AIRTRONIC / AIRTRONIC M...V = Combustion air Function2 and use 6 Description of functions Switching...

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 M Troubleshooting and Repair Instructions

25211595190112.2011

Airtronic Orderno.

AirtronicD2,12V 252069050000AirtronicD2,24V 252070050000AirtronicD2Camper,12V 252326050000

Completepackage

AirtronicD2,12V 252115050000AirtronicD2,24V 252116050000

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

https://eberspacher-russia.ru

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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


Heatflow(watt)

Heaterairflowratewithoutcounterpressure(kg/h) withhoodØ90mm

Fuelconsumption(l/h)

Elektr.powerconsumption(watt)

inoperation(12and24volt)


Ratedvoltage





Fuel


Heater

Dosingpump



Weight

Ventilationmode

Airtronic M

AirtronicB4

B4

Air

Stage


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)


–40°Cto+50°C –40°Cto+85°C

–40°Cto+20°C –40°Cto+125°C

max.+40°C


ca.4.5kg

possible



Please note!


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Heatertype

Heater

Version

Heatingmedium


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


Ratedvoltage





Fuel


Heater

Dosingpump



Weight

Ventilationmode

Airtronic M

AirtronicD3/AirtronicD4/AirtronicD4Plus

D3/D4/D4Plus

Air

Stage


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





–40°Cto+70°C –40°Cto+85°C

–40°Cto+50°C –40°Cto+125°C

max.+40°C


approx.4.5kg

possible



Please note!


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Heatertype

Heater

Version

Heatingmedium


Heatflow(watt) D4S

D4Camper/D4CamperPlus

Heaterairflowratewithoutcounterpressure(kg/h) D4S


Fuelconsumption(l/h)) D4S


Elektr.powerconsumption(watt) D4S

inoperation(12and24v) D4Camper/D4CamperPlus

atstart(12and24v)

Ratedvoltage





Fuel


Heater

Dosingpump



Weight

Ventilationmode

Airtronic M

AirtronicD4S/Airtronic D4Camper/AirtronicD4CamperPlus

D4S/D4Camper/D4CamperPlus

Air

Stage


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





–40°Cto+70°C –40°Cto+85°C

–40°Cto+50°C –40°Cto+125°C

max.+40°C


approx.4.5kg

possible



Please note!


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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.


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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


• Pressthembuttonofthemini-timer• Selectoperatingmode(seemini-timeroperatinginstruc-

tions)• PerformdiagnosisusingthediagnosticsunitortheEDiTH

diagnosticstool.• Switchoffthemini-timerafterfinishingthediagnosis• Removetheadaptercable

Mini-controller in combination with TP5


• 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

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<<icononthedesktop.• Selecttheairpressuresensorinthe»HeaterandTestSe-

lection«. Thefollowingactionsarepossible:

– Readoutthecurrentfaultandthefaultmemory.– Deletethefaultmemory.– Querythecurrentmeasuredairpressure.– Querytheoperatingstate.– Querythegeneraldata.– Printoutthefaultmemoryand/orthegeneraldata

• Exitthediagnosiswiththe»Stop«buttonorbyclosingallwindows.– Selection:Saveanalysis/Donotsaveanalysis

• RemoveISOadapterandadaptercablefromtheleadhar-nessandreconnecttheairpressuresensor/heater,controlunitconnector.

1 Airpressuresensor2 Adaptercable3 Cableloomfromheater4 Cableloomtocontrolunit

5 ISOadapter6 SUB-Dconnectioncable7 USBtoSerialRS-232adapter


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.


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.


• Inheaterswithconnectedairpressuresensorthemodulartimercannotbeusedtoperformdiagnoses.Thediagnos-ticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.



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.


• InheaterswithconnectedairpressuresensortheTP5radioremotecontrolcannotbeusedtoperformdiagnoses.ThediagnosticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.



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.


• Theheaterdiagnosiscanalsobeperformediftheairpres-suresensorisconnected.



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—>


• Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsensordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,fordiagramandtableofvaluesforflamesensorandoverheatingsensorpleaserefertoPage32.

014 Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge

Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge• Checkhotairpipesforblockage—>removeblockage.• Sumofthecomponentratingsofair-conductingpartsistoolarge—>


• Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsen-sordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,iffuelquantityok—>replacecontrolbox.Fordiagramandtableofvaluesforflamesensorandoverheatingsen-sor,seePage32.


