Air heaters B5L/D5L / B5LC/D5LC ' .

Trouble.hooting and repair manual

The Troubleshooting and Repair Manual Is valid for the following heaters:

BOL 201707 05 00 00 - 12 Volt 20 1708 05 00 00 - 24 Vol1

D5L 25 17290500 00 - 12 Volt 25 1730 05 00 00 - 24 Volt

Contents

sectional view ___ _ , ..... , ...... " .............. , ...................... ,

Description of operation.

In the event of faults, first check the following points",

Function and fault test...

Wiring diagrams

Repair instructions ..... ........ ............... .

Measuring the fuel quantity" ..

Using the test adapter

25 1861950862 04.1995 ModifIcation reserved.

BOLC 2017350500 00 - 12 Vc>1 20 1736 05 00 00 - 24 Volt

D5LC 251861 05 00 00 -12 VoI1 25 1862 05 00 00 - 24 van

Page

2

3

4

4.5

6. 7

8-13

14

15, 16

Printed In GIIrmany. C Copyright J . Eb6'spAchef

J . Eberspilcher GmbH &Co Ebersp:tcherstr. 24 0·73130 Esslingen

Telefon (zentlal) (011 1) 939-00 TelelllJ( (0111 ) 93>1{)500 http:lt-w. eberspaeche,-de

C29/C3O

Sectionlil dl'llwtng 0 SLID 5 L C

Parts list

1 Heating air blower wheel 2 PCB with temperature contrOl sensor 3 Combustion air blower wheel 4 Glow plug 5 Safety thermal cutout switch 6 Combustion chamber 7 Rame sensor 8 Heat exchanger 9 Outer casing

10 Flange seal 11 Fuel line

Wi

12 Blower motor 13 Combustion air intake silencer 14 Exhaust line 15 Fuel metering pump 16 Fuel filter 17 Main fuse, 25 A 18 Glow plug relay 19 Control unit 20 Actuating unit 21 Healing timer

2

F ~ Fresh air V ~ Combustion air B ~ Fuel W- Hot air A - Exhaust

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Switch-on: green pilot light in the operating unit ~ON·. After about 1 s&cond: healing coil of glow plug NON-. Blower ' ON" at full speed. After 33 - 70 seconds: fuel pump ·OW.

Once a stable llame has been obtained. the glow plug is switched off. To reach the operating temperature of the heat exchanger quickly, the healer is operated at an increased heating ca­pacily of 5.5 kW after being switched on. Once the heat exchanger operating temperature has been reached, the heating capacity is reduced 10 4.8 1NoI. The duration of heater operation with Increased capacity depends on the ambient temperature.

Reguldon In heatlna opention Once the intakelroom temperature as set at the operating unit has been reached, the heater switches to the " lOW" setting and then continues to run at low blower motor speed. If the heating capacity In the NLOW" control setting is in­sufficient, the heater switches to the "MEDIUM~ setting. The blower continues to operate at low speed. In most cases, the LOW/MEDIUM/LOW settings at low speed will provide the required heal. If the heating capacity in lhe QMEDIUM" sening is insuffi­cient. the heater switches back to the -HIGW setling. This entails full speed tor the blower motor again. _ If in some cases even less heating capacity is needed than the heater supplies in the "LOW' sening. the heater switches to the ·OFf" setting. The heater continues to run after shutdown, followed by constant after-ventilation prior to restart. The constant after-ventilation applies only lor heaters In recirculated air mode. The subsequent restart is in the -MEDIUMM setting at low blower motor speed. When the heater is finally switched off. the green pilot light goes out and the blower continues to run until II coots down. During continued operation, the glow plug is switched on for approx. 30 sees. to dean it of combustion residues. This continued operation will always end after about 4 to 5 minutes at low speed.

3

Control_nd ufety equipment The flame is monitored by the flame sensor (7). the maxi­mum permitted temperature by the safety thermal cutout switch (5). Both of them affect the control unit (19), which switches off the heater in the event of fauNs.

. 1. If the healer does not ignite wtthin 90 seconds of the start of fuel pumping, starting is repealed as described. If the healer still does not ignite after a further 90 se­conds, fauN shutdown follows.

2. If lhe flame goes out by itself during operation, a restart follows first. If the heater does not ignite within 90 seconds of fuel pumping being switched on. or It does Ignite but then goes out within 10 minutes, fault shutdown follows. The fault shutdown can be cancelled out by briefly switching the heater off and back on again.

3. In the event of overheating, the safety thermal cutout switch (5) leacts, the fuel supply is interrupted, and fault shutdown follows. If overheating is the cause of a fault shutdown, the switch-on pilot light (green) in the operating unit flashes steadily. Once the cause of the overheat has been remedied, the heater can be restarted by switching it off and then back on again.

