Heater Ordernumber
AirtronicB5,12volt 201859050000
Heater Ordernumber
AirtronicD5,12volt 252361050000AirtronicD5,24volt 252362050000
AIRTRONIC L Technical description, installation,
operation and maintenance instructions.
Air heater for diesel and petrol operating independently of the engine.
25236190976703.2014
Contents
Chapter Title Contents Page
2
Introduction
8
7
6
5
4
3
2
1
1
Introduction
Productinformation
Installation
Operationandfunc-tion
Electricalsystem
FaultsMaintenanceService
Environment
Lists
•Contents...................................................................................................... 2•Conceptofthismanual................................................................................ 3•Specialtextstructure,presentationandpicturesymbols.............................. 4•Importantinformationbeforestartingwork................................................... 4•Statutoryregulations................................................................................ 5,6•Safetyinstructionsforinstallationandoperation.......................................... 7•Accidentprevention..................................................................................... 7
•Scopeofsupply....................................................................................... 8,9•Technicaldata............................................................................................ 10•Maindimensions........................................................................................ 11
•Installationandmountingposition.............................................................. 12•Installingthe24voltheaterinavehicleforthetransportof
dangerousgoodsaccordingtoADR.......................................................... 12•Installationlocation.................................................................................... 13•Possiblemountingpositions...................................................................... 14•Installationandfixing.................................................................................. 15•Nameplate................................................................................................. 16•Hotairsystem.......................................................................................... 17•Exhaustsystem......................................................................................... 18•Combustionairsystem.............................................................................. 19•Fuelsupply........................................................................................ 20–24
•Operationinstructions/importantinformationforoperation....................... 25•Initialcommissioning.................................................................................. 25•Descriptionoffunctions............................................................................. 26•Controlandsafetydevices/EMERGENCYOFF........................................ 27
•Heaterwiring............................................................................................. 28•Partslistforthecircuitdiagrams/circuitdiagrams............................ 28–41
•Ifanyfaultsoccur,pleasecheckthefollowingitems.................................. 45•Troubleshooting........................................................................................ 45•Maintenanceinstructions........................................................................... 45•Service...................................................................................................... 45
•Certification.............................................................................................. 46•Disposal.................................................................................................... 46•EUDeclarationofConformity..................................................................... 46
•Listofkeywords................................................................................ 47,48•Listofabbreviations................................................................................... 48
3
Introduction1
Conceptofthismanual
Thismanualaimstosupporttheservicecompanyinstallingtheheaterandtoprovidetheuserwithallimportantinformationabouttheheater.Themanualhasbeendividedinto8chapterstomakeiteasiertofindthecorrespondinginformationquickly.
1
2
3
4
5
6
7
8
IntroductionThissectioncontainsimportantintroductoryinformationaboutinstallingtheheaterandaboutthestructureofthemanual.
ProductinformationHereyouwillfindinformationaboutthescopeofsupply,thetechnicaldataandthedimensionsoftheheater.
InstallationHereyouwillfindimportantinformationandinstructionsreferringtoinstallationoftheheater.
OperationandfunctionHereyouwillfindinformationabouttheoperationandfunctionoftheheater.
ElectricalsystemHereyouwillfindinformationabouttheelectronicsystemandelectroniccomponentsoftheheater.
Troubleshooting/maintenance/serviceHereyouwillfindinformationaboutpossiblefaults,troubleshooting,servicing/maintenanceandtheservicehotline.
EnvironmentHereyouwillfindinformationaboutcertificationanddisposaloftheheatertogetherwiththeEUDeclarationofConformity.
ListsHereyouwillfindthekeywordlistandabbrevia-tionslist.
4
Introduction1
Specialtextstructure,presentationandpicturesymbols
Thismanualusesspecialtextstructuresandpicturesymbolstoemphasisedifferentcontents.Pleaserefertotheexamplesbelowforthecorrespond-ingmeaningsandassociatedactions.
Specialstructureandpresentations
Adot(•)indicatesalistwhichisstartedbyaheading.Ifanindenteddash(–)followsadot,thislistissubordi-natetothedot.
Picturesymbols
Regulation!Thispicturesymbolwiththeremark“Regulation”referstoastatutoryregulation.FailuretocomplywiththisregulationresultsinexpiryofthetypepermitfortheheaterandpreclusionofanyguaranteeandliabilityclaimsonJ.EberspächerGmbH&Co.KGanditsas-sociatedcompanies.
Danger!Thispicturesymbolwiththeremark“Danger!”referstotheriskofafataldangertolifeandlimb.Undercertaincircumstances,failuretocomplywiththeseinstructionscanresultinsevereorlifethreateninginjuries.
Caution!Thispicturesymbolwiththeremark“Caution!”referstoadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.
Theseremarkscontainapplicationrecommendationsandusefultipsforinstallationoftheheater.
Pleasenote!
Importantinformationbeforestartingwork
RangeofapplicationoftheheaterTheairheateroperatingindependentlyofanengineisintendedforinstallationinthefollowingvehicles,de-pendingonitsheatingoutput:•Vehiclesofallkinds(max9seats)•Constructionmachinery•Agriculturalmachinery•Boats,shipsandyachts(onlydieselheaters)•Campervans
•Theheaters(onlydieselheaters,24volt)canbein-stalledinvehiclesusedforthetransportofdangerousgoodsasperADR.
•Thecurrentcontrolleristobereplacedbyaspecialcontrollerwhentheheateristobeusedtoheatthefreightcompartment/cargo(orderno.seeproductoverview).
Purposeoftheheater•Pre-heating,de-mistingwindows•Heatingandkeepingthefollowingwarm: –Driverandworkingcabs,Ship’scabins –Freightcompartments –Passengerandcrewcompartments –Campervans
Onaccountofitsfunctionalpurpose,theheaterisnotpermittedforthefollowingapplications:•Longtermcontinuousoperation,e.g.forpreheating
andheatingof: –Residentialrooms –Garages –Workhuts,weekendhomesandhuntinghuts –Houseboats,etc.•Heatingordrying: –Livingcreatures(peopleoranimals)byblowinghot airdirectlyatthesubject –Objects –Blowinghotairintocontainers
Caution!Safetyinstructionsforapplicationandproperpurpose•Theheatermustonlybeusedandoperatedforthe rangeofapplicationstatedbythemanufacturerin compliancewiththe“Operatinginstructions” includedwitheveryheater.
Pleasenote!
5
Introduction1
Statutoryregulations
TheFederalMotorTransportAuthorityhasissuedan“ECtypeapproval”,“EMCtype-approval”andtheapprovalforacomponentaccordingtoECER122andECE-R10fortheheaterforinstallationinmotorvehicleswiththefollowingofficialtype-approvalmarks,notedontheheaternameplate.
Type-approvalmarks
EG 000105
EMV 033971
ECE 122R-00010510R-033971
Regulations!ExtractfromDirective2001/56/ECAnnexVIIandECERegulationNo.122oftheEuropeanParlia-mentandoftheCouncil
Generalregulations
•Operatingstatedisplay–Aclearlyvisibleoperatingdisplayintheuser’sfieldof
visionmustindicatewhentheheaterisswitchedonandoff.
Regulationsconcerninginstallationinthevehicle•Scope
–Subjecttodifferingstipulationsinthefollowingsection,combustionheatersmustbeinstalledac-cordingtotheprovisionsofAnnexVII.
–ItisassumedthatClassOvehicleswithheatersforliquidfuelconformtotheprovisionsofthedirective.
•Arrangementoftheheater–Partsofthestructureandothercomponentsnear
theheatermustbeprotectedfromexcessiveheatexposureandpossiblefueloroilcontamination.
–Theheatermustnotposeafirehazardevenwhenitoverheats.Thisrequirementisdeemedtobefulfilledifadequateclearanceisensuredforallpartsduringinstallation,sufficientventilationisprovidedandfireproofmaterialsorheatshieldsareused.
–Theheatermustnotbemountedinthepassen-gercompartmentofvehiclesinclassM2andM3.However,aheaterinahermeticallysealedenclosurewhichalsocomplieswiththeaforementionedcondi-tionsmaybeused.
–Thefactorynameplateorduplicatemustbeaffixedsothatitcanstillbeeasilyreadwhentheheaterisinstalledinthevehicle.
–Allappropriateprecautionsmustbetakenwhenarrangingtheheatertominimisetheriskofinjuriestopersonsordamagetootherproperty.
•Fuelsupply–Thefuelintakeconnectionmustnotbelocatedin
thepassengercompartmentandmustbesealedwithaproperlyclosinglidtopreventanyfuelleaks.
–Inheatersforliquidfuelwheretheheaterfuelisseparatefromthevehiclefuel,thetypeoffuelandintakeconnectionmustbeclearlyidentified.
–Awarningsignistobefixedtotheintakeconnec-tionindicatingthattheheatermustbeswitchedoffbeforerefuelling.
•Exhaustsystem–Theexhaustoutletmustbearrangedsoasto
preventanypenetrationofexhaustfumesintothevehicleinteriorthroughtheventilationsystem,warmairintakesoropenwindows.