24



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



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,


057 Flamecutoutfromstartphase(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)

Aflamecutoutwasdetectedduringthestartphase..• Checkexhaustandcombustionairsystem.• Checkfuelsupply/measurefuelquantity,seePage36.• Checkglowplug(seefaultcode020and021).• Checkflamesensor,diagramandvaluestable,seepage32,


060 Externaltemperaturesensor–interruption

• DisconnecttheconnectorS4/B4oftheexternaltemperaturesensorandmeasuretheresistancevalueatconnectorB2,fordiagramandtableofva-luesseePage12,iftemperaturesensorok,reassembleconnectorS4/B4.

• DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalueinconnectorhousingB1betweenPIN6andPIN12.Ifinterruptedtheohmicvalueis>7175/3k*.Ifresistancevalueok—>replacecontrolbox.



26



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.



27



094 Controlboxdefective(EEPROM-Fehler)

• Replacecontrolbox.


096 Internaltemperaturesensordefective • Replacecontrolboxoruseanexternalroomtemperaturesensor..

097 Controlboxdefective • SReplacecontrolbox.


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


0 Nofaults —

11 Communicationloss Interruptionofthediagnosticscablebetweenthecontrolbox(heater)andtheairpressuresensor• Checkwiringandplug-inconnections

12 Noaltitudeadjustment Controlbox(heater)doesnotsupportaltitudeoperationwiththeairpressuresensor• Useacontrolbox(heater)whichsupportsaltitudeadjustment

13 Airpressuresensorfault Theairpressuresensorisdefective• Replacetheairpressuresensor



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

Please note!

Withtheglowplugdismantled,visuallycheckthesocketliningoftheinstalledglowplugfordirt.Iftheliningishighlysoiledanditssurfaceclosed,renewthelining.

Figure3

Glowplug Connectorfromglowplugcableloom Rubbergrommet

Removing the lining (see Figure 4)

Uselongnoseplierstopulltheliningoutofthesocketfromabove.Blowoutthesocketwithcompressedairandifnecessarycleanthesideventhole.

Usethespecialtooltoinstallthenewlining.Thespecialtoolisincludedwiththelining.Pushtheliningonthetool.Pushinthetooltogetherwiththelininguptothelimitstop.

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


inletside.


Please note!


42

Circuit diagram, control units – part 1

252069009701CPartslistPage41

Circuitdiagram6


43

Circuitdiagram6

252069009701CPartslistPage41



44



Circuitdiagram6


45



Circuitdiagram6


46



Circuitdiagram6


47



Circuitdiagram6


48


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-




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


EasyStart R+ control unit circuit diagram(Controlboxwithonediagnosticscable)


52

Circuitdiagram6EasyStart R+ control unit circuit diagram(Controlboxwithtwodiagnosticscables)



53

Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithoneortwodiagnosticscables)



54

Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithtwodiagnosticscables)



55

Circuitdiagram6EasyStart R control unit circuit diagram(Controlboxwithonediagnosticscable)



56

Circuitdiagram6EasyStart T control unit circuit diagram(Controlboxwithonediagnosticscable)

PartslistPage49 252069009708


57

Circuitdiagram6EasyStart T control unit circuit diagram(Controlboxwithtwodiagnosticscables)

PartslistPage49 252361009703


58

Circuitdiagram6Parts list circuit diagrams Airtronic / Airtronic M – ADR

1.1 Burnerengine1.2 Glowplug1.5 Overheatingandflamesensor2.1 Controlbox2.2 Meteringpump2.7 Mainfuse 12volt=20A 24volt=10A2.7.1Fuse,actuation5A5.1 Battery5.2.1Operatingswitchbatteryd) (operationcontrollede.g.viaignitionlock) EmergencyofffunctionforADR–Item5.2.2–5.55.2.2Isolatingswitchbatteryd)5.3 AuxiliarydriveHA+5.3.1Switch,auxiliarydrive5.5 GeneratorD+

a) Connectionofcontrolunitandexternalsensor correspondingto“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 Temperaturesetpointvalue •brws Groundconnectionforexternal

temperaturesensorandtemperature setpoint

b) Option •Vehiclefancontrol and/or •separatefreshairfan c) WiringforoperationwithADR(hazardousgoodstrans-

portinutilityvehiclesegment,e.g.tanker)

d) Ifonlyoneswitchingelementisusedforitems5.2.1and5.2.2,itisimportanttoensurethatonactivatingthe“openthebatteryisolatingswitch”function(EMERGEN-CYOFFfunctioninADR,etc.),theswitchalwaysbreakscontactimmediately(regardlessoftheheatercondition)andalltheheater’scircuitsaredisconnectedfromthebattery.

