaterpipestothenon-returnvalve.

Advantage:Simpleinstallation.

Disadvantage:Thecoolantflowsthroughthevehicleengineconstantlysothatinlargevehicleengines,adequatecabheatingisscarcelypossible.

Heatingcharacteristics:

Whentheheaterisswitchedon,theheatflowsthroughthevehicleheatexchangerandthevehicleengine.Oncethecoolingwaterhasreachedatemperatureofapprox.55°C,dependingontheselectedfansettingthevehiclefanisswitchedonandtheheatisalsoconveyedtothepassengercompartment.

1 Heater2 Non-returnvalve3 Heatexchanger4 Vehicleengine

Non-returnvalvemustbeorderedseparately,seead-ditionalpartscatalogueforOrderNo.

Please note!

Installation3

19

Connection to the coolant circuit

Integrate the heater with non-return valve, ther-mostat and T-piece in the coolant circuit

Disconnectthewaterfeedpipefromthevehicleenginetothevehicleheatexchangerandinsert thenon-returnvalve.Disconnectthewaterreturnpipefromtheheatex-changertothevehicleengineandinsertthe T-piece.Connecttheheaterandthermostatwithwaterhosestothenon-returnvaleandT-pieceasshowninthediagram.

Option:Inadditionasolenoidcanbefittedinthewater circuit.Whenopen,thisbypassesthethermostat andpre-heatstheengineassoonastheheater startstowork.

Heating characteristics

•Smallcoolantcircuit:fastheatingofthe pas-senger compartment

Initiallytheheatproducedbytheheaterisonlycon-veyedtothevehicleheatexchangeruptoacoolingwatertemperatureofapprox.70°C.

Thevehiclefanswitchesonatapprox.55°C.

•Largecoolingwatercircuit:heatingofthepassenger compartment and additional engine pre-heating

Ifthecoolingwatertemperaturecontinuestoincrease,thethermostatslowlychangesovertothelargecircuit(fullchange-overatapprox.75°C).

1 Heater2 Non-returnvalve3 Thermostat4 T-piece5 Heatexchanger6 Vehicleengine7 Solenoid(option)

Thethermostat,non-returnvalveandT-piecemustbeorderedseparately,seeadditionalpartscatalogueforOrderNo.Thesolenoidvalvehastobepurchasedthroughthetrade.

Thermostat functions

Small coolant circuitCoolingwatertemperature<70°C:Connectionno.1:opentotheheaterConnectionno.2:opentotheT-pieceConnectionno.3:closedtothenon-returnvalve

Large coolant circuitCoolingwatertemperature>75°C:Connectionno.1:opentotheheaterConnectionno.2:closedtotheT-pieceConnectionno.3:opentothenon-returnvalve

1 Connectiontotheheater2 ConnectiontotheT-piece3 Connectiontothenon-return

valve

Integratethethermostatintothewatercircuitwithcon-nections(1)(2)and(3)asshowninthediagram.

Please note!

Please note!

Installation3

20

Connection to the coolant circuit

Integrate the heater with a solenoid in the coolant circuit

Disconnectthewaterflowhosefromthevehicle‘senginetothevehicle‘sheatexchangerandinserttwoT-pieces.ConnecttheT-pieceswithahose.Disconnectthewaterreturnpipefromtheheatex-changertothevehicleengineandinsertthesolenoid.ConnecttheheaterandthesolenoidtotheT-piecewithwaterpipes,asshowninthediagram.

Option:Inaddition,anon-returnvalvewithconnectionhosesbetweenthetwoT-piecescanbeinsertedinthecoolingwatercircuit.Thispreventsthelossofeffectivevehicleheatingwhentheheaterisswitchedoff.

Heating characteristics

Byinstallingtheelectricsolenoidvalve,temperature-independentchoicebetweenthesmallcoolingwatercircuit(driver‘scab)andlargecoolingwatercircuit(vehicleenginewithdriver‘scab)ispossible.Alternatively,aplussignalfromthe12-pinconnectorB2,PINB1torelay2.5.7canbeusedtocontroltheso-lenoidvalve;thisenablesautomaticchangeoverofthesolenoidvalve(seecircuitdiagramspage32and34).Changeovertothelargecoolingwatercircuitatacool-ingwatertemperatureof68°C,ifthetemperaturedropsto58°C.Changeovertothesmallcoolingwatercircuitatacool-ingwatertemperatureof63°C,ifthetemperaturedropsto45°C.

1 Heater2 Solenoid3 T-piece4 Heatexchanger5 Vehicleengine6 Non-returnvalve

(option)

TheT-piecesandnon-returnvalvemustbeorderedseparately.ForOrderNo.,seeadditionalpartscata-logue.Thesolenoidvalvehastobepurchasedthroughthetrade.

Please note!

Installation3

21

Exhaust system(Exhaustdiagramseepage22)

Mounting the exhaust system

Theuniversalinstallationkitincludesaflexibleexhaustpipe,innerØ30mm,1300mmlongandanexhaustsilencer.Theexhaustsilencermustbeinstalled.Theflexibleexhaustpipecanbeshortenedto20cmorlengthenedtomax.1.8m,dependingontheinstallationconditions(Seesketchonpage22).Fastentheexhaustsilencertoasuitablepositioninthevehicle.Routetheflexibleexhaustpipefromtheheatertotheexhaustsilencerandfastenwithpipeclips.Ifnecessary,alsofastentheflexibleexhaustpipewithpipeclipsatsuitablepositionsinthevehicle.Connecttheexhaustendpipetotheexhaustsilencerwithanendsleeveandfastenwithapipeclip.

Danger! Risk of injuries and burns!

Everytypeofcombustionproduceshightemperaturesandtoxicexhaustfumes.Thisisthereasonwhytheexhaustsystemmustbeinstalledaccordingtotheseinstructions.