•Combustionairintake–Theairfortheheater’scombustionchambermust
notbesuckedinfromthevehicle’spassengercom-partment.
–Theairintakemustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyotherobjects.
•Hotairintake–Theheater’sairsupplymustconsistoffreshairor
circulatedairandmustbesuckedinfromacleanarea,whichcannotbecontaminatedbyexhaustfumesfromtheengine,thecombustionheateroranyothersourceinthevehicle.
–Theintakepipemustbeprotectedbyagridorothersuitablemeans.
•Hotairoutlet–Thehotairpipeswithinthevehiclemustbear-
rangedorprotectedinsuchawaythatthereisnoriskofinjuryordamageiftheyaretouched.
–Theairoutletmustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyanyobjects.
•Automaticcontroloftheheatingsystem–Iftheenginefails,theheatingsystemmustbeauto-
maticallyswitchedoffandthefuelsupplystoppedwithin5seconds.Theheatermayremaininopera-tionifamanualdevicehasalreadybeenactivated.
6
RegulationsAdditionalregulationsforcertainvehiclesnamedinDirective94/55/ECoftheADRAgreement
ScopeThisappendixappliestovehiclesforwhichthespecialprovisionsofDirective94/55/ECapplytocombustionheatersandtheirinstallation.
DefinitionoftermsusedThevehicledesignations“EX/II”,“EX/III”,“AT”,“FL”and“OX”accordingtoChapter9.1oftheADRAgree-mentDirective94/55/ECareusedforthepurposesofthisannex.
Technicalregulations
Generalprovisions(EX/II,EX/III,AT,FLandOXvehicles)
AvoidheatingandignitionThecombustionheatersandtheirexhaustgasroutingshallbedesigned,located,protectedorcoveredsoastopreventanyunacceptableriskofheatingorignitionoftheload.Thisrequirementshallbeconsideredasfulfilledifthefueltankandtheexhaustsystemoftheapplianceconformtoprovisionsin3.1.1.1and3.1.1.2.Compliancewiththeseregulationsshallbecheckedinthecompletevehicle.
FueltanksFueltanksforsupplyingtheheatershallconformtothefollowingregulations:•Intheeventofanyleakage,thefuelshalldraintothe
groundwithoutcomingintocontactwithhotpartsofthevehicleortheload;
•fueltankscontainingpetrolshallbeequippedwithaneffectiveflametrapatthefilleropeningorwithaclosureenablingtheopeningtobekepthermeticallysealed.
ExhaustsystemandexhaustpipelayoutTheexhaustsystemaswellastheexhaustpipesshalllaidoutorprotectedtoavoidanydangertotheloadthroughheatingorignition.Partsoftheexhaustsystemsituateddirectlybelowthefueltank(diesel)shallhaveaclearanceofatleast100mmorbeprotectedbyathermalshield.
SwitchingonthecombustionheaterThecombustionheatermayonlybeswitchedonmanu-ally.Automaticswitchingonviaaprogrammableswitchisnotpermitted.
EX/IIandEX/IIIvehiclesCombustionheatersforgaseousfuelsarenotpermit-ted.
FLvehiclesCombustionheatersmustbeabletobetakenoutofservice/disabledatleastbythemethodsdescribedinthefollowing:a) Switchingoffmanuallyinthedriver‘scabinb) Switchingoffthevehicle‘sengine;inthiscasethe
heatermaybemanuallyswitchedbackonbythevehicledriver;
c) Startingupofafeedpumpinstalledinthevehicleforthedangerousgoodscarried.
CombustionheaterafterrunAfterrunningoftheswitchedoffcombustionheaterispermitted.Inthecasesnamedinthe„FLvehicles“para-graphunderlettersb)andc)thesupplyofcombustionairmustbeinterruptedbysuitablemeansafteramaxi-mumafterrunperiodof40seconds.Onlycombustionheaterswhoseheatexchangersareverifiablynotdam-agedbythereducedafterrunperiodof40secondsbeyondtheirusualuseperiodmaybeused.
•Compliancewiththestatutoryregulations,the additionalregulationsandsafetyinstructionsis prerequisiteforguaranteeandliabilityclaims. Failuretocomplywiththestatutoryregulationsand safetyinstructionsandincorrectrepairsevenwhen usingoriginalsparepartsmaketheguaranteenull andvoidandprecludeanyliabilityfor J.EberspächerGmbH&Co.KG.•Subsequent installation of this heater must comply withtheseinstallationinstructions.•Thestatutoryregulationsarebindingandmustalso beobservedincountrieswhichdonothaveany specialregulations.•Whentheheateristobeinstalledinvehiclesnot subjecttotheGermanOrdinancefortheRegis- trationofMotorVehicles(StVZO),forexample ships,thespeciallyvalidregulationsand installationinstructionsforthesespecial applicationsmustbeobserved.•Installationoftheheaterinspecialvehiclesmust complywiththeregulationsapplyingtosuch vehicles.•Otherinstallationrequirementsarecontainedinthe correspondingsectionsofthismanual.
Introduction1
Pleasenote!
7
Safetyinstructionsforinstallationandoperation
Danger!Riskofinjury,fireandpoisoning!•Theheatermustonlybestartedupiftheintakeand
outflowhoodshavebeenfitted.
•Disconnectthevehiclebatterybeforecommencinganykindofwork.
•Beforeworkingontheheater,switchtheheateroffandletallhotpartscooldown.
•Theheatermustnotbeoperatedinclosedrooms,e.g.inthegarageorinamultistorycarpark.
•Adjustablehotairoutletsmustalwaysbeadjustedsothattheycannotblowhotairdirectlyatlivingcreatures(people,animals)orobjectsensitivetotemperature(looseand/orfastened).
Caution!Safetyinstructionsforinstallationandoperation!•Theyearofinitialcommissioningmustbemarkedon
thenameplate.
•Theheatexchangerofairheatersisacomponentsubjecttohighthermalloads,whichmustbereplaced10yearsaftertheinitialcommissioningoftheheater.
Inaddition,theinstallationdatemustbeenteredontheplate“originalsparepart“enclosedwiththeheatexchanger.Thenaffixtheplatenexttothenameplateontheheater.
•TheheatermustonlybeinstalledbyaJEpartner,authorisedbythemanufacturer,accordingtotheinstructionsinthisdocumentationandanyspecialinstallationrecommendations.Thesameappliestoanynecessaryrepairsorincaseofguaranteeclaims.
•OnlythecontrolelementsapprovedbyJ.EberspächerGmbH&Co.KGmustbeusedtooperatetheheater.
Useofothercontrolelementscancausemalfunctions.
•Repairsbynonauthorisedthirdpartiesorwithnotoriginalsparepartsaredangerousandthereforenotallowed.Theyresultinexpiryofthetypepermitoftheheater;consequently,wheninstalledinmotorvehiclestheycancauseexpiryofthevehicleoperatinglicence.
•Thefollowingmeasuresarenotallowed:–Changestocomponentsrelevanttotheheater.–Useofthirdpartycomponentsnotapprovedby
Eberspächer.
Introduction1
–Departuresfromthestatutoryregulations,safetyinstructionsand/orfunctionalspecificationsgiveninthesedocumentswithregardtoinstallationoroperation.Thisappliesinparticulartotheelectri-calwiring,fuelsupply,combustionairsystemandexhaustsystem.
•Onlyoriginalaccessoriesandsparepartsmaybeusedforinstallationorrepairs.
•Whencarryingoutelectricweldingonthevehicle,thepluspolecableatthebatteryshouldbedisconnectedandplacedatgroundtoprotectthecontroller.
•Donotoperatetheheateranywherewheretherearereadilyflammablematerials(e.g.drygrass,leaves,paper,etc.)intheareaoftheexhaustsystemorwhereignitablefumesanddustcanform,e.g.neara–fueldepot–coaldepot–wooddepot–graindepots,etc.
•Theheatermustbeswitchedoffwhenrefuelling.
•Iftheheaterisfittedinasafetycasing,etc.,theheater’sinstallationboxmustnotbeusedasstoragespaceandmustbekeptclear.
Inparticular,fuelcanisters,oilcans,spraycans,gascartridges,fireextinguishers,cleaningrags,itemsofclothing,paper,etc.mustnotbestoredortransportedonornexttotheheater.
•Defectivefusesmustonlybereplacedbyfuseswiththeprescribedfusevalue.
•Iffuelescapesfromtheheater’sfuelsystem(leak),arrangeforimmediaterepairofthedamagebyaJEservicepartner.
•Theafterrunningoftheheatermustnotbeprema-turelyinterruptede.g.bypressingthebatterydiscon-nectorswitch,exceptforanemergencystop.
Followinginstallation,attachthe„Switchoffheaterbeforerefuelling!“stickernearthetankfillerneck.
Accidentprevention
Generalaccidentpreventionregulationsandthecor-respondingworkshopandoperatingsafetyinstructionsaretobeobserved.