• Note heater type! • Thejumperlabelledwithy)inthecircuitdiagrammust

alwaysbeconnected.• Insulateunusedcableends.• Connectorsandbushhousingsareshownfromthecable

inletside.

Assignment of the circuit diagrams for Airtronic heatersThecircuitdiagramsareassignedviatheinstalledcontrolbox:• Controlboxwithonediagnosticscable: Atthe16pinconnectorthediagnosticscablebl/wsiscon-




Please note!


59

Circuit diagram – Airtronic / Airtronic M – ADR

252069009601BPartslistPage58

Circuitdiagram6

Thiscircuitdiagramisforheaterswithonediagnosticscableandwhosecontrolboxcableloomisfirmlyencapsulated.

Bitte beachten!


60

Circuit diagram – Airtronic / Airtronic M – ADR

Circuitdiagram6

PartslistPage58 252069009601C

Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.

Bitte beachten!


61

Circuitdiagram6Parts list circuit diagrams control unit EasyStart T – ADR

3.1.7 “OFF”button3.1.17 “Minicontroller”controlunit

3.2.15 TimerEasyStartT

a) Connectionofcontrolunitsattheheaterg) Connection“ON/OFF”key (optionale.g.OrderNo.:221000328400)x) ADRjumpery) Connectandinsulatecables

• Thejumperlabelledwithy)inthecircuitdiagrammustalwaysbeconnected.


inletside.

Assignment of the circuit diagrams for Airtronic heatersThecircuitdiagramsareassignedviatheinstalledcontrolbox:• Controlboxwith2diagnosticscablesandJEdiagnosis: Atthe16pinconnectorthediagnosticscablebl/wsis


• Controlboxwithonediagnosticscable: Atthe16pinconnectorthediagnosticscablebl/wsiscon-

nectedtochamber8.

Parts list circuit diagram control units – ADR

2.15.1 Temperaturesensor,external(roomtemperature)

3.1.11 Controlunit,round3.1.17 MinicontrollerAirtronic

3.2.8 Moduletimer(ADR–potentiometer)

3.9.1 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 Groundconnectionforexternal

temperaturesensorandtemperature setpoint

b) Terminal15 c) Lighting,terminal58d) Connection,diagnosticunit e) Connection,externaltemperaturesensor


inletside.


Please note!

Please note!



62

252069009901B

Circuit diagram, control units – ADR

PartslistPage61

Circuitdiagram6


63

Circuitdiagram6Circuit diagram, control unit EasyStart T – ADR(Controlboxwithonediagnosticscable)

252069009709PartslistPage61


64

Circuitdiagram6Circuit diagram, control unit EasyStart T – ADR(Controlboxwithtwodiagnosticscables)

252361009704PartslistPage61


65

Certification

ThehighqualityofEberspächer’sproductsisthekeytooursuccess.Toguaranteethisquality,wehaveorganisedallworkpro-cessesinthecompanyalongthelinesofqualitymanagement(QM).Evenso,westillpursuealargenumberofactivitiesforcon-tinuousimprovementofproductqualityinordertokeeppacewiththesimilarlyconstantlygrowingrequirementsmadebyourcustomers.Allthestepsnecessaryforqualityassurancearestipulatedininternationalstandards.Thisqualityistobeconsideredinatotalsense.Itaffectsproducts,proceduresandcustomer/supplierrela-tions.Officiallyapprovedpublicexpertsassessthesystemandthecorrespondingcertificationcompanyawardsacertificate.

Eberspächerhasalreadyqualifiedforthefollowingstandards:

Quality management in accordance with DIN EN ISO 9001:2000 and ISO/TS 16949:1999

Environmental management system in accordance withDIN EN ISO 14001:1996

Disposal

Disposal of materialsOlddevices,defectcomponentsandpackagingmaterialcanallbeseparatedandsortedintopure-gradefactionssothatallpartscanbedisposedofasrequiredinanenvironment-friendlymannerrecycledwhereapplicable.Electricmotors,controlboxesandsensors(e.g.temperaturesensors)aredeemedtobe“electronicscrap”.

