Airtronic M Orderno.
AirtronicD3,12V 252317050000
AirtronicB4,12V 201812050000
AirtronicD4,12V 252113050000AirtronicD4,24V 252114050000
AirtronicD4Plus,12V 252484050000AirtronicD4Plus,24V 252498050000
AirtronicD4S,12V 252144050000AirtronicD4S,24V 252145050000
AirtronicD3Camper,12V(seeAirtronicD3)
AirtronicD4Camper,12V 252318050000
AirtronicD4Camperplus,12V 252327050000
AIRTRONIC / AIRTRONIC MTroubleshooting and Repair Instructions
25.2115.95.1901 01.2019
Airtronic
AirtronicD2,12VAirtronicD2,24VAirtronicD2Camper,12V
Completepackage
AirtronicD2,12VAirtronicD2,24V
Orderno.
252069050000 252070050000 252326050000
252675050000 252676050000
Air heater for diesel and petroloperating independently of the engine.
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1Contents
ThislistofcontentsgivesyoupreciseinformationaboutthecontentsoftheTroubleshootingandRepairInstructions.
Introduction
Usetheindex,listofabbreviations,etc,tolookforaterm,technicalwordoranexplanationforanabbreviation.
Chapter Title Contents Page
Introduction • Foreword.................................................................................................................. 4 • Accidentprevention.................................................................................................. 4 • Specialtextstructure,presentationandpicturesymbols........................................... 4 • Importantinformationbeforestartingwork................................................................ 4
Function and use Cutawayview............................................................................................................ 5 • Descriptionoffunctions – Switchingon.......................................................................................................... 6 – StartingtheAirtronic.............................................................................................. 6 – StartingtheAirtronicM.......................................................................................... 6 – Temperatureselectionwiththecontrolelement...................................................... 6 – Controlinheatingmode......................................................................................... 6 – Ventilatingmode.................................................................................................... 6 – Switchingoff.......................................................................................................... 6 • Controlandsafetydevices........................................................................................ 7 – Forcedshut-downforADRoperation..................................................................... 7 – Emergencyshutdown–EMERGENCYOFF........................................................... 7
Technical data • Airtronic(fordiesel)................................................................................................... 8 • AirtronicM(forpetrol)................................................................................................ 9 • AirtronicM(fordiesel)........................................................................................ 10,11 • Checkvalues – Testspeedfortheblower..................................................................................... 12 – Resistan\cevalues............................................................................................... 12 – Switchingvalue.................................................................................................... 12 – Exhaustemissionspecification............................................................................. 12 – Check“externaltemperaturesensor”................................................................... 12 – Tableofvalues:“Externaltemperaturesensor”..................................................... 12
Troubleshooting • Whattocheckfirstincaseoffaults – Check.................................................................................................................. 13 – Electricalcomponents.......................................................................................... 13 – Measurebatteryvoltage....................................................................................... 13 – Measuresvoltagesupply..................................................................................... 13 – Checkswitch-onsignal........................................................................................ 13 – Checkcontrolunit................................................................................................ 13 • Overviewoftheindividualtestequipmentandcontrolunits..................................... 14 • Lockingthecontrolbox........................................................................................... 14 • Cancelthecontrolboxlock..................................................................................... 14 • Importantnotes(diagnosisofheaterswithmini-controller)....................................... 14 • Testingdeviceforthecontroldevice........................................................................ 15 • Faultdiagnosisusingthediagnosticunit........................................................... 15,16 • FaultdiagnosisusingtheEDiTHdiagnosticstoolwithISOadapter.......................... 17 • AirpressuresensordiagnosisusingEDiTHdiagnosticstoolandISOadapter.......... 18 • FaultdiagnosisusingtheEDiTHdiagnosticstoolwithbasicadapter....................... 19 • Faultdiagnosisusingthemoduletimer.................................................................... 20 • FaultdiagnosisusingtheradioremotecontrolTP5................................................. 21 • FaultdiagnosisusingtheEasyStartR+radioremotecontrolor theEasyStartTtimer............................................................................................... 22 • Faultcodetable...............................................................................................23–27
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Introduction
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Chapter Title Contents Page
Repair instructions • Repairinstructions.................................................................................................. 28 • Alwaysobservethefollowingsafetyinstructionsbeforeworkingontheheater........ 28 • Specialtool,AMPreleasetool................................................................................. 28 • AssemblydrawingAirtronic/AirtronicM................................................................. 29 • Repairstep1,removetheheatercover................................................................... 30 • Repairstep2,dismantlecontrolbox,checkcontrolbox......................................... 30 • Repairstep3,dismantleglowplug.......................................................................... 31 • Repairstep4,renewlining...................................................................................... 31 • Repairstep5,dismantlecombinationsensor(overheating/flamesensor............... 32 • Repairstep6,installcombinationsensor(overheating/flamesensor)..................... 33 • Repairstep7,dismantleheatexchanger/ dismantlecombustionairfan................................................................................... 34 • Repairstep8,dismantlecombustionchamber........................................................ 35 • Checkfuelsupply.................................................................................................... 36 • Measuringthefuelquantity...................................................................................... 36
Circuit diagrams Overviewofthepartslistsandcircuitdiagrams........................................................... 37 • PartslistcircuitdiagramsAirtronic/AirtronicM....................................................... 38 • CircuitdiagramAirtronic/AirtronicM..................................................................... 39 Thiscircuitdiagramisvalidforheaterswithonediagnosiscable andacontrolboxcableloomwichisfirmlyencapsulated. • CircuitdiagramAirtronic/AirtronicM..................................................................... 40 Thiscircuitdiagramisforheaterswith2diagnosticscableandwhose controlboxcableloomiswoundwithcabletape. • Partslistcircuitdiagrams,controlunits.................................................................... 41 • Circuitdiagramcontrolunits–part1....................................................................... 42 • Circuitdiagramcontrolunits–part2....................................................................... 43 • Circuitdiagramcontrolunits–part3....................................................................... 44 • Circuitdiagramcontrolunits–part4....................................................................... 45 • Circuitdiagramcontrolunits–part5....................................................................... 46 • Circuitdiagramcontrolunits–part6....................................................................... 47 • Circuitdiagramcontrolunits–part7....................................................................... 48 • PartslistcircuitdiagramcontrolunitEasyStartR+/R/T........................................ 49 • CircuitdiagramcontrolunitEasyStartR+(controlboxwith1diagnosticscable)...... 50 • CircuitdiagramcontrolunitEasyStartR+(controlboxwith1diagnosticscable)...... 51 • CircuitdiagramcontrolunitEasyStartR+(controlboxwith2diagnosticscable)...... 52 • CircuitdiagramcontrolunitEasyStartR(controlboxwith1/2diagnosticscables). 53 • CircuitdiagramcontrolunitEasyStartR(controlboxwith2diagnosticscables)...... 54 • CircuitdiagramcontrolunitEasyStartR(controlboxwith1diagnosticscables)...... 55 • CircuitdiagramcontrolunitEasyStartT(controlboxwith1diagnosticscable)........ 56 • CircuitdiagramcontrolunitEasyStartT(controlboxwith2diagnosticscable)........ 57 • PartslistcircuitdiagramsAirtronic/AirtronicM–ADR............................................ 58 • CircuitdiagramAirtronic/AirtronicM–ADR.......................................................... 59 1encapsulateddiagnosticscableandcontrolboxcableloomfirmlyencapsulated • CircuitdiagramAirtronic/AirtronicM–ADR.......................................................... 60 2diagnosticscablesandcontrolboxcableloomwithcabletape • Partslistcircuitdiagrams,controlunits–ADR......................................................... 61 • Partslistcircuitdiagrams,controlunits–EasyStartT–ADR................................... 61 • Circuitdiagramcontrolunits–ADR......................................................................... 62 • CircuitdiagramcontrolunitEasyStartT–ADR(controlboxwith1diag.cable)....... 63 • CircuitdiagramcontrolunitEasyStartT–ADR(controlboxwith2diag.cable)....... 64
Service • Certification............................................................................................................. 65 • Disposal.................................................................................................................. 65 • ECDeclarationofConformity.................................................................................. 65 • Listofkeywords..................................................................................................... 66 • Listofabbreviations................................................................................................ 67
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Special text structure, presentation and picture symbols
Specialtextformatsandpicturesymbolsareusedintheseinstructionstoemphasisedifferentsituationsandsubjects.Pleaserefertothefollowingexamplesfortheirmeaningsandappropriateaction.
Special text formats and presentations• Adot(•)indicatesalist,whichisstartedbyaheading.
– Ifanindenteddash(–)followsa“dot”,thislistisasub-sectionoftheblackdot.
Picture symbols
Danger!Thisinformationpointsoutadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.
Caution!Thisinformationpointsoutadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.
Important information before starting work
Initial commissioning of the heater or functional test after a repair
• Afterinstallingtheheater,thewholefuelsupplysystemmustbecarefullyvented:pleaserefertoandfollowthevehiclemanufacturer’sinstructions.
• Duringtheheatertrialrun,allfuelconnectionsmustbecheckedforleaksandsecure,tightfit.
• Iffaultsoccurwhiletheheaterisrunning,useadiagnosticunittodetermineandcorrectthecauseofthefault.
1 IntroductionForeword
TheseTroubleshootingandRepairInstructionsareapplicabletotheheaterslistedonthetitlePage,totheexclusionofallliabilityclaims.Dependingontheversionorrevisedstatusoftheheater,theremaybedifferencesbetweenitandthesetroubleshootingandrepairinstructions.Theusermustcheckthisbeforecarryingouttherepairworkand,ifnecessary,takethedifferencesintoaccount.
Caution!Safety instructions for installation and repair!
ImproperinstallationorrepairofEberspächerheaterscancauseafireorresultpoisonousexhaustenteringtheinsideofthevehicle.Thiscancauseseriousandevenfatalrisks.
Theheatermayonlybeinstalledaccordingtothespecifica-tionsinthetechnicaldocumentsorrepairedusingoriginalsparepartsbyauthorisedandtrainedpersons.Installationandrepairsbyunauthorisedanduntrainedper-sons,repairsusingnon-originalsparepartsandwithoutthetechnicaldocumentsrequiredforinstallationandrepairaredangerousandthereforearenotpermitted.