•Donotperformanyworkontheexhaustsystemwhiletheheaterisworking.

•Beforeworkingontheexhaustsystem,firstswitchtheheateroffandwaituntilallpartshavecooleddowncompletely,wearsafetyglovesifnecessary.

•Donotinhaleexhaustfumes.

Caution!Safety instructions for the exhaust system!

•Theexhaustoutletmustendintheopenair.

•Theexhaustpipemustnotprotrudebeyondthelaterallimitsofthevehicle.

•Installtheexhaustpipeslopingslightlydownwards.Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointtodrainoffcondensation.

•Importantfunctionalpartsofthevehiclemustnotbeimpaired(keepsufficientclearance).

•Mounttheexhaustpipewithsufficientclearancetoheat-sensitiveparts.Payparticularattentiontofuelpipes(plasticormetal),electricalcablesandbrakehosesetc.!

•Exhaustpipesmustbefastenedsafely(recommendedclearanceof50cm)toavoiddamagefromvibrations.

•Routetheexhaustsystemsothattheemittedfumesarenotsuckedinwiththecombustionair.

•Themouthoftheexhaustpipemustnotgetcloggedbydirtandsnow.

•Themouthoftheexhaustpipemustnotpointinthedirectionoftravel.

•Alwaysfastentheexhaustsilencertothevehicle.

•Complywiththeregulationsandsafetyinstructionsforthischapteronpage4–7.

•Theexhaustendpipeshouldbemuchshorterthantheflexibleexhaustpipefromtheheatertotheex-haustsilencer.

•Usepipeclipstosecureallconnectionsintheexhaustsystem.

Please note!

Installation3

22

Combustion air system

Mounting the combustion air system

Theuniversalinstallationkitincludesanintakesilencer,innerØ25mmforthecombustionair.Theintakesilencermustbeinstalledand,forheatingmodeupto1500masl,canbeextendedbyupto 2mmax.usingaflexiblepipe(innerØ25mm)andaconnectionpipe(outerØ24mm)–notincludedinthescopeofsupply.Fastentheintakesilencerandwhereapplicabletheflex-iblepipeatsuitablepointsinthevehicleusingfasteningclipsandcableties.

•Complywiththeregulationsandsafetyinstructionsforthischapteronpage4–7.

•Extensionoftheintakesilencerisnotallowedifmainlyheatingmodeisusedathighaltitudes(over1500masl).

•Usepipeclipstosecureallconnectionsinthecom-bustionairsystem.

•Forinstallationinshipsandboats,seemarinecata-logue,ifnecessaryconsultthemanufacturer.

Caution!Safety instructions for the combustion air system!

•Thecombustionairmustbedrawnfromanareainwhichthemaximumallowabletemperatureforthecombustionair,of45°C,isnotexceeded.

•Thecombustionairopeningmustbefreeatalltimes.

•Positionthecombustionairintaketobesurethatex-haustfumescannotbesuckedinwiththecombustionair.

•Thecombustionairintakemustnotgetcloggedwithdirtandsnow.

•Installthecombustionairintakesystemslopingslightlydownwards.

•Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointtodrainoffcondensation.

•Avoidtightbendswhenlayingtheintakesilencerandflexiblepipe.

Please note!

Installation3

1 Heaterflange2 Intakesilencer,565mmlong (OrderNo.201689800500)3 Flexibleexhaustpipe

4 Exhaustsilencer5 Flexibleexhaustendpipe6 Connector(OrderNo.251226890031)7 Flexiblepipe(OrderNo.102114210000)

Allowablecombustionairandexhaustpipelength

Withacombustionairsystemconsistingonlyofoneintakesilencer,heatingmodeispossibleuptoanaltitude3500masl(withHydronicM10/M12only).

Withacombustionairsystemconsistingofoneintakesilencerandanextension,heatingmodeispossibleuptoanaltitudeof1500masl(allheatermodels).

max.2m

min.0.2m

min.0.2m

max.1.8m

max.1.8m

23

Fuelsupply

Mounting the dosing pump, routing the fuel pipes and mounting the fuel tank

Thefollowingsafetyinstructionsmustbeobservedwhenmountingthedosingpump,routingthefuelpipesandmountingthefueltank.

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

Cautionwhenhandlingfuel.

•Switchoffthevehicleengineandheaterbeforerefuel-lingandbeforeworkingonthefuelsupply.

•Nonakedlightswhenhandlingfuel.

•Donotsmoke.

•Donotinhalefuelvapours.

•Avoidanycontactwiththeskin.

Caution!Safety instructions for routing the fuel pipes!

•Onlyuseasharpknifetocutofffuelhosesandpipes.Interfacesmustnotbecrushedandmustbefreeofburrs.

•Thefuelpipefromthedosingpumptotheheatershouldberoutedatacontinuousrise.

•Fuelpipesmustbefastenedsafelytoavoidanydam-ageand/ornoiseproductionfromvibrations(recom-mendedclearanceofapprox.50cm).

•Fuelpipesmustbeprotectedfromanymechanicaldamage.

•Routethefuelpipessothatanydistortionofthevehi-cle,enginemovementsetc.cannothaveanylastingeffectontheservicelife.

•Partscarryingfuelmustbeprotectedfrominterferingheat.

•Neverrouteorfastenthefuelpipestotheheaterorvehicleexhaustsystem.Whenthesystemscross,alwaysensurethereisasufficientheatclearance.Ifnecessary,installheatdeflectionplates.

•Drippingorevaporatingfuelmustneverbeallowedtocollectonhotpartsorigniteonelectricsystems.

•Whenconnectingfuelpipeswithafuelhose,alwaysmountthefuelpipesinabuttjointtopreventanybub-blesfromforming.

