Airtronic D4, B4, D3, D2 User Manual

AIRTRONIC / AIRTRONIC M

Technical description, installation,

operation and maintenance instructions.

AIRTRONIC Order no.

AIRTRONIC D2, 12 V 25 2069 05 00 00
AIRTRONIC D2, 24 V 25 2070 05 00 00

Complete package

AIRTRONIC D2, 12 V 25 2115 05 00 00
AIRTRONIC D2, 24 V 25 2116 05 00 00

AIRTRONIC M Order no.

AIRTRONIC D3, 12 V 25 2317 05 00 00

AIRTRONIC B4, 12 V 20 1812 05 00 00

AIRTRONIC D4, 12 V 25 2113 05 00 00
AIRTRONIC D4, 24 V 25 2114 05 00 00

AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

Air heater for diesel and petrol

operating independently of the engine.

25 2069 90 99 52

04.2009

Introduction

1

Contents

Chapter Title Contents Page

1

2

3

4

Introduction • Contents ................................................................................................ 2

• Concept of this manual .......................................................................... 3

• Special text structure, presentation and picture symbols ....................... 4

• Important information before starting work ............................................. 4

• Statutory regulations .......................................................................... 5, 6

• Safety instructions for installation and operation ................................... 7

• Accident prevention ............................................................................... 7

Product information • Scope of supply: heater, universal installation kit

and complete packages ..................................................................... 8, 9

• Scope of supply: heater and “Plus” installation kit .......................... 10, 11

• Technical data AIRTRONIC D2 ............................................................. 12

• Technical data AIRTRONIC D3, D4, D4 Plus......................................... 13

• Technical data AIRTRONIC B4 ............................................................. 14

• Main dimensions ................................................................................... 15

Installation • Installation and location ....................................................................... 16

• Installing the 24 V heater in a vehicle for the transport

of dangerous goods .............................................................................. 17

• Installation location ........................................................................ 16, 17

• Possible installation positions ............................................................... 18

• Cable harness connection, right or left ................................................. 18

• Mounting and fastening ........................................................................ 19

• Nameplate ............................................................................................ 20

• Heater air system ................................................................................. 21

• Exhaust system ..................................................................................... 22

• Combustion air system .......................................................................... 23

• Fuel supply ................................................................................... 24 – 28

Operation and • Operating instructions / important information for operation ................. 29

function • Initial commissioning ............................................................................. 29

• Description of functions ........................................................................ 30

• Control and safety devices / EMERGENCY OFF .................................... 31

5

6

7

8

2

Electrical system • Heater wiring ....................................................................................... 32

• Parts list for the circuit diagrams / Circuit diagrams ..................... 33 – 45

Troubleshooting • In case of faults, please check the following points .............................. 46

Maintenance • Troubleshooting .................................................................................... 46

Service • Maintenance instructions ..................................................................... 46

• Service ................................................................................................. 46

Environment • Certification .......................................................................................... 47

• Disposal ................................................................................................ 47

• EU Declaration of Conformity ................................................................ 47

Lists • List of key words ............................................................................ 48, 49

• List of abbreviations ............................................................................. 49

Introduction

1

Concept of this manual

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

Introduction

1

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

Product information

2

Here you will find information about the scope
of supply, the technical data and the
dimensions of the heater.

Installation

3

Here you will find important information and
instructions referring to installation of the
heater.

Operation and function

4 8

Here you will find information about the
operation and function of the heater.

Electric system

5

Here you will find information about the
electronic system and electronic components
of the heater.

Troub leshooting / maintenance / service

6

This section contains information on possible
faults and malfunctions, troubleshooting,
maintenance and the service hotline.

Environment

7

Here you will find information about certification
and disposal of the heater together with the EU
Declaration of Conformity.

Lists

Here you will find the key word list and
abbreviations list.

3

Introduction

1

Special text structure, presentation
and picture symbols

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

Special structure and presentations

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

Picture symbols

Regulation!

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

Danger!

This picture symbol with the remark “Danger!” refers
to the risk of a fatal danger to life and limb. Under

certain circumstances, failure to comply with these
instructions can result in severe or life-threatening
injuries.

Caution!

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

Please note!

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

Important information before
starting work

Range of application of the heater

The air heater operating independently of an engine is
intended for installation in the following vehicles,
depending on its heating output:

• Vehicles of all kinds (max 9 seats)

• Construction machinery

• Agricultural machinery

• Boats, ships and yachts (only diesel heaters)

• Camper vans

Please note!

• The heaters (only diesel heaters, 24 volt) can be in­stalled in vehicles used for the transport of dange­rous goods as per ADR.

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

• The "Plus" installation kits are intended for installa­tion in a camper van.

Purpose of the heater

• Pre-heating, de-misting windows

• Heating and keeping the following warm:
– Driver and working cabs, Ship’s cabins
– Freight compartments
– Passenger and crew compartments
– Camper vans

On account of its functional purpose, the heater is not
permitted for the following applications:

• Long-term continuous operation, e.g. for preheating
and heating of:

– Residential rooms
– Garages
– Work huts, weekend homes and hunting huts
– Houseboats, etc.

• Heating or drying:
– Living creatures (people or animals) by blowing hot

air directly at the subject
– Objects
– Blowing hot air into containers

Caution!
Safety instructions for application and
proper purpose

• The heater must only be used and operated for the

range of application stated by the manufacturer in
compliance with the “Operating instructions”
included with every heater.

4

Introduction

1

Statutory regulations

The Federal Road Transport Directorate has issued
an "EC type approval" and an "EMC type approval"
for the heater for installation in motor vehicles and
with the following official type approval marks, noted
on the heater name plate.

AIRTRONIC EC- e1 00 0025

EMC- e1 031516

AIRTRONIC M EC- e1 00 0026

EMC- e1 031653

Statutory Regulations!
Directive 2001 / 56 / EU of the European
Parliament and the Council

• Arrangement of the heater

– Parts of the structure and other components near

the heater must be protected from excess heat
exposure and possible contamination from fuel or
oil.

– The heater must not pose a fire hazard even when

it overheats.
This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and
fire-proof materials or heat plates are used.

– The heater must not be mounted in the passenger

compartment of vehicles in class M2 and M3.
But a heater in a hermetically sealed enclosure
which otherwise complies with the conditions
stated above may be used.

– The factory nameplate or duplicate must be affixed

so that it can still be easily read when the heater
is installed in the vehicle.

– All appropriate precautions must be taken when

arranging the heater to minimise the risk of injuries
to persons or damage to other property.

• Operating status display

– A clearly visible operating display in the user’s

field of vision must indicate when the heater is
switched on and off.

• Fuel supply

– The fuel intake connection must not be located in

the passenger compartment and must be sealed
with a properly closing lid to prevent any fuel leaks.

– In heaters for liquid fuel where the heater fuel is

separate from the vehicle fuel, the type of fuel and
intake connection must be clearly identified.

– A warning sign is to be fixed to the intake

connection indicating that the heater must be
switched off before refuelling.

• Exhaust system

– The exhaust outlet must be arranged so as to

prevent any penetration of exhaust fumes into the
vehicle interior through the ventilation system,
warm air intakes or open windows.

• Combustion air intake

– The air for the heater combustion chamber must

not be sucked in from the passenger compartment
of the vehicle.

– The air intake must be arranged or protected in

such a way that it cannot be blocked by other
objects.

• Heater air intake

– The heater air supply must consist of fresh air or

circulated air and be sucked in from a clean area
not contaminated by exhaust fumes of the drive
machine, the combustion heater or any other
source in the vehicle.

– The intake pipe must be protected by a grid or

other suitable means.

• Hot air outlet

– The hot air pipes within the vehicle must be

arranged or protected in such a way that there is
no risk of injury or damage if they are touched.

– The air outlet must be arranged or protected in

such a way that it cannot be blocked by any
objects.