Pleasenote!
8
Product information2
ScopeofsupplyforAirtronicL–B5
Quantity/Designation Orderno.
1 AirtronicL–B5,12V 201859050000
Tobeorderedseparately:1 Universalinstallationkit 2523618000001 Controlelement* –
ScopeofsupplyforAirtronicL–D5
Quantity/Designation Orderno.
1 AirtronicL–D5,12V 2523610500001 AirtronicL–D5,24V 252362050000
Tobeorderedseparately:1 Universalinstallationkit 2523618000001 Controlelement* –
*Controlelementsseepricelistorproductoverview.
Partslistforthepicture“Scopeofsupply“onpage9
Scopeofsupplyforheater
No.infigureDesignation
1 Heater2 Dosingpump
Scopeofsupplyforuniversalinstallationkit
No.infigureDesignation
3 Grid,Ø90mm4 Outflow5 Hoseclip,Ø90mm–110mm(2x)6 Flexiblepipe,Ø90mm7 Support(3x)8 Pipeclip,Ø50mm9 Intakesilencer10 Flexibleexhaustpipe,Ø24mm11 Cabletape200(2x10pcs)12 Fuelpipe,4x1.25,7.5mlong13 Fuseswitch14 Pluscable,12rt15 Pluscable,42rt16 Wiringharness17 Bracketdosingpump18 Fuelpipe,6x2,1.5mlong19 Hoseconnector8/6/820 Hoseconnector10/6/10
Pleasenote!
•Partswithoutafigureno.aresmallpartsandpackedinabag.
•Ifotherpartsarerequiredfortheinstallation,seeproductoverview.
9
Product information2
Scopeofsupply
10
Product information2
Technicaldata
Caution!Safetyinstructionsfortechnicaldata!Failuretocomplywiththetechnicaldatacanresultinmalfunctions.
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt)
Heaterairflowratewithoutcounterpressure(kg/h)
Heatercode
Fuelconsumption(l/h)
Elec.powerconsumption(watt)
inoperation
whilestarting
Ratedvoltage(volt)
Operatingrange
Lowervoltagelimit: Anundervoltageprotectorinstalledinthe
controlboxswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit: Anovervoltageprotectorinstalledinthe controlboxswitchesofftheheaterwhenthe
voltagelimitisreached.
Fuel
“Fuelquality“and“fuelatlowtemperatures“seeoperatinginstructionspage24.
Permissibleambienttemperature
Operation
Storage
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
AirtronicL
AirtronicB5 AirtronicD5
B5 D5
Air Air
Stage Stage
Power High Medium Low Power High Medium Low
5500 4800 2700 2000 5500 4800 2700 1600
280 275 180 125 280 275 190 155
10 10
0.75 0.65 0.37 0.27 0.66 0.58 0.34 0.20
85 80 30 15 85 80 35 25
<250 <250
12 12/24
ca.10.5voltresp.ca.21voltUndervoltageprotectionresponsetime:20seconds
ca.16voltresp.ca.32voltOvervoltageprotectionresponsetime:20seconds
Petrol–standard Dieselfuel–standard commercialquality commercialquality (DINEN51600/DINEN228) (DINEN590)
Heater Controller Dosing Heater Controller Dosing pump pump
–40°Cto –40°Cto –40°Cto –40°Cto –40°Cto –40°Cto +50°C +75°C +20°C +70°C +75°C +50°C
–40°Cto –40°Cto –40°Cto –40°Cto –40°Cto –40°Cto +85°C +85°C +85°C +85°C +85°C +85°C
+40°C
Suppressionclass5toDIN55025
ca.9.3kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttempera-ture20°CandreferencealtitudeEsslingen.
Pleasenote!
11
Product information2
Maindimensions
1 Minimuminstallationspace(clearance)requiredforhotairintakeandfordismantlingtheintakehood.
2 Minimuminstallationspace(clearance)requiredfordismantlingtheglowplugsandcontroller.
3 Wiringharnessconnection,rightorlefthandpossible(see“Wiringharnessconnection,rightorlefthand“).
A=ExhaustB=FuelV=Combustionair
Cableharnessconnection,optionallyrightorleft
Ifnecessary,thecableharnesscanbechangedovertotheoppositesideoftheheater.Thecontrollercanberemovedaftertheintakehoodhasbeendismantled.Unclipthesemicircularcableharnesscoveronthecontrollerandrelaythecableharness.Thenfitthesemicircularcableharnesscoverbackontothecon-troller.Installthecontroller.Pushthegrommetofthecableharnessandthedummygrommetinthecorrespondingholesoftheuppersleevecasing.Refittheintakehood.
12
Installationandmountingposition
Theheaterissuitableandapprovedforinstallationinvehicleinteriorsusedbypeople.Theheater,togetherwithitsheaterflangeandthemountedflangeseal,isfixeddirectlyontothefloorofthevehicleorinasuitablepositionintherearpanelofthevehicle.
•Ifinstalledinsidethevehicle,detachableconnectionsofexhaustgas,combustionairandfuellinesarenotallowed.
•Theflangesealmustbemountedontheheater,inordertosealofftheopeningsfortheexhaustgas,combustionairandfuellines.
•Installationinthedriver’scaborpassengercompart-mentofcommercialbuseswithmorethan9seats(8seats+driver’sseat)isnotallowed.
•TheADRregulationsmustalsobecompliedwithforinstallationoftheheaterinvehiclesusedtotransportdangerousgoods.
ForinformationontheADRregulations,seepage6,27andintheinformationsheetwithPrintNo.252161951580.
•Wheninstallingtheheater,ensuresufficientopenspaceisallowedforintakeoftheheatingairandforthedismantlingofglowplugsandcontrolbox(seepage15“maindimensions”).
•Observetheregulationsandsafetyinstructionsforthischapter,givenonpages4–7.
Installation3
Pleasenote!
13
Installation3
Installationlocation
Installationlocationinadeliverytruckorvan
Inadeliverytruckorvan,theheatershouldpreferablybeinstalledinthevehicleinteriororcargoarea.Ifitisnotpossibletoinstalltheheaterinthevehiclein-teriororcargoarea,theheatercanalsobefittedunderthevehiclefloor.
Installationlocationinatrailer
Inatrailer,theheaterispreferablyinstalledinaboxintheupperpartoftheendpanelofthetrailer.Inthiscase,forrecirculationmode,selecthotairintakeinthelowerpartofthetrailerandhotairoutflowinthelowerarea.
1 Heaterinthevehicleinteriororcargoarea2 Heaterfittedunderthevehiclefloor
1 Heater2 Battery3 Flexiblepipeforhotair4 Outletforhotair5 Additionalfueltank6 Exhaustpipe7 Combustionairhose8 Fueldosingpump
•Thepositionssuggestedintheinstallationinstructionsareexamples.
Othermountingpositionsarepossible,aslongastheycorrespondtotheinstallationrequirementsstatedintheseinstructions.
•Otherinstallationinformation(e.g.forboatsandships)isavailablefromthemanufactureronrequest.
•Observethepermissiblemountingpositionsaswellastheoperatingandstoragetemperatures.
Pleasenote!
14
Installation3
Permittedmountingpositions
Theheatershouldpreferablybeinstalledinthestandardpositionasshowninthedrawing.Dependingontheinstallationconditions,theheatercanbetiltedbymax.30°(flowdirectiondownwards!)orturnedbymax.90°arounditsownlongitudinalaxis(exhaustconnectionhorizontal,glowplugpointsupwards!),asshowninthedrawing.
Inheatingmode,thestandardormaximuminstallationpositionsshowncandifferbyupto+15°inalldirec-tions,duetotiltedvehicleorboatpositions,withoutimpairingtheheater’sfunction.
Normalhorizontalposition(exhaustconnectionfac-ingdownwards)withpermissibleswivelranges
1 Hotairintakeopening(fanwheel)2 Directionofflow3 Positionoftheglowplug
15
1 1
1
1
1
1
Installation3
Installationandfixing
Makethethroughholesforexhaust,combustionairandfuelasshowninthedrillingholepattern.
Thesupportsurfacefortheheaterbasemustbeflat.TheØ10.5mmholeforthe“dosingpump“cablesisnotincludedinthedrillingholepatternandmustbedrilleddependingontheinstallation.
Ifthesheetmetalofthesupportsurfaceisthinnerthan1.5mm,anadditionalreinforcingplatewillhavetobefitted.
Orderno:reinforcingplate251729890003
Drillingholepattern
Fixingtheheatertothevehiclefloor Fixingtheheaterhorizontallytothevehiclewall(panel)
1 Theremustbesufficientclearancebetweentheheaterandthevehiclefloor–inaddition,checkthatthefanwheelrunsfreely.
2 Themountingsurfacemustbeflatandsmooth.3 Theflangesealmustbefitted.
4 Thevehiclewallmustbeflatandsmooth.5 Springwasher6 4xM8hexagonalnut(tighteningtorque11+1Nm)7 Reinforcingplate(ifneeded,Orderno.