Arepairmayonlybecarriedoutinconnectionwiththere-spectiveunit-relatedtechnicaldescription,installationinstruc-tions,operatinginstructionsandmaintenanceinstructions.Thisdocumentmustbecarefullyreadthroughbefore/duringinstallationandrepairandfollowedthroughout.Particularattentionistobepaidtotheofficialregulations,thesafetyinstructionsandthegeneralinformation.
Please note!
Therelevantrulesofsoundengineeringpracticeandanyinformationprovidedbythevehiclemanufactureraretobeobservedduringtheinstallationandrepair.Eberspächerdoesnotacceptanyliabilityfordefectsanddamage,whichareduetoinstallationorrepairbyunauthor-isedanduntrainedpersons.Compliancewiththeofficialregulationsandthesafetyinstruc-tionsisprerequisiteforliabilityclaims.Failuretocomplywiththeofficialregulationsandsafetyinstructionsleadstoexclu-sionofanyliabilityoftheheatermanufacturer.
Accident prevention
Generalaccidentpreventionregulationsandthecorrespond-ingworkshopandoperatingsafetyinstructionsaretobeobserved.
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Cutaway view
1 Heaterimpeller 2 Controlbox 3 Combustionairfanimpeller 4 Glowplug 5 Cover 6 Heatexchanger 7 Combinationsensor(overheating/flamesensor) 8 Radioremotecontrol(mobileunit) 9 Radioremotecontrol(stationaryunit)10 Button11 Temperaturesensor(roomtemperature)12 Fusebracketwithmainfuseand“actuation”fuse13 Electricalmotor14 Fuelconnection15 Flangeseal
16 Combustionchamber17 Outlethood18 Combustionairhose19 Meteringpump20 Pot-typestrainer,installedinthedosingpump21 Outflow22 FlexibleexhaustpipeF= FreshairW= HotairA= ExhaustB= FuelV= Combustionair
Functionanduse2
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Description of functions
Switching on
Whentheheaterisswitchedon,thecontrollampinthecon-trolunitlightsup.Theglowplugisswitchedonandthefanstartsatlowspeed.
fthereisstilltoomuchresidualheatintheheatexchangerfromwhentheheaterwaslastused,firstlyonlythefanstartsup(coldblowing).Oncetheresidualheathasbeencleared,theheaterstarts.
Starting Airtronic
Afterapprox.65secondsthefuelsupplystartsandthefuel/airmixtureinthecombustionchamberignites.Oncethecombinedsensor(flamesensor)hasdetectedtheflame,theglowplugisswitchedoffafter60seconds.Theheaterisnowinstandardoperation.
Starting Airtronic M
Afterapprox.60secondsthefuelsupplystartsandthefuel/airmixtureinthecombustionchamberignites.Aftertheflamesensorhasdetectedtheflame,theglowplugisswitchedoffafterapprox.90sec.Theheaterisnowinstandardoperation.Afteranother120seconds,theheaterhasreachedthe“POWER”stage(maximumfuelquantity,maximumfanspeed).
Temperature selection with the control element
Thecontrolcanbeusedtopreselectaninteriortemperature.Theresultingtemperaturecanbewithintherangeof+10°Cto+30°Canddependsontheselectedheater,onthesizeofthespacetobeheatedandontheprevailingoutdoortem-perature.Thesettingtobeselectedatthecontrolisanempiricalvalue.
Control in the heating mode
Duringtheheatingmode,theroomtemperatureorthetem-peratureofthesuckedinheatingairisconstantlymeasured.Ifthetemperatureishigherthanthetemperatureselectedonthecontrolelement,theheaterstartstoregulateitsoutput.Thereare4controlstagessothattheoutflowofheatpro-ducedbytheheatercanbeadjustedfinelytotheheatingrequirements.Fanspeedandfuelquantitycorrespondtotheparticularcontrolstage.Ifthesettemperatureisstillexceededinthesmallestcontrolstage,theheatergoestothe“OFF”stagewiththefanrunningonforapprox.4minutestocooloff.Thefanthencontinuesrunningatminimumspeed(circulationmode)untiltherestartorisswitchedoff(freshairmodewithexternaltemperaturesensor).
Ventilating mode
TheEasyStartR+andEasyStartTcontrolunitsandthemini-controllercanbeusedtoactivatethe„Ventilate“function.The„Heat/Ventilate“switchisalsorequiredforthemodulartimerandcontroldevicewhereby,forfanmode,the„Heat/Ventilate“switchmustbepressedfirstandthentheheaterswitchedon.Theblowerrunsatmaximumspeedinfanmode.
Switching off
Whentheheaterisswitchedoff,thecontrollampgoesoffandthefuelsupplyisswitchedoff.Thefanrunsonforapprox.4minutestocooldown.Whilethefanisrunningon,theglowplugisswitchedonforapprox.40secondstoclean.Specialcase:Ifnofuelhasbeensuppliedoriftheheaterisinthe“OFF”stageuntilitisswitchedoff,theheaterisstoppedwithoutanyafterrunning.
Functionanduse2
Please note!
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Forced shut-down for ADR operation
Invehiclesforthetransportofdangerousgoods(e.g.tankertrucks),theheatermustbeswitchedoffbeforethetruckdrivesintoadangerarea(refinery,petrolstation,etc.).Failuretocomplyresultsintheheaterautomaticallyswitchingoffif:• thevehicleengineisswitchedoff,• anadditionalunitisstartedup(auxiliarydriveforunloading
pump,etc.),• avehicledoorisopened(ADR99regulation,onlyinFrance).Thefanthenrunsonformax.40seconds.
Functionanduse2
Emergency shutdown – EMERGENCY OFFIfanemergencyshutdown–EMERGENCYOFF–isre-quiredduringoperation,executethefollowing:• Switchtheheateroffatthecontrolelementor• removethefuseor• disconnecttheheaterfromthebattery.
Control and safety devices
• Iftheheaterdoesnotignitewithin90secondsafterstartingthefuelpump,thestartisrepeated.Iftheheaterstilldoesnotigniteafteranother90secondsofpumpingfuel,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4minutes.
• Iftheflamegoesoffbyitselfduringoperation,theheaterisrestarted.Iftheheaterdoesnotignitewithin90secondsafterthefuelpumphasstarted,orignitesandgoesoffagainwithin15minutes,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4minutes.Thisstatuscanberemediedbybrieflyswitchingoffandonagain.Donotrepeattheswitchingoff/onroutinemorethantwice.
• Inthecaseofoverheating,thecombinedsensor(flamesensor/overheatingsensor)triggers,thefuelsupplyisinterruptedandtheheaterswitchedoff.Oncethecauseoftheoverheatinghasbeeneliminated,theheatercanbere-startedbyswitchingoffandonagain.
• Iftheloweroruppervoltagelimitisreached,theheaterisswitchedoffafter20seconds.
• Theheaterdoesnotstartupiftheglowplugorblowermo-torisdefectiveoriftheelectricleadtothemeteringpumpisinterrupted.
• Ifthecombinedsensor(flamesensor/overheatingsensor)isdefectortheelectricleadinterrupted,theheaterstartsupandisthenswitchedoffagainduringthestartphase.
• Thespeedofthefanmotorismonitoredcontinuously.Ifthefanmotordoesnotstartuporifthespeeddeviatesbymorethan10%,theheaterisswitchedoffafter30sec.
• Whentheheaterisswitchedoff,theglowplugis switchedonfor40seconds(after-glowing)whilethe fanrunsontocleanoffanycombustionresidues.
Please note!
Donotrepeattheswitchingoff/onroutinemorethantwice.
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Technichaldata3
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt)
Heaterairflowratewithoutcounterpressure(kg/h) withhoodØ60mm
Fuelconsumption(l/h)
Elektr.powerconsumption(watt)
inoperation(12and24volt)
atstart(12and24volt)
Ratedvoltage
Operatingrange Lowervoltagelimit:Anundervoltageprotectioninthe
controllerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit: Anuppervoltageprotectioninthecontrollerswitchesoffthe
heaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic
AirtronicD2/AirtronicD2Camper
D2/D2Camper
Air
Stage
Power Large Medium Small Off
2200 1800 1200 850 –
105 90 60 40 13
0.28 0.23 0.15 0.10 –
34 22 12 8 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.2.7kg
possible
Please note!