Statutory Regulations!
Mounting the heater in a vehicle for the transport of
dangerous goods as per ADR

• When the heater is to be installed in vehicles for the

transport of dangerous goods, the regulations of
ADR must also be observed (see page 6).

5

Introduction

1

Statutory Regulations!
Additional regulations for certain vehicles named in
Directive 94 / 55 / EC (ADR Framework Directive)

Scope

This appendix applies to vehicles for which the special
provisions of Directive 94 / 55 / EC apply to
combustion heaters and their installation.

Definition of terms used

For the purposes of this appendix, the vehicle
designations "EX / II", "EX / III", "AT", "FL" and "OX"
according to Chapter 9.1 of Annex B of Directive 94 /
55 / EC are used.

Technical regulations

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

Avoid heating and ignition

The combustion heaters and their exhaust gas routing
shall be designed, located, protected or covered so
as to prevent any unacceptable risk of heating or
ignition of the load. This requirement shall be
considered as fulfilled if the fuel tank and the exhaust
system of the appliance conform to provisions in

3.1.1.1 and 3.1.1.2. Compliance with these
regulations shall be checked in the complete vehicle.

Fuel tanks

Fuel tanks for supplying the heater shall conform to
the following regulations:

• In the event of any leakage, the fuel shall drain to

the ground without coming into contact with hot
parts of the vehicle or the load;

• fuel tanks containing petrol shall be equipped with

an effective flame trap at the filler opening or with a
closure enabling the opening to be kept
hermetically sealed.

Exhaust system and exhaust pipe layout

The exhaust system as well as the exhaust pipes shall
laid out or protected to avoid any danger to the load
through heating or ignition. Parts of the exhaust
system situated directly below the fuel tank (diesel)
shall have a clearance of at least 100 mm or be
protected by a thermal shield.

Switching on the combustion heater

The combustion heater may only be switched on
manually. Automatic switching on via a programmable
switch is not permitted.

EX / II and EX / III vehicles

Combustion heaters for gaseous fuels are not
permitted.

FL vehicles

Combustion heaters must be able to be taken out of
service/disabled at least by the methods described in
the following:
a) Switching off manually in the driver's cabin
b) Switching off the vehicle's engine; in this case the

heater may be manually switched back on by the
vehicle driver;

c) Starting up of a feed pump installed in the vehicle

for the dangerous goods carried.

Combustion heater after-run
After-running of the switched off combustion heater is
permitted. In the cases named in the "FL vehicles"
paragraph under letters b) and c) the supply of
combustion air must be interrupted by suitable means
after a maximum after-run period of 40 seconds. Only
combustion heaters whose heat exchangers are
verifiably not damaged by the reduced after-run period
of 40 seconds beyond their usual use period may be
used.

Please note!

• Compliance with the statutory regulations, the
additional regulations and safety instructions is
prerequisite for guarantee and liability claims.
Failure to comply with the statutory regulations and
safety instructions and incorrect repairs even when
using original spare parts make the guarantee null
and void and preclude any liability for
J. Eberspächer GmbH & Co. KG.

• Subsequent installation of this heater must comply
with these installation instructions.

• The statutory regulations are binding and must also
be observed in countries which do not have any
special regulations.

• When the heater is to be installed in vehicles not
subject to the German Ordinance for the Regis­tration of Motor Vehicles (StVZO), for example
ships, the specially valid regulations and
installation instructions for these special
applications must be observed.

• Installation of the heater in special vehicles must
comply with the regulations applying to such
vehicles.

• Other installation requirements are contained in the
corresponding sections of this manual.

6

Introduction

1

Safety instructions for installation
and operation

Danger!

Risk of injury, fire and poisoning!

• The heater must only be started up when the
maintenance flap is closed and the outlet hood is
mounted in position.

• The maintenance flap must not be opened during
operation.

• Disconnect the vehicle battery before commencing
any kind of work.

• Before working on the heater, switch the heater off
and let all hot parts cool down.

• The heater must not be operated in closed rooms,
e.g. in the garage or in a multi-storey car park.

• Adjustable hot air outlets must always be adjusted
so that they cannot blow hot air directly at living
creatures (people, animals) or objects sensitive to
temperature (loose and / or fastened).

Caution!

Safety instructions for installation and operation!

• The year of initial commissioning must be marked on
the nameplate.

• The heat exchanger of air heaters is a component
subject to high thermal loads which must be
replaced 10 years after initial commissioning of the
heater. In addition, the installation date must be
entered on the plate “original spare part” enclosed
with the heat exchanger must. Then affix the plate
next to the nameplate on the heater.

• The heater must only be installed by a JE partner
authorised by the manufacturer according to the
instructions in this manual and possibly according to
special installation recommendations; the same
applies to any repairs to be carried out in the case
or repairs or guarantee claims.

• Only the control elements approved by
J. Eberspächer GmbH & Co. KG must be used to
operate the heater. The use of other control
elements can cause malfunctions.

• Repairs by unauthorised third-parties or with not
original spare parts are dangerous and therefore not
allowed. They result in expiry of the type permit of
the heater; consequently, when installed in motor
vehicles they can cause expiry of the vehicle
operating licence.

• The following measures are not allowed:
– Changes to components relevant to the heater.
– Use of third-party components not approved by

Eberspächer.

– Nonconformities in installation or operation from

the statutory regulations, safety instructions or
specifications relevant to safe operation as stated
in the installation instructions and operating
instructions. This applies in particular to the
electrical wiring, fuel supply, combustion air
system and exhaust system.

• Only original accessories and original spare parts
must be used during installation or repairs.

• When carrying out electric welding on the vehicle,
the plus pole cable at the battery should be
disconnected and placed at ground to protect the
controller.

• The heater must not be operated where there is a
risk of an accumulation of flammable vapours or
dust, for example close to
– fuel depot
– coal depot
– wood depot
– grain depots etc.

• The heater must be switched off when refuelling.

• When the heater is mounted in a safety housing
etc., the installation compartment of the heater is
not a stowage compartment and must be kept clear.
In particular fuel canisters, oil cans, spray cans,
gas cartridges, fire extinguishers, cleaning rags,
items of clothing, paper etc. must not be stored or
transported on or next to the heater.

• Defect fuses must only be replaced by fuses with
the prescribed rating.

• If fuel leaks from the heater fuel system, arrange
for the damage to be repaired immediately by a JE
service partner.

• After-running of the heater must not be interrupted
prematurely e.g. by pressing the battery
disconnecting switch, apart from in the case of an
emergency stop.

Accident prevention

General accident prevention regulations and the
corresponding workshop and operation safety
instructions are to be observed.

7

Product information

2

Heater scope of supply, complete
packages and universal installation kit

Heater Order No.

AIRTRONIC D2, 12 V 25 2069 05 00 00
AIRTRONIC D2, 24 V 25 2070 05 00 00
AIRTRONIC D3, 12 V 25 2317 05 00 00
AIRTRONIC B4, 12 V 20 1812 05 00 00
AIRTRONIC D4, 12 V 25 2113 05 00 00
AIRTRONIC D4, 24 V 25 2114 05 00 00
AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

The scope of supply includes:
No. in
figure Name

1 Heater
2 Metering pump

Complete package Order No.

AIRTRONIC D2, 12 V
Complete package 25 2115 05 00 00
AIRTRONIC D2, 24 V
Complete package 25 2116 05 00 00

Included in the scope of supply:
No. in
figure Name

1 Heater
2 Metering pump
– Installation kit with outlet hood Ø 60 mm
3 Minicontroller
4 Tank connection (only in complete package

25 2116 05 00 00)

Universal installation kit (all versions)

Included in the scope of supply:
No. in
figure Name

5 Lead harness, plus / minus
6 Lead harness, operation
7 Flexible exhaust pipe
8 Combustion air hose

9 Cable tie
10 Bracket, dosing pump
11 Pipe, 6 x 2
12 Pipe, 4 x 1.25
13 Hose clip (2x)
14 Air outlet, rotatable
15 Grid
16 Hood
17 Flexible pipe
18 Exhaust silencer
19 Cable harness, heater

Using the universal installation kits

Order No.