1 Correctconnection2 Incorrectconnection–bubbleformation

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

•Inbusesandcoaches,fuelpipesandfueltanksmustnotberoutedthroughthepassengercompartmentordriver’scab.

•Fueltanksinbusesandcoachesmustbepositionedinsuchawaythattheexitsarenotindirectdangerfromapossiblefire.

Complywiththeregulationsandsafetyinstructions forthischapteronpage4–7.

Please note!

Installation3

Please note!

•Deviationsfromtheinstructionsstatedherearenotallowed.

•Failuretocomplycanresultinmalfunctions.

•WhenreplacingtheHydronicM(Hydronic10)withtheHydronicM-II,themeteringpumpmustbereplacedtoo.

24

Fuelsupply

FuelfeedpointwithT-piecefromthefuelsupplyline from the tank fitting to the vehicle engine

1 Fuelfeedpipefromtankconnection2 Fuelreturnpipetothetankconnection3 Dosingpump4 T-piece5 Fuelfilter6 Fuelhose,5x3(di=Ø5mm)7 Fuelpipe,6x1(di=Ø4mm)8 Fuelpipe,4x1(di=Ø2mm)9 Fuelhose,5x3(di=Ø5mm),

approx.50mmlong10 Fuelhose,3.5x3(di=Ø3.5mm),approx.50mm

long11 Totheengine,mechanicalfuelorinjectionpump.

RequiredforHydronicM8biodieselforoperationwithFAMEonly.

12 Fuelpipeblue,6x1(di=Ø4mm)13 Transitionpiece3,5/5

Possible pipe lengths

Intake side Pressure sidea=max.2m b=min.1.5m–max.6m

•InserttheT-piece(4)inthefuelflowlineupstreamofthefeedpump.T-pieceisnotincludedinthe“installa-tionkit”scopeofsupply.Theorderno.isgivenintheadditionalpartscatalogue.

•Fuelfilter,Item(5),isrequiredforcontaminatedfuelonly.Fuelfilterisnotincludedinthe“installationkit”scopeofsupply.Theorderno.isgiveninthead-ditionalpartscatalogue.

•Items(12)and(13)areonlyincludedinthe“Hydronic M8Biodiesel”heater‘sscopeofsupply.

Installation position of the T-piece

UsetheinstallationpositionsshowninthediagramwheninsertingaT-piece.

1 Directionofflowfromthefueltank2 Directionofflowtothevehicleengine

Please note!

Installation3

25

Fuelsupply

Fuelfeedpointwithtankconnection– ascending pipe, integrated in the vehicle tank

1 Tankconnectionformetaltank– di=Ø4mm,da=Ø6mm2 Dosingpump3 Fuelfilter4 Fuelhose,5x3(di=Ø5mm)5 Fuelpipe,6x1(di=Ø4mm)6 Fuelhose,5x3(di=Ø5mm),approx.50mmlong7 Fuelpipe,4x1(di=Ø2mm)8 Fuelhose,3.5x3(di=Ø3.5mm),approx.50mm

long

RequiredforHydronicM8biodieselforoperationwithFAMEonly.

9 Fuelpipeblue,6x1(di=Ø4mm)10 Transitionpiece3,5/5

Possible pipe lengths

Intake side Pressure sidea=max.2m b=min.1.5m–max.6m

•Item(1),tankconnectionformetaltank,isnotincludedinthescopeofsupply“installationkit”.Orderno.seeextrapartscatalogue.

•Fuelfilter,Item(3),isrequiredforcontaminatedfuelonly.Fuelfilterisnotincludedinthe“installationkit”scopeofsupply.Theorderno.isgiveninthead-ditionalpartscatalogue.

•Items(9)and(10)areonlyincludedinthe“Hydronic M8Biodiesel”heater‘sscopeofsupply.

•Wheninstallingtankconnectionmaintainaminimumdistanceof50±2mmfromtheendoftheriserpipeandthebottomofthetank.

Caution!Safety instructions for the fuel supply!

•Thefuelmustnotbeconveyedbygravityoroverpres-sureinthefueltank.

•Withdrawaloffuelafterthevehicle’sfuelpumpisnotallowed.

•Whenthepressureinthefuelpipeismorethan4.0barorthereisanon-returnvalveinthereturnpipe(inthetank),aseparatetankconnectionmustbeused.

•WhenusingaT-pieceinaplasticpipe,alwaysusesupportsleevesintheplastic.ConnecttheT-pieceandtheplasticpipewithcorrespondingfuelhosesandsecurewithhoseclips.

Please note!

Installation3

26

Fuelsupply

Installation position of the dosing pump

Alwaysmountthedosingpumpwiththepressuresiderisingupwards.Everyinstallationpositionover15°isallowed,althoughaninstallationpositionbetween15°and35°ispreferable.

1 Installationpositionbetween0°and15°is notallowed.

2 Preferredinstallationpositioninrange15°to35°.3 Installationpositioninrange35°to90°isallowed.

1 Connectiontoheater2 Max.fuellevel3 Min.fuellevel

Possible intake and pressure height of the dosing pump

Pressureheightfromvehicletanktodosingpump: a=max.1000mm

Intakeheightfornon-pressurisedvehicletank: b=max.750mm

Intakeheightforavehicletankwithwithdrawalbynega-tivepressure(valvewith0.03barinthetanklid): b=max.400mm

Pressureheightfromthedosingpumptotheheater: c=max.2000mm

Checktankventing.

Caution!Safety instructions for installing the dosing pump

•Alwaysmountthedosingpumpwiththepressuresiderisingupwards–minimumincline15°.

•Protectthedosingpumpandfilterfromintolerableheat,donotmountneartothesilencersandexhaustpipes.

Please note!