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Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt)
Heaterairflowratewithoutcounterpressure(kg/h) withhoodØ90mm
Fuelconsumption(l/h)
Elektr.powerconsumption(watt)
inoperation(12and24volt)
atstart(12and24volt)
Ratedvoltage
Operatingrange Lowervoltagelimit:Anundervoltageprotectioninthe
controllerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit: Anuppervoltageprotectioninthecontrollerswitchesoffthe
heaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicB4
B4
Air
Stage
Power Large Medium Small Off
3800 3200 2100 1300 –
185 160 120 85 24
0.54 0.46 0.29 0.18 –
40 29 15 9 5
#100
12volt
approx.10.5voltUndervoltageprotectiontriggertime:20seconds
16voltOvervoltageprotectiontriggertime:20seconds
PetrolDINEN228(commerciallyavailable)
inoperation nooperation
–40°Cto+50°C –40°Cto+85°C
–40°Cto+20°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
ca.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
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Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt) D3
D4
D4Plus
Heaterairflowratewithoutcounterpressure(kg/h) D3withhoodØ90mm
D4withhoodØ90mm
D4PluswithhoodØ75mm
Fuelconsumption(l/h) D3
D4
D4Plus
Elektr.powerconsumption(watt) D3
inoperation(12and24volt) D4
D4Plus
atstart(12and24volt)
Ratedvoltage
Operatingrange Lowervoltagelimit:Anundervoltageprotectioninthe
controllerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit: Anuppervoltageprotectioninthecontrollerswitchesoffthe
heaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicD3/AirtronicD4/AirtronicD4Plus
D3/D4/D4Plus
Air
Stage
Power Large Medium Small Off
3000 2200 1600 900 –
4000 3000 2000 900 –
4000 3000 2000 900 –
150 120 90 60 24
185 150 110 60 24
175 140 100 55 22
0.38 0.28 0.2 0.11 –
0.51 0.38 0.25 0.11 –
0.51 0.38 0.25 0.11 –
24 16 10 7 5
40 24 13 7 5
55 30 16 7 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
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Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt) D4S
D4Camper/D4CamperPlus
Heaterairflowratewithoutcounterpressure(kg/h) D4S
D4Camper/D4CamperPlus
Fuelconsumption(l/h)) D4S
D4Camper/D4CamperPlus
Elektr.powerconsumption(watt) D4S
inoperation(12and24v) D4Camper/D4CamperPlus
atstart(12and24v)
Ratedvoltage
Operatingrange Lowervoltagelimit:Anundervoltageprotectioninthe
controllerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit: Anuppervoltageprotectioninthecontrollerswitchesoffthe
heaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicD4S/Airtronic D4Camper/AirtronicD4CamperPlus
D4S/D4Camper/D4CamperPlus
Air
Stage
Power Large Medium Small Off
3500 3000 2000 1000 –
4000/3500 3000 2000 900 –
160 140 100 60 22
185/160 150/140 110/100 60/55 24/22
0.44 0.38 0.25 0.13 –
0.51/0.44 0.38 0.25 0.11 –
40 30 16 8 5
40 24/30 13/16 7/8 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
12
Check values
Test speed for the blower
Airtronic D2 / D2 Camper(12volt/24volt)• 12volt 5000rpm±25% atU=10,0volt• 24volt 5000rpm±25% atU=18,0volt
AirtronicB4 (12volt)AirtronicD3 / D3 Camper(12volt)AirtronicD4(12volt/24volt)AirtronicD4 Camper(12volt)• 12volt 4400rpm±25% atU=10,0volt• 24volt 4400rpm±25% atU=18,5volt
AirtronicD4S/Airtronic D4 Plus (12volt/24volt)AirtronicD4 Camper Plus (12volt)• 12volt 4400rpm±25% atU=10,5volt• 24volt 4400rpm±25% atU=19,0volt
Resistance values at 20 °C
12 volt 24 volt
Glowplug 0.42 –0.70 1.2 –2.0Dosingpump 9.5±0.50 36.0±1.8
Control unit resistance values
Switch position, left limit stop
Switch position, right limit stop
Controldevice12volt/24volt
min.1720max.1760
min.2096max.2216
Modulartimerandmini-controller12volt/24volt
min.1730max.1780
min.2120max.2240
Switching value Overheatingsensor 140°C–170°C measuredinthe“High”controlstage andatadistanceof300mmdownstream fromthehotairoutletExhaust emission specificationCO2 in exhaustincontrolstage“high” 7,5–12,5Vol.%SmokespotnumberaccordingtoBacharach <4
Temperature (°C)
Res
ista
nce
(ohm
)
2200
2000
1800
1600
1400
1200
1000±40 ±20 0 20 40±10±30 10 30
2400
50
Technicaldata3
Check “external” temperature sensor(OrderNo.:251774890300)The“external”temperaturesensortestmustbecarriedoutusingadigitalmultimeter.Iftheresistancevalueisnotthesameasthecurveinthediagramorthetableofvalues,re-placethetemperaturesensor.
Table of values – “external” temperature sensor
Temperature°C Resistance
min. max.0 1600 16605 1670 1730
10 1745 180015 1820 187020 1895 195025 1970 203030 2050 211035 2130 219040 2210 228045 2295 2370
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Troubleshooting4What to check first in case of faults
• Check– Fuelinthetank?– Fuelpipesleaking?(visualcheck)– Summerdieselinthefuelpipe?– Combustionairsystemorexhaustsystemdamagedor
blocked?– Hotairsystemblocked?– Airpressuresensorinstalled?Ifyes,referto„Whattodo
if…?“chapterofthe„AltitudeKit“installationinstructions.– Newgenerationcontrolboxinstalled? Features: >Cableloomofcontrolboxwoundwithcabletie >Temperaturesensormountedonthesideofthecontrol
box(visiblewhencoverremoved)
• Electrical components– Cables,connectionsdamaged?– Contactscorroded?– Fusesdefective?– Incorrectwiring?(shortcircuits,interrupted/broken)
• Measure battery voltage– Batteryvoltage<10.5volt,theundervoltageprotectionof
the12voltheaterhastriggered.– Batteryvoltage<21volt,theun
• Measure voltage supply (Cl 30) Disconnectthe16-pinconnectorS1/B1andmeasurethe
voltageappliedatconnectorB1betweenchamber1(cable2.52rt)andchamber10(cable2.52br).
Ifitdiffersfromthebatteryvoltage,checkthefuses,thesupplycables,thenegativeconnectionandthepositivesupportpointonthebatteryforvoltagedrop(corrosion/interruption).
• Check switch-on signal Disconnectthe16-pinconnectorS1/B1andthenswitch
ontheheateratthecontrolunit. CheckwhethervoltageisappliedintheconnectorB1
betweenchamber4(cable0.52ge)andchamber10(cable2.52br).
Ifnovoltageismeasured,thencheckthesupplycable(ca-ble0.52ge),the5Afuse(item2.7.1inthecircuitdiagram)andthecontrolunit.
• Check control unit
Control device, mini-timer, mini-controller and modular timer
Disconnecttheconnectoratthecontrolunit;installajumperbetweenthered0.5²rtcableandtheyellow0.5²gecable.
IfavoltageismeasuredinconnectorB1betweencham-ber4(cable0.5²ge)andchamber10(cable2.5²br),thenreplacethecontrolunit.
EasyStart R+ / EasyStart R / EasyStart T Disconnecttheconnectoratthecontrolunit;installajumper
betweentheyellow0.5²gecableandthered0.5²rtcable. IfavoltageismeasuredinconnectorB1betweencham-
ber8(cable0.5²ge)andchamber10(cable2.5²br),thenreplacethecontrolunit.
14
Troubleshooting4Overview of the test equipment and control units suitable for diagnosis
Theelectroniccontrolboxcanstoreupto5faults,whichcanbereadoutanddisplayed.Thefollowingtestequipmentand/orcontrolunitscanbeusedtoquerythefaultmemoryinthecontrolboxandifnecessarytodeletethelockingofthecontrolbox:
Test equipment Order No.:
• Testingdevice forthecontroldevice 221509890000
• Diagnosticunit 221529890000 additionallyrequired: Adaptercable 221000318600
• EDiTHdiagnostictool – Basicadapterwithsoftware 221542890000 additionallyrequired: Airtronicextension 221537890000
– ISO-adapter 221541890000 additionallyrequired: Adaptercable 221000318600
– „Airpressuresensor“adaptercable221000333100 Onlyforheaterswithconnectedairpressuresensorfor
readingoutthe„airpressuresensor“faultmemory.
Ifadiagnosticscableisconnected,thefollowingcontrolunitscanalsobeused:
Control units Order No.:
• Moduletimer 221000303400
• TP5radioremotecontrol 221000320100
• EasyStartT 221000328800
• EasyStartR+ 221000328000
Please note!
Ifthefaultmemorycannotbereadout,checkthediagnosticscableforcorrectlayingandpossibledamage.
Important notes on diagnosis of heaters with mini-controller control unit
Caution!WhencheckingtheheaterwiththediagnosticsunitortheEDiTHdiagnosticstooltheordergiveninthefollowingnotesmustalwaysbefollowedasotherwisetheheaterdetectsError62(controlunit–interruption)andswitchestoemergencyoperation.
Mini-controller in stand-alone operation
• Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Selectoperatingmode(Heat/Ventilate)atthemini-control-ler
• PerformdiagnosisusingthediagnosticsunitortheEDiTHdiagnosticstool.
• Switchoffthemini-controllerafterfinishingthediagnosis• Removetheadaptercable
Mini-controller in combination with mini-timer
• Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Pressthembuttonofthemini-timer• Selectoperatingmode(seemini-timeroperatinginstruc-
tions)• PerformdiagnosisusingthediagnosticsunitortheEDiTH
diagnosticstool.• Switchoffthemini-timerafterfinishingthediagnosis• Removetheadaptercable
Mini-controller in combination with TP5
• Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Pressthe buttonoftheTP5radioremotecontrol• Selectoperatingmode(seeTP5radioremotecontroloper-
atinginstruction)• Performdiagnosis.• SwitchoffTP5radioremotecontrolafterfinishingthediag-
nosis• Removetheadaptercable
Please note!
IftheoperatingmodeistobechangedduringthetesttheheatermustbeswitchedofffirstusingthediagnosticsunitortheEDiTHdiagnosticstool,otherwisetheheaterdetectsError62(controlunit–interruption)andswitchestoemergencyoperation.
Test mini controller
Themini-controllermustbeconnectedtotheheaterfortest-ing.ThesetpointvaluecanbedisplayedusingtheEDiTHdiagnosticstool.Iftherotaryknobisattheleftlimitstopthesetpointvalueis8°C,attherightlimitstopitis34°C.
Please note!
Theresistanceofthesetpointvaluepotentiometercannotbemeasureddirectly.Themeasuredvaluesarenotmeaningful.
15
Troubleshooting4Testing device for the control device(OrderNo.:221509890000)
Prepare for testConnectthecorrectoperatingvoltage(12or24volt)tothete-stingdevice,withplusattheredconnectorsocketandminusattheblueconnectorsocket.
• Disconnectsocketfromthecontrolunit.• Connectcableloomfromtestingdevicewiththecontrol
unit.• Settherotaryknobofthecontrolunitto“Heat”,thecorre-
spondingredLEDinthetestingdevicemustlightup.• Setcontrolunitto“0”,thenpressthe“LED–red”button,
theredcontrollampinthecontrolunitmustlightup.• Setcontrolunitto“Heat”,thenpressthe“LED–green”
button,correspondingredcontrollampinthetestingdeviceandthegreencontrollampinthecontrolunitmustlightup.
Caution!Safety instructions for checking the control unit!Ensureyouusethecorrectoperatingvoltage,otherwisetheconnectedcomponentscanbeseverelydamaged.
Check the setpoint potentiometer of the control unitSetthe“Temperaturesensor/Potentiometer”switchinthetestingdevicetothe“Potentiometer”settingandslowlyturntherotaryknobofthecontrolunit.ThegreenLED–temperaturesensor/potentiometermustlightupcontinuously.Incaseofafault,replacethecontrolunit.