Universal installation kit 25 2069 80 00 00

• with outlet hood Ø 60 mm,
heater guide number 6, usable with:

– AIRTRONIC D2, 12 V 25 2069 05 00 00
– AIRTRONIC D2, 24 V 25 2070 05 00 00

Universal installation kit 25 2113 80 00 00

• with outlet hood Ø 90 mm,
heater guide number 10, usable with:

– AIRTRONIC D3, 12 V 25 2317 05 00 00

– AIRTRONIC B4, 12 V 20 1812 05 00 00

– AIRTRONIC D4, 12 V 25 2113 05 00 00
– AIRTRONIC D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 90 mm,
heater guide number 15, usable with:

– AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
– AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

Universal installation kit 25 2144 80 00 00

• with outlet hood Ø 75 mm,
heater guide number 3, usable with:

– AIRTRONIC D3, 12 V 25 2317 05 00 00

– AIRTRONIC B4, 12 V 20 1812 05 00 00

– AIRTRONIC D4, 12 V 25 2113 05 00 00
– AIRTRONIC D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 75 mm,
heater guide number 8, for recirculation mode
heater guide number 10, for fresh air mode
usable with:

– AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
– AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

Please note!

• For controls, please refer to the price list or
accessories catalogue.

• Parts without a figure no. are small parts and packed
in a bag.

• Please consult the additional parts catalogue if any
other parts are required for installation.

• For notes on the units' guide numbers, please refer to
additional parts catalogue.

8

Product information

2

Scope of supply: Heater, universal inst allation kit and complete packages

* Only in complete package AIRTRONIC D2

** Only for AIRTRONIC D3, B4, D4, D4 Plus

*** Only for AIRTRONIC D2

**** Only in complete package AIRTRONIC D2, 24 volt

9

Product information

2

Scope of supply
Heater and “Plus” installation kit

Heater Order No.

AIRTRONIC D2, 12 V 25 2069 05 00 00
AIRTRONIC D2, 24 V 25 2070 05 00 00
AIRTRONIC D3, 12 V 25 2317 05 00 00
AIRTRONIC B4, 12 V 20 1812 05 00 00
AIRTRONIC D4, 12 V 25 2113 05 00 00
AIRTRONIC D4, 24 V 25 2114 05 00 00
AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

The scope of supply includes:
No. in
figure Name

1 Heater
2 Metering pump

“Plus” installation kit (all versions)

The scope of supply includes:
No. in
figure Name

3 Combustion air intake silencer
4 Exhaust silencer
5 Hose connecting sockets
6 Grid
7 Y branch
8 Tank connection kit

9 Temperature control sensor
10 Cable loom for temperature control sensor
11 EasyStart T timer
12 Lead harness, plus / minus
13 Lead harness, operation
14 Hose clip (2x)
15 Hose clip (6x)
16 Pipe 4 x 1.25 (included in Item 8)
17 Cable harness, heater
18 Flexible exhaust pipe
19 Grid
20 Bracket metering pump
21 Cable tie (2 sets)
22 Hood
23 Outlet (2x)
24 Adapter Ø 6 / 4
25 Pipe 4 x 1 (included in Item 8)
26 Pipe clip, Ø 50 mm
27 Flexible pipe for hot air system

Using the “Plus” installation kits

Order No.

“Plus” installation kit 25 2069 81 00 00

• with outlet hood Ø 75 mm,
heater guide number 12, usable with:

– AIRTRONIC D2, 12 V 25 2069 05 00 00
– AIRTRONIC D2, 24 V 25 2070 05 00 00

“Plus” installation kit 25 2313 81 00 00

• with outlet hood Ø 90 mm,
heater guide number 10, usable with:

– AIRTRONIC D3, 12 V 25 2317 05 00 00

– AIRTRONIC B4, 12 V 20 1812 05 00 00

– AIRTRONIC D4, 12 V 25 2113 05 00 00
– AIRTRONIC D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 90 mm,
heater guide number 15, usable with:

– AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
– AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

“Plus” installation kit 25 2484 81 00 00

• with outlet hood Ø 75 mm,
heater guide number 8, for recirculation mode
heater guide number 10, for fresh air mode
usable with:

– AIRTRONIC D4 Plus, 12 V 25 2484 05 00 00
– AIRTRONIC D4 Plus, 24 V 25 2498 05 00 00

Please note!

• For controls, please refer to the price list or
accessories catalogue.

• Parts without a figure no. are small parts and packed
in a bag.

• Please consult the additional parts catalogue if any
other parts are required for installation.

• For notes on the units' guide numbers, please refer to
additional parts catalogue.

• The “Plus” installation kits are particularly suitable for
installations in camper vans and boats.

10

Product information

2

Scope of supply: Heater and “Plus” installation kit

11

Product information

2

Technichal data

Heater type

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt)

Heater air flow rate with hood Ø 60 mm
without counterpressure (kg/h)

Fuel consumption (l/h)

Elektr. power consumption (watt)

in operation (12 and 24 volt)

at start (12 and 24 volt)

Rated voltage

Operating range

Lower voltage limit:
An undervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Upper voltage limit:
An uppervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Fuel

“Fuel quality“ and “Fuel at low temperatures“
see page 28.

Tolarable ambient temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

AIRTRONIC

AIRTRONIC D2

D2

Air

Stage

Power Large Medium Small Off

2200 1800 1200 850 –

105 90 60 40 13

0.28 0.23 0.15 0.10 –

34 22 12 8 5

ⱕ100

12 or 24 volt

approx. 10.5 volt resp. 21 volt

Undervoltage protection trigger time: 20 seconds

approx. 16 volt resp. 32 volt

Overvoltage protection trigger time: 20 seconds

Commercially available diesel fuel (DIN EN 590)

Operation Not running

–40 °C to +70 °C –40 °C to +85 °C

–40 °C to +50 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 2.7 kg

possible

Caution!

Safety instructions for technical data!

Failure to comply with the technical data
can result in malfunctions.

12

Please note!

Provided no limit values are given, the technical data
listed is subject to the tolerances usually applicable
to heaters of ±10% for nominal voltage, ambient
temperature 20 °C and reference altitude Esslingen.

Product information

2

Technichal data

Heatertyp

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt) D3

D4

D4 Plus

Heater air flow rate D3 with hood Ø 90 mm

without counter- D4 with hood Ø 90 mm

pressure (kg/h) D4 Plus with hood Ø 75 mm

Fuel consumption (l/h) D3

D4

D4 Plus

Elektr. power consumption (watt) D3

in operation (12 and 24 volt) D4

D4 Plus

at start (12 and 24 volt)

Rated voltage

Operating range

Lower voltage limit:
An undervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Upper voltage limit:
An uppervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Fuel

“Fuel quality“ and “Fuel at low temperatures“
see page 28.

Tolarable ambient temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

AIRTRONIC M

AIRTRONIC D3 / AIRTRONIC D4 / AIRTRONIC D4 Plus

D3 / D4 / D4 Plus

Air

Stage

Power Large Medium Small Off

3000 2200 1600 900 –

4000 3000 2000 900 –

4000 3000 2000 900 –

150 120 90 60 24

185 150 110 60 24

175 140 100 55 22

0.38 0.28 0.2 0.11 –

0.51 0.38 0.25 0.11 –

0.51 0.38 0.25 0.11 –

24 16 10 7 5

40 24 13 7 5

55 30 16 7 5

ⱕ100

12 or 24 volt

approx. 10.5 volt resp. 21 volt

Undervoltage protection trigger time: 20 seconds

approx. 16 volt resp. 32 volt

Overvoltage protection trigger time: 20 seconds

Commercially available diesel fuel (DIN EN 590)

Operation Not running

–40 °C to +70 °C –40 °C to +85 °C

–40 °C to +50 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 4.5 kg

possible

Safety instructions for technical data and see page 12.