251729890003)
1 Contourofthebearingsurface.
16
Installation3
Nameplate
Thenameplateisfixedontotheupperjacketshell.A2ndnameplate(duplicate)isavailableasanadditionalpart.
Observetheregulationsandsafetyinstructionsforthischaptergivenonpage5.
Pleasenote!
1 Originalnameplate
17
Installation3
Hotairsystem
Theuniversalinstallationkitincludesa0.5mlongflex-iblepipe,anoutlet,threesupportswithcabletapesandasafetygridforthehotairsystem.Iffurtherductingpartsarerequiredfortheinstallation,seeproductoverview.
Danger!Riskofburningandinjuries!•Thehotairsystemhosesandthehotairoutletareto
belaidandfastenedinsuchawaythattheydonotposearisktopeople,animalsormaterialssensitivetotemperatureduetoradiation/contactordirectblow-ing.
Ifnecessary,acoveristobefittedoverthehotairductingand/orthehotairoutlet.
•Theoutflowhoodmustbefittedonthehotairoutflowside.
•Ifnoairhosesarefitted,asafetygridmustbefittedtothehotairintakesideandoutflowside,topreventinjuriesfromtheheaterfanorburnsfromtheheatexchanger.
•Hightemperaturesoccurinthehotairsystemwhiletheheaterisrunningandimmediatelyafterwards.
Thisiswhyitisimportanttoavoidworkinginthevicin-ityofthehotairsystemwhiletheheaterisrunning.Insuchcases,switchofftheheaterbeforehandandwaituntilallpartshavecompletelycooleddown.
Ifnecessary,wearsafetygloves.
•Complywiththeregulationsandsafetyinstructionsforthischaptergivenonpage4–7.
•Whenconnectingpartswhichconductair,observetheheatercodenumbergiveninthetechnicaldata(page10).
Pleasenote!
Caution!Safetyinstructions!•Thehotairintakeopeningsmustbepositionedin
suchawaythat,undernormalcircumstances,itisnotpossibleforexhaustfromthevehicleengineandheatertobesuckedintothesystem,orforthehotairtobecontaminatedwithdust,saltspray,etc.
•Forcirculatingairmode,positionthecirculatingairintakeinsuchawaythattheoutflowinghotaircannotbedirectlysuckedinagain.
•Intheeventofoverheating,itispossibleforlocallotairtemperaturesofuptomax.150°Corsurfacetem-peraturesofuptomax.90°Ctooccurimmediatelybeforethesafetylockout.
Thereforeonlytemperatureresistanthotairhosesapprovedbyusmustbeusedforthehotairsystem!
•Whencheckingthefunctions,themeandischargetemperaturemeasuredapprox.30cmfromtheoutletaftertheheaterhasbeenrunningforabout10minutesshouldnotexceed110°C(withanintaketemperatureofapprox.20°C).
•Ifthereisariskofthedriverandpassengerstouchingtheheaterduringnormalvehicleoperation,atouchguardmustbefitted.
Hotairsystem(example)
1 Connectorswithsafetygrid2 Hoseclip3 Flexiblepipe
4 Safetygrid5 Outlet
18
Installation3
Exhaustsystem
(Forexhaustsystemdiagramseepage19)
InstallingtheexhaustsystemTheuniversalinstallationkitincludesaflexibleexhaustpipe,innerØ24mm,1300mmlong.Theflexibleex-haustpipecanbeshortenedto20cmorlengthenedtomax.2m,dependingontheinstallationconditions.Inaddition,anexhaustsilencercanbeinsertedintheexhaustpipesystem.Inthiscase,fixtheexhaustsilencertothevehicleinasuitableposition.Laytheflex-ibleexhaustpipefromtheheatertotheexhaustsilencerandfastenwithapipeclip(tighteningtorque7+0.5Nm).Connectanexhaustendpipewithanendsleevetotheexhaustsilencerandfixwithapipeclip(tighteningtorque7+0.5Nm).
Caution!Safetyinstructions!Thewholeexhaustsystemgetsveryhotwhiletheheaterisrunningandimmediatelyafterwards.Thisiswhytheexhaustsystemmustbelaidaccordingtotheseinstallationinstructions
•Theexhaustoutletmustendintheopenair.•Theexhaustpipemustnotprotrudebeyondthelateral
limitsofthevehicle.•Installtheexhaustpipeslopingslightlydownwards.If
necessary,makeadrainholewithanapprox.Øof5mmatthelowestpointasacondensationoutlet.
•Importantfunctionalpartsofthevehiclemustnotbeimpaired(keepsufficientclearance).
•Installtheexhaustpipewithsufficientclearancefromheatsensitivecomponents.Payparticularattentiontofuelpipes(madeofplasticormetal),electricalcablesandbrakehoses,etc.!
•Exhaustpipesmustbesafelyfixed(recommendedclearanceof50cm)toavoiddamagefromvibrations.
•Laytheexhaustsystemsothattheoutflowingexhaustgasesarenotsuckedinascombustionair.
•Themouthoftheexhaustpipemustnotbecomecloggedwithdirtandsnow.
•Themouthoftheexhaustpipemustnotpointinthedirectionoftravel.
•Alwaysfixtheexhaustsilencertothevehicle.
Danger!Riskofinjuriesandburns!Everytypeofcombustionproduceshightemperaturesandtoxicexhaustfumes.Thisiswhytheexhaustsys-temmustalwaysbelaidaccordingtotheseinstallationinstructions.
•Donotperformanyworkontheexhaustsystemwhiletheheaterisworking.
•Beforeworkingontheexhaustsystem,switchofftheheaterfirstandwaituntilallthepartshavecompletelycooleddown,wearsafetyglovesifnecessary.
•Donotinhaleexhaustfumes.
•Complywiththeregulationsandsafetyinstructionsforthischaptergivenonpage4–7.
•Theexhaustendpipeshouldbemuchshorterthantheflexibleexhaustpipefromtheheatertotheex-haustsilencer.
•Topreventcontacterosion,theclipsusedtofixtheexhaustpipemustbemadeofstainlesssteel.TheorderNo.forthestainlesssteelfixingclipsisgivenintheproductoverview.
Pleasenote!
19
Installation3
Combustionairsystem
InstallingthecombustionairsystemTheuniversalinstallationkitincludesacombustionairsi-lencer,whichmustbefitted(tighteningtorque3+0.5Nm).Ifnecessary,thecombustionairsystemcanbelength-eneduptomax.2musingaconnectorandaflexiblecombustionairhose,internalØ25mm(pleaserefertothepeoductoverviewfortheorderno.).
Fixthecombustionairsilencertotheheaterusingapipeclipanduseahosecliptofixatasuitablepoint.
•Thecombustionairsilencermustalwaysbeinstalled.•Complywiththeregulationsandsafetyinstructionsfor
thischaptergivenonpage4–7.
Pleasenote!
Caution!Safetyinstructionsforthecombustionairsystem!•Thecombustionairopeningmustbefreeatalltimes.•Laythecombustionairintaketoensurethatexhaust
fumescannotbesuckedinascombustionair.•Donotpointthecombustionairintakeagainstthe
vehicle’sairstream.•Thecombustionairintakemustnotbecomeclogged
withdirtandsnow.•Installthecombustionairsystemslopingslightly
downwards.Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointasacondensationoutlet.
1 Combustionairsilencer2 Connectionpipe,optional3 Combustionairsilencer,optional4 Flexibleexhaustpipe,di=24mm5 Exhaustsilencer,optional6 Exhaustendpipewithendsleeve7 Hoseclip8 Combustionairpipeconnection9 Exhaustconnection
max.2m min.0.2mmax.2m
20
Installation3
Fuelsupply
Installingthedosingpump,layingthefuelpipesandinstallingthefueltankThefollowingsafetyinstructionsmustalwaysbeob-servedwheninstallingthedosingpump,layingthefuelpipesandinstallingthefueltank.Deviationsfromtheinstructionsstatedherearenotallowed.Failuretocomplycanresultinmalfunctions.
Danger!Riskoffire,explosion,poisoningandinjuries!
Cautionwhenhandlingfuel.
•Switchoffthevehicleengineandtheheaterbeforerefuellingandbeforeworkingonthefuelsupply.
•Avoidnakedflameswhenhandlingfuel.
•Donotsmoke.
•Donotinhalefuelvapours.
•Avoidanycontactwiththeskin.
Caution!Safetyinstructionsforlayingthefuelpipes!
•Onlyuseasharpknifetotrimthefuelhosesandpipes.
Interfacesmustnotbecrushedandmustbefreeofburrs.
•Thefuelpipefromthedosingpumptotheheatershouldbelaidwithacontinuousrise.
•Fuelpipesmustbesecurelyfixedtoavoidanydam-ageand/ornoiseduetovibrations(recommendedguidelinevalue:atspacingsofapprox.50cm).
•Fuelpipesmustbeprotectedagainstmechanicaldamage.