1 Testingdevice2 Controldevice
Diagnostic unit(OrderNo.:221529890000)
Anadditionaladaptercableisrequiredtoconnectthediag-nosticunit(OrderNo.:221000318600).
Thecurrentfaultisdisplayedas“AF”anda2-digitnumberandisalwayswritteninthememorypositionF1.PrecedingfaultsaremovedtothememorylocationsF2–F5,ifnecessarythecontentsofmemorypositionF5isoverwrit-ten.
• Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
• Inheaterswithconnectedairpressuresensorthediagnos-ticsunitcanbeusedtoreadoutthefaultmemoryoftheheateronly.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
• Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
l–Deletefaultmemoryl–Deletefaultmemoryd–Switchheateron/off,requestdiagnosise–Reverse,F5–F1f–Forward,F1–F5,currentfault(AF)
Connectdiagnosticsunit,seepage16.
Please note!
16
Connect diagnostic unit• Disconnectthe8-pinconnectoroftheheater’scablehar-
nessandconnecttheadaptercable.• Connectthediagnosticunittotheadaptercable. Displayisasfollows:
Query fault memory• UsetheDkeytoswitchontheheater. Displayisasfollows:
• After8secthefollowingisdisplayed: Displayisasfollows:
Heaterhasnomalfunction or
e.g.currenterror/faultcode64
or
Faultdiagnosisnotpossible
Possiblecauses: – Adaptercableisnotproperlyconnected. – Controlboxisdefectiveorisnotcapableofdiagnosing
(notauniversalcontrolbox).
Display of the fault memory F1 – F5 or F5 – F1• Presstheeorfbutton,orpressseveraltimes,todisplay
thefaultmemory. Displayisasfollows:
e.g.faultmemory2/faultcode10
Onlythefaultmemorypositionswithanerrorassignedtothemaredisplayed.
Delete fault memory• PressbothLbuttonssimultaneouslyuntilthefollowingap-
pearsinthedisplay: Displayisasfollows:
• Ifthefaultmemoryhasbeendeletedthemostrecentcur-rentfaultisdisplayed.Thecurrentfaultisnotresetto00untiltheheaterisrestarted–providedthereisnonew,morerecentfault.
Displayisasfollows:
Heaterhasnomalfunction
Cancel the control box lock• Deletethefaultmemoryasdescribedandswitchoffthe
heaterusingthedkey.• Thecontrolboxlockiscancelledandthediagnosisclosed. Displayisasfollows:
Troubleshooting4
1 Heater2 Adaptercable3 Diagnosticunit
1
2
3
Please note!
17
Troubleshooting4EDiTH diagnostic tool with ISO adapter(OrderNo.:221541890000)
AnadditionaladaptercableisrequiredtoconnecttheISOadapter(OrderNo.:221000318600).
• Itisveryimportanttoalwaysinstallinthegivenorder.• Notonlythedefectivecomponent,butalsoadefectivecur-
rentcircuitresultsinafaultbeingdisplayed.• Faultcode,faultdescription,cause/remedialactionare
describedonPages23–27.• TheEDiTHdiagnosticstoolscopeofsupplydoesnot
includethesoftware;thismustbedownloadedfromtheServicePortal.
Connect ISO adapter
• Disconnecttheheater’scableharness.• Connecttheadaptercabletothecableharness–asshown
inthesketch.• ConnecttheadaptercabletotheISOadapter.• ConnecttheSUB-DconnectioncablewiththePCandthe ISOadapter.
Installing the software on your PC• Doubleclickthe“setup.exe”filetostarttheinstallationand
followingtheSETUPprograminstructions.
Query / delete fault memory F1 – F5 or cancel the control box lock• StartthesoftwareonyourPC: – onthedesktop—>doubleclickthe“EDiTH”icon – Selectheatertype – Pressthe“GO”button.
• Deletefaultmemoryorcancelthecontrolboxlock: – pressthe“Deletefaultmemory”button —>thestoredfaultsF1–F5aredeletedandthecontrol
boxisunlocked.
Quit diagnosis• Pressthe“STOP”button—>faultmemoryqueryisended.
1 Heater2 Adaptercable3 ISOadapter
4 SUB-Dconnectioncable5 USBtoSerialRS-232adapter
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�
�
�
Please note!
18
Troubleshooting4Air pressure sensor diagnosis using EDiTH diagnostics tool and ISO adapter(OrderNo.221524890000)
AnadditionaladaptercableisrequiredtoconnecttheISOadapter(OrderNo.:221000333100).
Theairpressuresensorconnectedtotheheatercanbediag-nosed.Iffaultsoccurduringthealtitudeadjustmenttheyarestoredintheairpressuresensor.Ifnecessary,faultscanbereadoutusingtheISOadapterinconjunctionwiththeEDiTHdiagnosticstool–fromVersionS3V7-F–andtheadditionallynecessaryadaptercable.
Please note!
• Itisveryimportanttoalwaysinstallinthegivenorder.• Notonlythedefectivecomponent,butalsoadefectivecur-
rentcircuitresultsinafaultbeingdisplayed.• Faultcode,faultdescription,cause/remedialactionare
describedonpages27.• TheEDiTHdiagnosticstoolscopeofsupplydoesnot
includethesoftware;thismustbedownloadedfromtheServicePortal.
Perform diagnosis of the air pressure sensor
Disconnecttheconnectorbetweentheairpressuresensor/heater,controlunit,connecttheISOadapterwiththeadaptercable(seesketch).Startthediagnosisoftheairpressuresensor.
• Double-clickthe>>EDiTH
19
Caution! Magnetic field!Duringthetestoperationamagneticfielddevelopsattheadapter.Therefore,donotplaceanyobjectssuchasdatamedia,creditcards,etc.ontheadapterorinitsimmediatevicinity.
Troubleshooting4
(A) Basicadapter(B) SUB-Dconnectioncable(C) Mainsconnection(D) Mainsswitch(E) USBtoSerialRS-232adapter(F) Adapter(G) Controlbox
Cable colourssw = blackgn = greenbl = blue
EDiTH diagnostic tool with basic adapterEDiTHbasicadapter(OrderNo.:221542890000)
Anadditionalextensionisrequiredtocheckthecontrolbox(OrderNo.:221537890000).
• Itisimportanttoalwaysfollowthepreciseconnectionorderasgivenbelow!
• TheHallsensorintegratedinthecontrolboxcanonlybeproperlytestedinthecontrolboxiscorrectlyplacedontheextension.
• Onlypushorpullontheconnectors,notonthecables!• OnlyusethenetworkcableandRS232cablewithsnap
ferritesincludedinthescopeofsupply.Useoriginalacces-sorieswithsnapferritesonlytoconnectthetestequipment.
• Notonlythedefectivecomponent,butalsoadefectivecurrentcircuitresultsinafaultbeingdisplayed.
• Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Connect basic adapter• Startcomputerandwaituntilthesystemhassuccessfully
booted.• StartPCsoftware.• Inserttheunitconnectorofthemainscableinthebasic
adapter(A)andconnectthemainsconnection(C)tothemains.
• ConnecttheSUB-Dconnectioncable(B)withthePCandbasicadapter(A).
Connect extension and test control box• Connecttheextensiontothebasicadapter(A).• Connectthecontrolbox(E)totheextensionandtheadap-
ter(F).• Switchonthebasicadapter(A)atthemainsswitch(D).• Selectthecontrolboxversionandoperatingvoltage
(12V/24V)inthePCsoftware.• StartthecontrolboxtestwiththePCsoftware.Amorede-
taileddescriptionofhowtooperatethebasicadapters(A)isgivenintheEDiTHonlinehelp.
Please note!
20
Troubleshooting4Module timer(OrderNo.:221000303400)
Thecurrentfaultisdisplayedas“AF”andisalwayswritteninmemorypositionF1.PrecedingfaultsaremovedtothememorylocationsF2–F5,ifnecessarythecontentsofmemorypositionF5isoverwrit-ten.
• Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
• Inheaterswithconnectedairpressuresensorthemodulartimercannotbeusedtoperformdiagnoses.Thediagnos-ticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
• Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Query fault memory F1 – F5 Condition:Theheaterisswitchedoff.
• Pressckey–>theheaterisswitchedon.
• Pressakeyandkeeppressed, thenpresspkeywithin2seconds. Displayisasfollows: AF=currentfault 3digitnumber=faultcode cflashes.
• Pressfkeyonceorseveraltimes,faultmemorypositionsF1–F5aredisplayed.
Cancel the control box lock and simultaneously delete the fault memoryCondition:Anelectricalconnectionexistsfromterminal15(ignition)tothemoduletimer,12-pinconnector,chamber10.
• Pressckey Displayisasfollows: thecurrentfaultF15orF50.
• Pressbuttona,keepitdepressedandthenpressbuttonpwithin2seconds.
Themoduletimerisnowinthe“Queryfaultmemory”pro-gram.
• Switchoffignition(terminal15).
• Simultaneouslypressbuttonaandbuttonp,inaddition,switchontheignition(terminal15)andwaituntilthefollow-ingappearsinthedisplay.
Afterignition“ON”thefollowingappearsinthedisplay:
Displayflashes, Heatersymboldoesnotflash
• Switchtheheateroffandon–>thecontrolboxisunlocked,theheaterrestarts.
Afterswitchingtheheateroffandonandrenewedqueryofthefaultmemory,thefollowingappearsinthedisplay:
Displayflashes, Heatersymboldoesnotflash
a–Timep–Presetc–Heate–Reversef–Forward
Please note!
21
Troubleshooting4TP5 radio remote control(OrderNo:221000320100)
Iffaultsoccurwhiletheheaterisrunning,theyaredisplayedwith“Err”afterthemobileunitisactivated.
Afterthediagnosticscable(bl/ws)hasbeenconnectedandthefirstlogshavearrivedatthestationaryunit,thediagnosecanbecarriedoutusingthemobileunitoftheTP5radioremotecontrol.Thecurrentfault“F0”isdisplayed.Thestoredfaults“F1”to“F5”canbequeried.