Installation3

27

Fuelsupply

Fuelquality

•HydronicM8Biodiesel,M10andM12heaterseasilyprocessstandarddieselfueltoEN590.

Duringthewintermonthsthedieselfuelisadaptedtolowtemperaturesfrom0°Cto–20°C.Problemscanthereforeonlyariseifoutdoortemperaturesareextremelylow–whichalsoappliestothevehicle‘sengine–pleaserefertothevehiclemanufacturer‘sregulations.

•Inspecialcasesandatoutdoortemperaturesabove 0°CtheheatercanalsoberunonheatingoilEL accordingtoDIN51603.

•Iftheheaterisrunfromaseparatetank,pleasecom-plywiththefollowingrules:

–Ifoutdoortemperaturesover0°C: UsedieselfuelaccordingtoDINEN590.

–Ifoutdoortemperaturesfrom0°Cto–20°C: UsewinterdieselfuelaccordingtoDINEN590.

–Ifoutdoortemperatures–20°Cto–40°C: UseArcticDieselorPolarDiesel.

•Itisnotpermittedtoaddusedoil!

•Afterrefuellingwithwinterorcolddieselorthelistedblends,thefuelpipesandthedosingpumpmustbefilledwiththenewfuelbylettingtheheaterrunfor 15mins!

Operation with biodiesel (FAMEfordieselenginesaccordingto DIN EN 14 214)

Hydronic M8 BiodieselTheheaterisapprovedforoperationwithbiodieseluptoatemperatureof–8°C(theflowabilityreducesattemperaturesbelow0°C).

•Whenusing100%biodiesel,theheatershouldberunondieselfueltwiceayear(inthemiddleandattheendofaheatingperiod)toburnoffpossiblyac-cumulatedbiodieseldeposits.Todoso,letthevehicletankrunalmostemptyandfillwithdieselfuelwithoutaddinganybiodiesel.Whilerunningonthistankfilling,switchtheheateron2to3timesfor30minutesatatimeatthehighesttemperaturesetting.

•Ifconstantlyoperatedwithdiesel/biodieselmixturesofupto50%biodiesel,intermediateoperationwithpuredieselfuelisnotnecessary.

Hydronic M10 / Hydronic M12Bothheatersarenotapprovedforoperationwithbiodiesel.Upto10%biodieselmaybeadded.

Please note!

Please note!

Installation3

28

Operation and function4

Operating instructions

Theheaterisoperatedbyacontrolunit.Thecontrolunitisaccompaniedbydetailedoperatinginstructionswhichyouwillreceivefromthecompanyinstallingtheheater.

Initial commissioning

Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.

•Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

•Openthecoolantcircuitbeforethetrialrun(setthetemperaturecontrolto“WARM”).

•Duringthetrialrunoftheheater,checkallwaterandfuelconnectionsforleaksandfirmfitting.

•Iftheheatershowsafaultduringoperation,findandeliminatethecauseofthefaultusingadiagnosisunit(ContactJEservicepartner).

Important instructions for operation

Safety checks before the start

Afteralongerintervalinoperations(afterthesummermonths)thefusemustbeputinpositionand/ortheheaterconnecteduptothebattery.Checkthatallpartsfitfirmly(tightenscrewswherenecessary).Checkthefuelsystemvisuallyforanyleaks.

Before switching on

Beforeswitchingonorpre-programmingtheheater,adjusttheheatingcontrolinthevehicleto“WARM”(maximumsetting)andthefanto“SLOW”(lowpowerconsumption).Invehicleswithautomaticheating,adjusttheheatingcontrolto“MAX”andopentheheatingventsbeforeswitchingtheignitionoff.

Temperature drop (optional)Thecontrolstagesarereachedearlierandtheheater’scontrolactionisadjustedtothelowerheatrequirement.Itispossibletolowerthetemperaturebyconnectingaplussignaltothe12-pinconnectorB2,PINC3,ifnecessarybyintegratinganON-OFFswitch(seecircuitdiagramspage32and34).Theswitch-ontemperature(55°C)andswitch-offtem-perature(40°C)ofthecoolingwaterforswitchingonoroffthevehiclefanareloweredby10°C.

Description of functions

Switching onOnbeingswitchedon,theswitch-oncheckisdisplayedinthecontrolunit.Theheaterstarts,wherebythewaterpumpandthecombustionairblowerstartupfirst.Theglowphaseoftheglowpencilsbeginssimultane-ouslywithdistributionofthecombustionair.Themeteringpumpstartsfuelfeedsomewhatdelayed.Theglowpencilsareswitchedoffifastableflamehasformedinthecombustionchamber.

Heating modeAfterstarting,theheaterrunswith“POWER”stageuntilthewatertemperatureexceedsthe“POWER“/“HIGH”changeoverthreshold.Hydronic M8 Biodiesel / M10Then,dependingontheheatrequirement,theheaterswitchestothe“HIGH–MEDIUM–LOW–OFF”stages.Hydronic M12Then,dependingontheheatrequirement,theheaterswitchestothe“HIGH–MEDIUM1/MEDIUM2/MEDIUM3–LOW–OFF”stages.Iftheheatingrequirementinthe“LOW”stageissosmallthatthecoolingwatertemperaturereaches86°C,theheaterswitchesfrom“LOW”to“OFF”.Anafter-runofapprox.180secondsfollows.Thewaterpumpremainsactiveuntilthecontrolledstart.Ifthecoolingwaterhascooledtoapprox.72°C,theHydronicM8/M10heaterstartsin“MEDIUM”stage,theHydronicM12heaterstartsin“MEDIUM1”stage.Ifthecoolingwatertemperaturereaches55°C,theve-hiclefanswitcheson;ifthetemperaturedropsto40°C,thevehiclefanswitchesbackoffagain.

