+ All Categories
Home > Documents > AIRTRONIC / AIRTRONIC M 2...Airtronic D2, 24 V 25 2116 05 00 00 Airtronic M Order no. Airtronic B3...

AIRTRONIC / AIRTRONIC M 2...Airtronic D2, 24 V 25 2116 05 00 00 Airtronic M Order no. Airtronic B3...

Date post: 27-Jan-2021
Category:
Upload: others
View: 4 times
Download: 0 times
Share this document with a friend
52
AIRTRONIC / AIRTRONIC M Technical description, installation, operation and maintenance instructions. Air heater for diesel and petrol operating independently of the engine. Airtronic Order no. Airtronic D2, 12 V 25 2069 05 00 00 Airtronic D2, 24 V 25 2070 05 00 00 Complete package Airtronic D2, 12 V 25 2115 05 00 00 Airtronic D2, 24 V 25 2116 05 00 00 Airtronic M Order no. Airtronic B3 Plus, 12 V 20 1944 05 00 00 Airtronic B4, 12 V 20 1812 05 00 00 Airtronic D3, 12 V 25 2317 05 00 00 Airtronic D4, 12 V 25 2113 05 00 00 Airtronic D4, 24 V 25 2114 05 00 00 Airtronic D4 Plus, 12 V 25 2484 05 00 00 Airtronic D4 Plus, 24 V 25 2498 05 00 00 20 1944 90 00 01 11.2012
Transcript
  • AIRTRONIC / AIRTRONIC M Technical description, installation, operation and maintenance instructions.

    Air heater for diesel and petrol operating independently of the engine.

    Airtronic Orderno.

    AirtronicD2,12V 252069050000AirtronicD2,24V 252070050000

    Complete packageAirtronicD2,12V 252115050000AirtronicD2,24V 252116050000

    Airtronic M Orderno.

    AirtronicB3Plus,12V 201944050000AirtronicB4,12V 201812050000

    AirtronicD3,12V 252317050000

    AirtronicD4,12V 252113050000AirtronicD4,24V 252114050000

    AirtronicD4Plus,12V 252484050000AirtronicD4Plus,24V 252498050000

    20194490000111.2012

  • 2

    6

    5

    4

    3

    2

    1

    8

    7

    Introduction1

    Contents

    Chapter Title Contents Page

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

    Product information •Scopeofsupply:heater,universalinstallationkit andcompletepackages......................................................................8,9 •Scopeofsupply:heaterand“Plus”installationkit............................10,11 •TechnicaldataAirtronicD2....................................................................12 •TechnicaldataAirtronic D3,D4,D4Plus................................................13 •TechnicaldataAirtronicB3Plus,B4......................................................14 •Maindimensions....................................................................................15

    Installation •Installationandlocation.........................................................................16 •Installationlocation..........................................................................16,17 •Possibleinstallationpositions.................................................................18 •Cableharnessconnection,rightorleft...................................................18 •Mountingandfastening.........................................................................19 •Nameplate.............................................................................................20 •Heaterairsystem..................................................................................21 •Exhaustsystem.....................................................................................22 •Combustionairsystem..........................................................................23 •Fuelsupply.................................................................................... 24–28

    Operation and •Operatinginstructions/importantinformationforoperation...................29 function •Initialcommissioning..............................................................................29 •Descriptionoffunctions.........................................................................30 •Controlandsafetydevices/EMERGENCYOFF....................................31

    Electrical system •Heaterwiring.........................................................................................32 •Partslistforthecircuitdiagrams/Circuitdiagrams....................... 33–45

    Troubleshooting •Incaseoffaults,pleasecheckthefollowingpoints...............................46 Maintenance •Troubleshooting....................................................................................46 Service •Maintenanceinstructions.......................................................................46 •Service..................................................................................................46

    Environment •Certification..........................................................................................47 •Disposal................................................................................................47 •EUDeclarationofConformity.................................................................47

    Lists •Listofkeywords............................................................................48,49 •Listofabbreviations...............................................................................49

  • 3

    Introduction1

    Concept of this manual

    This manual aims to support the service company installing the heater and to provide the user with all important information about the heater.The manual has been divided into 8 chapters to make it easier to find the corresponding information quickly.

    IntroductionHere you will find important introductory information about installation of the heater and about the structure of the manual.

    Product informationHereyouwillfindinformationaboutthescopeofsupply,thetechnicaldataandthedimensionsoftheheater.

    InstallationHereyouwillfindimportantinformationandinstructionsreferringtoinstallationoftheheater.

    Operation and functionHereyouwillfindinformationabouttheopera-tionandfunctionoftheheater.

    Electric systemHereyouwillfindinformationabouttheelec-tronicsystemandelectroniccomponentsoftheheater.

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

    EnvironmentHereyouwillfindinformationaboutcertificationanddisposaloftheheatertogetherwiththeEUDeclarationofConformity.

    ListsHereyouwillfindthekeywordlistandabbrevia-tionslist.

    2

    3

    4 8

    7

    6

    51

  • 4

    Introduction1

    Special text structure, presentation and picture symbols

    This manual uses special text structures and picture symbols to emphasise different contents.Please refer to the examples below for the corre-sponding meanings and associated actions.

    Special structure and presentations

    A dot (•) indicates a list which is started by a head-ing. If an indented dash (–) follows a dot, this list is subordinate to the dot.

    Picture symbols

    Regulation!This picture symbol with the remark “Regulation” refers to a statutory regulation. Failure to comply with this regulation results in expiry of the type permit for the heater and preclusion of any guarantee and li-ability claims on J. Eberspächer GmbH & Co. KG and its associated companies.

    Danger!This picture symbol with the remark “Danger!” refers to the risk of a fatal danger to life and limb. Undercer-taincircumstances,failuretocomplywiththeseinstruc-tionscanresultinsevereorlifethreateninginjuries.

    Caution!This picture symbol with the remark “Caution!” refers to a dangerous situation for a person and / or the product.Failure to comply with these instructions can result in injuries to people and / or damage to machinery.

    These remarks contain application recommendations and useful tips for installation of the heater.

    Important information before starting work

    Range of application of the heaterThe air heater operating independently of an engine is intended for installation in the following vehicles, depending on its heating output:• All types of vehicles (max. 8 seats + driver’s seat)

    and their trailers•Constructionmachinery•Agriculturalmachinery•Boats,shipsandyachts(onlydieselheaters)•Campervans

    •Theheaters(onlydieselheaters,24volt)canbein-stalledinvehiclesusedforthetransportofdangerousgoodsasperADR.

    • The current controller is to be replaced by a special controller when the heater is to be used to heat the freight compartment / cargo (order no. see heater price list or spare parts list).

    • The „Plus“ installation kits are intended for installa-tion in a camper van.

    Purpose of the heater• Pre-heating, de-misting windows• Heating and keeping the following warm: – Driver and working cabs, Ship’s cabins – Freight compartments – Passenger and crew compartments – Camper vans

    On account of its functional purpose, the heater is not permitted for the following applications:•Longtermcontinuousoperation,e.g.forpreheating

    andheatingof: – Residential rooms – Garages – Work huts, weekend homes and hunting huts – Houseboats, etc.• Heating or drying: – Living creatures (people or animals) by blowing hot air directly at the subject – Objects – Blowing hot air into containers

    Caution!Safety instructions for application and proper purpose•Theheatermustonlybeusedandoperatedforthe

    rangeofapplicationstatedbythemanufacturerincompliancewiththe“Operatinginstructions”includedwitheveryheater.

    Please note!

    Please note!

  • 5

    Introduction1

    Statutory regulations

    TheFederalMotorTransportAuthorityhasissuedan“ECtypeapproval”,“EMCtype-approval”andtheapprovalforacomponentaccordingtoECER122andECE-R10fortheheaterforinstallationinmotorvehicleswiththefollowingofficialtype-approvalmarks,notedontheheaternameplate.

    Type-approvalmarks

    Airtronic AirtronicM

    EG 000025 000026

    EMV 031516 031653

    ECE122R-00002510R-031516

    122R-00002610R-031653

    Regulations!Extract from Directive 2001 / 56 / EC Annex VII and ECE Regulation No. 122 of the European Parlia-ment and of the Council

    General regulations

    • Operating state display–Aclearlyvisibleoperatingdisplayintheuser’sfieldof

    visionmustindicatewhentheheaterisswitchedonandoff.

    Regulations concerning installation in the vehicle• Scope

    –Subjecttodifferingstipulationsinthefollowingsection,combustionheatersmustbeinstalledac-cordingtotheprovisionsofAnnexVII.

    –ItisassumedthatClassOvehicleswithheatersforliquidfuelconformtotheprovisionsofthedirective.

    • Arrangement of the heater–Partsofthestructureandothercomponentsnear

    theheatermustbeprotectedfromexcessiveheatexposureandpossiblefueloroilcontamination.

    –Theheatermustnotposeafirehazardevenwhenitoverheats.Thisrequirementisdeemedtobefulfilledifadequateclearanceisensuredforallpartsduringinstallation,sufficientventilationisprovidedandfireproofmaterialsorheatshieldsareused.

    –Theheatermustnotbemountedinthepassen-gercompartmentofvehiclesinclassM2andM3.However,aheaterinahermeticallysealedenclosurewhichalsocomplieswiththeaforementionedcondi-tionsmaybeused.

    –Thefactorynameplateorduplicatemustbeaffixedsothatitcanstillbeeasilyreadwhentheheaterisinstalledinthevehicle.

    –Allappropriateprecautionsmustbetakenwhenarrangingtheheatertominimisetheriskofinjuriestopersonsordamagetootherproperty.