4. Further fauN indicating signals cen be obtained with additional equipment, and are described in the trouble­shooting and repair Instructions on pages 4 and 5.

5. If the voltage drops below about 10.5 or 21 V. Of rises above 15 or 30 V as the cese may be, fault shutdown follows.

6. If the glow plug is defective and the electric line to the metering pump has a break, the heater will not start.

7. When the heater is started the functioning of the blower motor is checked once. 11 it does not start, the heater will undergo fault shutdown. During operation, the blower motor is monitored in cyc­les (4 mlns.). If the molor speed Is below the permitted limit, lauN shutdown follows.

PIe8 .. not.: For electric welding work on the vehicle, the positive ter­minal of the battery must be disconnected and earthed in order to protect the control unit.

I

e Fuel in the tank? eFusesOK? e Electrical lines and connecttons OK?

·c.

• Combustion air and exhaust piping !'Iystems tree?

When combustion produces soot, check the following:

Combustion air and exhaust piping systems clogged? ......... Remove cause of clogging. Fuel metering pump conveying too much? ......... Measure fuel quantity, replacing fuel metering pump if necessary. Deposits in the heat exchanger? ......... Clean heat exchanger, or replace illf necessary,

Cliling of dIIlftOdc ...... 18 Connec1 a switch to terminals 4 and 6 of the operating unil. Turn on the switch and compare the diagnostic signal displayed by the operating unit with the list on page 5, Deal with lhe Irouble as descnbed under 'Remedy".

Checkweluee Speed of blower motof in HIGH set1ing: 5000 rpm ±10% in MEDIUM and LON settlng5: 3000 rpm ± 10% in continued operation: 3000 rpm ± 10% in after ventilation : 850 rpm (only In recirculated air mode)

4

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DIopIojod by ...... LID o 1 2 31 r n r SOCS. A-.dy

Operation

Warning of olJer-lundelVoltage ••• Check controller, charge battery

Overvoltage cutout •• Check controller, jf necessary test charger. Heater must be connected directly to the battery.

Undervollage cutout • Charge battery, check control~r.

Check glow plug. glow plug series resistor(for B 5 LI Glow plug break •••• 05L 24 V), replace. Check connecting lines and

connection, check connection to glow plug relay.

Burner motor does not turn, Check mdtor speed (test adapter), If necessary speed changeover relay does nol replace blower. Check speed changeover function (tast adapter), if necessary replace PCB.

Rated speed: high = 4500± 10%rpm, medlumJlow - 3000 ± 10 % rpm

ShOf1-circuit at glow-plug ~I Replace glow-plug relay relay contacts

Saf~ty time exceeded ••• Check fuel supply, test glow plug 0nterrupted coil, no start yet sooty connection), replace if necessary. I ,

Check heating air lines inlet and outlet for clogging,

Overheat ~ ..... --- if necessary remove clog. Check electrical lines, contacts to metering pump. Check safety thermal cutout switch (test adapter).

Short circuil of fuel ~ .. Check metering pump and supply lines, metering pump replace if necessary.

Plug connection to temperature sensor in cable harness made internally/externally? Check PCB,

Temperature sensor defective ~. internal temperature sensor (test adapter). If neces-sary test the external temperature sensor directly. Check connection to operating device, and check the latter (test equipment for operating device).

Flame sensor defective ~. • Check flame sensor or connection, and also PCB (test adapter). •

Rame goes out at "Low" or

•• Check fuel quantity -Medium" stage Check blower speed Heater goes out by Itself

Rame goes out at "High~ stage ••• Check fuel quantity Heater goes out by Itself Check blower speed

Control unit defective Replace control unit

External disturbing voltages • •• Remove cause

Erroneous flame reoognition • Check flame sensor.

5

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1.1 Burner motor 1,2 Glow plug 1.5 Safety thermal cutout switch 1.7 PCB with temperature control

sensor, speed change and multiple-blade connector

1.12 Aameaenaor 1.13 Tcmperaturesensor 2.1 Control unit 2.2 Fuel metering pump 2.5.1 Glow plug relay 2.7 Main fuse. 25 A

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_) test (wOfbhopl digital timer b) to terminlll15 c) lighting, terminel58 dl if timer Is connected,

break lin. here 81 If tempenltlire sensor is connected.

<M1ach existing socket housing and fit todc:et houlirtg of tempenture sentor

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1.1 Bumer motOf 1.12 Flame sensor 1.2 Glow plug 1.1 3 Temperature sensor 1.2.1 Glow plug resistor 2 .1 Control unit 1.5 Safety thermal cutout switch 2.2 Fuel metering pump 1.7 PCB with temperature control 2.5.1 Glow plug relay

sensor, speed chenge and 2 .7 Main fuse, 25 A multiple-blade connector

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detach existing socket housing and fit socket: housing of temperature. sensor

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hrts u.t 1.1 Burner motor 1.2 Glow plug ' .6 Safety thermal cutout switch 1.7 PCB with controller temperature

,ensor, speed regulator and plug distributor

1.12 Fleme monitor 1.13 Temp.retur sensor

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5.1 Battery

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Plug housing and locket housing ahown from the lid. where line enters.