Please note!

13

Product information

2

Technichal data

Heatertyp

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt)

Heater air flow rate with hood Ø 90 mm
without counterpressure (kg/h)

Fuel consumption (l/h)

Elektr. power consumption (watt)

in operation (12 volt)

at start (12 volt)

Rated voltage

Operating range

Lower voltage limit:
An undervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Upper voltage limit:
An uppervoltage protection in the controller
switches off the heater when the voltage
limit is reached.

Fuel

“Fuel quality“ and “Fuel at low temperatures“
see page 28.

Tolarable ambiet temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

AIRTRONIC M

AIRTRONIC B4

B4

Air

Stage

Power Large Medium Small Off

3800 3200 2100 1300 –

185 160 120 85 24

0.54 0.46 0.29 0.18 –

40 29 15 9 5

ⱕ100

12 volt

approx. 10.5 volt

Undervoltage protection trigger time: 20 seconds

approx. 16 volt

Undervoltage protection trigger time: 20 seconds

Commercially available petrol fuel (DIN EN 228)

Operation Not running

–40 °C to +50 °C –40 °C to +85 °C

–40 °C to +20 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 4.5 kg

possible

Caution!

Safety instructions for technical data!

Failure to comply with the technical data
can result in malfunctions.

14

Please note!

Provided no limit values are given, the technical data
listed is subject to the tolerances usually applicable
to heaters of ±10% for nominal voltage, ambient
temperature 20 °C and reference altitude Esslingen.

Product information

2

Main dimensions AIRTRONIC

Main dimensions AIRTRONIC M

*

**

1 Minimum installation clearance (space) for opening the lid and for

dismantling the glow plug and the controller.

2 Minimum installation clearance (space) for intake of heater air.

* Outlet hood for AIRTRONIC D2:

- Ø 60 mm, included in the universal installation kit

- Ø 75 mm, included in the “Plus” installation kit

** Outlet hood for AIRTRONIC D3, B4, D4:

- Ø 75 mm, included in the universal installation kit

- Ø 90 mm, included in the universal installation kit or in
the “Plus” installation kit
Outlet hood for AIRTRONIC D4 Plus:

- Ø 75 mm, included in the universal installation kit or in
the “Plus” installation kit

- Ø 90 mm, included in the universal installation kit or in
the “Plus” installation kit

A = Exhaust
B = Fuel
V = Combustion air

Please note!

Installation of spherical reduction hood is not
permitted in the Airtronic D4 Plus.

15

Installation

3

Installation and location

The heater is suitable and certified for installation in
parts of vehicles used by persons.
Installation in the cab or passenger compartments of
coaches or buses with more than 9 seats is not
allowed.

When installing in compartments used by persons, the
exhaust, combustion air and fuel pipes in these areas
must not have any detachable connections and must
be routed splash-waterproof in the breakthroughs. For
this reason, the heater can be mounted with its foot
using the flange seal in the foot to the vehicle floor or
to an outer wall of the vehicle.

The electronic control is integrated in the heater which
makes wiring during installation much easier.

Please note!

• When installing the heater, always make sure there
is sufficient clearance left for intake of the heater air
and for dismantling the glow plug and controller (see
page 15 “main dimensions“).

• The regulations and safety instructions to be
observed for this chapter are on page 4 – 7.

Installation position

Installing the diesel heater 24 V in a vehicle
for the transport of dangerous goods as per
ADR

The 24 Volt diesel heater can be installed in vehicles
used for the transport of dangerous goods as per ADR.

The heater fulfils the regulations of ADR with the
corresponding electrical wiring, see circuit diagrams at
the end of this manual.

For information about the ADR regulations, please refer
to page 6, 31 and to the information leaflet no.
25 2161 95 15 80.

Please note!

For installation of the heater in vehicles for the
transport of dangerous goods, the regulations of
ADR must be observed.

Installation position in a camper van

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

Please note!

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

16

1 Heater in front of the passenger seat
2 Heater between the driver’s seat and the

passenger seat
3 Heater under the vehicle floor
4 Heater under the back seat
5 Heater in the boot

3

Installation

3

Installation

Installation in a car or people carrier

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

1 Heater in front of the passenger seat
2 Heater between the driver’s seat and the

passenger seat
3 Heater under the vehicle floor
4 Heater under the back seat
5 Heater in the boot

Installation in an excavator cab (only diesel heaters)

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

Installation in a truck (only diesel heaters)

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

1 Heater in the passenger’s foot room
2 Heater on the cab rear wall
3 Heater under the bed
4 Heater in the tool box

1 Heater in the seat box
2 Heater on the cab rear wall
3 Heater in a protective case

Please note!

• The installation suggestions made in the
installation instructions are just examples. Other
installation locations are possible, as long as they
correspond to the installation requirements stated
in these instructions.

• Other installation information (e.g. for boats and
ships) is available from the manufacturer on
request.

• Observe the tolerable installation position together
with the operating and storage temperatures.

17

Installation

3

Possible installation positions

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

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

1 Heater air intake opening (fan wheel)
2 Position of the glow plug
3 Direction of flow

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

Cable harness connection, right or left

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

18

Installation

3

Mounting and fastening

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

If the sheet metal of the support surface is thinner
than 1.5 mm, an additional reinforcement plate will
have to be fitted.

Order no: reinforcement plate 20 1577 89 00 03
Order no: special tool 99 1201 46 53 29

Picture hole

1 Contour of the bearing surface

Fastening the unit on the vehicle floor

Special tool

Fastening the heater horizontally
to the vehicle wall

1 There must be sufficient clearance between the

heater and the vehicle floor – also check that

the fan wheel runs freely.
2 The mounting surface must be flat and smooth.
3 The flange seal must be mounted.

4 The vehicle wall must be flat and smooth.
5 Reinforcement plate (if required, see above)
6 Spring washer
7 Hexagon nut M6 (torque 5

+1 Nm

)

19

Installation

3

Nameplate

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

Please note!

The regulations and safety instructions to be
observed for this chapter are stated on page 5.

1 Original nameplate

nd

nameplate (duplicate)

22

20

Installation

3

Heater air system

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

Danger!

Risk of burning and injuries!

• The hoses of the heater air system and the hot air

outlet are to be routed and fastened in such a way
that they pose no temperature risk to people,
animals or materials sensitive to temperature from
radiation / contact or blowing directly. If necessary,
a cover is to be fitted to the heater air system or
hot air outlet.

• The outflow hood must be fitted on the hot air

outflow side.

• A safety grid must be fitted to the heater air intake

side and outflow side if no air hoses are mounted,
to prevent any injuries from the heater air fan or
burns from the heat exchanger.

• High temperatures occur in the heater air system

during and after the heater has been working.
This is why it is important to avoid working in the
vicinity of the heater air system while the heater is
working. In such cases, switch the heater off
beforehand and wait until all parts have cooled
down completely.
If necessary, wear safety gloves.

Please note!

• Installation of spherical reduction hood is not
permitted in the Airtronic D4 Plus.

• The regulations and safety instructions to be observed
for this chapter are on page 4 – 7.

• If air duct parts are connected the heater code
number in “Using Universal Installation Kits”, page 8
and “Using Plus Installation Kits”, page 10 must be
observed.

Caution!

• The heater air intake openings must be arranged in
such a way that under normal circumstances, it is
not possible for exhaust from the vehicle engine and
heater to be sucked into the system, or for the
heating air to be contaminated with dust, salt spray,
etc.