    • Fuel supply–Thefuelintakeconnectionmustnotbelocatedin

    thepassengercompartmentandmustbesealedwithaproperlyclosinglidtopreventanyfuelleaks.

    –Inheatersforliquidfuelwheretheheaterfuelisseparatefromthevehiclefuel,thetypeoffuelandintakeconnectionmustbeclearlyidentified.

    –Awarningsignistobefixedtotheintakeconnec-tionindicatingthattheheatermustbeswitchedoffbeforerefuelling.

    • Exhaust system–Theexhaustoutletmustbearrangedsoasto

    preventanypenetrationofexhaustfumesintothevehicleinteriorthroughtheventilationsystem,warmairintakesoropenwindows.

    • Combustion air intake–Theairfortheheater’scombustionchambermust

    notbesuckedinfromthevehicle’spassengercom-partment.

    –Theairintakemustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyotherobjects.

    • Hot air intake–Theheater’sairsupplymustconsistoffreshairor

    circulatedairandmustbesuckedinfromacleanarea,whichcannotbecontaminatedbyexhaustfumesfromtheengine,thecombustionheateroranyothersourceinthevehicle.

    –Theintakepipemustbeprotectedbyagridorothersuitablemeans.

    • Hot air outlet–Thehotairpipeswithinthevehiclemustbear-

    rangedorprotectedinsuchawaythatthereisnoriskofinjuryordamageiftheyaretouched.

    –Theairoutletmustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyanyobjects.

    • Automatic control of the heating system–Iftheenginefails,theheatingsystemmustbeauto-

    maticallyswitchedoffandthefuelsupplystoppedwithin5seconds.Theheatermayremaininopera-tionifamanualdevicehasalreadybeenactivated.

  • 6

    Introduction1

    Statutory Regulations!Additional regulations for certain vehicles named in Directive 94 / 55 / EC of the ADR Agreement

    ScopeThisappendixappliestovehiclesforwhichthespecialprovisionsofDirective94/55/ECapplytocombustionheatersandtheirinstallation.

    Definition of terms usedThevehicledesignations“EX/II”,“EX/III”,“AT”,“FL”and“OX”accordingtoChapter9.1oftheADRAgree-mentDirective94/55/ECareusedforthepurposesofthisannex.

    Technical regulations

    General provisions (EX / II, EX / III, AT, FL and OX vehicles)

    Avoid heating and ignitionCombustionheatersandtheirexhaustpipesmustbedesigned,arranged,protectedorcoveredsothatanyunacceptableriskofheatingorignitionoftheloadisavoided.Thisregulationisdeemedtobecompliedwithifthefueltankandtheexhaustsystemoftheunitcon-formtotheregulationsdescribedinthe“Fueltank”and“Exhaustsystemandexhaustpipelayout”paragraphs.Thecompletevehiclemustbecheckedforcompliancewiththeseregulations.

    Fuel tanksFueltanksforsupplyingtheheatershallconformtothefollowingregulations:•Intheeventofanyleakage,thefuelshalldraintothe

    groundwithoutcomingintocontactwithhotpartsofthevehicleortheload;

    •fueltankscontainingpetrolshallbeequippedwithaneffectiveflametrapatthefilleropeningorwithaclosureenablingtheopeningtobekepthermeticallysealed.

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

    Switching on the combustion heaterThecombustionheatermayonlybeswitchedonmanu-ally.Automaticswitchingonviaaprogrammableswitchisnotpermitted.

    EX / II and EX / III vehiclesCombustionheatersforgaseousfuelsarenotpermit-ted.

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

    heatermaybemanuallyswitchedbackonbythevehicledriver;

    c) Startingupofafeedpumpinstalledinthevehicleforthedangerousgoodscarried.

    CombustionheaterafterrunAfterrunningoftheswitchedoffcombustionheaterispermitted.Inthecasesnamedinthe„FLvehicles“para-graphunderlettersb)andc)thesupplyofcombustionairmustbeinterruptedbysuitablemeansafteramaxi-mumafterrunperiodof40seconds.Onlycombustionheaterswhoseheatexchangersareverifiablynotdam-agedbythereducedafterrunperiodof40secondsbeyondtheirusualuseperiodmaybeused.

    Please note!

    •Compliancewiththestatutoryregulations,theaddi-tionalregulationsandsafetyinstructionsisprerequisiteforguaranteeandliabilityclaims.

    FailuretocomplywiththestatutoryregulationsandsafetyinstructionsandincorrectrepairsevenwhenusingoriginalsparepartsmaketheguaranteenullandvoidandprecludeanyliabilityforJ.EberspächerGmbH&Co.KG.

    •Subsequentinstallationofthisheatermustcomplywiththeseinstallationinstructions.

    •Thestatutoryregulationsarebindingandmustalsobeobservedincountrieswhichdonothaveanyspecialregulations.

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

    •Installationoftheheaterinspecialvehiclesmustcomplywiththeregulationsapplyingtosuchvehicles

    •Otherinstallationrequirementsarecontainedinthecorrespondingsectionsofthismanual.

  • 7

    Safety instructions for installation and operation

    Danger!Risk of injury, fire and poisoning!•Theheatermustonlybestartedupwhenthemainte-

    nanceflapisclosedandtheoutlethoodismountedinposition.

    •Themaintenanceflapmustnotbeopenedduringoperation.

    •Disconnectthevehiclebatterybeforecommencinganykindofwork.

    •Beforeworkingontheheater,switchtheheateroffandletallhotpartscooldown.

    •Theheatermustnotbeoperatedinclosedrooms,e.g.inthegarageorinamultistoreycarpark.

    •Adjustablehotairoutletsmustalwaysbeadjustedsothattheycannotblowhotairdirectlyatlivingcreatures(people,animals)orobjectssensitivetotemperature(looseand/orfastened).

    Caution!Safety instructions for installation and operation!•Theyearofinitialcommissioningmustbemarkedon

    thenameplate.•Theheatexchangerofairheatersisacomponent

    subjecttohighthermalloadswhichmustbereplaced10yearsafterinitialcommissioningoftheheater.Inaddition,theinstallationdatemustbeenteredontheplate“originalsparepart”enclosedwiththeheatexchangermust.Thenaffixtheplatenexttothenameplateontheheater.

    •TheheatermustonlybeinstalledbyaJEpartnerauthorisedbythemanufactureraccordingtotheinstructionsinthismanualandpossiblyaccordingtospecialinstallationrecommendations;thesameappliestoanyrepairstobecarriedoutinthecaseorrepairsorguaranteeclaims.

    •OnlythecontrolelementsapprovedbyJ.EberspächerGmbH&Co.KGmustbeusedtooperatetheheater.Theuseofothercontrolelementscancausemalfunc-tions.

    •Repairsbyunauthorisedthirdpartiesorwithnotoriginalsparepartsaredangerousandthereforenotallowed.Theyresultinexpiryofthetypepermitoftheheater;consequently,wheninstalledinmotorvehiclestheycancauseexpiryofthevehicleoperatinglicence.

    Introduction1

    •Thefollowingmeasuresarenotallowed:–Changestocomponentsrelevanttotheheater.–Useofthirdpartycomponentsnotapprovedby

    Eberspächer.–Nonconformitiesininstallationoroperationfromthe

    statutoryregulations,safetyinstructionsorspecifica-tionsrelevanttosafeoperationasstatedintheinstallationinstructionsandoperatinginstructions.Thisappliesinparticulartotheelectricalwiring,fuelsupply,combustionairsystemandexhaustsystem.

    •Onlyoriginalaccessoriesandoriginalsparepartsmustbeusedduringinstallationorrepairs.

    •Whencarryingoutelectricweldingonthevehicle,thepluspolecableatthebatteryshouldbedisconnectedandplacedatgroundtoprotectthecontroller.

    •Donotoperatetheheateranywherewheretherearereadilyflammablematerials(e.g.drygrass,leaves,paper,etc.)intheareaoftheexhaustsystemorwhereignitablefumesanddustcanform,e.g.neara–fueldepot–coaldepot–wooddepot–graindepots,etc.

    •Theheatermustbeswitchedoffwhenrefuelling.•Whentheheaterismountedinasafetyhousingetc.,

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

    •Defectfusesmustonlybereplacedbyfuseswiththeprescribedrating.

    •Iffuelleaksfromtheheaterfuelsystem,arrangeforthedamagetoberepairedimmediatelybyaJEservicepartner.

    •Afterrunningoftheheatermustnotbeinterruptedprematurelye.g.bypressingthebatterydisconnectingswitch,apartfrominthecaseofanemergencystop.

    Please note!

    Followinginstallation,attachthe„Switchoffheaterbeforerefuelling!“stickernearthetankfillerneck.

    Accident prevention

    Generalaccidentpreventionregulationsandthecor-respondingworkshopandoperationsafetyinstructionsaretobeobserved.

  • 8

    Using the universal installation kits

    OrderNo.Universal installation kit 25 2069 80 00 00•withoutlethoodØ60mm, heaterguidenumber6,usablewith:

    –Airtronic D2,12V 252069050000–Airtronic D2,24V 252070050000

    Universal installation kit 25 2113 80 00 00•withoutlethoodØ90mm, heaterguidenumber10,usablewith:

    –Airtronic D3,12V 252317050000

    –Airtronic B4,12V 201812050000

    –Airtronic D4,12V 252113050000–Airtronic D4,24V 252114050000

    •withoutlethoodØ90mm, heaterguidenumber15,usablewith:

    –Airtronic D4Plus,12V 252484050000–Airtronic D4Plus,24V 252498050000

    •withoutlethoodØ90mm, heaterguidenumber30,usablewith:

    –Airtronic B3Plus,12V 201944050000

    Universal installation kit 25 2484 80 00 00•withoutlethoodØ75mm, heaterguidenumber3,usablewith:

    –Airtronic D3,12V 252317050000

    –Airtronic B4,12V 201812050000

    –Airtronic D4,12V 252113050000–Airtronic D4,24V 252114050000

    •withoutlethoodØ75mm, heaterguidenumber8,forrecirculationmode heaterguidenumber10,forfreshairmode usablewith:

    –Airtronic B3Plus,12V 201944050000–Airtronic D4Plus,12V 252484050000–Airtronic D4Plus,24V 252498050000

    Please note!