Heatingmodeathighaltitudes–upto3500masl

Thecombustionbehaviouroftheheaterchangeswithincreasingaltitude,duetothelowerairdensity.Theheaterhasanautomaticaltitudedetectiondevicewhichitusestoautomaticallycompensateforthechangeinairdensity,i.e.thecombustionratiobetweenfuelandairisadaptedtotheambientcondi-tionsbyreducingthefuelquantity.

•Theusualswitchinglimitforaltitudedetectionliesbe-tween1000masland2000maslandsolelydependsonthelocalclimaticconditions.

•ThemaximumheatingoutputoftheHydronicM10/M12in“AltitudeMode”is8.5kW.

•TheHydronicM8Biodieseldoesnothaveanaltitudedetectiondevice.Unrestrictedheatingmodeispos-sibleupto1500masl.

•Heaterssuitableforhighaltitudeshave“HKit”markedonthesideofthenameplate.

Please note!

29

•Thespeedofthefanmotorismonitoredcontinuously.Iftheblowermotordoesnotstartupifitisblocked,orifthespeeddiffersby>12.5%fromthedesiredspeedasafetylockout(shutdownonfaults)takesplaceafter60sec.*

•Thewaterpump‘sfunctioniscontinuouslymonitored.

* Thisstatuscanberemediedbybrieflyswitchingoffandonagain.

**Fordetailsofhowtocancelthelockandtoreadouterrors,refertotheTroubleshootingandRepairinstruc-tionsoftheheater.

Donotswitchtheheateroffandonagainmorethantwice.

Forcedshut-downforADR/ADR99operation

Invehiclesforthetransportofdangerousgoods (e.g.tankertrucks),theheatermustbeswitchedoffbeforethetruckdrivesintoadangerarea(refinery,fuelservicestation,etc.)Failuretocomplyresultsintheheaterswitchingoffautomaticallywhen:•Thevehicleengineisswitchedoff.•Anadditionalunitisstartedup(e.g.auxiliarydriveforunloadingpumpetc.).

•Avehicledoorisopened(ADR99regulation,onlyinFrance).

Thefanthenrunsonformax.40seconds.

Operation and function4

Emergencyshutdown–EMERGENCYOFFIfanemergencyshutdown–EMERGENCYOFF–isnecessaryduringoperation,proceedasfollows:•Switchtheheateroffwiththecontrolor•pullthefuseoutor•disconnecttheheaterfromthebattery.

Control and safety devices

Theheaterisequippedwiththefollowingcontrolandsafetydevices:

•Iftheheaterdoesnotignitewithin74secondsafterstartingthefuelpump,thestartisrepeated.Iftheheaterstilldoesnotigniteafteranother65seconds,theheaterisswitchedoff.*

Afteranunacceptablenumberoffailedstartattempts,thecontrollerislocked.**

•Iftheflamegoesoffbyitselfduringoperation,theheaterisrestarted.Iftheheaterdoesnotignitewithin74secondsafterthefuelpumphasstartedagain,theheaterisswitchedoff.*

Afteranunacceptablenumberoffailedstartattempts,thecontrollerislocked.**

•Inthecaseofoverheating(e.g.lackofwater,poorlyventedcoolantcircuit),theoverheatingsensortrig-gers,thefuelsupplyisinterruptedandtheheaterswitchedoff.*

Oncethecauseofoverheatinghasbeeneliminated,theheatercanbere-startedbyswitchingoffandonagain(onconditionthattheheaterhascooleddownagainsufficiently,coolingwatertemperature

30

Electrical system5

Heater wiring

TheheateristobeconnectedupelectricallyaccordingtotheEMCdirectives.

Caution!Safety instructions for wiring the heater

EMCcanbeaffectediftheheaterisnotconnectedupcorrectly.Forthisreason,complywiththefollowinginstructions:

•Ensurethattheinsulationofelectricalcablesisnotdamaged.Avoid:chafing,kinking,jammingorexpo-suretoheat.

•Inwaterproofconnectors,sealanyconnectorcham-bersnotinusewithfillerplugstoensuretheyaredirt-andwater-proof.

•Electricalconnectionsandgroundconnectionsmustbefreeofcorrosionandfirmlyconnected.

•Lubricateconnectionsandgroundconnectionsout-sidetheheaterinteriorwithcontactgrease.

Complywiththefollowingwhenwiringtheheaterandthecontrolelement:

•Electricalleads,switchgearandcontrollersmustbearrangedinthevehiclesothattheycanfunctionperfectlyundernormaloperatingconditions(e.g.heatexposure,moistureetc.).

•Thefollowingcablecrosssectionsaretobeusedbetweenthebatteryandheater.Thisensuresthatthemax.tolerablevoltagelossinthecablesdoesnotexceed0.5Vfor12Vor1Vfor24Vratedvoltage.

Cablecrosssectionsforacablelengthof:–upto5m(pluscable+minuscable)= cablecrosssection4mm²–from5to8m(pluscable+minuscable)=

cablecrosssection6mm² Connectionofthecables(pluscableandminus

cable)toconnectorB2requiresareductioninthecablecross-sectionto2.5mm².

•Ifthepluscableistobeconnectedtothefusebox(e.g.terminal30),thevehiclecablefromthebatterytothefuseboxmustbeincludedinratingtheoverallcablelengthandpossiblyre-dimensionedifnecessary.

•Insulateunusedcableends.

Please note!

Notes on rewiring the 12-pin cable harness connector

If,onreplacingtheHydronicM(Hydronic10)withtheHydronicM-II,thecableharnessalreadyinstalledinthevehicleistobereuseditisnecessarytoremovethe12-pinconnectorusingtheAMPreleasetoolandtorewireitaccordingtothefollowingtable (AMPOrderNo.1-1579007-4).