• For circulating air, position the circulating air intake
in such a way that the outflowing hot air cannot be
directly sucked in again.

• In the event of possible overheating, it is possible
for local lot air temperatures of up to max. 150 °C
or surface temperatures of up to max. 90 °C to
occur immediately before the defect shutdown.
Therefore only temperature-resistant hot air hoses
approved by us must be used for the heater air
system!

• When checking the functions, the mean outflow
temperature measured after the heater has been
running about 10 minutes at approx. 30 cm from the
outlet should not exceed 110 °C (at an intake
temperature of approx. 20 °C).

• If there is a risk of the driver and passengers
touching the heater when the vehicle is being driven
normally, a contact protection device must be fitted.

Heater air system (example)

1 Safety grid
2 Outflow hood
3 Hose clip
4 Flexible hose

5 Rotating outflow
6 Connection fitting
7 Safety grid

21

Installation

3

Exhaust system

Mounting the exhaust system

The “Universal” and “Plus” installation kits include a
flexible exhaust pipe, inner Ø 24 mm, 1000 mm long
and an exhaust silencer. The flexible exhaust pipe can
be shortened to 20 cm or lengthened to max. 2 m,
depending on the installation conditions.
Fasten the exhaust silencer to a suitable position in
the vehicle.
Route the flexible exhaust pipe from the heater to the
exhaust silencer and fasten with pipe clips. Use a
pipe clip to fix a short exhaust pipe end (with end
sleeve) to the exhaust silencer.

Danger!

Risk of injuries and burns!

Every type of combustion produces high temperatures
and toxic exhaust fumes. This is the reason why the
exhaust system must be installed according to these
instructions.

• Do not perform any work on the exhaust system
while the heater is working.

• Before working on the exhaust system, first switch
the heater off and wait until all parts have cooled
down completely, wear safety gloves if necessary.

• Do not inhale exhaust fumes.

Caution!

Safety instructions!

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

• The exhaust outlet must end in the open air.

• The exhaust pipe must not protrude beyond the
lateral limits of the vehicle.

• Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm at
the lowest point to drain off condensation.

• Important functional parts of the vehicle must not be
impaired (keep sufficient clearance).

• Mount the exhaust pipe with sufficient clearance to
heat-sensitive parts. Pay particular attention to fuel
pipes (plastic or metal), electrical cables and brake
hoses etc.!

• Exhaust pipes must be fastened safely
(recommended clearance of 50 cm) to avoid damage
from vibrations.

• Route the exhaust system so that the emitted fumes
are not sucked in with the combustion air.

• The mouth of the exhaust pipe must not get clogged
by dirt and snow.

• The mouth of the exhaust pipe must not point in the
direction of travel.

• Always fasten the exhaust silencer to the vehicle.

Please note!

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

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

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

22

Installation

3

Combustion air system

Mounting the combustion air system

The universal installation kit includes a flexible
combustion air hose, inner Ø 25 mm , 100 mm long.
If necessary the flexible combustion air hose can be
shortened by 20 cm or lengthened by max. 2 m
depending on the installation conditions.
Fasten the combustion air hose to the heater with
a pipe clip and at suitable points with hose clips or
cable ties.
Fit an end sleeve after completing the installation.

The „Plus“ installation kit includes a combustion air
intake silencer with a flexible connection hose (inner
diameter 25 mm).
Fasten the flexible connection hose to the heater with
a pipe clip and fasten the combustion air intake
silencer with hose clips or cable ties at suitable points.
Fit an end sleeve after completing the installation.

Caution!
Safety instructions for the combustion
air system!

• The combustion air opening must be free at all

times.

• Position the combustion air intake to be sure that

exhaust fumes cannot be sucked in with the
combustion air.

• Do not arrange the combustion air intake to pointing

against the wind blast.

• The combustion air intake must not get clogged with

dirt and snow.

• Install the combustion air intake system sloping

slightly downwards. If necessary, make a drain hole
approx. Ø 5 mm at the lowest point to drain off
condensation.

Please note!

• For AIRTRONIC and AIRTRONIC M heaters a combu-

stion air intake silencer can be fitted instead of the
combustion air hose to reduce the noise level. The
order number is stated in the Accessories Cata­logue.

• Comply with the regulations and safety instructions

for this chapter on page 4 – 7.

min. 0.2 – max. 2 m

1 Combustion air hose, di = 25 mm
2 Combustion air silencer,

– Included in the “Plus” installation kit
3 Exhaust pipe, de = 24 mm
4 Exhaust silencer
5 Intake / outlet opening – protect from wind,

snow, dirt and water.
6 End sleeve, combustion air
7 End sleeve, exhaust
8 Combustion air connection
9 Exhaust connection
10 End sleeve, combustion air
11 Hose clip
12 Exhaust hose clip

min. 0.2 m

max. 2 m

23

Installation

3

Fuel supply

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

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

Danger!

Risk of fire, explosion, poisoning and injuries!

Caution when handling fuel.

• Switch off the vehicle engine and heater before
refuelling and before working on the fuel supply.

• No naked lights when handling fuel.

• Do not smoke.

• Do not inhale fuel vapours.

• Avoid any contact with the skin.

Caution!

Safety instructions for routing the fuel pipes!

• Only use a sharp knife to cut off fuel hoses and
pipes.
Interfaces must not be crushed and must be free
of burrs.

• The fuel pipe from the dosing pump to the heater
should be routed at a continuous rise.

• Fuel pipes must be fastened safely to avoid any
damage and / or noise production from vibrations
(recommended clearance of approx. 50 cm).

• Fuel pipes must be protected from any mechanical
damage.

• Route the fuel pipes so that any distortion of the
vehicle, engine movements etc. cannot have any
lasting effect on the service life.

• Parts carrying fuel must be protected from
interfering heat.

• Never route or fasten the fuel pipes to the heater or
vehicle exhaust system. At crossings, always ensure
adequate heat clearance, if necessary attach heat
deflection plates or protective hose (for Order No.
protective hose please refer to additional parts
catalogue).

• Dripping or evaporating fuel must never be allowed
to collect on hot parts or ignite on electric systems.

• When connecting fuel pipes with a fuel hose, always
mount the fuel pipes in a butt joint to prevent any
bubbles from forming.

1 Correct connection
2 Incorrect connection – bubble formation

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

• In buses and coaches, fuel pipes and fuel tanks
must not be routed through the passenger
compartment or driver’s cab.

• Fuel tanks in buses and coaches must be
positioned in such a way that the exits are not in
direct danger from a possible fire.

Please note!

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

• For noise reasons, do not rigidly fit fuel pipes onto
structural sound transferring components.
A sponge rubber hose can be pushed over the fuel
tubes for nose reduction.

24

Installation

3

Fuel supply

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

1 Fuel flow line, vehicle tank
2 To the vehicle's engine, mechanical fuel or

injection pump
3 T-piece, 8-6-8 or 10-6-10
4 Dosing pump
5 Fuel pipe, 4 x 1 (di = Ø 2 mm)
6 Fuel pipe, 6 x 2 (di = Ø 2 mm)
7 Fuel hose, 5 x 3 (di = Ø 5 mm)
8 Fuel pipe, 4 x 1,25 (di = Ø 1,5 mm)
9 Adapter Ø 6 / 4
10 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm),

approx. 50 mm long
11 Fuel hose, 5 x 3 (di = Ø 5 mm),

approx. 50 mm long
12 Pipe connectors, da = Ø 4 mm
13 Fuel filter - required for contaminated fuel only.

Installation position of the T-piece

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

Possible pipe lengths

Intake side

AIRTRONIC

a = max. 5 m

AIRTRONIC M
a = max. 2 m

Please note!

• Insert the T-piece (3) in the fuel flow line upstream of
the feed pump.

• Items (5), (9) and (12) are included in the "Plus"
installation kit only.