    •Controlelementsseepricelistorproductoverview.•Partswithoutafigureno.aresmallpartsandpacked

    inabag.•Ifotherpartsarerequiredfortheinstallation,see

    productoverview.•Fornotesontheunitratings,refertoproductover-

    view.

    Product information2

    Heater scope of supply, complete packages and universal installation kit

    Heater Order No.

    Airtronic D2,12V 252069050000Airtronic D2,24V 252070050000Airtronic B3Plus,12V 201944050000Airtronic D3,12V 252317050000Airtronic B4,12V 201812050000Airtronic D4,12V 252113050000Airtronic D4,24V 252114050000Airtronic D4Plus,12V 252484050000Airtronic D4Plus,24V 252498050000

    Thescopeofsupplyincludes:No.infigure Name

    1 Heater2 Meteringpump

    Complete package Order No.

    Airtronic D2,12VCompletepackage 252115050000Airtronic D2,24VCompletepackage 252116050000

    Includedinthescopeofsupply:No.infigure Name

    1 Heater 2 Meteringpump – InstallationkitwithoutlethoodØ60mm 3 Minicontroller 4 Tankconnection(onlyincompletepackage 252116050000)

    Universal installation kit (allversions)

    Includedinthescopeofsupply:No.infigure Name

    5 Leadharness,plus/minus 6 Leadharness,operation 7 Flexibleexhaustpipe,1mlong 8 Combustionairhose,1mlong 9 Cabletie(10x) 10 Bracket,dosingpump 11 Pipe,6x2,1.5mlong 12 Pipe,4x1.25,7.5mlong 13 Hoseclip(2x) 14 Airoutlet,rotatable 15 Grid 16 Hood 17 Flexiblepipe 18 Exhaustsilencer 19 Cableharness,heater

  • 9

    Scope of supply: Heater, universal installation kit and complete packages

    * OnlyincompletepackageAirtronicD2 ** OnlyforAirtronic B3Plus,D3,B4,D4,D4Plus *** OnlyforAirtronic D2 **** OnlyincompletepackageAirtronicD2,24volt

    Product information2

  • 10

    Using the “Plus” installation kits

    OrderNo.“Plus” installation kit 25 2069 81 00 00•withoutlethoodØ75mm, heaterguidenumber12,usablewith:

    –Airtronic D2,12V 252069050000–Airtronic D2,24V 252070050000

    “Plus” installation kit 25 2113 81 00 00•withoutlethoodØ90mm, heaterguidenumber10,usablewith:

    –Airtronic D3,12V 252317050000

    –Airtronic B4,12V 201812050000

    –Airtronic D4,12V 252113050000–Airtronic D4,24V 252114050000

    •withoutlethoodØ90mm, heaterguidenumber15,usablewith:

    –Airtronic D4Plus,12V 252484050000–Airtronic D4Plus,24V 252498050000

    •withoutlethoodØ90mm, heaterguidenumber30,usablewith:

    –Airtronic B3Plus,12V 201944050000

    “Plus” installation kit 25 2484 81 00 00•withoutlethoodØ75mm, heaterguidenumber8,forrecirculationmode heaterguidenumber10,forfreshairmode usablewith:

    –Airtronic B3Plus,12V 201944050000–Airtronic D4Plus,12V 252484050000–Airtronic D4Plus,24V 252498050000

    Please note!

    •Controlelementsseepricelistorproductoverview.•Partswithoutafigureno.aresmallpartsandpacked

    inabag.•Ifotherpartsarerequiredfortheinstallation,see

    productoverview.•Fornotesontheunitratings,refertoproductover-

    view.•The“Plus”installationkitsareparticularlysuitablefor

    installationsincampervansandboats.

    Scope of supplyHeater and “Plus” installation kit

    Heater Order No.

    Airtronic D2,12V 252069050000Airtronic D2,24V 252070050000Airtronic B3Plus,12V 201944050000Airtronic D3,12V 252317050000Airtronic B4,12V 201812050000Airtronic D4,12V 252113050000Airtronic D4,24V 252114050000Airtronic D4Plus,12V 252484050000Airtronic D4Plus,24V 252498050000

    Thescopeofsupplyincludes:No.infigure Name

    1 Heater 2 Meteringpump

    “Plus” installation kit (allversions)

    Thescopeofsupplyincludes:No.infigure Name

    3 Combustionairintakesilencer 4 Exhaustsilencer 5 Hoseconnectingsockets 6 Grid 7 Ybranch 8 Tankconnectionkit 9 Temperaturecontrolsensor 10 Cableloomfortemperaturecontrolsensor 11 EasyStartTtimer 12 Leadharness,plus/minus 13 Leadharness,operation 14 Hoseclip(2x) 15 Hoseclip(6x) 16 Pipe4x1.25,6mlong,(includedinItem8) 17 Cableharness,heater 18 Flexibleexhaustpipe,1mlong 19 Grid 20 Bracketmeteringpump 21 Cabletie(10x) 22 Hood 23 Outlet(2x) 24 AdapterØ6/4 25 Pipe4x1,6mlong,(includedinItem8) 26 Pipeclip,Ø50mm 27 Flexiblepipeforhotairsystem

    Product information2

  • 11

    Product information2

    Scope of supply: Heater and “Plus” installation kit

  • 12

    Product information2

    Caution!Safety instructions for technical data!Failure to comply with the technical data can result in malfunctions.

    Please note!

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

    Technichal data

    Heatertype Airtronic

    Heater AirtronicD2

    Version D2

    Heatingmedium Air

    Controloftheheatflow Stage

    Power Large Medium Small Off

    Heatflow(watt) 2200 1800 1200 850 –

    Heaterairflowratewithoutcounterpressure(kg/h)

    105 87 60 42 13withhoodØ60mm

    Fuelconsumption(l/h) 0,28 0,23 0,15 0,10 –

    Elektr.powerconsumption(watt)

    34 23 12 8 4inoperationt

    atstart 100

    Ratedvoltage 12or24volt

    Operatingrange•Lowervoltagelimit: Anundervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds

    •Uppervoltagelimit: Anuppervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds

    Fuel “Fuelquality“and“Fuelatlowtemperatures“

    seepage28.Commerciallyavailabledieselfuel(DINEN590)

    Tolarableambienttemperature Operation Notrunning

    Heater –40°Cto+70°C –40°Cto+85°C

    Dosingpump –40°Cto+50°C –40°Cto+125°C

    Maximumairintaketemperature +40°C

    Interferencesuppression Interferencesuppressionclass5toDINEN55025

    Weight approx.2,7kg

    Ventilationmode possible

  • 13

    Product information2

    Safetyinstructionsfortechnicaldataseepage12.

    Please note!

    Technichal data

    Heatertype Airtronic M

    Heater AirtronicD3/AirtronicD4/AirtronicD4Plus

    Version D3/D4/D4Plus

    Heatingmedium Air

    Controloftheheatflow Stage

    Power Large Medium Small Off

    Heatflow(watt) D3 3000 2200 1600 900 –

    D4 4000 3000 2000 900 –

    D4Plus 4000 3000 2000 900 –

    Heaterairflowratewithoutcounterpressure(kg/h)

    150 120 90 60 24D3withhoodØ90mm

    D4withhoodØ90mm 185 150 110 60 22

    D4PluswithhoodØ75mm 185 140 100 55 –

    Fuelconsumption(l/h) D3 0,38 0,28 0,24 0,11 –

    B4 0,51 0,38 0,25 0,11 –

    D4Plus 0,51 0,38 0,25 0,11 –

    Elektr.powerconsumption(watt)iinoperationt(12and24volt)

    D3 24 16 10 7 5

    B4 40 24 13 7 5

    D4Plus 55 30 16 7 5

    atstart(12and24volt) 100

    Ratedvoltage 12or24volt

    Operatingrange•Lowervoltagelimit: Anundervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds

    •Uppervoltagelimit: Anuppervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds

    Fuel “Fuelquality“and“Fuelatlowtemperatures“

    seepage28.Commerciallyavailabledieselfuel(DINEN590)

    Tolarableambienttemperature Operation Notrunning

    Heater –40°Cto+70°C –40°Cto+85°C

    Dosingpump –40°Cto+50°C –40°Cto+125°C

    Maximumairintaketemperature +40°C

    Interferencesuppression Interferencesuppressionclass5toDINEN55025

    Weight approx.4,5kg

    Ventilationmode possible

  • 14

    Product information2

    Caution!Safety instructions for technical data!Failure to comply with the technical data can result in malfunctions.

    Please note!