12-pin connection pin assignment

CableharnessHydronic M

Rewiring12-pinconnector

Connection Cross-sectionCablecolour

Hydronic MPIN

Hydronic M-IIPIN

Dosingpump 1,52

gnC4 A1

Terminal31 42

brC3 A2*

Terminal30 42

rtC2 A3*

Plussignaltothebat-terypowerswitch

1,52ws/rt

C1 A4

Plussignaltotherelaysolenoidvalve

– B4 B1

Diagnosis 12

blB3 B4

PlussignalfromtheADRauxiliarydrive

12vi

B2 B3

ExternalcontrolWaterpump

– B1remainsunused**

Relay,blower 12

rt/geA4 C1

Plussignal(D+)totheheater–inADRmode

12vi/gn

A3 C2

Temperaturedrop – A2 C3

HeaterON 12

geA1 C4

* ConnectionofthecablestoconnectorB2requiresareductioninthecablecross-sectionto2.5mm².

** ExternalcontrolofthewaterpumpisnotplannedforHydronicM-II.

Connectorisshownfromthecableentryside.

31

Parts list for the circuit diagramsHydronicM-II–12Volt/24Volt

1.1 Burnerengine1.2 Glowplug11.2.1 Glowplug2(optional12kW/FAME)1.5 Overheatingsensor1.12 Flamesensor1.13 Temperaturesensor

2.1 Controller2.2 Dosingpump2.5.7 Relay,forcontrolofvehiclefan2.5.18 Relay,forcontrolofelectricalsolenoidvalvein

thewatercircuit–optional2.7 Mainfuse 12volt=20A 24volt=15A2.7.1 Fuse,actuation5A2.7.5 Fuse,vehiclefan25A2.12 Waterpump

5.1 Battery5.1.2 Fuseblockinthevehicle5.9.1 Switch,vehicleblower5.10 Vehiclefan

a) Connection,controlunitsa2) Diagnosisa3) Switch-onsignalS+a4) Powersupply,positive(+)terminal30a5) Powersupply,minus(–)terminal31• EasyStartR+/R/T:usethe0.752bl/wscable,12-pinconnectorB2,PINB4

• Usethe0.752gecable,12-pinconnectorB2,PINC4forallothercontrolunits

b1) Plussignalforelectricsolenoidvalveb2) (+)Terminal30viafuseforrelay2.5.18c) Heaterconnection

Connectorpinassignment:12-pinconnectorB2(external)PIN-No. Connection Cablecross-sectionmm2

A1 Dosingpump 1.5

B1 Solenoidvalve,optional 1.0

C1 Relay,blower 1.0

A2 Terminal31 4.0/2.5fortheconnec-tion at connector B2

B2 Diagnosiscable(OEM) –

C2 unused –


B3 unused –

C3 Temperaturedrop 1.0

A4 Plussignaloutput. 1.5

B4 Diagnosis(HELJED) 1.0

C4 HeaterON 1.0

Cable colours

rt = redbl = bluews = whitesw = blackgn = greengr = greyge = yellowvi = violet

Please note!

Electrical system5

d) Temperatureloweringofthecontrolstagesby7°C,switchingonandofftemperatureofthevehiclefanby10°CwithplussignalatPINC3.

e) (+)Controlbatterydisconnectingswitch (diode:orderno.20800012)

f) Only2.5mm²cableswithappropriateindi-vidualcoresealingmaybeinstalledinPINA2andA3from12-pinconnectorB2.

Ifa4mm²or6mm²cableisused,a100mmto200mmlong2.5mm²cablemustbeweldedontoitsendandinsulatedwatertight.

x) Disconnectcable

•In12Vrelay2.5.7(fromterminal30toterminal87a),amaximumpowerconsumptionof40Aisallowed;i.e.thevalueofthevehicle’sownfanfusemaynotbe>40A.

•Connectorsandbushhousingsareshownfromthecableinletside.

•Seepage32forcircuitdiagram.

32

Electrical system5

Circuit diagram HydronicM-II–12Volt/24Volt

252435009601CPartslistpage31

33

f) Temperatureloweringofthecontrolstagesby7°C,switchingonandofftemperatureofthevehiclefanby10°CwithplussignalatPINC3.

g) Ifonlyoneswitchingelementisusedforitems5.2.1and5.2.2,itisnecessarytoensurethatonpressingthebatterydisconnectingswitch(EMERGENCYOFFfunctioninADR),theswitchalwaysbreakscontactimmediately(regardlessoftheheatercondition)andalltheheater‘scircuitsaredisconnectedfromthe battery.

h) (+)Controlbatterydisconnectingswitch (diode:orderno.20800012)

i) Only2.5mm²cableswithappropriateindi-vidualcoresealingmaybeinstalledinPINA2andA3from12-pinconnectorB2.

Ifa4mm²or6mm²cableisused,a100mmto200mmlong2.5mm²cablemustbeweldedontoitsendandinsulatedwatertight.

x) Disconnectlead

•In12Vrelay2.5.7(fromterminal30toterminal87a),amaximumpowerconsumptionof40Aisallowed;i.e.thevalueofthevehicle’sownfanfusemaynotbe>40A.

•Connectorsandbushhousingsareshownfromthecableinletside.

•Seepage34forcircuitdiagram.

Please note!