• Item (6) is included in the universal installation kit
only.

• Items (7) and (13) must be ordered separately. The
order no. is given in the additional parts catalogue.

Pressure side

Diesel heaters

• For suction pipe di = Ø 2 mm,
b = max. 6 m

• For suction pipe di = Ø 5 mm,
b = max. 10 m

Petrol heater

• b = max. 4 m

1 Direction of flow from the fuel tank
2 Direction of flow to the vehicle engine

25

Installation

3

Fuel supply

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

1 Tank connection for metal tank -

di = Ø 2 mm, da = Ø 6 mm

2 Tank connection for tank fitting -

di = Ø 2 mm, da = Ø 4 mm
3 Dosing pump
4 Fuel pipe, 4 x 1 (di = Ø 2 mm)
5 Fuel pipe, 6 x 2 (di = Ø 2 mm)
6 Fuel hose, 5 x 3 (di = Ø 5 mm)
7 Fuel filter - required for contaminated fuel only.
8 Fuel pipe, 4 x 1,25 (di = Ø 1,5 mm)
9 Pipe connectors, da = Ø 4 mm
10 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm)

approx. 50 mm long
11 Adapter Ø 6 / 4
12 Fuel hose, 5 x 3 (di = Ø 5 mm),

approx. 50 mm long

Caution!

Safety instructions for the fuel supply!

• The fuel must not be conveyed by gravity or

overpressure in the fuel tank.

• Withdrawal of fuel after the vehicle’s fuel pump is

not allowed.

• When the pressure in the fuel pipe is more than

0.2 bar to max. 4,0 bar, use a pressure reducer
(order no. 22 1000 20 08 00) or separate tank
connection.

Possible pipe lengths
Intake side

AIRTRONIC

a = max. 5 m

AIRTRONIC M
a = max. 2 m

Please note!

• Items (2), (4), (8), (9) and the connection parts are
included in the “Tank Connection” kit, Order No. 22
1000 20 13 00 (The “Tank Connection” kit is included
in the "Plus" installation kit).

• Item (5) is included in the universal installation kit
only.

• Item (11) is included in the “Plus” installation kit only.

• Items (6) and (7) must be ordered separately, for Order
No. please refer to additional parts catalogue.

• When installing tank connection maintain a minimum
distance of 50 ± 2 mm from the end of the riser pipe
and the bottom of the tank.

• When the pressure in the fuel pipe is more than
4,0 bar or there is a non-return valve in the return
pipe (in the tank), a separate tank connection must
be used.

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

Pressure side

Diesel heaters

• For suction pipe di= Ø 2 mm,
b = max. 6 m

• For suction pipe di= Ø 5 mm,
b = max. 10 m

Petrol heater

• b = max. 4 m

26

Installation

3

Fuel supply

Installation position of the dosing pump

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

Possible suction and pressure height
of the dosing pump

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

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

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

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

1 Installation position between 0° and 15°

is not allowed.
2 Preferred installation position in range 15° to 35°.
3 Installation position in range 35° to 90° is allowed.

Please note!

Check tank venting.

Caution!
Safety instructions for installing
the dosing pump

• Always mount the dosing pipe with the pressure

side rising upwards – minimum incline 15°.

• Protect the dosing pump and filter from intolerable

heat, do not mount near to the silencers and
exhaust pipes.

1 Connection to heater
2 Max. fuel level
3 Min. fuel level

27

Installation

3

Fuel supply

Fuel quality for petrol heaters

The heater runs without problems on normal
commercial petrol according to DIN EN 228.

Fuel quality for diesel heaters

• The heater runs without problems on normal
commercial diesel fuel according to DIN EN 590.
During the winter months the diesel fuel is adapted to
low temperatures from 0 °C to -20 °C. Problems can
therefore only arise if outdoor temperatures are
extremely low - which also applies to the vehicle's
engine - please refer to the vehicle manufacturer's
regulations.

• In special cases and at outdoor temperatures above
0 °C the heater can also be run on heating oil EL
according to DIN 51603.

• If the heater is run from a separate tank, please
comply with the following rules:

– if outdoor temperatures over 0 °C,

Use diesel fuel according to DIN EN 590.

– if outdoor temperatures from 0 °C to –20 °C,

Use winter diesel fuel according to DIN 590.

- if outdoor temperatures –20 °C to –40 °C,

Use Arctic Diesel or Polar Diesel.

Please note!

• Mixtures with used oil are not allowed!

• After refuelling with winter or cold diesel, the fuel
pipes and the metering pump must be filled with the
new fuel by letting the heater run for 15 min!

Operation with biodiesel (FAME)

AIRTRONIC

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

AIRTRONIC M

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

Please note!

• Bio diesel fuel (FAME) according to DIN EN 14 214
– during the winter months is adapted to low

temperatures from 0 °C to –20 °C.

– The Flowability reduces at temperatures below

0 °C.

• When using 100 % bio diesel, the heater should be
operated twice a year with diesel fuel (in the middle
and at the end of a heating period) in order to burn
off any possible biodiesel residues deposited.
To do so, let the vehicle tank run almost empty and
then fill with diesel fuel. While running on this tank
filling, switch the heater on 2 to 3 times for 30
minutes at a time at the highest temperature setting.

• When operating with diesel / bio diesel mixtures of up
to 50 % bio diesel, intermediate operation with pure
diesel fuel is not necessary.

28

Operation and function

4

Operating instructions

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

Please note!

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

Important instructions for operation

Safety checks before the start

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

Heating at high altitudes

When using the heater at high altitudes, please note:

• Heating at altitudes up to 1500 m:
– Unlimited heating possible.

• Heating at altitudes over 1500 m – 3000 m:

– Heating is possible for short periods at this altitude

(e.g. driving over a mountain pass or taking a
break in a journey).

– During longer stays, e.g. winter camping, the fuel

supply must be adjusted to the altitude. This can
be done by installing an air pressure sensor. The
air pressure sensor is included in the Altitude kit ­Order No. 22 1000 33 22 00.

Initial commissioning

The following points are to be checked by the
company installing the heater during initial
commissioning.

• After installation of the heater, the coolant circuit
and the whole fuel supply system must be vented
carefully. Comply with the instructions issued by the
vehicle manufacturer.

• During the trial run of the heater, check all water and
fuel connections for leaks and firm fitting.

• If the heater shows a fault during operation, find
and eliminate the cause of the fault using a
diagnosis unit.

Please note!

During the initial start-up of the heater, odours can be
produced for a short time. This is fully normal during
the first few minutes of operation and does not
indicate a malfunction in the heater.

Please note!

Heaters suitable for high altitudes are labelled with
“H-Kit” on the side nameplate.

29

Operation and function

4

Description of functions

Switching on

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

Please note!

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

Starting AIRTRONIC

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

Control in the heating mode

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

Ventilating mode

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

Starting AIRTRONIC M

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

Temperature selection with the control element

The control can be used to preselect an interior
temperature.
The resulting temperature can be within the range of
+10 °C to +30 °C and depends on the selected
heater, on the size of the space to be heated and on
the prevailing outdoor temperature.
The setting to be selected at the control is an
empirical value.

30

Switching off

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

Operation and function

4

Control and safety devices

• If the heater does not ignite within 90 seconds after
starting the fuel pump, the start is repeated. If the
heater still does not ignite after another 90 seconds
of pumping fuel, the heater is switched off, i.e. the
fuel supply is off and the fan runs on for approx.
4 minutes.

• If the flame goes off by itself during operation, the
heater is restarted. If the heater does not ignite
within 90 seconds after the fuel pump has started,
or ignites and goes off again within 15 minutes, the
heater is switched off, i.e. the fuel supply is off and
the fan runs on for approx. 4 minutes.
This status can be remedied by briefly switching off
and on again.
Do not repeat the switching off/on routine more
than twice.