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

    Technichal data

    Heatertyp Airtronic M

    Heater AirtronicB3Plus/AirtronicB4

    Version B3Plus/B4

    Heatingmedium Air

    Controloftheheatflow Stage

    Power Large Medium Small Off

    Heatflow(watt) B3Plus 3000 2300 1700 1200 –

    B4 3800 3200 2100 1300 –

    Heaterairflowratewithoutcounterpressure(kg/h)

    175 143 115 85 24B3PluswithhoodØ90mm

    B4withhoodØ90mm 185 160 120 85 24

    Fuelconsumption(l/h) B3Plus 0,43 0,33 0,24 0,16 –

    B4 0,54 0,46 0,29 0,18 –

    Elektr.powerconsumption(watt)inoperation

    B3Plus 33 20 13 8 5

    B4 40 29 15 9 5

    atstart 100

    Ratedvoltage 12volt

    Operatingrange•Lowervoltagelimit: Anundervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.10.5voltUndervoltageprotectiontriggertime:20seconds

    •Uppervoltagelimit: Anuppervoltageprotectioninthecontroller

    switchesofftheheaterwhenthevoltagelimitisreached.

    approx.16voltUndervoltageprotectiontriggertime:20seconds

    Fuel “Fuelquality“and“Fuelatlowtemperatures“

    seepage28.Commerciallyavailablepetrolfuel(DINEN228)

    Tolarableambiettemperature Operation Notrunning

    Heater –40°Cto+50°C –40°Cto+85°C

    Dosingpump –40°Cto+20°C –40°Cto+125°C

    Maximumairintaketemperature +40°C

    Interferencesuppression Interferencesuppressionclass5toDINEN55025

    Weight approx.4,5kg

    Ventilationmode possible

  • 15

    Main dimensions Airtronic

    A = ExhaustB = FuelV = Combustion air

    1 Minimuminstallationclearance(space)foropeningthelidandfordismantlingtheglowplugandthecontroller.

    2 Minimuminstallationclearance(space)forintakeofheaterair.

    Main dimensions Airtronic M

    * OutlethoodforAirtronic D2: Ø60mm,includedintheuniversalinstallationkit Ø75mm,includedinthe“Plus”installationkit

    ** OutlethoodforAirtronic B3Plus,D3,B4,D4: Ø75mm,includedintheuniversalinstallationkit Ø90mm,includedintheuniversalinstallationkitorinthe

    “Plus”installationkit OutlethoodforAirtronic D4Plus:

    Ø75mm,includedintheuniversalinstallationkitorin the“Plus”installationkit Ø90mm,includedintheuniversalinstallationkitorin the“Plus”installationkit

    Product information2

    **

    *

    Please note!

    InstallationofsphericalreductionhoodisnotpermittedintheAirtronicD4Plus.

  • 16

    Installation3

    1 Heaterinfrontofthepassengerseat2 Heaterbetweenthedriver’sseatandthepassenger

    seat3 Heaterunderthevehiclefloor4 Heaterinlivingspace5 Heaterintheboot

    Installation position in a camper van

    In a camper van, the heater is preferably installed in the inner compartment or luggage compartment.If it is not possible to install the heater in the pas-senger compartment or boot, the heater can also be mounted, protected against splashing water, under the vehicle floor.

    The „Plus“ installation kits are intended for installation in a camper van.

    Please note!

    Installation and mounting position

    Theheaterissuitableandapprovedforinstallationinvehicleinteriorsusedbypeople.Theheater,togetherwithitsheaterflangeandthemountedflangeseal,isfixeddirectlyontothefloorofthevehicleorinasuitablepositionintherearpanelofthevehicle.

    •Ifinstalledinsidethevehicle,detachableconnectionsofexhaustgas,combustionairandfuellinesarenotallowed.

    •Theflangesealmustbemountedontheheater,inordertosealofftheopeningsfortheexhaustgas,combustionairandfuellines.

    •Installationinthedriver’scaborpassengercompart-mentofcommercialbuseswithmorethan9seats(8seats+driver’sseat)isnotallowed.

    •TheADRregulationsmustalsobecompliedwithforinstallationoftheheaterinvehiclesusedtotransportdangerousgoods.

    ForinformationontheADRregulations,seepage6,31andintheinformationsheetwithPrintNo.252161951580.

    •Wheninstallingtheheater,ensuresufficientopenspaceisallowedforintakeoftheheatingairandforthedismantlingofglowplugsandcontrolbox(seepage15“maindimensions”).

    •Observetheregulationsandsafetyinstructionsforthischapter,givenonpages4–7.

    Please note!

  • 17

    Installation

    Installation in a car or people carrier

    In a car or people carrier, the heater is preferably installed in the passenger compartment or boot. If it is not possible to install the heater in the pas-senger compartment or boot, the heater can also be mounted, protected against splashing water, under the vehicle floor.

    1 Heaterinfrontofthepassengerseat2 Heaterbetweenthedriver’sseatandthepassenger

    seat3 Heaterunderthevehiclefloor4 Heaterunderthebackseat5 Heaterintheboot

    Installation in a truck (only diesel heaters)

    In a truck, the heater is preferably installed inside the driver’s cab. If it is not possible to install the heater inside the driver’s cab, it can also be mounted in the tool box or in a storage box.

    Installation in an excavator cab (only diesel heat-ers)

    In an excavator, the heater is preferably installed in the cab. If it is not possible to install the heater in the cab, the heater can also be installed in a storage box outside the cab.

    1 Heaterinthepassenger’sfootroom2 Heateronthecabrearwall3 Heaterunderthebed4 Heaterinthetoolbox

    1 Heaterintheseatbox2 Heateronthecabrearwall3 Heaterinaprotectivecase

    •Theinstallationsuggestionsmadeintheinstallationinstructionsarejustexamples.Otherinstallationloca-tionsarepossible,aslongastheycorrespondtotheinstallationrequirementsstatedintheseinstructions.

    •Otherinstallationinformation(e.g.forboatsandships)isavailablefromthemanufactureronrequest.

    •Observethetolerableinstallationpositiontogetherwiththeoperatingandstoragetemperatures.

    Installation

    Please note!

    3

  • 18

    Possible installation positions

    The heater is preferably installed in the normal posi-tion as shown in the drawing.Depending on the installation conditions, the heater can be tilted by max. 30° (flow direction to the bot-tom) or turned by max. 90° around its own longitu-dinal axis (exhaust connection horizontal, glow plug points upwards!).

    Normal position horizontal (exhaust connection downwards) with tolerable swivel range

    Cable harness connection, optionally right or left

    If necessary, the cable harness connection can be changed over to the other side of the heater. To do so, the controller has to be removed and the lower semi-circular cable harness cover unclipped.The cable harness can then be rerouted in the con-troller.Then mount the controller again, position the jacket shell and insert the cable harness bush and the bungs in the corresponding recesses in the lower jacket shell.

    1 Heaterairintakeopening(fanwheel)2 Positionoftheglowplug3 Directionofflow

    In the heating mode, the heater can deviate from the shown normal or maximum installation positions by up to +15° in all directions because of a slanting position of the vehicle or boat, without any impaired functions.

    Installation3

    Please note!

  • 19

    1 Theremustbesufficientclearancebetweentheheaterandthevehiclefloor–alsocheckthatthefanwheelrunsfreely.

    2 Themountingsurfacemustbeflatandsmooth.3 Theflangesealmustbemounted.

    4 Thevehiclewallmustbeflatandsmooth.5 Reinforcementplate(ifrequired,forOrderNo.see

    above)6 Springwasher7 HexagonnutM6(torque5+1Nm)

    Mounting and fastening Make the necessary breakthroughs for exhaust, combustion air and fuel as shown in the hole diagram. The support surface for the heater foot must be flat. An appropriate tool can be purchased from the manufacturer for drilling the breakthroughs and also smoothing the support surface.The hole Ø 10.5 mm for the cable harness “dosing pump” is not included in the picture drawing and must be drilled after installation.

    Picture hole Special tool

    If the sheet metal of the support surface is

  • 20

    Nameplate

    The nameplate is fastened to the front of the heater. The second nameplate (duplicate) is included in the scope of supply of the heater.If required, the duplicate nameplate can be adhered in a clearly visible position on the heater or near to the heater.

    The regulations and safety instructions to be ob-served for this chapter are stated on page 5. 1 Originalnameplate

    2 2ndnameplate(duplicate)

    Installation3

    Please note!

  • 21

    Heater air system (example)

    Heater air system

    The parts for the hot air system are included in the scope of supply of the „Universal“ and „Plus“ instal-lation kits.The „Plus“ installation kit does not include the flexible pipe Ø 75 mm or Ø 90 mm, these must be ordered separately. The order no. is given in the additional parts catalogue.

    Danger!Risk of burning and injuries!•Thehosesoftheheaterairsystemandthehotair

    outletaretoberoutedandfastenedinsuchawaythattheyposenotemperaturerisktopeople,animalsormaterialssensitivetotemperaturefromradiation/contactorblowingdirectly.Ifnecessary,acoveristobefittedtotheheaterairsystemorhotairoutlet.

    •Theoutflowhoodmustbefittedonthehotairoutflowside.

    •Asafetygridmustbefittedtotheheaterairintakesideandoutflowsideifnoairhosesaremounted,topreventanyinjuriesfromtheheaterairfanorburnsfromtheheatexchanger.

    •Hightemperaturesoccurintheheaterairsystemdur-ingandaftertheheaterhasbeenworking.Thisiswhyitisimportanttoavoidworkinginthevicinityoftheheaterairsystemwhiletheheaterisworking.Insuchcases,switchtheheateroffbeforehandandwaituntilallpartshavecooleddowncompletely.Ifnecessary,wearsafetygloves.

    Caution!•Theheaterairintakeopeningsmustbearrangedin

    suchawaythatundernormalcircumstances,itisnotpossibleforexhaustfromthevehicleengineandheatertobesuckedintothesystem,orfortheheatingairtobecontaminatedwithdust,saltspray,etc.

    •Forcirculatingair,positionthecirculatingairintakeinsuchawaythattheoutflowinghotaircannotbedirectlysuckedinagain.

    •Intheeventofpossibleoverheating,itispossibleforlocallotairtemperaturesofuptomax.150°Corsurfacetemperaturesofuptomax.90°Ctooccurimmediatelybeforethedefectshutdown.Thereforeonlytemperature-resistanthotairhosesapprovedbyusmustbeusedfortheheaterairsystem!