Dismantling the heaterTheheaterisdismantledaccordingtotherepairstagesinthecurrenttroubleshooting/repairinstructions.

PackagingThepackagingoftheheatercanbekeptincaseithastobesentback.

EC Declaration of Conformity

Withregardtothefollowingproducts

Heater type Airtronic / Airtronic M

weherewithconfirmthatitconformswiththeprimesafetyrequirementsstipulatedinthedirectivesoftheEUCouncilforharmonisationofthelegalregulationsofthememberstateswithregardtoelectromagneticcompatibility(89/336/EEC).ThisdeclarationappliestoallheatersproducedaccordingtotheproductiondrawingsAirtronic/AirtronicM–whichareanintegralpartofthisdeclaration.Thefollowingstandards/directiveshavebeenusedtoassesstheproductwithregardtoelectromagneticcompatibility:• EN50081–1Basicforminterferenceemission• EN50082–1Basicformofinterferenceimmunity• 72/245/EEC–Modificationstatus2006/28/EC. Interferencesuppressioninmotorvehicles.

Service7


66

Service7List of key words / A – Z index

AAccidentprevention...............................................................4ADR..........................................................................7,59,69Alwaysobservethefollowingsafetyinstructionsbeforework-ingontheheater.................................................................28AMPreleasetool.................................................................28Assemblydrawing...............................................................29Assignmentofthecircuitdiagrams......................................49

Bbasicadapter......................................................................19

CCancelthecontrolboxlock...........................................16,20cancelthecontrolboxlock..................................................17Certification.........................................................................65Checkcombinationsensor..................................................32Checkfuelsupply................................................................36Checkvalues.......................................................................12Circuitdiagram....................................................................37Circuitdiagram,controlunits...............................................42Controlandsafetydevices.....................................................7Controlintheheatingmode...................................................6Cutawayview........................................................................5

DDescriptionoffunctions.........................................................6Diagnosticunit.....................................................................15Disposal..............................................................................65

EEasyStartR+radioremotecontrol.......................................22EasyStartTtimer.................................................................22ECDeclarationofConformity...............................................65ECtype-approval.................................................................69EDiTHdiagnostictool....................................................17,19EMCdirective......................................................................69EMERGENCYOFF................................................................7Emergencyshutdown............................................................7

FFAME..................................................................................69Faultcode...........................................................................23Faultdescription..................................................................23Forcedshut-down.................................................................7Foreword...............................................................................4

IImportantinformation............................................................4ISOadapter.........................................................................17

LListofabbreviations.............................................................69

MMeasuringthefuelquantity..................................................36Moduletimer.......................................................................20

OOverviewofthepartslistsandcircuitdiagrams....................37

PPartslistcircuitdiagramcontrolunits...................................49Partslistcircuitdiagramcontrolunits–ADR........................61Partslistcircuitdiagrams...............................................38,58Partslistcircuitdiagrams,controlunits................................41

RRepairinstructions.........................................................28,30Representativesabroad.................................................66,67

SService................................................................................65Specialtool..........................................................................28StartingAirtronic...................................................................6StartingAirtronicM................................................................6Switchingoff..........................................................................6Switchingon..........................................................................6

TTableofflamesensorvalues................................................32Tableofoverheatingsensorvalues......................................32Tableofvalues–fuelquantity..............................................36Technichaldata.....................................................8,9,10,11Temperatureselection............................................................6Testingdeviceforthecontroldevice....................................15TP5radioremotecontrol.....................................................21Troubleshooting...................................................................13

VVentilatingmode....................................................................6

WWhattocheckfirst..............................................................13

Keyword Page Keyword Page


67

Service7List of abbreviations

ADREuropeanagreementabouttheinternationaltransportofdan-gerousgoodsontheroad.

EC type-approvalPermitawardedbytheFederalVehicleOfficefortheproduc-tionofaheaterforinstallationinmotorisedvehicles.

EMC directiveElectromagneticcompatibility.

JE-PartnersJ.Eberspächerpartner.

FAME (biodiesel)FAMEfordieselenginesaccordingtoDINEN14214.


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J.EberspächerGmbH&Co.KG Eberspächerstraße24 D-73730Esslingen Telephone0711939-00 Facsimile0711939-0643


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AIRTRONIC / AIRTRONIC M...V = Combustion air Function2 and use 6 Description of functions Switching...

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