•Laythefuelpipessothatanydistortionorshakingofthevehicle,enginemovements,etc.donothaveadisadvantageouseffectontheservicelife.
•Usehoseclipstosecureallhoseconnectionsinthefuelsupply(tighteningtorque1+0.2Nm).
•Partscarryingfuelmustbeprotectedfromdisruptiveheat.
•Neverlayorfixthefuelpipesimmediatelynexttotheheater’sexhaustsystempipesoralongthevehicle’sexhaustsystem.
Ifthesystemscross,alwaysensurethereissufficientheatclearance.Ifnecessary,installheatradiationguards.
•Drippingorevaporatingfuelmustneverbeallowedtocollectonhotpartsorigniteonelectricequipment.
•Whenconnectingfuelpipeswithafuelhose,alwaysinstallthefuelpipeswithabuttjointtopreventanybubblesfromforming.
1 Correctconnection2 Pipelaidincorrectly–bubblesform
Caution!Safetyinstructionsforfuelpipesandfueltanksinbusesandcoaches!
•Inbusesandcoaches,fuelpipesandfueltanksmustnotberoutedthroughthepassengercompartmentordriver’scab.
•Fueltanksinbusesandcoachesmustbepositionedinsuchawaythattheexitsarenotinimmediatedangerifafireoccurs.
Complywiththeregulationsandsafetyinstructionsforthischaptergivenonpage4–7.
Pleasenote!
21
Installation3
Fuelsupply
FuelextractionusingaT-piecefromthefuelflowline,fromthetankfittingtothevehicleengine
1 Fuelflowlinefromthetankconnection2 Fuelreturnlinefromthetankconnection3 Dosingpump4 Tpiece5 Fuelfilter–onlyneededforcontaminatedfuel.6 Fuelhose,5x3(di=5mm)7 Fuelpipe,6x2(di=2mm)8* Fuelpipe,4x1.25(di=1.5mm)9 Fuelhose,5x3(di=5mm),ca.50mmlong10 Fuelhose,3.5x3(di=3.5mm),ca.50mmlong11 Totheengine,mechanicalfuelorinjectionpump.
* Ifnecessary,afuelpipe4x1(di=2mm)canbeusedfordieselheatersinsteadofthefuelpipe4x1.25(di=1.5mm),Item(8).
Thedetailsregardingthepipelengthsremainun-changed.
Thefuelpipe,4x1mustbeorderseparately,OrderNo.seesparepartslistorproductoverview.
Permissiblepipelengths
Intakeside Pressuresidea=max.2m b=max.4mforpetrol b=max.6mfordiesel
•InserttheTpiece(4)inthefuelflowlineupstreamofthefeedpump.
•Item(5)isnotincludedinthescopeofsupply“installationkit“.Theorderno.isgivenintheproductoverview.
Pleasenote!
InstallationpositionoftheT-piece
InstallanyTpieceinthesameinstallationpositionsshowninthediagram.
1 Directionofflow–fromthefueltank2 Directionofflow–tothevehicleengine
22
Fuelsupply
Fuelextractionforpetrolinjectionenginesanddieselengines
1 Tankconnectionformetaltank–di=2mm,da=6mm
2 Tankconnectionfortankfitting–di=2mm,da=4mm
3 Dosingpump4 Fuelfilter–onlyrequiredforcontaminatedfuel.5 Fuelhose,5x3(di=5mm)6 Fuelpipe,6x2(di=2mm)7 Fuelpipe,4x1(di=2mm)8 Fuelhose,3.5x3(di=3.5mm),ca.50mmlong9 Fuelhose,5x3(di=5mm),ca.50mmlong10*Fuelpipe,4x1.25(di=1.5mm)11 Pipeconnectors,da=4mm
* Ifnecessary,afuelpipe4x1(di=2mm)canbeusedfordieselheatersinsteadofthefuelpipe4x1.25(di=1.5mm),Item(10).
Thedetailsregardingthepipelengthsremainun-changed.
Thefuelpipe,4x1mustbeorderseparately,OrderNo.seesparepartslistorproductoverview.
Permissiblepipelengths
Intakeside Pressuresidea=max.2m b=max.4mforpetrol b=max.6mfordiesel
•Items(2),(7)and(11)areincludedinthe“tankcon-nection“kit.
•Wheninstallingtankconnectionmaintainaminimumdistanceof50±2mmfromtheendoftheriserpipeandthebottomofthetank.
Pleasenote!
Caution!Safetyinstructionsforthefuelsupply!
•Thefuelmustnotbedischargedbymeansofgravityoroverpressureinthefuelcontainer.
•Itisnotpermittedtoextractfueldownstreamofthevehicle’sownfuelpump.
•Ifthepressureinthefuelpipeismorethan0.2baruptomax.4.0bar,useapressurereducer(orderno.221000200800)oraseparatetankconnection.
Installation3
•Ifthepressureinthefuelpipeisover4.0barorifthereisanonreturnvalveinthereturnpipe(inthetank),aseparatetankconnectionmustbeused.
•IfusingaTpieceinaplasticpipe,alwaysinsertsup-portsleevesintheplasticpipe.
ConnecttheTpieceandtheplasticpipewiththerelevantfuelhosesandsecurewithhoseclips.
23
Installation3
Fuelsupply
Mountingpositionofthedosingpump
Alwaysinstallthedosingpumpwiththedeliverysiderisingupwards.Anymountingpositionover15°isallowed,althoughamountingpositionbetween15°and35°ispreferable.
1 Mountingpositionbetween0°–15°isnotallowed.2 Preferredmountingpositionwithintherange
15°–35°.3 Mountingpositionwithintherange35°–90°isal-
lowed.
Permissiblesuctionanddeliveryheadofthedos-ingpump
Deliveryheadfromvehicletanktodosingpump:a=max.3000mm
Suctionheadinpressurelessvehicletank:b=max.500mmforpetrolb=max.1000mmfordiesel
Suctionheadinavehicletankinwhichnegativepres-sureoccursduringextraction(valvewith0.03barinthetankcap):b=max.150mmforpetrolb=max.400mmfordiesel
Deliveryheadfromthedosingpumptotheheater:c=Max.2000mm
Checkthefueltankventline.
1 Connectionattheheater2 Max.fuellevel3 Min.fuellevelPleasenote!
Caution!Safetyinstructionsforinstallingthedosingpump!
•Alwaysinstallthedosingpumpwiththedeliverysiderisingupwards–minimumslope15°.
•Protectthedosingpumpandfilterfromimpermissibleheating,donotinstallneartosilencersandexhaustpipes.
24
Installation3
Fuelsupply
FuelqualityforpetrolheatersTheheaterrunsproblemfreeonstandardcommercialqualityfuelinaccordancewithDINEN51600/DINEN228,whichyouusetorunyourvehicleengine.
Fuelqualityfordieselheaters
•TheheaterrunsproblemfreeonstandardcommercialqualityfuelinaccordancewithDINEN590,whichyouusetorunyourvehicleengine.
•Fuelforspecialcases Inspecialcasestheheatercanalsoberunonheating
oil(above0°C)orkerosene/paraffinoil.
•Fuelforlowtemperatures Refineriesandpetrolstationsautomaticallyadjustfuel
tonormalwintertemperatures(winterdiesel). Therefore,difficultiescanonlyoccurifthereare
extremedropsintemperature,thesameasappliestothevehicleengine.Pleasealsorefertothevehiclemanual.
•Iftheheaterisrunfromaseparatetank,pleasecom-plywiththefollowingrules:
Attemperaturesabove0°C,anykindofdieselfueltoDINEN590canbeused.
•Ifnospecialdieselfuelisavailableforlowtempera-tures,thenparaffinoil/keroseneorpetrolshouldbemixedwiththefuelaccordingtothefollowingtable:
Temperature Winterdiesel Admixture20°Cto–25°C 100% ––– –25°Cto–40°C 150%* 50%paraffinoil/ keroseneorpetrol
*or100%specialcolddieselfuel(Arcticdiesel)
•Itisnotpermittedtoaddusedoil!
•Afterrefuellingwithwinterorcolddieselorthelistedblends,thefuelpipesandthedosingpumpmustbefilledwiththenewfuelbylettingtheheaterrunfor15minutes!
Operationwithbiodiesel(FAME)Theheaterisapprovedforoperationwithbiodiesel(FAME)toDINEN14214(theflowabilityreducesattemperaturesbelow0°C).
Pleasenote!
25
Operation and function4
Operatinginstructions
Theheaterisoperatedbyacontrolelement.Detailedoperatinginstructionsareenclosedwiththecontrolunit.
Theworkshop/garageinstallingtheheaterwillissueyouwiththeoperatinginstructions.
Importantinstructionsforoperation
SafetychecksbeforethestartAfteralengthyperiodofnonuse(summermonths)checkthatallpartsfitsecurely(tightenscrewswherenecessary).Carryoutavisualcheckofthefuelsystemforleaks.
HeatingathighaltitudesWhenusingtheheaterathighaltitudes,pleasenote:
•Heatingataltitudesupto1500m: –Unlimitedheatingpossible.