Electrical system5

Parts list for the circuit diagramsHydronicM-II,12Volt/24Volt,ADR

1.1 Burnermotor1.2 Glowplug11.2.1 Glowplug21.5 Overheatingswitch1.12 Flamesensor1.13 Temperaturesensor

2.1 Controller2.2 Fueldosingpump2.5.7 Relay,forcontrolofvehiclefan2.5.18 Relay,forcontrolofelectricalsolenoidvalvein

thewatercircuit–optional2.7 Mainfuse 12volt=20A 24volt=15A2.7.1 Fuse,actuation5A2.7.5 Fuse,vehiclefan25A2.12 Waterpump

5.1 Battery5.1.2 Fuseblockinthevehicle5.9.1 Switch,vehicleblower5.10 Vehiclefan

a) Connection,controlunitsa1) ADRfeedbacka2) Diagnosisa3) Switch-onsignalS+a4) Powersupply,positive(+)terminal30a5) Powersupply,minus(–)terminal31• EasyStartR+/R/T:usethe0.752bl/wscable,12-pinconnectorB2,PINB4

• Usethe0.752gecable,12-pinconnectorB2,PINC4forallothercontrolunits

b) ForADRD+(dynamo)c) ForADRHA+(auxiliarydrive/secondarydrive) minuscircuit,ifnotpresent,routeleadto+d1) Plussignalforelectricsolenoidvalved2) (+)Terminal30viafuseforrelay2.5.18e) Connectionheater

12-pinconnectionpinassignment(external)PIN-No. Connection Cablecross-sectionmm2

A1 Dosingpump 1.5

B1 Solenoidvalve,optional 1.0

C1 Relay,blower 1.0


B2 Diagnosiscable(OEM) –

C2 D+ 1.0


B3 TRSsignal(ADR) 1.0

C3 Temperaturedrop 1.0

A4 Plussignaloutput 1.5

B4 Diagnosis(HELJED) 1.0

C4 HeaterON 1.0

Cable colours


34

Circuit diagram HydronicM-II,12Volt/24Volt,ADR

Partslistpage33 252435009602C

Electrical system5

35

Parts list for the circuit diagrams for the control elements EasyStart R+ / EasyStart R /EasyStartTandEasyStartT–ADR

2.15.1 Temperaturesensor(roomtemperature) (includedintheEasyStartR+scopeofsupply, optionalforEasyStartT)2.15.9 Externaltemperaturesensor

3.1.7 ”ON/OFF“button3.1.16 Radioremotecontrolbutton

3.2.15 EasyStartTtimer

3.3.9 EasyStartRradioremotecontrol (stationaryunit)

3.3.10 EasyStartR+radioremotecontrol (stationaryunit)

3.6.1 Adaptercable

3.8.3 Antenna

c) Terminal58(lighting)e) EasyStartTtimerconnectiong) External”ON/OFF“button(optional)x) ADRjumper

•Thetimer/radioremotecontrolmustbeconnectedinaccordancewiththecircuitdiagrams(page36–39).

•Insulateunusedcableends.•Connectorsandbushhousingsareshownfromthecableinletside.

Cable colours


Please note!

Electrical system5

36

Circuit diagram for the control element EasyStart R+

252435009701APartslistpage35

Electrical system5

37

Circuit diagram for the control element EasyStart R


Electrical system5

38

Circuit diagram for the control element EasyStart T


Electrical system5

39

CircuitdiagramforthecontrolelementEasyStartT–ADR


5 Electrical system

40

In case of faults, please check the following points

•Iftheheaterdoesnotstartafterbeingswitchedon:–Switchtheheateroffandonagain.

•Iftheheaterstilldoesnotstart,checkwhether:–Thereisfuelinthetank?–ThefusesareOK?–Theelectricalcables,connectionsetc.areOK?–Anythingiscloggingthecombustionairsupplyorexhaustsystem?

•Checktheopeningsofthecombustionairsupplyandexhaustsystemafterlongerstandstillperiods,cleanifnecessary!

Troubleshooting

Iftheheaterremainsfaultyevenafterthesepointshavebeenchecked,oranothermalfunctionoccursinyourheater,pleasecontact:•Forinstallationexworks,yourcontractworkshop.•Forsubsequentinstallation,theworkshopwhoinstalledyourheater.

Pleasenotethatwarrantyclaimscanbebecomevoidiftheheaterischangedbyathirdpartyorbythisinstalla-tionofthirdpartyparts.

Troubleshooting / Maintenance / Service6

Maintenance instructions

•Switchtheheaterononceamonthforabout10minutes,evenoutsidetheheatingperiod.

•Beforetheheatingperiodstarts,theheatershouldundergoatrialrun.Ifpersistentextremesmokedevel-ops,unusualburningnoisesoraclearfuelsmellcanbeperceivedorifelectric/electronicpartsheatup,theheatermustbeswitchedoffandputoutofservicebyremovingthefuse.

Inthiscase,theheatershouldnotbestartedupagainuntilithasbeencheckedbyqualifiedstaffwhohavebeentrainedonEberspächerheaters.

Service

Ifyouhaveanytechnicalqueriesorproblemswithyourpre-heater,dialthefollowingservicephonenumber:

HotlinePhone0049(0)800/1234300

FaxhotlineFax0049(0)1805/262624

OutsideofGermany,pleasecontacttherespectivenationalEberspächerserviceagent.

Please note!

41

Environment7

Certification

ThehighqualityofEberspächer’sproductsisthekeytooursuccess.Toguaranteethisquality,wehaveorganisedallworkprocessesinthecompanyalongthelinesofqualitymanagement(QM).Evenso,westillpursuealargenumberofactivitiesforcontinuousimprovementofproductqualityinordertokeeppacewiththesimilarlyconstantlygrowingrequire-mentsmadebyourcustomers.Allthestepsnecessaryforqualityassurancearestipu-lated in international standards.Thisqualityistobeconsideredinatotalsense.Itaffectsproducts,proceduresandcustomer/supplierrelationships.Officiallyapprovedpublicexpertsassessthesystemandthecorrespondingcertificationcompanyawards acertificate.