• Inordertocarryoutthediagnosis,thediagnosticscable(bl/ws)mustbeconnectedtothestationaryunitandtheheatercableharness.Tothisend,pleaserefertoandfollowthecircuitdiagramfortheTP5radioremotecontrolandtheheater.
• Ifthediagnosticscable(bl/ws)isnotconnected,the“Diag-nosis”menuisblocked.
• Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
• InheaterswithconnectedairpressuresensortheTP5radioremotecontrolcannotbeusedtoperformdiagnoses.ThediagnosticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
• Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Buttontoactivate/deactivatethemobileunit
Buttonforforwardtimesetting
Buttonforbackwardtimesetting
Buttonforactivatingthepossiblesettings
Buttonforswitchingheat/ventilateON/OFF; Activate/deactivatepreselectedtime
Enquire / delete fault memoryUsethe keytoactivatethemobileunit.Switchontheheaterwiththe key.Pressthe keytwicetoopentheTimesettingmenu–thetimeflashesinthedisplay.
Pressthe keyforapprox2sec–untilthefollowingap-pearsinthedisplay:
Press key.Press key.Press keytwice.Press key.
Malfunctioninheater: Heaterhasnomalfunction:
Usethe and buttonstocallupthefaultmemoryposi-tions1to5.
Delete fault memory / Cancel the control box lockUsethe keytodeletethefaultmemory.
Toconfirm,pressthe keyforapprox2secuntil lightsupinthedisplay–faultmemoryisdeleted.
Please note!
22
The following actions are possible• Callupfaultmemory. CallupthefaultmemorypositionsF1–F5with or .
• Callupfaultmemoryagain. Brieflypress and simultaneously.
• Deletefaultmemory (displaydEL) Press .
Press again.
The diagnosis is completed.
Switch off heater.
Enquire / delete fault memoryActivatemobilepart/timer(seeEasyStartR+/EasyStartToperatinginstructions)
Confirmsymbol with .
Heater is switched on.
Confirmoperatingtimewith .
Brieflypress and simultaneously.
Troubleshooting4EasyStart R+ radio remote control(Order-No.:221000328000)
EasyStart T timer(Order-No.:221000328800)
Iffaultsoccurwhiletheheaterisrunning,theyaredisplayedwith“Err”afterthemobileunitortimerisactivated.
Thecurrentfaultisdisplayed.Thestoredfaults“F1”to“F5”canbequeried.
• Inordertocarryoutthediagnosis,thediagnosticscable(bl/geatheaterconnector,bl/wsatcableharnessconnector)mustbeconnectedtothestationaryunitandtheheatercableharness.Tothisend,pleaserefertoandfollowthecircuitdiagramfortheradioremotecontrolandtheheater.
• Ifthediagnosticscableisnotconnected,the“Diagnosis”menuisblocked.
• Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
• Theheaterdiagnosiscanalsobeperformediftheairpres-suresensorisconnected.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
• Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Backcontrolkey
Nextcontrolkey
ON/OFFactivationkeymobileunit/timer
OKkey(symbolselection/confirminput)
Please note!
23
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
000 Nofaults ——
004 Warning:Shortcircuitincontrolbox,freshairoutput
• DisconnectconnectorS1/B1attheheaterandattheconnectorB1,PIN16checkthecableuptothefreshairfanrelayforshortcircuittonegative,ifok—>replacecontrolbox.
005 Warning:Shortcircuitincontrolbox,caralarmoutput
• DisconnectconnectorS1/B1attheheaterandattheconnectorB1,PIN15checkthecableuptotherelayisolatingswitchorburglaralarmsysteminputforshortcircuittonegative,ifok—>replacecontrolbox.
006 Warning:Inexplicableatmosphericaltitudeinformation(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
Controlboxhasnotreceivedanyexplicablealtitudeinformation.• ReadoutfaultmemoryintheairpressuresensorusingtheEDiTHdiagnos-
ticstoolandcorrectfault.
009 Cut-offADR ADRshutdownduetosignalchangefrom(+)to(–)atconnectorS1,PIN13(D+)orplussignalatconnectorS1,PIN14(HA+).
010 Overvoltage–cut-off Overvoltageappliedtocontrolboxforatleast20secondswithoutinterruption–heaternotworking.• DisconnectconnectorS1/B1attheheater,startthevehicle’sengine,
measurethevoltageatconnectorB1betweenPIN1(cable2.52rt)andPIN10(cable2.52br).
Airtronic12volt–voltage>16volt—>checkgeneratorregulator Airtronic24volt–voltage>32volt—>checkgeneratorregulator
011 Undervoltage–cut-off Undervoltageappliedtocontrolboxforatleast20secondswithoutinterrup-tion–heaternotworking.• DisconnectconnectorS1/B1attheheater,thevehicle’sengineisswitched
off,measurethevoltageatconnectorB1betweenPIN1(cable2.52rt)andPIN10(cable2.52br).
Themeasuredvalueandthevoltageatthebatteryshouldbethesame. Incaseofavoltagedrop,checkthefuses,thesupplycables,thenegative
connectionsandthepositivesupportpointonthebatteryforcorrosionandcorrectcontact.
012 Overheatingattheoverheatingsensor Temperatureoftheoverheatingsensortoohigh.• Checkhotairpipesforblockage—>removeblockage.• Sumofthecomponentratingsofair-conductingpartsistoolarge—>
Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
• Checkoverheatingsensor,fordiagramandtableofvaluespleaserefertoPage32,ifok—>measurefuelquantity,seePage36.
013 Overheatingattheflamesensor Flamesensorsignalstemperatureatheatexchangeristoohigh.• Checkhotairpipesforblockage—>removeblockage.• Sumofthecomponentratingsofair-conductingpartsistoolarge—>
Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
• Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsensordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,fordiagramandtableofvaluesforflamesensorandoverheatingsensorpleaserefertoPage32.
014 Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge
Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge• Checkhotairpipesforblockage—>removeblockage.• Sumofthecomponentratingsofair-conductingpartsistoolarge—>
Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
• Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsen-sordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,iffuelquantityok—>replacecontrolbox.Fordiagramandtableofvaluesforflamesensorandoverheatingsen-sor,seePage32.
24
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
015 Operatinglock-out Thefaultcode015isdisplayed,iftheheaterwasswitchedbackonafterthefaultcodedisplay017.
Thehardwarethresholdvaluefortheoverheatingsensorhasbeenexceeded—>thecontrolboxislocked.
• Replacecontrolbox.
017 Overheating Thehardwarethresholdvaluefortheoverheatingsensorhasbeenexceeded,becausethecontrolboxfailedtorecognisethefaultcode012or013–>thecontrolboxislocked.Iftheheaterisswitchedonagain,thefaultcode015isdisplayed.• Replacecontrolbox.
018 Startingenergyoftheglowplugistoolow(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
• Checkglowplug(seefaultcode020and021),ifok• Checkglowplugcableharnessforcorrectlayinganddamage,ifok—>
checkcableharnessforcontinuity,ifok—>replacecontrolbox.
019 Ignitionenergytoolow • Checkglowplug(seefaultcode020and021),ifok• Checkglowplugcableharnessforcorrectlayinganddamage,ifok—>
checkcableharnessforcontinuity,ifok—>replacecontrolbox.
020
021
Glowplug–interruption
Glowplug–shortcircuit,overloadorshortcircuitafternegative
• Checkglowplugforfunctionandcontinuityatambienttemperature20°C. 12voltheater–0.42upto±0.7 24voltheater–1.2upto±2.0
• Ifthevaluesareok—>checkglowplugleadharnessfordamageandcon-tinuity,ifok—>replacecontrolbox.
022 * Glowplug,output(+)–shortcircuitafterUB(batteryvoltage)
• Checkglowplugleadharnessforcorrectlayinganddamage,ifok—>checkleadharnessforcontinuity,ifok—>replacecontrolbox.
025 * Diagnosticscablebl/ws–shortcircuit–afterUB(batteryvoltage)
Faultcodedisplayisnotpossible.Thisfaultcodecannotbereadoutfromthefaultmemoryuntilthefaulthasbeencorrected.• Checkdiagnosticscableforcorrectlayingandpossibledamage.
031 Blower–interruption • Checkthattheleadharnessoftheblowermotorhasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessatcontrolboxandcheckforcontinuity,ifok—>replacecontrolbox.
032 Blowermotor–shortcircuitafternegative
Please note!
Ensurecompliancewiththetestvolt-age(seepage12).Thecomponentisdestroyedifthevoltagevalueisexceeded.Ensure the power pack has ad-equate short-circuit resistance – min 20 A.
• Carryoutfunctionaltestontheblowermotor,todothisremovethecon-nectorfromthecontrolbox.Applyatestvoltage(seepage12)totheblow-ermotorandmeasurethecurrentintensityafter40sec.
Currentintensity<6.5A–blowermotorok–>replacecontrolbox. Currentintensity>6.5A—>replaceblower.• Checkwiringforshortcircuit.
033 Blowermotorwon’trotateorshortcircuitafternegative
Please note!
Ensurecompliancewiththetestvolt-age(seepage12).Thecomponentisdestroyedifthevoltagevalueisexceeded.Ensure the power pack has ad-equate short-circuit resistance – min 20 A.
Speeddeviation>10%fromsetpointvalueforlongerthan30seconds.Useanon-contactr.p.m.countertomeasurethespeedofthecombustionair
fan(seepage12fortestspeedandtestvoltage).• Speedtoolow: Blowerblocks–checkblowerforfreerunning,ifnecessaryremoveforeign
body,ifok—>checkblower(seefaultcode032).• Speedtoohigh: – Magnetmissingfromblowerimpeller—>replaceblower. – Speedsensorincontrolboxisdefective—>replacecontrolbox.• Checkwiringforshortcircuit.
* Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
25
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
034 * Blowermotor,outlet(+)shortcircuitafterUB(batteryvoltage)
• Checkthattheleadharnessoftheblowermotorhasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessatcontrolboxandcheckforcontinuity,ifok—>replacecontrolbox.
047 Meteringpump–shortcircuitoroverload
• Removeconnectorfromthemeteringpump,ifthefaultcode048(inter-ruption)isdisplayedthemeteringpumpisdefective—>replacemeteringpump.