• In the case of overheating, the combined sensor
(flame sensor / overheating sensor) triggers, the
fuel supply is interrupted and the heater switched
off. Once the cause of the overheating has been
eliminated, the heater can be re-started by
switching off and on again.

• If the lower or upper voltage limit is reached, the
heater is switched off after 20 seconds.

• The heater does not start up when the glow plug is
defect or when the electric lead to the dosing pump
is interrupted.

• If the combined sensor (flame sensor / overheating
sensor) is defect or the electric lead interrupted, the
heater starts up and is then switched off again
during the start phase.

• The speed of the fan motor is monitored
continuously. If the fan motor does not start up or if
the speed deviates by more than 10%, the heater is
switched off after 30 sec.

• When the heater is switched off, the glow plug is
switched on for 40 seconds (after-glowing) while the
fan runs on to clean off any combustion residues.

Please note!

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

Forced shutdown in ADR / ADR99 mode
(only for diesel heaters)

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

• The vehicle engine is switched off.

• An additional unit is started up (e.g. auxiliary drive
for unloading pump etc.).

• A vehicle door is opened (ADR99 regulation,
only in France).

The fan then runs on for max. 40 seconds.

Emergency shutdown – EMERGENCY OFF

If an emergency shutdown – EMERGENCY OFF –
is necessary during operation, proceed as follows:

• Switch the heater off with the control or

• pull the fuse out or

• disconnect the heater from the battery.

31

Electrical system

5

Heater wiring

Caution!

Safety instructions for wiring the heater!

The heater is to be connected up electrically
according to the EMC directives.
EMC can be affected if the heater is not connected
up correctly. For this reason, comply with the following
instructions:

• Ensure that the insulation of electrical cables is not
damaged. Avoid: chafing, kinking, jamming or
exposure to heat.

• In waterproof connectors, seal any connector
chambers not in use with filler plugs to ensure they
are dirt-proof and water-proof.

• Electrical connections and ground connections must
be free of corrosion and firmly connected.

• Lubricate connections and ground connections
outside the heater interior with contact grease.

Please note!

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

• Electrical leads, switchgear and controllers must be
arranged in the vehicle so that they can function
perfectly under normal operating conditions
(e.g.heat exposure, moisture etc.).

• The following cable cross sections are to be used
between the battery and heater. This ensures that
the max. tolerable voltage loss in the cables does
not exceed 0.5 V for 12 V or 1 V for 24 V rated
voltage.
Cable cross sections for a cable length of:
– up to 5 m (plus cable + minus cable) =
cable cross section 4 mm²
– from 5 to 8 m (plus cable + minus cable) =
cable cross section 6 mm²

• If the plus cable is to be connected to the fuse box
(e.g. terminal 30), the vehicle cable from the battery
to the fuse box must be included in rating the overall
cable length and possibly re-dimensioned if
necessary.

• Insulate unused cable ends.

32

Electrical system

5

Parts list for the circuit diagrams

AIRTRONIC / AIRTRONIC M and
AIRTRONIC / AIRTRONIC M – ADR mode

1.1 Burner engine

1.2 Glow plug

1.5 Overheating and flame sensor

2.1 Controller

2.2 Dosing pump

2.7 Main fuse 12 volt = 20 A

2.7.1 Fuse, actuation 5 A

5.1 Battery

5.2.1 Battery operation switch d)
(operation, e.g. controlled by the ignition
key)

5.2.2 Battery separating switch d)
(Emergency off function for ADR / ADR99)

5.3 Auxiliary drive HA+

5.3.1 Switch, auxiliary drive

5.5 Generator D+

a) Connection of the control unit and external

sensor according to the circuit diagram
“control units”

• rt Power supply, plus – terminal 30

• ge Switch-on signal – S+

• gr Actual temperature

• wsrt Switch off burglar alarm

• br Power supply, minus – terminal 31

• blws Diagnosis

• grrt Nominal temperature

• brws Reference signal sensor

b) Option

• Vehicle fan control
and / or

• separate fresh air fan

c) Wiring for operation to ADR / ADR99 (HGV

vehicle transporting dangerous goods,
e.g. tanker truck)

d) When only one switching element is used for

item 5.2.1 and 5.2.2 it must be ensured that
on activating the function “open the battery
separating switch” (EMERGENCY OFF
function for ADR / ADR99 etc.), the switch
always separates immediately (regardless of
the heater status) and all the heater circuits
are disconnected from the battery.

24 volt = 10 A

(ADR / ADR99 – feedback for timer)

Please note!

Circuit diagram for AIRTRONIC / AIRTONIC M
on page 34.
Circuit diagram for AIRTRONIC / AIRTONIC M - ADR
on page 35.

33

Electrical system

5

AIRTRONIC / AIRTRONIC M

25 2069 00 98 01 BParts list page 32

34

Electrical system

5

AIRTRONIC / AIRTRONIC M – ADR mode

Parts list page 32

25 2069 00 96 01 C

35

Electrical system

5

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

2.15.1 Sensor – room temperature, display
(included in the EasyStart R+ scope of
supply, optional for EasyStart R / T)

2.15.9 Sensor – outdoor temperature, display

3.1.7 ”ON / OFF“ button

3.1.16 Radio remote control button

3.1.17 ”Mini controller“ control unit

3.2.15 EasyStart T timer

3.3.9 EasyStart R radio remote control
(stationary unit)

3.3.10 EasyStart R+ radio remote control
(stationary unit)

3.6.1 Adapter cable

3.8.3 Antenna

a) Connection of control units at the heater
c) Terminal 58 (lighting)
d) Parking ventilation with vehicle blower

(optional)

e) EasyStart T timer connection
g) External ”ON / OFF“ button (optional)
h) Parking ventilation with vehicle blower

(optional)

x) ADR jumper
y) Connect and insulate cables

Please note!

• The timer / radio remote control must be connected

in accordance with the circuit diagrams
(page 37 – 41).

• Insulate unused cable ends.

• Connectors and bush housings are shown from the

cable inlet side.

• You must definitely create the jumper marked in the

circuit diagram with y.

Cable colours

sw = black
ws = white
rt = red
ge = yellow
gn = green
vi = violet
br = brown
gr = grey
bl = blue
li = purple

Pin assignment at the stationary unit connector

EasyStart R+

1 Terminal 31 (negative)
2– –
3 Ventilate (switching signal –)
4 DAT cable
5 Pushbutton / LED (negative)
6 Temperature sensor (negative)
7 Terminal 30 (positive)
8 S+ (switching on signal)

9 LED (positive)
10 Diagnosis cable (K line)
11 Pushbutton (negative)
12 Temperature sensor (positive)

EasyStart R

1 Terminal 31 (negative)

2– –

3– –

4 DAT cable

5 Pushbutton / LED (negative)

6– –

7 Terminal 30 (positive)

8 S+ (switching on signal)

9 LED (positive)
10 Diagnosis cable (K line)
11 Pushbutton (negative)
12 – –

Pin assignment at connector B1

EasyStart T

1 Terminal 30 (positive) rt

2 S+ (switching on signal) ge

3 Terminal 31 (negative) br

4 DAT cable vi

5 Diagnosis cable (K line) bl/ws

6 Terminal 58 gr/sw

7 Temperature sensor (positive) gr

8 Temperature sensor (negative) br/ws

9– – – –

36

Electrical system

5

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

25 2361 00 97 01 CParts list page 36

37

Electrical system

5

Circuit diagram – EasyStart R in combination with mini controller

Parts list page 36

38

25 2361 00 97 05 B

Electrical system

5

Circuit diagram – EasyStart R+ in combination with EasyStart T

Parts list page 36

25 2361 00 97 02 B

39

Electrical system

5

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

Parts list page 36 25 2361 00 97 03 A

40

Electrical system

5

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

Parts list page 36

25 2361 00 97 04 A

41

Electrical system

5

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

2.15.9 Sensor – outdoor temperature, display

2.15.10 Sensor – control temperature, external
(interior)

3.1.9 Changeover "heating / venting"

3.1.17 Mini controller

3.2.8 Module timer (ADR potentiometer)

3.2.14 Timer, mini – 12 / 24 volt

a) Connection of control elements at the heater

• rt Power supply, plus – terminal 30

• ge Switch-on signal – S+

• gr Actual temperature

• wsrt Switch off burglar alarm

(ADR – feedback for timer)

• br Power supply, minus – terminal 31

• blws Diagnosis

• grrt Nominal temperature

• brws Ground connection for
externaltemperature sensor and
nominaltemperature

c) Lighting, terminal 58
e) Connection, Sensor – control temperature,

external (interior)

g) Connection, external heating button
h) Connection, radio remote control TP4i
j) Connection, Sensor – outdoor temperature,

display

l) Connection, "heating / ventilation" selector

switch (option). To start: Actuate changeover
switch "heat / ventilate", then switch on the
heater

z) Lighting, terminal 58

Connectors and bush housings are shownfrom the
cable inlet side.