Eberspächerhasalreadyqualifiedforthefollowingstandards:

Quality management as per DINENISO9001:2000andISO/TS16949:1999

Environment management system as per DINENISO14001:1996

Disposal

Disposal of materialsOlddevices,defectcomponentsandpackagingmate-rialcanallbeseparatedandsortedintopure-gradefactionssothatallpartscanbedisposedofasrequiredinanenvironment-friendlymannerorrecycledwhereapplicable.Electricmotors,controllersandsensors(e.g.tempera-turesensors)aredeemedtobe“electronicscrap”.

Dismantling the heaterTheheaterisdismantledaccordingtotherepairstagesinthecurrenttroubleshooting/repairinstructions.

PackagingThepackagingoftheheatercanbekeptincaseithastobesentback.

EU Declaration of Conformity

Withregardtothefollowingproducts

Heater type Hydronic M-II

weherewithconfirmthatitconformswiththeprimesafetyrequirementsstipulatedinthedirectivesoftheEUCouncilforharmonisationofthelegalregulationsofthememberstateswithregardtoelectromagneticcompat-ibility(89/336/EEC).Thisdeclarationappliestoallheatersproducedaccord-ingtotheproductiondrawingsHydronicM-IIwhichareanintegralpartofthisdeclaration.

Thefollowingstandards/directiveshavebeenusedtoassesstheproductwithregardtoelectromagneticcompatibility:•EN50081–1Basicforminterferenceemission.•EN50082–1Basicforminterferenceresistance.•72/245/EEC–Modificationstatus2006/28/EGinterferencesuppressioninmotorvehicles.

42

Lists8

AAccidentprevention ..................................................... 7ADR ........................................................ 2,4,6,14,29ADR99 ...................................................................... 29Ambienttemperature ......................................... 10 – 12Arrangement ............................................................... 5

BBiodiesel .............................................................. 10,27

CCertification ............................................................... 41Circuitdiagrams .................................... 31,33,35–38Combustionair .......................................................... 22Combustionairintake .................................................. 5Combustionairsystem .............................................. 22Contents ..................................................................... 2Coolingwatercircuit .......................................... 17 – 19Controlofheatflow ........................................... 10 – 12Controls ................................................................. 7,29

DDangerousgoods .................................... 2,4,6,14,29Declarationofconformity ........................................... 41Descriptionoffunctions ............................................. 28Disposal .................................................................... 41Diesel,commerciallyavailable ............................ 10 – 12Dosingpump ........................................10–12,23–26

EElectricalpowerconsumption ............................ 10 – 12Emergencyoff ........................................................... 29EMCdirectives .......................................................... 30Environment .............................................................. 41Exhaust ..................................................................... 11Exhaustsystem ..................................................... 5,21

FFaults .................................................................. 28,40Fastening ................................................................... 15Faxhotline ................................................................. 40Forcedshut-down ..................................................... 29Fuses .................................................................. 30,32Fuelfeedpipe ............................................................ 24Fuelquality ................................................................ 27Fuelconsumption .............................................. 10 – 12Fuelsupply .................................................... 5,23–27Fueltank ................................................................... 23

HHeatflow ........................................................... 10 – 12Heatingoperation ...................................................... 28Heatingcharacteristics ...................................... 18 – 20Heatingmedium ................................................ 10 – 12Heatingperiod ........................................................... 40Hotline ....................................................................... 40

IIntakeside ........................................................... 24,25Installation ................................................................. 14Interferencesuppressionclass ........................... 10 – 12Initialcommissioning .................................................. 28Installationlocation .................................................... 14Installationexample ................................................... 14Installationposition ........................................ 15,24,26

LListofabbreviations ................................................... 43

MMaindimensions........................................................ 13Maintenanceinstructions ........................................... 40Minimumwaterflowrate .................................... 10 – 12

NNameplate ................................................................. 16Non-returnvalve ........................................................ 18Normalposition ......................................................... 15

OOperatinginstructions ................................................ 28Operatingrange ................................................ 10 – 12Operatingpressure ............................................ 10 – 12Operatingstatus .......................................................... 5

PPartslist ........................................................ 31,33,35Picturesymbols ........................................................... 4Powerconsumption .......................................... 10 – 12Pressureside ....................................................... 24,25Pressureheight .......................................................... 26Purpose ....................................................................... 4

RRatedvoltage .................................................... 10 – 12Rangeofapplication .................................................... 4Regulations ......................................................... 4,5,6

SSafetycheck .............................................................. 28Scopeofsupply ...................................................... 8,9Service ...................................................................... 40Solenoidvalve ........................................................... 19Switchingon .............................................................. 28

TTankconnection ........................................................ 25Tankfitting ................................................................. 24Technicaldata ................................................... 10 – 12Thermostat ................................................................ 19T-piece ................................................................ 19,20Troubleshooting ......................................................... 40

UUniversalinstallationkit ................................................ 8

ListofkeywordsA–Z

Keyword Page Keyword Page

43

Lists8

List of abbreviations

ADREuropeanagreementabouttheinternationaltransportofdangerousgoodsontheroad.

EC type approvalPermitawardedbytheFederalVehicleOfficefortheproductionofaheaterforinstallationinmotorisedvehicles.

EMC directiveElectromagneticcompatibility.

JE partnerJ.Eberspächerpartner.

FAME(Biodiesel)(FAMEfordieselenginesaccordingtoDINEN14214)

VVoltagelimit ....................................................... 10 – 12

WWaterflowrate .................................................. 10 – 12Water inlet ................................................................. 13Wateroutlet ............................................................... 13Weight ............................................................... 10 – 12Wiring ........................................................................ 30

Keyword Page

J.EberspächerGmbH&Co.KGEberspächerstraße24D-73730EsslingenTelefon0711939-00Telefax0711939-0643info@eberspaecher.com

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hydronic m-ii m...hydronic m-ii eg- e1 00 0215 emv- – ae1 035075 regulation! directive 2001 / 56 /...

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