•Heatingataltitudesover1500m: –Heatingispossibleforshortperiodsatthis altitude(e.g.drivingoveramountainpassor takingabreakinajourney). –intheeventofalengthystay,e.g.winter camping,itisnecessarytoadjustthefuelsupply tothealtitude,pleasecontactaJEpartnerfor furtherinformation.
Installationofanaltitudekit(OrderNo.221000332200)enablesoperationofdieselheatersataltitudesabove1500m,evenforalengthystay.
Pleasenote!
Initialcommissioning
Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.
•Afterinstallingtheheater,thewholefuelsupplysystemmustbecarefullyvented:pleaserefertoandfollowthevehiclemanufacturer’sinstructions.
•Duringtheheatertrialrun,allfuelconnectionsmustbecheckedforleaksandsecure,tightfit.
•Iffaultsoccurwhiletheheaterisrunning,useadiag-nosticsdevicetodetermineandcorrectthecauseofthefault.
Pleasenote!
Pleasenote!
Duringtheinitialstartupoftheheater,odourscanbeproducedforashorttime.Thisisfullynormalduringthefirstfewminutesofoperationanddoesnotindicateamalfunctionintheheater.
26
Operation and function4
Descriptionoffunctions
Switchingon/startingtheheaterWhentheheaterisswitchedon,thecontrollampinthecontrolunitlightsup.Thefanstartsupinthefanstage„LOW“.Theglowplugstartswitha3seconddelay.Afterapprox.50secondsthefuelsupplystartsandthefuel/airmixtureinthecombustionchamberignites.Thefanswitchesfromfanstage„LOW“tofanstage„MEDIUM“.Theglowplugisswitchedoffafter130sec-onds,whenastableflamehasformed.Thefanswitchesfromfanstage„MEDIUM“tofanstage„HIGH“.Inordertoquicklyreachtheheater’soperatingtempera-ture,theheaterisrunatahigherheatingoutputof5.5kW(„POWER“controlstage).Iftheheater’soperatingtemperaturehasbeenreached,theheatingoutputisreducedto4.8kW(„HIGH“controlstage).Thelengthoftimeforwhichtheheaterisrunwithanincreasedheat-ingoutputdependsontheambienttemperature.
ControlintheheatingmodeDuringtheheatingmode,theroomtemperatureorthetemperatureofthesuckedinheatingairisconstantlymeasured.Ifthetemperatureishigherthanthetemperatureselect-edonthecontrolelement,theheaterstartstoregulateitsoutput.Thereare4controlstagessothattheoutflowofheatproducedbytheheatercanbeadjustedfinelytotheheatingrequirements.Fanspeedandfuelquantitycorrespondtotheparticularcontrolstage.Ifthesettemperatureisstillexceededinthesmallestcontrolstage,theheatergoestothe„OFF“stagewiththefanrunningonforapprox.4minutestocooloff.Theblowerthencontinuestorunatminimumspeedin„MEDIUM“controlstage(circulationmode)untiltherestartoruntilitisswitchedoff(freshairmodewithexternaltemperaturesensor).
TemperatureselectionwiththecontrolelementThecontrolcanbeusedtopreselectaninteriortem-perature.Theresultingtemperaturecanbewithintherangeof+10°Cto+30°Canddependsontheselectedheater,onthesizeofthespacetobeheatedandonthepre-vailingoutdoortemperature.Thesettingtobeselectedatthecontrolisanempiricalvalue.
VentilatingmodeTheEasyStartR+andEasyStartTcontrolunitsandtheMiniControllercanbeusedtoactivatethe„Ventilate“function.The„Heat/Ventilate“switchisalsorequiredforthemoduletimerandthecontrolunit,wherebyforfanoperation,the„Heat/Ventilate“switchmustbeactuatedfirstandthentheheatermustbeswitchedon.Theblowerrunsatmaximumspeedinfanmode.
SwitchingoffWhentheheaterisswitchedoff,thecontrollampgoesoffandthefuelsupplyisswitchedoff.Thefanrunsonforapprox.4minutestocooldown.Whilethefanisrunningon,theglowplugisswitchedonforapprox.30secondstoclean.Specialcase:Ifnofuelhasbeensuppliedoriftheheaterisinthe„OFF“stageuntilitisswitchedoff,theheaterisstoppedwithoutanyafterrunning.
27
Operation and function4
Controlandsafetydevices
•Iftheheaterdoesnotignitewithin90secondsafterthefuelpumpisstarted,thestartisrepeated.Iftheheaterstilldoesnotigniteafteranother90secondsofpumpingfuel,asafetylockoutoccurs,i.e.thefuelsupplyisoffandthefancontinuestorunforapprox.4minutes.Afteranimpermissiblenumberoffailedstartattempts,thecontrollerislocked.*
•Iftheflamegoesoffbyitselfduringoperation,theheaterisfirstrestarted.Iftheheaterstilldoesnotignitewithin90secondsafterthefuelpumphasbeenrestarted,orignitesandbutgoesoffagainwithin15minutes,asafetylockoutoccurs,i.e.thefuelsupplyisoffandthefancontinuestorunforapprox.4minutes.Thesafetylockoutcanbecancelledbybrieflyswitchingoffandonagain.Donotrepeattheswitchingoff/onroutinemorethantwice.
•Inthecaseofoverheating,thecombinedsensor(flamesensor/overheatingsensor)responds,thefueldeliveryisinterruptedandasafetylockoutoccurs.Oncethecauseoftheoverheatinghasbeenelimi-nated,theheatercanberestartedbyswitchingitoffandonagain.Afteranimpermissiblenumberoffailedstartattempts,thecontrollerislocked.*
•Iftheloweroruppervoltagelimitisreached,asafetylockoutoccursafter20seconds.
•Theheaterwillnotstartiftheglowplugorfanmotorisdefectiveoriftheelectricleadtothedosingpumpisinterrupted.
•Ifthecombinedsensor(flamesensor/overheatingsensor)isdefectiveortheelectricleadinterrupted,theheaterstartsupandthesafetylockoutdoesnotoccuruntilduringthestartphase.
•Thespeedofthefan’smotoriscontinuouslymonitored.Ifthefanmotordoesnotstartuporifthespeeddeviatesbymorethan10%,asafetylockoutoccursafter30secs.
•Whentheheaterisswitchedoff,theglowplugisswitchedonfor40seconds(afterglowing)whilethefancontinuestoruninordertocleanoffanycombus-tionresidues.
* Thelockcanbecancelledandthefaultsreadoff:•usingthemoduletimer/EasyStartT•usingtheradioremotecontrolTP5/EasyStartR+/
EasyStartR.Forothercontrols:•byconnectingthediagnosisunit•usingthecustomerserviceprogramKD2000/
EDiTH.Foroperationandfaultlist,pleaserefertotheenclosedoperatinginstructionsorthetroubleshootingandrepairinstructionsfortheheater.
Donotrepeattheswitchingoff/onroutinemorethantwice.
Forcedshut-downduringADRInvehiclesforthetransportofdangerousgoods(e.g.tankers),theheatermustbeswitchedoffbeforethetruckdrivesintoadangerarea(refinery,petrolstation,etc.).Failuretocomplyresultsintheheaterautomaticallyswitchingoffif:•Thevehicleengineisswitchedoff.•Anadditionalunitisstartedup(e.g.auxiliarydrivefor
unloadingpump,etc.).Thefanthencontinuestorunbriefly,formax.40seconds.
Pleasenote!
Emergencyshutdown–EMERGENCYOFFIfanemergencyshutdown–EMERGENCYOFF–isnecessaryduringoperation,proceedasfollows:•Switchtheheateroffatthecontrolor•removethefuseor•disconnecttheheaterfromthebattery.
28
Electrical system5
HeaterwiringTheelectroniccontrolboxisintegratedintheheater,whichconsiderablysimplifiesthewiringrequiredduringinstallation.
Caution!Safetyinstructions!TheheateristobeconnectedupelectricallyaccordingtotheEMCDirective.ImpropertamperingwiththeheatercanaffecttheEMC.Forthisreason,complywiththefollowinginstructions:•Ensurethattheinsulationofelectricalcablesisnot
damaged. Avoid: Chafing,kinking,jammingorexposuretoheat.•Sealanyconnectionchambersofwaterproofcon-
nectorsnotinusewithfillerplugstoensuretheyaredirtproofandwaterproof.
•Electricalconnectorsandearthconnectionsmustbefreeofcorrosionandsecurelyconnected.
•Lubricateconnectorsandgroundconnectionsoutsidetheheaterinteriorwithcontactprotectiongrease.
Complywiththefollowingwhenwiringtheheaterandthecontrolelement:•Withtheappropriateelectricalwiring,theheater
(dieselheater,24volt)fulfilstheADRregulations;pleaserefertothecircuitdiagramsattheendofthisdocument.
•Electricalleads,switchandcontrolgearmustbeposi-tionedinthevehiclesothattheycanfunctionperfectlyundernormaloperatingconditionswithoutimpairment(e.g.duetoheatexposure,moisture,etc.)