• Ifthefaultcode047continuestobedisplayed,disconnectconnectorS1/B1attheheater,andattheconnectorB1,PIN5checkthecable12gn/rtuptothemeteringpumpforshortcircuittonegative(PIN10),ifok–>replacecontrolbox.
048 Meteringpump–interruption • Disconnectconnectorfrommeteringpumpandmeasuretheresistancevalueofthemeteringpump(seePage12forvalues),ifresistancevalueok,re-connectthecableloomtothemeteringpump.
• DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalue(seePage12)betweenPIN5andPIN10,ifok—>replacecontrolbox.
049 * Meteringpumpoutlet(+)Shortcircuit–afterUB(batteryvoltage)
• Checkthattheleadharnessofthemeteringpumphasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessandcheckforconti-nuity,ifok—>replacecontrolbox.
050 Toomanyfailedstartattempts(opera-tinglock-out)
Thecontrolboxlocksaftertoomanyfailedstartattempts(max.255startat-tempts).• Unlockthecontrolboxbydeletingthefaultmemorywiththetimer,thedi-
agnosticunit,EDiTHdiagnostictool,theTP5radioremotecontrol/EasyS-tartR+andtheEasyStartTtimer.
051 Flamedetectedwhenswitchingon If,afterbeingswitchedon,theresistancevalueoftheflamesensoris1274(>70°C)theheater’sfanrunsforapprox15mintocooldown,iftheresist-ancedoesnotfallbelowtheaforementionedvaluewithin15mintheheaterisswitchedoff.
• Checkflamesensor,seePage32fordiagramandtableofvalues,ifok—>replacecontrolbox.
052 Safetytimeexceeded Noflamedetectedwithinthestartphase.• Checkexhaustandcombustionairsystem.• Checkfuelsupply/measurefuelquantity,seePage36.• Checksparkplug(seefaultcode020and021)• Checkflamesensor,diagramandtableofvalues,seePage32,
ifok—>replacecontrolbox.
053
054
055
056
Flamecutoutinthe
“POWER”controlstage
“HIGH”controlstage
“MEDIUM”controlstage
“LOW”controlstage
Theheaterhasignited(flamedetected)andsignalsflamecutoutduringapowerstage.
• Checkexhaustandcombustionairsystem.• Checkfuelsupply/measurefuelquantity,seePage36.• Checkflamesensor,diagramandtableofvalues,seePage32,
ifok—>replacecontrolbox.
057 Flamecutoutfromstartphase(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
Aflamecutoutwasdetectedduringthestartphase..• Checkexhaustandcombustionairsystem.• Checkfuelsupply/measurefuelquantity,seePage36.• Checkglowplug(seefaultcode020and021).• Checkflamesensor,diagramandvaluestable,seepage32,
ifok—>replacecontrolbox.
060 Externaltemperaturesensor–interruption
• DisconnecttheconnectorS4/B4oftheexternaltemperaturesensorandmeasuretheresistancevalueatconnectorB2,fordiagramandtableofva-luesseePage12,iftemperaturesensorok,reassembleconnectorS4/B4.
• DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalueinconnectorhousingB1betweenPIN6andPIN12.Ifinterruptedtheohmicvalueis>7175/3k*.Ifresistancevalueok—>replacecontrolbox.
* Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
26
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
061 Externaltemperaturesensor–shortcircuit
• DisconnectconnectorS4/B4oftheexternaltemperaturesensor,iffaultcode060isdisplayed—>checkexternaltemperaturesensor,diagramandtableofvalues,seePage32.Iftemperaturesensorok—>checkconnec-tioncables0.5grand0.5br/wsforshortcircuit,ifok,reassemblethecon-nectorS2/B2.
• DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalueinconnectorhousingB1betweenPIN6andPIN12.Incaseofshortcircuittheohmicvalueis<486/<800*.
Iferror061continuestobedisplayed—>replacecontrolbox.
062 Controlunit–interruption
Please note!
Refertonotesondiagnosiswithmini-controlleronpage14.
Heaterrunsin„High“controlstageonly• Removeconnectoratthecontrolunitandmeasuretheresistancevalueof
thesetpointpotentiometer,forconnectorpinsseePage42onwards.Iftheresistancevalueisok,reconnectconnectoratthecontrolunit.
• DisconnectconnectorS1/B1attheheater,measuretheresistancevaluebetweenPIN6andPIN7inconnectorhousingB1,ifresistancevalueok—>replacecontrolbox.Resistancevalueincaseofinterruption>7175 />3k *.Normalvalues:seepage12.
063 Controlunit–shortcircuit
Faultrecognitiononlyworksinhea-tingmode.If,ontheotherhand,theshortcircuithasalreadyoccurredandthentheheaterisswitchedon,„Venti-lation“isactive(notafaultcode).
• Ifthe“Ventilate”switchisinstalled,disconnectitandcheckitworks.Ifnotok—>replaceswitch.
• Disconnectconnectoratcontrolunit,iferrorcode062isdisplayed,replacethecontrolunit.Ifcontrolunitok,checkconnectioncables0.5gr/rtand0.5br/wsforshortcircuit,ifok—>reconnectconnectoratcontrolunit.
• DisconnectconnectorS1/B1attheheater,iftheerror063continuestobedisplayed—>replacecontrolbox.Resistancevalueincaseofshort-circuit<486 / <800 *.Normalvalues:seepage12.
064 Flamesensor–interruption • Dismantlecontrolboxanddisconnectgreenconnectorfromcontrolbox.Checkflamesensor,diagramandtableofvalues,seePage32,ifflamesen-sorok—>replacecontrolbox.Resistancevalueincaseofinterruption>7175 />3k *.
065 Flamesensor–shortcircuit Dismantlecontrolbox,removegreenconnectorfromcontrolbox,iferror064isdisplayed—>replacecombinationsensor.
Iferror065continuestobedisplayed—>replacecontrolbox. Resistancevalueincaseofshortcircuit<486 /<500*,seealsodia-
gramonPage32.
071 Overheatingsensor–interruption • Dismantlecontrolbox,disconnectblueandgreenconnectorsfromcontrolbox.MeasureresistancevalueatblueconnectorPIN1(cable0.52bl)andatgreenconnectorPIN2(cable0.52br/ws),ifok,—>replacecontrolbox.
Resistancevalueincaseofinterruption>223k />1600k *,seealsodiagramonPage32.
072 Overheatingsensor–shortcircuit • Dismantlecontrolbox,removeblueconnectorfromcontrolbox,iferror071isdisplayed—>replacecombinationsensor.
Iferror072continuestobedisplayed—>replacecontrolbox. Resistancevalueincaseofshortcircuit<183 /<95*,seealsodia-
gramonPage32.
074 * Controlboxdefective • Overheatingthresholdvalueisnotdetectedbycontrolbox—>replacecon-trolbox.
090 Controlboxdefective(internalfault) • Replacecontrolbox.
091 Externalinterferencevoltage • Controlboxfaultduetointerferencevoltagesfromthevehicle’selectricalsystem.Possiblecauses:
Poorbattery,charger—>removeinterferencevoltage.
092 Controlboxisdefective(ROMerror) • Replacecontrolbox.
093 * Controlboxdefective • Replacecontrolbox.
* Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
27
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
094 Controlboxdefective(EEPROM-Fehler)
• Replacecontrolbox.
095 * Controlboxdefective • Replacecontrolbox.
096 Internaltemperaturesensordefective • Replacecontrolboxoruseanexternalroomtemperaturesensor..
097 Controlboxdefective • SReplacecontrolbox.
098 * Controlboxdefective • Replacecontrolbox.
099 * Toomanyresetsinsequence
Transistorerrorincontrolbox
• Voltageshort-term<5–6volt(for12volt)or<7–8volt(for24volt). Incaseofavoltagedrop,checkthefuses,thesupplycables,thenegative
connectionsandthepositivesupportpointonthebatteryforcorrosionandcorrectcontact.
Testcontrolboxwithtestingdevice,ifok—>checkleadharnessoftheex-ternalcomponentshasbeencorrectlylaidandcheckfordamage,ifok—>checkleadharnessforcontinuity,ifok—>replacecontrolbox.
Air pressure sensor fault code displayFault code display
Fault description Comments• Remedial action
0 Nofaults —
11 Communicationloss Interruptionofthediagnosticscablebetweenthecontrolbox(heater)andtheairpressuresensor• Checkwiringandplug-inconnections
12 Noaltitudeadjustment Controlbox(heater)doesnotsupportaltitudeoperationwiththeairpressuresensor• Useacontrolbox(heater)whichsupportsaltitudeadjustment
13 Airpressuresensorfault Theairpressuresensorisdefective• Replacetheairpressuresensor
* Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
28
Repair instructions
Thepermittedrepairworktotheheaterisdescribedinthe“RepairInstructions”chapter.Ifextensiverepairsarenecessary,itmakessensetodismantletheheater.
Theheaterisassembledinthereverseorder,ifapplicablenotadditionalinstructions.
Aftercompletingalltheworkontheheater,youmustcarryoutafunctionalcheck(seePage4).
Always observe the following safety instructions before working on the heater:
Danger!Risk of injury, burns and poisoning!• Alwaysswitchofftheheaterbeforehandandleaveittocool.• Disconnectthebattery.• Theheatermustnotbeoperatedinclosedroomssuchas
garagesorworkshops. Exception: Exhaustsuctionavailabledirectlyattheentrytotheexhaust
pipe.
Caution!• Thesealsofdismantledcomponentsmustberenewed.• Duringrepairwork,checkallcomponentsfordamageandif
necessaryreplace.• Checkconnectorcontacts,plug-inconnectionsandcables
forcorrosionanddamageandifnecessaryrepair.• OnlyeveruseEberspächersparepartsifreplacementsare
necessary.• Operationortheafterrunningoftheheatermayonlybe
stoppedinanemergency(see“EMERGENCYOFF”Page8)byinterruptingthebatterycurrent(riskofheateroverheat-ing).
Repairinstructions5Special tool
AMP release tool
TheAMPreleasetoolisusedtoreleaseplug-incontactsinaconnectorhousing.
ThisreleasetoolcanbeordereddirectlyfromAMP.
• ForMicroTimer: AMPOrderNo.0-0539960-1
• ForJunior-Power-Timer: AMP-Bestell-Nr.1-1579007-6
Please note!