    •Whencheckingthefunctions,themeanoutflowtem-peraturemeasuredaftertheheaterhasbeenrunningabout10minutesatapprox.30cmfromtheoutletshouldnotexceed110°C(atanintaketemperatureofapprox.20°C).

    •Ifthereisariskofthedriverandpassengerstouchingtheheaterwhenthevehicleisbeingdrivennormally,acontactprotectiondevicemustbefitted.

    Installation3

    1 Safetygrid2 Outflowhood3 Hoseclip4 Flexiblehose

    5 Rotatingoutflow6 Connectionfitting7 Safetygrid

    Please note!

    •Installationofsphericalreductionhoodisnotpermit-tedintheAirtronicD4Plus.

    •Theregulationsandsafetyinstructionstobeobservedforthischapterareonpage4–7.

    •Ifairductpartsareconnectedtheheatercodenumberin“UsingUniversalInstallationKits”,page8and“UsingPlusInstallationKits”,page10mustbeobserved.

  • 22

    Installation3

    Exhaust system

    Mounting the exhaust system

    The “Universal” and “Plus” installation kits include a flexible exhaust pipe, inner Ø 24 mm, 1000 mm long and an exhaust silencer. The flexible exhaust pipe can be shortened to 20 cm or lengthened to max. 2 m, depending on the installation conditions.Fasten the exhaust silencer to a suitable position in the vehicle. Use a pipe clip to fix a short exhaust pipe end (with end sleeve) to the exhaust silencer (Anzugsdrehmo-ment7+0.5Nm).Useapipeclip(tighteningtorque7+0.5Nm)tofixashortexhaustendpipe(withendsleeve)totheexhaustsilencer.

    Caution!Safety instructions!The whole exhaust system gets very hot during and immediately after the heater has been working. This is the reason why the exhaust system must be installed according to these instructions.•Theexhaustoutletmustendintheopenair.•Theexhaustpipemustnotprotrudebeyondthelateral

    limitsofthevehicle.•Installtheexhaustpipeslopingslightlydownwards.If

    necessary,makeadrainholeapprox.Ø5mmatthelowestpointtodrainoffcondensation.

    •Importantfunctionalpartsofthevehiclemustnotbeimpaired(keepsufficientclearance).

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

    •Exhaustpipesmustbefastenedsafely(recommendedclearanceof50cm)toavoiddamagefromvibrations.

    •Routetheexhaustsystemsothattheemittedfumesarenotsuckedinwiththecombustionair.

    •Themouthoftheexhaustpipemustnotgetcloggedbydirtandsnow.

    •Themouthoftheexhaustpipemustnotpointinthedirectionoftravel.

    •Alwaysfastentheexhaustsilencertothevehicle.

    Danger!Risk of injuries and burns!Every type of combustion produces high tempera-tures and toxic exhaust fumes. This is the reason why the exhaust system must be installed according to these instructions.•Donotperformanyworkontheexhaustsystemwhile

    theheaterisworking.•Beforeworkingontheexhaustsystem,firstswitchthe

    heateroffandwaituntilallpartshavecooleddowncompletely,wearsafetyglovesifnecessary.

    •Donotinhaleexhaustfumes.

    • Comply with the regulations and safety instructions for this chapter on page 4 – 7.

    • If a silencer is fitted, the exhaust end pipe must be much shorter than the flexible exhaust pipe be-tween the heater and the exhaust silencer.

    • Small arrows indicating the direction of flow have been cast into the fittings to differentiate between the combustion air and the exhaust fittings at the heater (see diagram page 23).

    •Topreventcontacterosion,theclipsusedtofixtheexhaustpipemustbemadeofstainlesssteel.TheorderNo.forthestainlesssteelfixingclipsisgivenintheproductoverview.

    Please note!

  • 23

    Caution!Safety instructions for the combustion air system!•Thecombustionairopeningmustbefreeatalltimes.•Positionthecombustionairintaketobesurethatex-

    haustfumescannotbesuckedinwiththecombustionair.

    •Donotarrangethecombustionairintaketopointingagainstthewindblast.

    •Thecombustionairintakemustnotgetcloggedwithdirtandsnow.

    •Installthecombustionairintakesystemslopingslightlydownwards.Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointtodrainoffcondensation.

    Combustion air system

    Mounting the combustion air system

    Theuniversalinstallationkitincludesaflexiblecombus-tionairhose,innerØ25mm,1000mmlong.Ifnecessarytheflexiblecombustionairhosecanbeshortenedto20cmorlengthenedtomax.2mdepend-ingontheinstallationconditions.Useapipeclip(tighteningtorque3+0.5Nm)tofixtheflexiblecombustionairhosetotheheaterandusehoseclipsorcabletiestofixinsuitablepositions.Fitanendsleeveaftercompletingtheinstallation.

    The„Plus“installationkitincludesacombustionairintakesilencerwithaflexibleconnectionhose(innerdiameter25mm).Useapipeclip(tighteningtorque3+0.5Nm)tofixtheflexibleconnectionhosetotheheaterandusehoseclipsorcabletiestofixinsuitablepositions.Fitanendsleeveaftercompletingtheinstallation.

    1 Combustionairhose,di=25mm2 Combustionairsilencer, –Includedinthe“Plus”installationkit3 Exhaustpipe,di=24mm4 Exhaustsilencer5 Intake/outletopening–protectfromwind, snow,dirtandwater.6 Endsleeve,combustionair7 Endsleeve,exhaust8 Combustionairconnection9 Exhaustconnection10 Endsleeve,combustionair11 Hoseclip12 Exhausthoseclip

    Installation3

    Please note!

    •ForAirtronic andAirtronic Mheatersacombustionairintakesilencercanbefittedinsteadofthecombustionairhosetoreducethenoiselevel.OrderNo.seesparepartslistorproductoverview.

    • Comply with the regulations and safety instructions for this chapter on page 4 – 7.

    max.2m

    min.0.2mmin.0.2–max.2m

  • 24

    Installation3

    1 Correctconnection2 Incorrectconnection–bubbleformation

    Fuel supply

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

    The following safety instructions must be observed when mounting the dosing pump, routing the fuel pipes and mounting the fuel tank.Deviations from the instructions stated here are not allowed.Failure to comply can result in malfunctions.

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

    Caution when handling fuel.

    •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.

    •Usehoseclipstosecureallhoseconnectionsinthefuelsupply(tighteningtorque1+0.2Nm).

    •Partscarryingfuelmustbeprotectedfrominterferingheat.

    •Neverrouteorfastenthefuelpipestotheheaterorvehicleexhaustsystem.Atcrossings,alwaysensureadequateheatclearance,ifnecessaryattachheatdeflectionplatesorprotectivehose(ForOrderNo.ofprotectivehose,seeproductoverview).

    •Drippingorevaporatingfuelmustneverbeallowedtocollectonhotpartsorigniteonelectricsystems.

    •Whenconnectingfuelpipeswithafuelhose,alwaysmountthefuelpipesinabuttjointtopreventanybub-blesfromforming.

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

    •Inbusesandcoaches,fuelpipesandfueltanksmustnotberoutedthroughthepassengercompartmentordriver’scab.

    •Fueltanksinbusesandcoachesmustbepositionedinsuchawaythattheexitsarenotindirectdangerfromapossiblefire.

    Please note!

    •Complywiththeregulationsandsafetyinstructionsforthischapteronpage4–7.

    •Fornoisereasons,donotrigidlyfitfuelpipesontostructuralsoundtransferringcomponents.

    Aspongerubberhosecanbepushedoverthefueltubesfornosereduction.

  • 25

    Fuel supply

    Fuel feed point with T-piece from the fuel supply line from the tank fitting to the vehicle engine

    1 Fuelflowline,vehicletank2 Tothevehicle‘sengine,mechanicalfuelorinjection

    pump3 Tpiece,868or106104 Dosingpump5 Fuelpipe,4x1(di=Ø2mm)6 Fuelpipe,6x2(di=Ø2mm)7 Fuelhose,5x3(di=Ø5mm)8* Fuelpipe,4x1.25(di=Ø1,5mm)9 AdapterØ6/410 Fuelhose,3.5x3(di=Ø3.5mm), approx.50mmlong11 Fuelhose,5x3(di=Ø5mm), approx.50mmlong12 Pipeconnectors,da=Ø4mm13 Fuelfilterrequiredforcontaminatedfuelonly.

    * Ifnecessary,afuelpipe4x1(di=Ø2mm)canbeusedfordieselheatersinsteadofthefuelpipe4x1.25(di=Ø1.5mm),Item(8).

    Thedetailsregardingthepipelengthsremainun-changed.

    Thefuelpipe,4x1mustbeorderseparately.OrderNo.seesparepartslistorproductoverview.

    Installation3

    •InserttheTpiece(3)inthefuelflowlineupstreamofthefeedpump.

    •Items(5),(9)and(12)areincludedinthe„Plus“instal-lationkitonly.

    •Item(6)isincludedintheuniversalinstallationkitonly.•Items(7)and(13)mustbeorderedseparately.The

    orderno.isgivenintheproductoverview.

    Please note!

    Installation position of the T-piece

    Use the installation positions shown in the diagram when inserting a T-piece.