•Thefollowingcablecrosssectionsaretobeusedbetweenthebatteryandheater.Withthis,themax.allowablevoltagelossof1.5Vwith12Vand1Vwith24Vnominalvoltageisnotexceeded,includingdur-ingthestartphase(glowplugon).
Cablecrosssectionsforacablelength(pluscable+minuscable)of:–upto5m=cablecrosssection4mm2
–from5mupto8m=cablecrosssection6mm2
•Ifthepluscableistobeconnectedtothefusebox(e.g.terminal30),thevehicle’scablefromthebatterytothefuseboxmustalsobeincludedinthecalcula-tionforthetotalcablelengthandredimensionedifnecessary.
•Insulateunusedcableends.
Pleasenote!
Partslistforthecircuitdiagrams
PartslistfortheAirtronicLcircuitdiagrams1.1 Burnerengine1.2 Glowplug1.5 Overheatingandflamesensor
2.1 Controller2.2 Dosingpump2.7 Mainfuse 12volt=25A 24volt=20A2.7.1 Fuse,actuation(5A)
5.1 Battery5.2.1 Batteryoperatingswitch (Operation,e.g.controlledbytheignitionlock)d)5.2.2 Batterydisconnector (EMERGENCYOFFfunctionforADR)d)5.3 Auxiliarydrive(HA+)5.3.1 Auxiliarydriveswitch5.5 Generatorterminal(D+)
a) Connection of the control elements and ambi-ent temperature sensor according to the circuitdiagramsforthe“controlelements“.
•ge Switchonsignal(–S+) •brws Referencesignalsensor •grrt Temperature(setpoint) •blws Diagnosis •br Powersupply,minus(terminal31) •wsrt Switchoffburglaralarm(ADR – feedbackfortimer) •gr Temperature(actualvalue) •rt Powersupply,plus(terminal30)
b) Option •Freshairfan •Vehiclefancontrol
c) ADRdangerousgoodstransporterintheutilityvehiclerange(e.g.tanker)
d) Ifonlyoneswitchingelementisusedforitem5.2.1and5.2.2itmustbeensuredthatonwhenthe“openthebatterydisconnector“functionisactuated(EMERGENCYOFFfunctionforADR,etc.),theswitchalwaysbreakscontactimmediately(regardlessoftheheaterstatus)andalltheheatercircuitsaredisconnectedfromthebattery.
•Insulateunusedcableends.•Connectorsandbushhousingsareshownfromthe
cableentryside.
Pleasenote!
29
Electrical system5
Partslistforthecircuitdiagrams
Partslistforthecircuitdiagramsforthecontrolelements2.15.1 Temperaturesensor(roomtemperature)2.15.9 Temperaturesensor(outsidetemperature)
3.1.9 “Heating/ventilation“selectorswitch3.1.16 Radioremotecontrolbutton3.1.17 Airtronicminicontroller3.1.18 Calltronicbutton3.2.8 Moduletimer(ADR–potentiometer)3.2.12 Timer,mini–12/24volt3.2.14 Lighting,minitimer–12voltonly3.3.6 RadioremotecontrolstationarypartTP41i3.3.7 RadioremotecontrolstationarypartTP53.3.8 Calltronicremotecontrol3.8.3 Antenna3.9.1 Diagnosis,JEdiagnosis
a) ConnectioncontrolelementstotheAirtronic •rt Powersupply,plus–terminal30 •ge Switchonsignal–S+ •gr Temperature–actualvalue •wsrt Switchoffburglaralarm(ADR– feedbackfortimer) •br Powersupply,minus–terminal31 •blws Diagnosis •grrt Temperature–setpoint •brws Groundconnectionforexternal
temperaturesensorandtemperature setpoint
b) Terminal15–necessaryforTP4iconnectionc) Lighting,terminal58d) Connection,diagnosisdevicee) Connection,externaltemperaturesensorg) Connection,externalheatingbuttonh) Connection,radioremotecontrolTP4ij) Connection,temperaturesensor(outdoortem-
perature)l) Connection,“heating/ventilation“selectorswitch
(option). To start: Set the “heating / ventilation“selectorswitchthenswitchtheAirtronicon.
z) Lighting,terminal58
Cablecolourssw =blackws =whitewsrt =white/redrt = redge = yellowgn =greenvi = violetbr =brownbrws=brown/whitegr =greygrrt =grey/redbl =blueblws =blue/whiteli =purple
•Insulateunusedcableends.•Connectorsandbushhousingsareshownfromthe
cableentryside.
Pleasenote!
30
Electrical system5
AirtronicLcircuitdiagram
Filter
natural
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Electrical system5
Circuitdiagramforcontrolelements
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252069009701C
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Circuitdiagramforcontrolelements
PartslistPage28,29 252069009702A
Electrical system5
33
Electrical system5
PartslistPage28,29 252069009702A
Circuitdiagramforcontrolelements
34
Electrical system5
Circuitdiagramforcontrolelements
PartslistPage28,29 252069009704A
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Electrical system5
Circuitdiagramforcontrolelements
PartslistPage28,29 252069009704A
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Electrical system5
AirtronicL–ADRcircuitdiagram
PartslistPage28,29 252361009601A
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natural
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Electrical system5
CircuitdiagramforADRcontrolelements
PartslistPage28,29 252069009601B
38
Electrical system5
Cablecolourssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple
Partslistforthecircuitdiagramsforthecontrolelements
2.15.1 Temperaturesensor(roomtemperature) (includedintheEasyStartR+scopeofsupply, optionalforEasyStartT)2.15.9 Externaltemperaturesensor
3.1.7 ”ON/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 EasyStartRradioremotecontrol(stationaryunit)
3.3.10 EasyStartR+radioremotecontrol(stationaryunit)
3.6.1 Adaptercable
3.8.3 Antenna
a) Connectionofcontrolunitsattheheaterc) Terminal58(lighting)d) Parkingventilationwithvehicleblower(optional)e) EasyStartTtimerconnectiong) External”ON/OFF“button(optional)h) Parkingventilationwithvehicleblower(optional)x) ADRjumpery) Connectandinsulatecables
•Thetimer/radioremotecontrolmustbeconnectedinaccordancewiththecircuitdiagrams(page40–44).
•Thetimermustbeconnectedasshowninthecircuitdiagramsattheendoftheinstallationinstructions.
•Noteheatertype!•Insulateunusedcableends. Connectorsandbushhousingsareshownfromthe
cableinletside.•Youmustdefinitelycreatethejumpermarkedinthe
circuitdiagramwithy.
Pleasenote!
AssignmentofthecircuitdiagramstothedifferentAirtronicLandAirtronicLheaterstoADR
Thecircuitdiagramsareassignedaccordingtotheinstalledcontrolbox:Thecircuitdiagramsofthe•EasyStartR+ 252361009701C•EasyStartR 252361009702B•EasyStartT 252361009703Aand 252361009704Aapplytotheheater•with2diagnosticcables,whichareconnectedtothe
16pinheaterconnectorS1–OEMdiagnosticscable bl/wsinchamber3,–Universalversionofdiagnosticscable bl/geinchamber8.
•withacontrolboxcableloom,whichiswoundwithcabletape.
39
Electrical system5
EasyStartR+Pinassignmentatthestationaryunitconnector
1 Terminal31(negative)2 ––3 Ventilate(switchingsignal–)4 DATcable5 Pushbutton/LED(negative)6 Temperaturesensor(negative)7 Terminal30(positive)8 S+(switchingonsignal)9 LED(positive)10 Diagnosiscable(Kline)11 Pushbutton(negative)12 Temperaturesensor(positive)
EasyStartRPinassignmentatthestationaryunitconnector
1 Terminal31(negative)2 ––3 ––4 DATcable5 Pushbutton/LED(negative)6 ––7 Terminal30(positive)8 S+(switchingonsignal)9 LED(positive)10 Diagnosiscable(Kline)11 Pushbutton(negative)12 ––
EasyStartTPinassignmentEasyStartTconnectorS1
1 Terminal30(positive) rt2 S+(switchingonsignal) ge3 Terminal31(negative) br4 DATcable vi5 Diagnosiscable(Kline) bl/ws6 Terminal58 gr/sw7 Temperaturesensor(positive) gr8 Temperaturesensor(negative) br/ws9 –– ––
40
Electrical system5
Controlelements–EasyStartR+
252361009701C
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
Pleasenote!
PartslistPage38
41
Electrical system5
Controlelements–EasyStartR
252361009705B
PartslistPage38
42
Electrical system5
Thiscircuitdiagramisvalidforcontrolboxeswithtwodiagnosticscables,seePage38.
.
Controlelements–EasyStartR
252361009702B
PartslistPage38
Pleasenote!
43
Electrical system5
Controlelements–EasyStartT
252361009703A
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
PartslistPage38
Pleasenote!
44
Electrical system5
Controlelements–EasyStartT–ADR
252361009704A
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
PartslistPage38
Pleasenote!