29
Assembly drawing Airtronic / Airtronic M
Partslist
1 Combustionairfan 2 Seal–combustionairfan/heatexchanger 3 Combustionchamber 4 Seal–combustionchamber/heatexchanger 5 Heatexchanger 6 Controlbox 7 Combinationsensor(overheating/flamesensor)with
assemblytool
8 Bracket 9 Glowplug,withspecialtool(SW12)10 Lining–glowplugsocket,withassemblytool11 Cover12 Outershell(bottomsection)13 Flangeseal14 Sleeve(forpetrolonly)
Repairinstructions5
30
Repair step 1Remove the heater’s cover (seeFigure1)
Unlockbothfasteningclips,liftthecoverandremovefromthefront.
Theheater’scovermustberemovedforallrepairsteps.Ifnecessary,waituntiltheunithascooleddown.
Cableharnessoutletfromthehousingoptionallyonleftorright-handside.
1. 2.
Figure1
Cover Fasteningclips
Repair step 2Dismantle control box (seeFigure2)
• Repairstep1.• Unscrewfixingscrew,• Presstogethertheretainingclamps.• Removethecontrolboxfromabove.• Unclipcablesfromholderoncontrolbox (Notethepositionofthecables).• Pullgrommetoutoftheoutershell(bottomsection).• Pullconnectoroutofcontrolbox,thecontrolboxcannow
beremoved.
Whenassemblingthecontrolbox,ensurethecablesareclip-pedintotheholderonthecontrolboxandtheconnectorsarepluggedintothecontrolbox(unmistakeable).TighteningtorqueofthefixingscrewItem:2+0.2Nm
Figure2
Fixingscrew Retainingclamp Controlbox Grommet
Check control box
TheEDiTHdiagnostictoolisrequiredtocheckthecontrolboxwhenitisdismantled.Forconnection,useandOrderNo.,seePage19.
5 Repairinstructions
Please note!
Please note!
31
Repair step 3Dismantle glow plug (seeFigure3)
Important!Safety instruction for installation of the rubber grommetTopreventleaks,inserttherubbergrommetpreciselyintheglowplugholeintheheatexchanger.Failuretocomplywiththisinstructioncanresultinpersonalinjuriesaswellasmalfunctioningordamagetotheheater.
• Repairstep2.• Disconnectconnectorfrom“glowplug”cableloomoncon-
trolbox.• Removerubbergrommetandunscrewtheglowplugusing
thespecialtool(SW12).(Thespecialtoolisincludedwiththeglowplug).
Tighteningtorqueforglowplug:6+0.5Nm
Specialglowplugtool
Figure3
Glowplug Connectorfromglowplugcableloom Rubbergrommet
Please note!
Withtheglowplugdismantled,visuallycheckthesocketliningoftheinstalledglowplugfordirt.Iftheliningishighlysoiledanditssurfaceclosed,renewthelining.
Removing the lining (see Figure 4)
Uselongnoseplierstopulltheliningoutofthesocketfromabove.Blowoutthesocketwithcompressedairandifnecessarycleanthesideventhole.
Usethespecialtooltoinstallthenewlining.Thespecialtoolisincludedwiththelining.Pushtheliningonthetool.Pushinthetooltogetherwiththelininguptothelimitstop.Welding points of lining must lie opposite the fuel intake.
Figure4
Specialtool Lining
5
Repairinstructions
32
Repair step 5 Dismantle combination sensor (overheating / flame sen-sor) (seeFigure5)
• Repairstep2.• Removebothconnectorsfromthe“combinationsensor”
cableloomatthecontrolbox.• Unlockbracketfromcombinationsensor.• Removethecombinationsensor.
Figure5
“Combinationsensor”cableloom Bracket,unlocked
Check combination sensor
Theexternaltemperaturesensormustbecheckedwithadigi-talmultimeter.Replacetheoverheatingorflamesensoriftheresistancevalueisnotthesameasthecurveinthediagramorthetableofvalues.
Table of overheating sensor values
Temperature °C Resistance k min. max. – 40 1597.00 1913.00 – 20 458.80 533.40 0 154.70 175.50 20 59.30 65.84 40 25.02 28.04 60 11.56 13.16 80 5.782 6.678 100 3.095 3.623 120 1.757 2.081 140 1.050 1.256 160 0.6554 0.792 180 0.4253 0.5187 200 0.2857 0.3513
Table of flame sensor values
Temperature °C Resistance min. max.– 40 842.7 825.9 859.6– 20 921.6 803.2 940.0 0 1000.0 980.0 1020.0 20 1077.9 1056.4 1099.5 40 1155.4 1132.3 1178.5 60 1232.4 1207.8 1257.1 80 1308.9 1282.8 1335.1 100 1385.1 1357.4 1412.8 120 1460.7 1431.5 1489.9 140 1535.8 1505.1 1566.6 160 1610.5 1578.3 1642.8
Res
ista
nce
(kO
hm)
Temperature(°C)
5
Notethemax.temperatureof320°Cforthetest.
Temperature(°C)
Res
ista
nce
(Ohm
)
Overheating sensor Flame sensor
Repairinstructions
Please note!
33
Sketch2
Specialtool–onlyrequiredforAirtronic Combinationsensor
Figure6
Specialtool–onlyrequiredforAirtronic Combinationsensor
Repair step 6 Install combination sensor (overheating / flame sensor)(seeFigure6,7andSketch2–4)
•Repairstep2.• ForAirtronic(assemblywithspecialtool,seeSketch2) Pushthespecialtoolaontothecombinationsensorb.Use
thespecialtooltopositionthecombinationsensorontheheatexchanger,thespecialtoolslidesontheheatexchang-eruntilthecombinationsensorhitsthecollar(installationpositionofthecombinationsensor).
Lockthecombinationsensor’sbracketandremovethespecialtool.Thenalwayscheckthatthecombinationsen-sorsitsflatontheheatexchanger.Ifnecessary,useaidssuchasamirrorandlamp.
Laythe“combinationsensor”cableloomalongthebracket,throughthebracketeyeletuptothecontrolboxandcon-nect.
• ForAirtronicM(assemblywithoutspecialtool) Placethecombinationsensorontheheatexchanger;itis
importanttoensurethecombinationsensorsitsflatontheheatexchanger.
Lockthecombinationsensor’sbracketandcheckagainthatthecombinationsensorissittingflatontheheatex-changer.
Laythe“combinationsensor”cableloomalongthebracket,throughthebracketeyeletuptothecontrolboxandcon-nect.
Sketch4
Bracket Combinationsensor
Figure7
Bracket,locked “Combinationsensor”cableloom Specialtool–onlyrequiredforAirtronic
Circuit diagram for combination sensor (overheating sensor / flame sensor)
Sketch3
NTC50KΩ=overheatingsensorPT1000=flamesensor
Connectorblue
Connectorgreen
5 Repairinstructions
34
Repair step 7 Dismantle heat exchanger (seeFigure8andSketch5)Dismantle combustion air fan (seeFigure8andSketch5)
• Repairstep2.• Removeflangeseal.Removeheaterfromtheoutershell
(bottomsection). Unscrewthe4fixingscrewsfromthecombustionairfan. Removethecombustionairfanandthesealfromtheheat
exchanger.
Caution!Wheninstallingthecombustionairfanthesealmustalwaysberenewed.
Tightenthe4fixingscrewsofthecombustionairfan–intheordershowninSketche–withatighteningtorqueof4+0.5Nm. Figure8
Combustionairfan Heatexchanger Fixingscrew
Sketch5
1–4 Tightenthefixingscrewsinthisorderwithatightening
torqueof4+0.5Nm
5
5 Alwaysrenewthesealbetweenthecombustionairfanandtheheatexchanger.
5
2
4
3
1
Repairinstructions
35
Repair step 8Dismantle combustion chamber (seeFigure9andSketch6)
• Repairstep3.• Repairstep7.• Unscrewthefixingscrews. IntheAirtronic=3fixingscrews, intheAirtronicM=4fixingscrews.• Pulloutthecombustionchamberfromthefrontandremove
theheatexchanger’sseal.
Caution!Whenassemblingthecombustionchamber,alwaysrenewtheseal,whichisincludedwiththesparepart.
Tightenthefixingscrewsofthecombustionchamberwithatighteningtorqueof5+0.5Nm
Iftheheatexchangerisreplacedthecombinationsensor(overheatingsensor/flamesensor)mustbedismantledandfittedonthenewheatexchanger(seeRepairstep6,Page33).
Sketch6
1Combustionchamber2Alwaysrenewthesealbetweenthecombustionchamber
andtheheatexchanger.3Heatexchanger
4Fixingscrew Airtronic=3fixingscrews AirtronicM=4fixingscrews
Figure9
Combustionchamber Heatexchanger Fixingscrew Airtronic=3fixingscrews AirtronicM=4fixingscrews
5
4
1
2
3
Repairinstructions
Please note!
36
Measuring the fuel quantity
1. Preparation
Removethefuelpipeattheheaterandinsertameasuringcylinder(size10ml).Switchontheheater,ifthefuelisuniformlypumped(beginsapprox.60secafterbeingswitchedon),thefuelpipeisfullandvented.Switchoffheaterandemptymeasuringcylinder.
Forprecisefuelmeasurementatleast11volt/22voltormaximum13volt/26voltshouldbeappliedtothecontrolboxduringthemeasurement.
2. Measurement
Thefuelbeginstobepumpedapprox.60secafterswitchingontheheater.Holdthemeasuringcylinderatglowpluglevelduringthemeasurement.
Airtronic Afterapprox.90secofthefuelbeingpumpeditisautomati-callyswitchedoff.
Caution!Switch off heater,asotherwiseitwillstartupagain.
Readoffthequantityoffuelinthemeasuringcylinder.
Airtronic MAfterapprox.105secofthefuelbeingpumpeditisautomati-callyswitchedoff.
Caution!Switch off heater,asotherwiseitwillstartupagain.
Readoffthequantityoffuelinthemeasuringcylinder..
Ifthemeasuredfuelquantityliesoutsidethevaluesgivenbelow,themeteringpumpmustbereplaced.