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3.2.5 Timer 3.2.6 Tlm.r 3.2.7 Timar

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3.6.1 Cable harness for 3.1.11 3,6,2 Cable harness for 3.1.13 3.B.3 Cabl. harn.s. for 3.1 .14 3.6.4 Ceble harness for 3.2.7

3.S.1 Timer relay

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al Te" (garag') digital timer b) to terminal 15 c) lighting t.rmin.1 68 d) break line here to connector tim.r f) 3.2.6/ 3.2.6/3.2.7 to be

connected here g) Connection control elements

to h.at.r hI Remov. S 3 and fit S 2

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22

1 Combustion air blower 2 Blower wheel 3 Cover 4 Uning 5 Seal 6 Blower 7 Seal 8 PCB 9 Heat exchanger

10 Cover 11 Seal

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10

17

12 Safety thermal cutout switch 13 Flame sensor 14 Plug strainer 15 Glow plug 16 Series resistor (for BS L/D5 L 24 V only) 17 Upper casing half 18 Lower casing half 19 Intake end piece 20 Outlet end piece 21 Flange seal 22 Sealing 23 Carrier

--1. Remove cable harness plus cap 2. Remove glow plug 3. Remove plug strainer 4. Remove PCB 5. Remove outlet end piece 6. Remove upper casing half end upper

heat protection plate 7. Remove safety thenna! cutout switch

1. R .... ove o.bIe hi.,.... plUi ClIp

Unscrew the cap from the heater and detach the plug connector from the PCB and glow plug.

2. _ glow plug

Unscrew the glow plug conn9dQf. Unscrew the glow plug.

When fitting _ new glow plug, pI __ note the following: Check the plug strainer in the glow plug connection, clean it if necessary, or failing that replace it.

3. Remove plug etIIIlMI'

Take the plug strainer out of the plug connection us ing pliers. Clean the plug strainer, replace it if necessary .

• ."."".ntIWhen fitting the plug strainer. ensure the nose is in the right position. Slide in the plug strainer carefully as far as it will go. The hole for plug area ventilation must then be free.

11

a. Remove flame sensor 9. Remove series resistor for glow plug

(8 5L105L 24 Von~) 10. Remove blower wheel 11. Remove cover from blower motOf and

fit new lining 12. Remove blower from heat exchanger 13, Remove cover from heat exchanger

I

4. Aemove PCB

Detach the plug connector from the PCB. Press the PCB downwards and pull it out.

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Unscrew the four fastening screws of the outlet end piece, then remove the end piece.

e. Romoveu __ hoII __ _

protection -Unscrew the fastening screws of the casing half, then remove the casing half. Remove both securing clips from the heat protection plale. Remove the heat protection plate.

ImpotUlnt: Use new securing clips when putting the heat protection plate beck in.

12

7. Remove safety thermal cutout switch

Detach the plug connector from the PCB. Remove both securing clips from the safety thermal cutout switch. Remove the safety thermal cutout switch.

Important! Use new securing clips when pulling the safely thermal cutout switch back in.

Removing the safety thermal cutout SWitch

8. Remove flame sensor

Remove the retaining spring with a screwdriver. Remove the lIame sensor and the intermediate piece.

See also page 12.

Fitting the safety thermal cutout switch

13

Removing the flame sensor

9. Remove series resistor for glow plug (85 L ID 5 L 24 V only)

Note on removal : The series resistor is fi"ed with a clamping ring, not a thread !

Unscrew the connection at the series resistor. Remove the series resistor as shown in the figure.

Fitting the series resislor: Drive the series res istor with an 18 x 1 diameter pipe into its mounting by lighl hammer blows.

10. Remove bktwer whee'

Remove the lock ring from the blower wheel using a screwdriver. Pull the blower wheel off the shalt of the electric molor.

Filling the flame sensor

14

11. "-nove c::cwerfrom blower motor end tit new 1InI""

Unscrew the fastening screws from the cap. Remove the cap, and fit a new lining if necessary.

Importantl When fitting the cover, use only the original screws or new ones (Taptile M5 x 12).

13. Removecovertrom hMtexchenger

Unscrew the fastening screws from the cover. lift the cover off the heal exchanger using an angled hook through the exhaust connection.

Importantl Slide the pipe of the combustion air system into the caver. When fitting the cover, use a new seal. When fitting the caver, use only the original screws or new ones (Taplite M5 x 12).