    1 Directionofflowfromthefueltank2 Directionofflowtothevehicleengine

    Possible pipe lengths

    Intake sideAirtronica=max.5m

    Airtronic Ma=max.2m

    Pressure sideDieselheaters•Forsuctionpipedi=Ø2mm, b=max.6m•Forsuctionpipedi=Ø5mm, b=max.10m

    Petrolheater•b=max.4m

  • 26

    Fuel feed point with tank connection – ascending pipe, integrated in the vehicle tank or in the tank fitting

    1 Tankconnectionformetaltank di=Ø2mm,da=Ø6mm2 Tankconnectionfortankfitting di=Ø2mm,da=Ø4mm3 Dosingpump4 Fuelpipe,4x1(di=Ø2mm)5 Fuelpipe,6x2(di=Ø2mm)6 Fuelhose,5x3(di=Ø5mm)7 Fuelfilterrequiredforcontaminatedfuelonly.8* Fuelpipe,4x1.25(di=Ø1,5mm)9 Pipeconnectors,da=Ø4mm10 Fuelhose,3.5x3(di=Ø3.5mm) approx.50mmlong11 AdapterØ6/412 Fuelhose,5x3(di=Ø5mm), approx.50mmlong

    * Ifnecessary,afuelpipe4x1(di=Ø2mm)canbeusedfordieselheatersinsteadofthefuelpipe4x1.25(di=Ø1.5mm),Item(8).

    Thedetailsregardingthepipelengthsremainun-changed.

    Thefuelpipe,4x1mustbeorderseparately.OrderNo.seesparepartslistorproductoverview.

    Fuel supply

    •Items(2),(4),(8),(9)andtheconnectionpartsareincludedinthe“TankConnection”kit,OrderNo.221000201300(The“TankConnection”kitisincludedinthe„Plus“installationkit).

    •Item(5)isincludedintheuniversalinstallationkitonly.•Item(11)isincludedinthe“Plus”installationkitonly.•Items(6)and(7)mustbeorderedseparately.The

    orderno.isgivenintheproductoverview.•Wheninstallingtankconnectionmaintainaminimum

    distanceof50±2mmfromtheendoftheriserpipeandthebottomofthetank.

    •Consultthevehiclemanufacturerbeforeinstallingthetankconnectioninametaltank.

    Installation3

    Caution!Safety instructions for the fuel supply!

    • The fuel must not be conveyed by gravity or overpressure in the fuel tank.• Withdrawal of fuel after the vehicle’s fuel pump is not allowed.•Whenthepressureinthefuelpipeismorethan

    0.2bartomax.4,0bar,useapressurereducer(orderno.221000200800)orseparatetankconnection.

    •Whenthepressureinthefuelpipeismorethan4,0barorthereisanonreturnvalveinthereturnpipe(inthetank),aseparatetankconnectionmustbeused.

    • When using a T-piece in a plastic pipe, always use support sleeves in the plastic. Connect the T-piece and the plastic pipe with corresponding fuel hoses and secure with hose clips.

    Please note!

    Possible pipe lengthsIntake sideAirtronica=max.5m

    Airtronic Ma=max.2m

    Pressure sideDieselheaters•Forsuctionpipedi=Ø2mm, b=max.6m•Forsuctionpipedi=Ø5mm, b=max.10m

    Petrolheater•b=max.4m

  • 27

    Possible suction and pressure height of the dosing pump

    Pressure height from vehicle tank to dosing pump: a = max. 3000 mm

    Intake height in pressure-less vehicle tank: b = max. 1000 mm for dieselb = max. 1500 mm for petrol

    Intake height in vehicle tanks with withdrawal by negative pressure (valve with 0.03 bar in tank cap): b = max. 400 mm

    Pressure height of the dosing pump to the heater: c = max. 2000 mm

    Check tank venting.

    1 Connectiontoheater2 Max.fuellevel3 Min.fuellevel

    Installation3

    Fuel supply

    Installation position of the dosing pump

    Always mount the dosing pump with the pressure side rising upwards. Every installation position over 15° is allowed, although an installation position between 15° and 35° is preferable.

    1 Installationpositionbetween0°and15°isnotal-lowed.

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

    Caution!Safety instructions for installing the dosing pump•Alwaysmountthedosingpipewiththepressureside

    risingupwards–minimumincline15°.

    •Protectthedosingpumpandfilterfromintolerableheat,donotmountneartothesilencersandexhaustpipes.

    Please note!

  • 28

    Installation3

    Fuel supply

    Caution!Fuel supply safety informationItisnotpermittedtooperatetheheaterwithunap-provedfuel/fuelmixturesortheadditionofusedoil.Failuretocomplywiththiscanleadtopersonalinjuriesaswellasamalfunctionordamagetotheheater.Onlythefuelapprovedbythemanufacturerorbythevehiclemanufactureristobeused.

    Fuel quality for petrol heatersTheheaterrunswithoutproblemsonnormalcommer-cialpetrolaccordingtoDINEN228.

    Fuel quality for diesel heaters•Theheaterrunswithoutproblemsonnormalcom-

    mercialdieselfuelaccordingtoDINEN590. Duringthewintermonthsthedieselfuelisadapted

    tolowtemperaturesfrom0°Cto–20°C.Problemscanthereforeonlyariseifoutdoortemperaturesareextremelylowwhichalsoappliestothevehicle‘senginepleaserefertothevehiclemanufacturer‘sregulations.

    •Inspecialcasesandatoutdoortemperaturesabove0°CtheheatercanalsoberunonheatingoilELac-cordingtoDIN51603.

    •Iftheheaterisrunfromaseparatetank,pleasecom-plywiththefollowingrules:

    –ifoutdoortemperaturesover0°C, UsedieselfuelaccordingtoDINEN590.

    –ifoutdoortemperaturesfrom0°Cto–20°C, UsewinterdieselfuelaccordingtoDIN590.

    ifoutdoortemperatures–20°Cto–40°C, UseArcticDieselorPolarDiesel.

    Please note!

    Afterrefuellingwithwinterorcolddiesel,thefuelpipesandthemeteringpumpmustbefilledwiththenewfuelbylettingtheheaterrunfor15min!

    Operation with biodiesel (FAME)

    Airtronic The heater is not approved for operation with bio diesel fuel (FAME). Up to 10 % bio diesel fuel (FAME) may be added.

    Airtronic M The diesel heater is approved for operation with bio diesel fuel (FAME) according to DIN EN 14 214.

    •Biodieselfuel(FAME)accordingtoDINEN14214–duringthewintermonthsisadaptedtolowtem-

    peraturesfrom0°Cto–20°C.–TheFlowabilityreducesattemperaturesbelow0°C.

    •Whenusing100%biodiesel,theheatershouldbeoperatedtwiceayearwithdieselfuel(inthemiddleandattheendofaheatingperiod)inordertoburnoffanypossiblebiodieselresiduesdeposited.

    Todoso,letthevehicletankrunalmostemptyandthenfillwithdieselfuel.Whilerunningonthistankfilling,switchtheheateron2to3timesfor30minutesatatimeatthehighesttemperaturesetting.

    •Whenoperatingwithdiesel/biodieselmixturesofupto50%biodiesel,intermediateoperationwithpuredieselfuelisnotnecessary.

    Please note!

  • 29

    Operation and function4

    Operating instructions

    The heater is operated by a control element.Detailed operating instructions are enclosed with the control unit.

    The workshop / garage installing the heater will issue you with the operating instructions.

    Important instructions for operation

    Safety checks before the startAfter a lengthy period of non-use (summer months) check that all parts fit securely (tighten screws where necessary).Check the fuel system visually for any leaks.

    Heating at high altitudes• upto1500maltitude,heatingmodeispossiblewit-

    houtaltitudeadjustment.

    • from1500m–3000m,heatingmodeforshortstays(e.g.ifcrossingapassorstoppingforabreak)ispossiblewithoutadjustingtheheateraltitude.

    Incaseofalengthystay,e.g.wintercamping,itisnecessarytoadjusttheheater‘saltitude.

    Theheater‘saltitudeisadjustedbyinstallinganairpressuresensor;thisisincludedinthealtitudekit–OrderNo.221000332200.

    Please note!

    Heaterssuitableforhighaltitudesarelabelledwith“HKit”onthesidenameplate.

    Initial commissioning

    The following points are to be checked by the com-pany installing the heater during initial commissioning.

    •Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

    •Duringthetrialrunoftheheater,checkallwaterandfuelconnectionsforleaksandfirmfitting.

    •Iftheheatershowsafaultduringoperation,findandeliminatethecauseofthefaultusingadiagnosisunit.

    Please note!

    Duringtheinitialstartupoftheheater,odourscanbeproducedforashorttime.Thisisfullynormalduringthefirstfewminutesofoperationanddoesnotindicateamalfunctionintheheater.

    Please note!

  • 30

    Description of functions

    Switching on

    When the heater is switched on, the control lamp in the control element lights up.The glow plug is switched on and the fan starts at low speed.

    Please note!

    If there is still too much residual heat in the heat exchanger from when the heater was last used, firstly only the fan starts up (cold blowing).Once the residual heat has been cleared, the heater starts.

    Starting Airtronic

    After approx. 65 seconds the fuel supply starts and the fuel / air mixture in the combustion chamber ignites.Once the combined sensor (flame sensor) has de-tected the flame, the glow plug is switched off after 60 seconds. The heater is now in standard operation.

    Starting Airtronic M

    After approx. 60 seconds the fuel supply starts and the fuel / air mixture in the combustion chamber ignites.After the flame sensor has detected the flame, the glow plug is switched off after approx. 90 sec. The heater is now in standard operation.After another 120 seconds, the heater has reached the “POWER” stage (maximum fuel quantity, maxi-mum fan speed).

    Temperature selection with the control element

    Thecontrolcanbeusedtopreselectaninteriortem-perature.Theresultingtemperaturecanbewithintherangeof+10°Cto+30°Canddependsontheselectedheater,onthesizeofthespacetobeheatedandonthepre-vailingoutdoortemperature.Thesettingtobeselectedatthecontrolisanempiricalvalue.