1 Heater2 Meteringpump
Check fuel supply
Beforemeasuringthefuelquantity,checkthefollowingpointsinthefuelsupply.
• Checkthescreeninthemeteringpump.• Checkthelayingofthefuelpipes.• Checkfuelpipesforleaks.• Checkandtightenthehoseconnections.• Isthefuelremovalinstalledaccordingtothedetailsinthe
technicaldescription?
5
3 Measuringcylinder(size10ml)4 Disconnectfuelpipeatheaterandinsertinameasuringcylinder.
1
2
3
4
Table of values – fuel quantity
Heater Fuel Fuel quantity
Minimal Maximal
Airtronic diesel 3,5ml/90sec 4,3ml/90sec
AirtronicM petrol 6,8ml/105sec 7,6ml/105sec
AirtronicM diesel 5,0ml/105sec 6,0ml/105sec
Bitte beachten!
Repairinstructions
37
Circuitdiagram6Overview of the parts lists and circuit diagrams
PartslistcircuitdiagramAirtronic/AirtronicM................................................................................................................................ 38CircuitdiagramAirtronic/AirtronicM.............................................................................................................................................. 39 Thiscircuitdiagramisforheaterswithonediagnosticscableandacontrolboxcableloomwhichisfirmlyencapsulated.CircuitdiagramAirtronic/AirtronicM.............................................................................................................................................. 40 Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
Partslistcontrolunits..................................................................................................................................................................... 41Circuitdiagramscontrolunits...................................................................................................................................................42–48
PartslistEasyStartR+/R/Tcontrolunits..................................................................................................................................... 49EasyStartR+circuitdiagram...................................................................................................................................................50–52EasyStartRcircuitdiagram......................................................................................................................................................53–55EasyStartTcircuitdiagram....................................................................................................................................................... 56,57
PartslistcircuitdiagramAirtronic/AirtronicM–ADR..................................................................................................................... 58CircuitdiagramAirtronic/AirtronicM–ADR................................................................................................................................... 59 Thiscircuitdiagramisforheaterswithonediagnosiscableandacontrolboxcableloomwhichisfirmlyencapsulated.CircuitdiagramAirtronic/AirtronicM–ADR................................................................................................................................... 60 Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
Partslistcontrolunits–ADR.......................................................................................................................................................... 61Circuitdiagramcontrolunits–ADR............................................................................................................................................... 62EasyStartT–ADRcircuitdiagram............................................................................................................................................ 63,64
38
Parts list circuit diagrams Airtronic / Airtronic M
1.1 Burnerengine1.2 Glowplug1.5 Overheatingandflamesensor2.1 Controlbox2.2 Meteringpump2.7 Mainfuse 12volt=20A 24volt=10A2.7.1Fuse,actuation5A5.1 Battery
a) Connectionofcontrolunitandexternalsensoraccord-ingto“controlunits”circuitdiagram
•rt Powersupply,plus–terminal30 •ge Switch-onsignal–S+ •gr Temperature–actualvalue •wsrt Switchofftheanti-theftalarmsystem (ADR–feedbacksignalfortimer) •br Powersupply,minus–terminal31 •blws Diagnosis •grrt Temperature–setpoint •brws Groundconnectionforexternaltempera-
turesensorandtemperaturesetpoint b) Option •Vehiclefancontrol and/or •separatefreshairfan
Thecircuitdiagramsareassignedviatheinstalledcontrolbox:• Controlboxwithonediagnosticscable: Atthe16pinconnectorthediagnosticscablebl/wsiscon-
nectedtochamber8.• Controlboxwith2diagnosticscablesandJEdiagnosis: Atthe16pinconnectorthediagnosticscablebl/wsis
connectedtochamber3,thediagnosticscablebl/geisconnectedtochamber8.
• Insulateunusedcableends.• Connectorsandbushhousingsareshownfromthecable
inletside.
Circuitdiagram6
Cable colours circuit diagramssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple
Please note!
39
Circuit diagram – Airtronic / Airtronic M
252069009801APartslistPage38
Circuitdiagram6
Thiscircuitdiagramisforheaterswithadiagnosticscableandwhosecontrolboxcableloomwhichisfirmlyencapsulated.
Please note!
40
Circuit diagram – Airtronic / Airtronic M
Circuitdiagram6
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolunitcableloomiswoundwithcabletape.
252069009801BPartslistPage38
Bitte beachten!
41
Circuitdiagram6Parts list circuit diagrams, control units
2.15.1 Temperaturesensor,external(roomtemperature)2.15.9 Temperaturesensor(externaltemperature)3.1.9 Changeoverswitch“heat/ventilate”3.1.11 Controlunit,round3.1.16 Radioremotecontrolbutton3.1.17 MinicontrollerAirtronic3.1.18 ButtonCalltronic3.2.8 Moduletimer(ADR–potentiometer)3.2.12 Timer,mini–12/24volt3.2.14 Lighting,timer,mini–12voltonly3.3.6 RadioremotecontrolstationarypartTP41i3.3.7 RadioremotecontrolstationarypartTP53.3.8 RemotecontrolCalltronic3.8.3 Antenna3.9.1 Diagnosis,JEdiagnosis
a)ConnectioncontrolelementstotheAirtronic •rt Powersupply,plus–terminal30 •ge Switch-onsignal–S+ •gr Temperature–actualvalue •wsrt Switchoffburglaralarm (ADR–feedbackfortimer) •br Powersupply,minus–terminal31 •blws Diagnosis •grrt Temperature–setpoint •brws Groundconnectionforexternaltempera-
turesensorandtemperaturesetpoint b) Terminal15–necessaryforconnectionTP4i c) Lighting,terminal58d) Connection,diagnosticunit e) Connection,externaltemperaturesensor g) Connection,externalheatingbutton h) Connection,radioremotecontrolTP4i j) Connection,temperaturesensor(outsidetemperature) k) Ifconnectingtimerorradioreceiver– Disconnectcablehere l) Connection,change-overswitch“heat/ventilate” option) Initialoperation:Activatechangeoverswitch “heat/ventilate”,thenswitchontheheater. z) Lighting,terminal58
• Insulateunusedcableends.• Connectorsandbushhousingsareshownfromthecable
inletside.
Cable colours circuit diagramssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple
Please note!
42
Circuit diagram, control units – part 1
252069009701CPartslistPage41
Circuitdiagram6
43
Circuitdiagram6
252069009701CPartslistPage41
Circuit diagram, control units – part 2
44
Circuit diagram, control units – part 3
252069009702APartslistPage41
Circuitdiagram6
45
Circuit diagram, control units – part 4
252069009702APartslistPage41
Circuitdiagram6
46
Circuit diagram, control units – part 5
252069009704APartslistPage41
Circuitdiagram6
47
Circuit diagram, control units – part 6
252069009704APartslistPage41
Circuitdiagram6
48
Circuit diagram, control units – part 7
PartslistPage41
Circuitdiagram6
252069009703B
49
Circuitdiagram6Parts list circuit diagram control units – EasyStart R+ / R / T
2.15.1 Temperaturesensor(roomtemperature) (includedinscopeofsupplyforEasyStartR+, optionalforEasyStartR/T)2.15.9 Outsidetemperaturesensor(optional)
3.1.7 “OFF”button3.1.9 “Heat/ventilate”switch3.1.11 “Round”controlunit3.1.16 Radioremotecontrolbutton3.1.17 “Minicontroller”controlunit
3.2.15 EasyStartTtimer
3.3.9 RadioremotecontrolEasyStartR(stationaryunit)3.3.10 RadioremotecontrolEasyStartR+(stationaryunit)
3.6.1 Leadharness
3.8.3 Antenna
a) Connectionofcontrolunitsattheheaterc) Terminal58(lighting)d) Parkingventilationwithvehiclefan(optional)e) ConnectionofEasyStartTtimertimerg) Connection“ON/OFF”key (optionale.g.OrderNo.:221000328400)h) Connectionof“Ventilate”viaEasyStartR+x) ADRjumpery) Connectandinsulatecables
•Note heater type!•Thejumperlabelledwithy)inthecircuitdiagrammustalways
beconnected.•Insulateunusedcableends.•Connectorsandbushhousingsareshownfromthecable
inletside.
Assignment of the circuit diagrams for Airtronic heatersThecircuitdiagramsareassignedviatheinstalledcontrolbox:• Controlboxwithonediagnosticscable: Atthe16pinconnectorthediagnosticscablebl/wsiscon-
nectedtochamber8.• Controlboxwith2diagnosticscablesandJEdiagnosis: Atthe16pinconnectorthediagnosticscablebl/wsis
connectedtochamber3,thediagnosticscablebl/geisconnectedtochamber8.
Cable colours circuit diagramssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple
Please note!
EasyStart TPinassignmentEasyStartT-connectorS1
1 Terminal 30 (positive) rt 2 S+(switchingonsignal) ge 3 Terminal 31 (negative) br 4 DATcable vi 5 Diagnosis cable (K line) bl/ws 6 Terminal58 gr/sw 7 Temperaturesensor(positive)) gr 8 Temperaturesensor(negative) br/ws 9 –– ––
EasyStart R Pinassignmentatthestationaryunitconnector
1 Terminal31(negative) 2 –– 3 –– 4 DATcable 5 Pushbutton/LED(negative) 6 –– 7 Terminal30(positive) 8 S+(switching on signal) 9 LED(positive)10 Diagnosiscable(Kline))11 Pushbutton(negative)12 ––
EasyStart R+ Pinassignmentatthestationaryunitconnector
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)
Pin assignments
50
Circuitdiagram6EasyStart R+ control unit circuit diagram(Controlboxwithonediagnosticscable)
PartslistPage49 252069009706B
51
Circuitdiagram6
PartslistPage49 252069009706B
EasyStart R+ control unit circuit diagram(Controlboxwithonediagnosticscable)
52
Circuitdiagram6EasyStart R+ control unit circuit diagram(Controlboxwithtwodiagnosticscables)
PartslistPage49 252361009701B
53
Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithoneortwodiagnosticscables)
PartslistPage49 252361009705B
54
Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithtwodiagnosticscables)
PartslistPage49 252361009702B
55
Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithonediagnosticscable)
PartslistPage49 252069009707B
56
Circuitdiagram6EasyStart T control unit circu