1 Heal exchanger 2 Cover 3 Pipe of combustion air system

15

12. Remove blower from heat .xct.nger

Unscrew the fastening screws from the support. Remove the support trom the blower. Unscrew the fastening screws from the blower. Remove the blower and dear the heal exchanger and blower of sealing residues.

Importantl When assembling the heal exchanger and blower, replace the seal.

5

1 Cover 2 Lining 3 Support 4 Blower 5 Heal exchanger

1

M_rtno lIMo fuoI_ IMPORTANTl Only measure the fuel when the battery is sufficienlly charged. AI least 11/22 V or max. 13126 V should be applied to the control unit during measurement

1. __

Detach the plug connector under the cover cap on the healer and connect a lest lamp. Detach the luelline from the healer and insert it into a measuring glass. Connect a voltmeter to the 4-pin plug, terminals 3 (+) and 4 H, of the control unit. Switch on the heater; when fuel is being pumped steadily (around 25 - 55 sees. after switch-on), the fuel line is filled and free of air. Switch off the heater and empty the measuring glass.

2. Meuurement Switch on the healer. Fuel is pumped after about 25 - 55 sees. after switch-on. Hold the measuring glass al the level of lhe plug during measurement. Read off the voltage at the voltmeter. After 90 sees. of fuel pumping, this stops automatically. Switch otlthe heater. Read off the fuel quantity In the measuring glass.

Test ap.,.ret:ue

------,

3. Evaluation Transpose the readings onto the graph. Fuel consumption is OK when the inlers9CIion 01 roth vatues is within the limit curve. If the intersection is outside the CUNe, the luel metering pump must be replaced.

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The fuel metering pump, when swi1ched on, supplies: - lor B 5 L the fuel quantity for the ~ High~ setting.

Rated quantity at 12 Vl24 V"'"' 16.25 ml/90 sees . • for 0 5 L the fuel quantity for the ~ Medium~ setting.

Rated quantity at 12 Vl24 V - 8.5 ml/90 sees.

= oon1l0l unH Voltmeler

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Connection 01 vOltmeter to control uM

-. U.&ng the teet adapter and the test Instrument for the oper1ItIng unit

To identify certain faults (see page 5), the test adapter (PCB) and the test instrument for the operating unit are necessary.

1. T..tIng the blower motor Detach the p lug from the PCB. instead connect up a lest adapter. Apply operaling voltage + and -10 the adapter. An ohmmeter is nol required for this measuremenl The blower molor must start up at once.

Measu ring the speed: Switch closed, 3000 rpm Switch open, 800 rpm Press button: the molor switches to high speed, 5OCX) rpm.

" the motor does not run: Check PCB visually for burnouts. If OK, change the blower. If the speed changeover does not work, change the PCB.

2. T .. ting the Ntety thennal cutout ,witch: The test lamp must come on as soon as the operating voltage has been connected. 11 it does not come on, check the PCB, cable, plug con­tacts for breaks, check the safety thermal cutout switch for continuity.

Teat adapter for PCB

3. Tutlng the temperature .ensor (lntemal) and flame .. ntor:

The internal temperature sensor arranged on the PCB and the flame sensor arranged on the heat exchanger can be tested as follows (operating voltage does not have to be connected) :

Connect an ohmmeter to the test adapter as shown in the sketch. The values given in the sketch must be complied with.

In the event of a fault, check the PCB for breaks or short­circuits. If the temperature sensor is defective, replace the PCB; il the flame sensor value is 00, replace the Ilame sensor.

" an external temperature sensor is connected, its resi­stance value must be in the same range. For this purpose, connect the extemal temperature sensor directly to the ohmmeter.

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Temperature sensor 1800 - 22000

Flame sensor 900 -11()()0 when heater is cold (when heat exchanger is hot, up to 22000)

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mes on when safety switch is OK

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~ Pushbutt on : speed changeover to 5000 rpm

Switch: speed changeover from 800 rpm to 3000 rpm

17

Teet unit for opeqtlng de¥ice

Delach Ihe plug of the operaling device from the cable harness, inslead connect Ihe lesl unillo Ihe operaling de­vice, and apply operating vonage. Sel lhe switch on the operating device 10 Ihe -Heating and Vemilation" position. The appropriate lights must come on. The pilot light in the switch must also come on.*

• This test is unnecessary in operation with heating timer.

Tnt unit for operating device

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Ventilation

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18

Turn off the switch in the operating device. Call up lighting with key 1. Press key 1, press key 2 in addilion. Pilot light must change from red to green.

Connec1 ohmmeler, turn ralary knob. Set value of 800 10 1200 must be maintained without a break. tn the event of an error change the operati ng device .

sw --'---' - Key 2

lEO green

+ Key 1 lighting red

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