    Operation and function4

    Control in the heating mode

    During the heating mode, the room temperature or the temperature of the sucked in heating air is constantly measured.If the temperature is higher than the temperature selected on the control element, the heater starts to regulate its output. There are 4 control stages so that the outflow of heat produced by the heater can be adjusted finely to the heating requirements. Fan speed and fuel quantity correspond to the particular control stage.If the set temperature is still exceeded in the smallest control stage, the heater goes to the “OFF” stage with the fan running on for approx. 4 minutes to cool off. Then the fan continues at minimum speed (circula-tion mode) or is switched off (fresh air mode) until the heater is started again.

    Ventilating mode

    In the ventilating mode, first the changeover switch “heating / venting” has to be activated and then the heater is switched on.

    Switching off

    When the heater is switched off, the control lamp goes off and the fuel supply is switched off.The fan runs on for approx. 4 minutes to cool down.While the fan is running on, the glow plug is switched on for approx. 40 seconds to clean.Special case:If no fuel has been supplied or if the heater is in the “OFF” stage until it is switched off, the heater is stopped without any after running.

  • 31

    Forced shutdown in ADR mode (only for diesel heaters 24 volt)

    In vehicles for the transport of dangerous goods (e.g. tanker trucks), the heater must be switched off be-fore the truck drives into a danger area (refinery, fuel service station, etc.).Failure to comply results in the heater switching off automatically when:•Thevehicleengineisswitchedoff.•Anadditionalunitisstartedup(e.g.auxiliarydrivefor

    unloadingpumpetc.).The fan then runs on for max. 40 seconds.

    Control and safety devices

    •Iftheheaterdoesnotignitewithin90secondsafterstartingthefuelpump,thestartisrepeated.Iftheheaterstilldoesnotigniteafteranother90secondsofpumpingfuel,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4min-utes.

    •Iftheflamegoesoffbyitselfduringoperation,theheaterisrestarted.Iftheheaterdoesnotignitewithin90secondsafterthefuelpumphasstarted,orignitesandgoesoffagainwithin15minutes,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4minutes.Thisstatuscanberemediedbybrieflyswitchingoffandonagain.Donotrepeattheswitchingoff/onroutinemorethantwice.

    •Inthecaseofoverheating,thecombinedsensor(flamesensor/overheatingsensor)triggers,thefuelsupplyisinterruptedandtheheaterswitchedoff.Oncethecauseoftheoverheatinghasbeenelimi-nated,theheatercanbere-startedbyswitchingoffandonagain.

    •Iftheloweroruppervoltagelimitisreached,theheaterisswitchedoffafter20seconds.

    •Theheaterdoesnotstartupwhentheglowplugisdefectorwhentheelectricleadtothedosingpumpisinterrupted.

    •Ifthecombinedsensor(flamesensor/overheatingsensor)isdefectortheelectricleadinterrupted,theheaterstartsupandisthenswitchedoffagainduringthestartphase.

    •Thespeedofthefanmotorismonitoredcontinu-ously.Ifthefanmotordoesnotstartuporifthespeeddeviatesbymorethan10%,theheaterisswitchedoffafter30sec.

    •Whentheheaterisswitchedoff,theglowplugis

    switchedonfor40seconds(after-glowing)whilethefanrunsontocleanoffanycombustionresidues.

    Please note!

    Do not switch the heater off and on again more than twice.

    Operation and function4

    Emergency shutdown – EMERGENCY OFFIf an emergency shutdown – EMERGENCY OFF – is necessary during operation, proceed as follows:• Switch the heater off with the control or• pull the fuse out or• disconnect the heater from the battery.

  • 32

    Electrical system5

    Heater wiringTheelectroniccontrolboxisintegratedintheheater,whichconsiderablysimplifiesthewiringrequiredduringinstallation.

    Caution!Safety instructions for wiring the heater!The heater is to be connected up electrically accord-ing to the EMC directives.EMC can be affected if the heater is not connected up correctly. For this reason, comply with the following instructions:

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

    •Inwaterproofconnectors,sealanyconnectorcham-bersnotinusewithfillerplugstoensuretheyaredirt-proofandwater-proof.

    •Electricalconnectionsandgroundconnectionsmustbefreeofcorrosionandfirmlyconnected.

    •Lubricateconnectionsandgroundconnectionsout-sidetheheaterinteriorwithcontactgrease.

    Please note!

    Comply with the following when wiring the heater and the control element:

    •Withtheappropriateelectricalwiring,theheaterfulfilstheADRregulations;pleaserefertothecircuitdiagramsattheendofthisdocument.

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

    •Thefollowingcablecrosssectionsaretobeusedbetweenthebatteryandheater.Thisensuresthatthemax.tolerablevoltagelossinthecablesdoesnotexceed0.5Vfor12Vor1Vfor24Vratedvoltage.

    Cablecrosssectionsforacablelengthof(pluscable+minuscable):–upto5m=cablecrosssection4mm²–from5to8m=cablecrosssection6mm²

    •fthepluscableistobeconnectedtothefusebox(e.g.terminal30),thevehiclecablefromthebatterytothefuseboxmustbeincludedinratingtheoverallca-blelengthandpossiblyre-dimensionedifnecessary.

    •Insulateunusedcableends.

  • 33

    1.1 Burnerengine1.2 Glowplug1.5 Overheatingandflamesensor2.1 Controller2.2 Dosingpump2.7 Mainfuse 12volt=20A 24volt=10A2.7.1 Fuse,actuation5A5.1 Battery5.2.1 Batteryoperationswitchd)

    (operation,e.g.controlledbytheignitionkey)5.2.2 Batteryseparatingswitchd) (EmergencyofffunctionforADR/ADR99)5.3 AuxiliarydriveHA+5.3.1 Switch,auxiliarydrive5.5 GeneratorD+

    a) Connectionofthecontrolunitandexternalsensoraccordingtothecircuitdiagram“con-trolunits”

    •rt Powersupply,plus–terminal30 •ge Switchonsignal–S+ •gr Actualtemperature •wsrt Switchoffburglaralarmsystem,

    PIN15,positivesignaloutputfor relay,Imax=200mA forADR–feedbacksignalfortimer

    •br Powersupply,minus–terminal31 •blws Diagnosis •grrt Nominaltemperature •brws Referencesignalsensor

    b) Option Activationofvehicleblowerand/orseparate

    freshairfanThepositivesignalisonlyappliedduringthe“Low”controlstage(PIN16,positivesignalforrelay,Imax=200mA)

    c) WiringforoperationtoADR(HGVvehicletransportingdangerousgoods,e.g.tankertruck)

    d) Whenonlyoneswitchingelementisusedforitem5.2.1and5.2.2itmustbeensuredthatonactivatingthefunction“openthebatteryseparatingswitch”(EMERGENCYOFFfunc-tionforADRetc.),theswitchalwaysseparatesimmediately(regardlessoftheheaterstatus)andalltheheatercircuitsaredisconnectedfromthebattery.

    Parts list for the circuit diagramsAirtronic / Airtronic M andAirtronic / Airtronic M – ADR mode

    Electrical system5

    Please note!

    CircuitdiagramforAirtronic /Airtronic Monpage34.CircuitdiagramforAirtronic /Airtronic MADRonpage35.

  • 34

    Airtronic / Airtronic M

    252069009801BPartslistpage32

    Electrical system5

  • 35

    Electrical system5

    Airtronic / Airtronic M – ADR mode

    252069009601CPartslistpage32

  • 36

    EasyStart R+

    1 Terminal31(negative) 2 –– 3 Ventilate(switchingsignal–) 4 DATcable 5 Pushbutton/LED(negative) 6 Temperaturesensor(negative) 7 Terminal30(positive) 8 S+(switchingonsignal) 9 LED(positive)10 Diagnosiscable(Kline)11 Pushbutton(negative)12 Temperaturesensor(positive)

    EasyStart R

    1 Terminal31(negative) 2 –– 3 –– 4 DATcable 5 Pushbutton/LED(negative) 6 –– 7 Terminal30(positive) 8 S+(switchingonsignal) 9 LED(positive)10 Diagnosiscable(Kline)11 Pushbutton(negative)12 ––

    Pin assignment at connector B1

    EasyStart T

    1 Terminal30(positive) rt 2 S+(switchingonsignal) ge 3 Terminal31(negative) br 4 DATcable vi 5 Diagnosiscable(Kline) bl/ws 6 Terminal58 gr/sw 7 Temperaturesensor(positive) gr 8 Temperaturesensor(negative) br/ws 9 –– ––

    Electrical system5

    Cable colourssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple

    Parts list, circuit diagrams EasyStart R+ / R / T and EasyStart T - ADR mode

    2.15.1 Sensor–roomtemperature,display (includedintheEasyStartR+scopeofsupply,

    optionalforEasyStartR/T)2.15.9 Sensor–outdoortemperature,display

    3.1.7 ”ON/OFF“button3.1.16 Radioremotecontrolbutton3.1.17 ”Minicontroller“controlunit

    3.2.15 EasyStartTtimer

    3.3.9 EasyStartRradioremotecontrol (stationaryunit)3.3.10 EasyStartR+radioremotecontrol (stationaryunit)

    3.6.1 Adaptercable

    3.8.3 Antenna

    a) Connectionofcontrolunitsattheheaterc) Terminal58(lighting)d) Parkingventilationwithvehicleblower(op-

    tional)e) EasyStartTtimerconnectiong) External”ON/OFF“button(optional)h) Parkingventilationwithvehicleblower(op-

    tional)x) ADRjumpery) Connectandinsulatecables

    •Thetimer/radioremotecontrolmustbeconnectedinaccordancewiththecircuitdiagrams(page37–41).