45
Troubleshooting / maintenance / service6
Ifanyfaultsoccur,pleasecheckthefollow-ingitems
•Iftheheaterdoesnotstartafterbeingswitchedon:–Switchtheheateroffandonagain.
•Iftheheaterstillwon’tstart,then checkwhether:
–Thereisfuelinthetank?–Thefusesareok?–Theelectricalcables,connections,terminals,are
ok?–Thehotair,combustionairorexhaustsystemsare
blocked?
Troubleshooting
If,aftercheckingtheseitems,theheaterisstillfaultyoranothermalfunctionoccursinyourheater,pleasecontact:
•Iffactoryinstalled,yourcontractworkshop/garage.
•Ifsubsequentlyinstalled,theworkshop/garagewhichinstalledtheheater.
Pleasenotethatguaranteeclaimscanexpireiftheheaterismodifiedbyathirdpartyorifnonoriginalpartsareinstalled.
Maintenanceinstructions
•Switchtheheaterononceamonthforabout10minutes,evenoutsidetheheatingperiod.
•Beforetheheatingperiodstarts,atrialrunshouldbecarriedoutfortheheater.Ifthick,persistentsmokedevelops,unusualburningnoisesoraclearfuelsmelloccursorifelectric/electronicpartsoverheat,theheatermustbeswitchedoffandputoutofservicebyremovingthefuse.Inthiscase,theheatershouldnotbestartedupagainuntilithasbeencheckedbyqualifiedstaffwhohavebeentrainedonEberspächerheaters.
•Checktheopeningsofthehotair,combustionairandexhaustsystemsafterlengthystoppages,cleanifnecessary!
Service
Ifyouhaveanytechnicalqueriesorproblemswithyourpreheater,dialthefollowingservicephonenumber:
HotlinePhone.0800/1234300
FaxhotlineFax01805/262624
OutsideofGermany,pleasecontacttherespectivenationalEberspächerserviceagent.
Pleasenote!
46
Environment7
Certification
ThehighqualityofEberspächerproductsisthekeytooursuccess.Toguaranteethisquality,wehaveorganisedallworkprocessesinthecompanyforthepurposesofqualitymanagement(QM).Nevertheless,westillpursuealargenumberofactivitiesforcontinuousimprovementofproductqualityinordertokeeppacewithourcustomers’constantlygrowingrequirements.Allthestepsnecessaryforqualityassurancearestipu-latedininternationalstandards.Thisqualityistobeconsideredinacomprehensiveandtotalsense.Itaffectsproducts,proceduresandcustomer/supplierrelations.Officiallyapprovedexpertsassessthesystemandthecorrespondingcertificationcompanyawardsacertificate.
Eberspächerhasalreadyqualifiedforthefollowingstandards:
QualitymanagementinaccordancewithDINENISO9001:2000andISO/TS16949:1999
EnvironmentalmanagementsysteminaccordancewithDINENISO14001:1996
Disposal
DisposalofmaterialsOlddevices,defectivecomponentsandpackagingma-terialscanallbeseparatedandsortedintopuregradefactions,ifnecessary,sothatallpartscanbedisposedofinanenvironmentfriendlywayorthematerialsrecycled.Electricmotors,controllersandsensors(e.g.tempera-turesensors)aredeemedtobe“electronicscrap“.
DismantlingtheheaterTheheaterisdismantledaccordingtotherepairstagesinthecurrenttroubleshooting/repairinstructions.
PackagingTheheater’spackagingcanbekeptincaseithastobesentback.
EUDeclarationofConformity
Themanufacturer:
J.EberspächerGmbH&Co.KG
Address:Eberspächerstraße24D-73730Esslingen
herewithdeclaresthatthefollowingproduct:
Productname Vehicleheater
Type AirtronicL
Version B5D5
fulfilstherequirementsofthefollowingECDirectives:a) Heatingsystemsdirective2001/56/EC Revisionstatus2006/119/EC
b) Radiointerference(EMC)ofvehicles72/245/EEC, Revisionstatus2005/83/EC
c) HeatercontrolECE-R122, Revisionstatus00
d) EMCofvehiclesECE-R10, Revisionstatus02
ThefollowingECDirectivesandUNregulationshavebeenusedtoassesstheproduct:2001/56/EC;72/245/EEC;ECE-R122;ECE-R10
47
Lists8
AAccidentprevention..................................................... 7Additionalparts........................................................... 8ADR........................................................... 4,6,12,27ADR99...................................................................... 27Altitude...................................................................... 25Ambienttemperature................................................. 10
CCablecolours............................................................ 29Certificates................................................................ 46Circuitdiagrams...................................30–37,40–44Combustionairinlet..................................................... 5Combustionairsystem.............................................. 19Conceptofthismanual................................................ 3Contents..................................................................... 2Controldevices.......................................................... 27Controlinheatingmode............................................ 26
DDangerousgoods................................................ 12,27Declarationofconformity........................................... 46Degreeofprotection.................................................. 10Deliveryhead............................................................. 23Deliveryside........................................................ 21,22Descriptionoffunctions............................................. 26Dismantlingtheheater............................................... 31Disposal.................................................................... 31Dosingpump....................................................... 20,23Drillingholepattern.................................................... 15
EElectronicpowerconsumption................................... 10Electronicsystem.................................... 28,29,38,39Emergencyoff........................................................... 27Emergencyshutdown................................................ 27Environmentalprotection........................................... 46EUDeclarationofConformity..................................... 46Exhaustsystem(pipes).............................................. 18Exhaustsystem............................................... 5,18,19Exhaust..................................................................... 18
FFaults........................................................................ 45Fixing......................................................................... 15Forcedshutdown...................................................... 27Formationofairbubbles............................................ 20Fuelextraction............................................. 20,21–22Fuelforlowtemperatures.......................................... 24Fuelforspecialcases................................................ 24Fuelquality.......................................................... 10,24Fuelsystem....................................................... 20–24Fuel............................................................... 5,20–24
ListofkeywordsA–Z
HHeatflow................................................................... 10Heatercodenumber................................................. 10Heatingoperation................................................ 25,26Hotairsystem(ducting)............................................. 17Hotline....................................................................... 45
IImportantinstructionsforoperation........................... 25Information.................................................................. 4Initialcommissioning.................................................. 25Installationarea.......................................................... 15Installationlocation.............................................. 12,13Installation......................................................... 12–24Installation........................................................... 12,15Intendeduse............................................................... 4Interferencesuppression............................................ 10Introduction........................................................... 2–7
MMaindimensions........................................................ 11Maintenance.............................................................. 45Maximumairintaketemperature................................ 10Mountingpositionofthedosingpump....................... 23Mountingpositions.................................................... 14
NNameplate................................................................. 16Noiseemission.......................................................... 10Notes...................................................................... 4,5
OOperatinginstructions................................................ 25Operatingstatusdisplay.............................................. 5Operationandfunction...................................... 25–27Operationwithbiodiesel(FAME)................................. 24Operation.................................................................. 25
PPackaging................................................................. 46Partslist.............................................................. 28,29Permissibleambienttemperature............................... 10Permissiblemountingpositions.................................. 14Permissiblepipelengths...................................... 21,22Permissiblesuctionanddeliveryhead........................ 23Picturesymbols/pictograms...................................... 4Positionoftheheater..................................... 5,12–15Powerconsumption.................................................. 10Productinformation............................................. 8–11
Keyword Page Keyword Page
48
Lists8
RRatedvoltage............................................................ 10Regulations............................................................. 5,6Representations.......................................................... 4
SScopeofsupply...................................................... 8,9Service...................................................................... 45Startprocedure......................................................... 26Statutoryregulations................................................ 5,6Storagetemperature.................................................. 10Suctionhead............................................................. 23Switchingoff.............................................................. 26Switchingon.............................................................. 26
TTechnicaldata........................................................... 10Temperatureselection................................................ 26Testmark.................................................................... 5Textstructure............................................................... 4Tpiece...................................................................... 21Transport................................................................... 12Troubleshooting......................................................... 45
VVentilationmode........................................................ 26Voltagelimit............................................................... 10Voltage...................................................................... 10
WWeight....................................................................... 10Wiring........................................................................ 28
ListofkeywordsA–Z Listofabbreviations
ADREuropeanagreementontheinternationaltransportofdangerousgoodsbyroad.
ECEregulationInternationallyagreed,uniformtechnicalspecificationsforvehicles,partsandequipmentofmotorvehicles.
ECtypeapprovalApprovalawardedbytheGermanFederalOfficeforMo-torTrafficfortheproductionofaheaterforinstallationinmotorisedvehicles.
EMCDirectivesElectromagneticcompatibility.
FAMEBiodieselaccordingtoDINV14214.
JE-partnerJ.Eberspächerpartner.
Keyword Page
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EberspächerClimateControlSystemsGmbH&Co.KGEberspächerstr.24D73730EsslingenTelefon071193900Telefax07119390643info@eberspaecher.com