hg_201859050000_tech_EN_14155.pdf

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.

25236190976706.2012

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


Scopeofsupply

10


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


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


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


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

PartslistPage28,29 252361009801A

31

Electrical system5

Circuitdiagramforcontrolelements

PartslistPage28,29 252069009703B

252069009701C

32



Electrical system5

33

Electrical system5



34

Electrical system5



35

Electrical system5



36

Electrical system5

AirtronicL–ADRcircuitdiagram


Filter

natural

37

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


PartslistPage38

Pleasenote!

44

Electrical system5

Controlelements–EasyStartT–ADR

252361009704A


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

Sub

ject

toc

hang

es

Prin

ted

inG

erm

any

©

J.E

bers

päch

erG

mbH

&C

o.K

G

www.eberspaecher.com

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

Documents

hg_201859050000_tech_EN_14155.pdf