    •Insulateunusedcableends.•Connectorsandbushhousingsareshownfromthe

    cableinletside.•Youmustdefinitelycreatethejumpermarkedinthe

    circuitdiagramwithy.

    Please note!

    Pin assignment at the stationary unit connector

  • 37

    Electrical system5

    252361009701CPartslistpage36

    Circuit diagram - EasyStart R+ and EasyStart R+ in combination with EasyStart T

  • 38

    Electrical system5

    Partslistpage36

    252361009705B

    Circuit diagram – EasyStart R in combination with mini controller

  • 39

    Electrical system5

    Partslistpage36

    252361009702B

    Circuit diagram – EasyStart R+ in combination with EasyStart T

  • 40

    Electrical system5

    Partslistpage36 252361009703A

    Circuit diagram - EasyStart T and EasyStart T in combination with EasyStart T

  • 41

    Electrical system5

    Partslistpage36 252361009704A

    Circuit diagram - ADR modeEasyStart T and EasyStart T in combination with EasyStart T

  • 42

    Electrical system5

    Parts list for the circuit diagrams for the control units and ADR mode controls

    2.15.9 Sensor–outdoortemperature,display2.15.10 Sensor–controltemperature,external(interior)3.1.9 Changeover„heating/venting“3.1.17 Minicontroller3.2.8 Moduletimer(ADRpotentiometer)3.2.14 Timer,mini–12/24volt

    a) Connectionofcontrolelementsattheheater •rt Powersupply,plus–terminal30 •ge Switchonsignal–S+ •gr Actualtemperature •wsrt Switchoffburglaralarm (ADR–feedbackfortimer) •br Powersupply,minus–terminal31 •blws Diagnosis •grrt Nominaltemperature •brws Groundconnectionforexternaltem-

    peraturesensorandnominaltemperaturec) Lighting,terminal58e) Connection,Sensor–controltemperature,

    external(interior)g) Connection,externalheatingbuttonh) Connection,radioremotecontrolTP4ij) Connection,Sensor–outdoortemperature,

    displayl) Connection,„heating/ventilation“selector switch(option).Tostart:Actuatechangeover switch„heat/ventilate“,thenswitchonthe heaterz) Lighting,terminal58

    Connectorsandbushhousingsareshownfromthecableinletside.

    Please note!

    Circuitdiagramsforthecontrolsonpage43and44.CircuitdiagramsfortheADRcontrolsonpage45.

    Cable colourssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple

  • 43

    Electrical system5

    Partslistpage42

    Circuit diagram for control units

  • 44

    Electrical system5

    Partslistpage42

    Circuit diagram for control units

  • 45

    Electrical system5

    Partslistpage42

    Circuit diagram, ADR mode controls

  • 46

    Troubleshooting / Maintenance / Service6

    In case of faults, please check the following points

    • If the heater does not start after being switched on: – Switch the heater off and on again. • If the heater still does not start, check whether: – There is fuel in the tank? – The fuses are OK? – The electrical cables, connections etc. are OK? – Anything is clogging the combustion air supply or exhaust system?

    Troubleshooting

    If the heater remains faulty even after these points have been checked, or another malfunction occurs in your heater, please contact:

    •Forinstallationexworks,yourcontractworkshop.

    •Forsubsequentinstallation,theworkshopwhoinstalledyourheater.

    Please note that warranty claims can be become void if the heater is changed by a third party or by this installation of third party parts.

    Maintenance instructions•Switchtheheaterononceamonthforabout10min-

    utes,evenoutsidetheheatingperiod.

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

    •Checktheopeningsofthecombustionairsupplyandexhaustsystemafterlongerstandstillperiods,cleanifnecessary!

    Service

    If you have any technical queries or problems with your pre-heater, dial the following service phone number:

    HotlinePhone. 0800 / 12 34 300

    Fax hotlineFax 01805 / 26 26 24

    Outside of Germany, please contact the respective national Eberspächer service agent.

    Please note!

  • 47

    Environment7

    Certification

    The high quality of Eberspächer’s products is the key to our success.To guarantee this quality, we have organised all work processes in the company along the lines of quality management (QM).Even so, we still pursue a large number of activities for continuous improvement of product quality in order to keep pace with the similarly constantly grow-ing requirements made by our customers.All the steps necessary for quality assurance are stipulated in international standards.This quality is to be considered in a total sense.It affects products, procedures and customer / sup-plier relationships.Officially approved public experts assess the system and the corresponding certification company awards a certificate.

    Eberspächer has already qualified for the following standards:

    Quality management as per DIN EN ISO 9001:2000 and ISO/TS 16949:1999

    Environment management system as per DIN EN ISO 14001:1996

    Disposal

    Disposal of materialsOld devices, defect components and packaging material can all be separated and sorted into pure-grade factions so that all parts can be disposed of as required in an environment-friendly manner or recy-cled where applicable.Electric motors, controllers and sensors (e.g. temper-ature sensors) are deemed to be “electronic scrap”.

    Dismantling the heaterThe heater is dismantled according to the repair stages in the current troubleshooting / repair instruc-tions.

    PackagingThe packaging of the heater can be kept in case it has to be sent back.

    EU Declaration of Conformity

    Themanufacturer:

    J. Eberspächer GmbH & Co. KG

    Address:Eberspächerstraße24D-73730Esslingen

    herewithdeclaresthatthefollowingproduct:

    Productname Vehicle heater

    Type Airtronic Airtronic M

    Version D2 B3 PlusB4D3D4D4 Plus

    fulfilstherequirementsofthefollowingECDirectives:a) Heatingsystemsdirective2001/56/EC Revisionstatus2006/119/EC

    b) Radiointerference(EMC)ofvehicles72/245/EEC, Revisionstatus2006/28/EC

    c) HeatercontrolECE-R122, Revisionstatus00

    d) EMCofvehiclesECE-R10, Revisionstatus03

    ThefollowingECDirectivesandUNregulationshavebeenusedtoassesstheproduct:2001/56/EC;72/245/EEC;ECE-R122;ECE-R10

  • 48

    List of key words A – Z

    Keyword Page

    AAccident prevention ................................................... 7ADR .......................................................................... 16Altitude ..................................................................... 29Ambient temperature ........................................ 12 – 14

    CCable harness connection ....................................... 18Certificates ............................................................... 47Circuit diagrams ......................34, 35, 37 – 41, 43 – 45Combustion air system ............................................. 23Control devices ........................................................ 31Control in heating mode ........................................... 30Contents ..................................................................... 2

    DDangerous goods ............................................... 16, 31Declaration of conformity ......................................... 47Description of functions ............................................ 30Disposal .................................................................... 47Dosing pump .................................................... 24 – 27

    EElectronic components ................................. 33, 36, 42Emergency off .......................................................... 31Environment management ....................................... 47EU Declaration of Conformity ................................... 47Exhaust system ........................................................ 22

    FFaults ........................................................................ 46Fastening .................................................................. 19Fan operation ........................................................... 30Forced shut-down .................................................... 31Formation of air bubbles .......................................... 24Fuel supply ................................................... 5, 24 – 28Fuel consumption ............................................. 12 – 14Fuel quality ............................................................... 28

    HHeat flow ........................................................... 12 – 14Hotline ...................................................................... 46

    Keyword Page

    IIntroduction ............................................................ 4, 5Installation ........................................................ 16 – 28Installation area .................................................. 16, 17Interference suppression class ........................ 12 – 14Initial commissioning ................................................ 29Installation location ............................................. 16, 17Installation position ................................................... 18Information ................................................................. 4Important instructions ............................................... 29

    LList of abbreviations ................................................. 49

    MMaintenance ............................................................. 46Main dimensions ...................................................... 15

    NNameplate ................................................................ 20

    OOperation .................................................................. 29Operating instructions .............................................. 29

    PPicture symbols .......................................................... 4Power consumption .......................................... 12 – 14Pressure height ........................................................ 27Pressure side ...................................................... 25, 26Presentation ................................................................ 4Purpose ...................................................................... 4

    RRated voltage ................................................... 12 – 14Regulations ............................................................. 5, 6

    SSafety devices .......................................................... 31Safety check (before starting) .................................. 29Scope of supply ................................................. 8 – 11Storage temperature ........................................ 12 – 14Statutory regulations ............................................... 5, 6Start procedure ........................................................ 30Suction height ........................................................... 27Switching on ............................................................. 30Switching off ............................................................. 30

    Lists8

  • 49

    Lists8

    Keyword Page

    TTechnical data .................................................. 12 – 14Temperature selection .............................................. 30Test symbol ................................................................. 5Text structure .............................................................. 4T-piece ...................................................................... 25Transport .................................................................. 16Troubleshooting ........................................................ 46

    UUse ............................................................................. 4

    VVoltage .............................................................. 12 – 14Voltage limit ...................................................... 12 – 14

    WWeight .............................................................. 12 – 14 Wiring ....................................................................... 32

    List of abbreviations

    ADREuropeanagreementabouttheinternationaltransportofdangerousgoodsontheroad.

    EC Type approvalPermitawardedbytheFederalVehicleOfficefortheproductionofaheaterforinstallationinmotorisedvehicles.

    EMC directiveElectromagneticcompatibility.

    JE partnerJ.Eberspächerpartner.

    FAMEBiodieselaccordingtoDINV14214.

    List of key words A – Z

  • Sub

    ject

    toc

    hang

    es

    P

    rinte

    din

    Ger

    man

    y

    ©J

    .Ebe

    rspä

    cher

    Gm

    bH&

    Co.

    KG

    www.eberspaecher.com

    J.EberspächerGmbH&Co.KGEberspächerstr.24D73730EsslingenTelefon071193900Telefax07119390643info@eberspaecher.com


Recommended