Please note!

Circuit diagrams for the controls on page 43 and 44.
Circuit diagrams for the ADR controls on page 45.

Cable colours

sw = black
ws = white
rt = red
ge = yellow
gn = green
vi = violet
br = brown
gr = grey
bl = blue
li = purple

42

Electrical system

5

Circuit diagram for control units

Parts list page 42

43

Electrical system

5

Circuit diagram for control units

Parts list page 42

44

Electrical system

5

Circuit diagram, ADR mode controls

Parts list page 42

45

Troubleshooting / Maintenance / Service

6

In case of faults, please check the following
points

• If the heater does not start after being switched on:

– Switch the heater off and on again.

• If the heater still does not start, check whether:

– There is fuel in the tank?
– The fuses are OK?
– The electrical cables, connections etc. are OK?
– Anything is clogging the combustion air supply
or exhaust system?

Troubleshooting

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

• For installation ex works, your contract workshop.

• For subsequent installation, the workshop who

installed your heater.

Please note!

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

Maintenance instructions

• Switch the heater off once a month for about
10 minutes, even outside the heating period.

• Before the heating period starts, the heater should
undergo a trial run.
If persistent extreme smoke develops, unusual
burning noises or a clear fuel smell can be perceived
or if electric / electronic parts heat up, the heater
must be switched off and put out of service by
removing the fuse.
In this case, the heater should not be started up
again until it has been checked by qualified staff
who have been trained on Eberspächer heaters.

• Check the openings of the combustion air supply
and exhaust system after longer standstill periods,
clean if necessary!

Service

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

Hotline
Phone. 0800 / 12 34 300

Fax hotline
Fax 01805 / 26 26 24

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

46

Environment

7

Certification

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

Eberspächer has already qualified for the following
standards:

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

Environment management system as per
DIN EN ISO 14001:1996

Disposal

Disposal of materials

Old devices, defect components and packaging
material can all be separated and sorted into pure­grade factions so that all parts can be disposed of as
required in an environment-friendly manner or recycled
where applicable.
Electric motors, controllers and sensors (e.g.
temperature sensors) are deemed to be “electronic
scrap”.

Dismantling the heater

The heater is dismantled according to the repair
stages in the current troubleshooting / repair
instructions.

Packaging

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

EU Declaration of Conformity

With regard to the following products

heater type AIRTRONIC / AIRTRONIC M

we herewith confirm that it conforms with the prime
safety requirements stipulated in the directives of the
EU Council for harmonisation of the legal regulations
of the member states with regard to electromagnetic
compatibility (89 / 336 / EEC).
This declaration applies to all heaters produced
according to the production drawings

AIRTRONIC

declaration.

The following standards / directives have been used
to assess the product with regard to electromagnetic
compatibility:

• EN 50081 – 1 Basic form interference emission.

• EN 50082 – 1 Basic form interference resistance.

• 72 / 245 / EEC – Modification status 2005 / 83 / EU
interference suppression in motor vehicles.

M, which are an integral part of this

AIRTRONIC

/

47

Lists

8

List of key words A – Z

Keyword Page

A

Accident prevention ................................................... 7

ADR .......................................................................... 16

ADR99 ...................................................................... 31

Altitude ..................................................................... 29

Ambient temperature ........................................ 12 – 14

C

Cable harness connection ........................................ 18

Certificates ............................................................... 47

Circuit diagrams ..................... 34, 35, 37 – 41, 43 – 45

Combustion air system ............................................. 23

Control devices ........................................................ 31

Control in heating mode ............................................ 30

Contents .....................................................................2

D

Dangerous goods .............................................. 16, 31

Declaration of conformity ......................................... 47

Description of functions ........................................... 30

Disposal ....................................................................47

Dosing pump ..................................................... 24 – 27

E

Electronic components ................................ 33, 36, 42

Emergency off .......................................................... 31

Environment management ......................................... 47

EU Declaration of Conformity .................................... 47

Exhaust system ........................................................ 22

F

Faults ....................................................................... 46

Fastening ..................................................................19

Fan operation ........................................................... 30

Forced shut-down ..................................................... 31

Formation of air bubbles ........................................... 24

Fuel supply .................................................. 5, 24 – 28

Fuel consumption ............................................. 12 – 14

Fuel quality ............................................................... 28

H

Heat flow .......................................................... 12 – 14

Hotline ...................................................................... 46

Keyword Page

I

Introduction ........................................................... 4, 5

Installation ........................................................16 – 28

Installation area ................................................. 16, 17

Interference suppression class ........................ 12 – 14

Initial commissioning ................................................ 29

Installation location ........................................... 16, 17

Installation position .................................................. 18

Information ................................................................. 4

Important instructions .............................................. 29

L

List of abbreviations .................................................49

M

Maintenance ............................................................. 46

Main dimensions ....................................................... 15

N

Nameplate ................................................................ 20

O

Operation ..................................................................29

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

P

Picture symbols .......................................................... 4

Power consumption ........................................... 12 – 14

Pressure height ........................................................ 27

Pressure side .................................................... 25, 26

Presentation ............................................................... 4

Purpose ...................................................................... 4

R

Rated voltage ...................................................12 – 14

Regulations ............................................................ 5, 6

S

Safety devices ..........................................................31

Safety check (before starting) .................................. 29

Scope of supply ................................................. 8 – 11

Storage temperature ......................................... 12 – 14

Statutory regulations ............................................. 5, 6

Start procedure ......................................................... 30

Suction height ........................................................... 27

Switching on ............................................................. 30

Switching off ............................................................. 30

48

Lists

8

List of key words A – Z

Keyword Page

T

Technical data .................................................. 12 – 14

Temperature selection .............................................. 30

Test symbol ................................................................ 5

Text structure .............................................................4

T-piece ...................................................................... 25

Transport .................................................................. 16

Troubleshooting ........................................................ 46

U

Use ............................................................................. 4

V

Voltage ............................................................. 12 – 14

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

W

Weight .............................................................. 12 – 14

Wiring ....................................................................... 32

List of abbreviations

ADR

European agreement about the international transport
of dangerous goods on the road.

EC Type approval

Permit awarded by the Federal Vehicle Office for the
production of a heater for installation in motorised
vehicles.

EMC directive

Electromagnetic compatibility.

JE partner

J. Eberspächer partner.

FAME

Biodiesel according to DIN V 14 214.

49

www.eberspaecher.com

J. Eberspächer
GmbH & Co. KG
Eberspächerstr. 24
D - 73730 Esslingen
Telefon [phone] - 00
Telefax 0711 939 - 0643
[e-mail]

25 2069 90 99 52 EN 04.2009 Subject to changes Printed in Germany © J. Eberspächer GmbH & Co. KG