Eberspächer Airtronic D2 24 V, Airtronic D3 12 V, Airtronic D2 Camper 12 V, Airtronic D4 12 V, Airtronic D4 24 V Troubleshooting And Repair Instructions
...
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
Airtronic D4S, 12 V 25 2144 05 00 00
Airtronic D4S, 24 V 25 2145 05 00 00
Airtronic D3 Camper, 12 V
(see Airtronic D3)
Airtronic D4 Camper, 12 V 25 2318 05 00 00
Airtronic D4 Camper plus, 12 V 25 2327 05 00 00
AIRTRONIC / AIRTRONIC M
Troubleshooting and Repair Instructions
25 2115 95 19 01
12.2011
Airtronic Order no.
Airtronic D2, 12 V 25 2069 05 00 00
Airtronic D2, 24 V 25 2070 05 00 00
Airtronic D2 Camper, 12 V 25 2326 05 00 00
Complete package
Airtronic D2, 12 V 25 2115 05 00 00
Airtronic D2, 24 V 25 2116 05 00 00
Air heater for diesel and petrol
operating independently of the engine.
2
4
3
1
2
1
Contents
This list of contents gives you precise information about the
contents of the Troubleshooting and Repair Instructions.
Introduction
Use the index, list of abbreviations, etc, to look for a term,
technical word or an explanation for an abbreviation.
Chapter Title Contents Page
Introduction • Foreword .................................................................................................................. 4
• Accident prevention .................................................................................................. 4
• Special text structure, presentation and picture symbols ........................................... 4
• Important information before starting work ................................................................ 4
Function and use Cutaway view ............................................................................................................ 5
• Description of functions
– Switching on .......................................................................................................... 6
– Starting the Airtronic .............................................................................................. 6
– Starting the Airtronic M .......................................................................................... 6
– Temperature selection with the control element ...................................................... 6
– Control in heating mode ......................................................................................... 6
– Ventilating mode .................................................................................................... 6
– Switching off .......................................................................................................... 6
• Control and safety devices ........................................................................................ 7
– Forced shut-down for ADR operation..................................................................... 7
– Emergency shutdown – EMERGENCY OFF ........................................................... 7
Technical data • Airtronic (for diesel) ................................................................................................... 8
• Airtronic M (for petrol) ................................................................................................ 9
• Airtronic M (for diesel) ........................................................................................ 10, 11
• Check values
– Test speed for the blower ..................................................................................... 12
– Resistan\ce values ............................................................................................... 12
– Switching value .................................................................................................... 12
– Exhaust emission specification ............................................................................. 12
– Check “external temperature sensor” ................................................................... 12
– Table of values: “External temperature sensor” ..................................................... 12
Troubleshooting • What to check first in case of faults
– Check .................................................................................................................. 13
– Electrical components.......................................................................................... 13
– Measure battery voltage ....................................................................................... 13
– Measures voltage supply ..................................................................................... 13
– Check switch-on signal ........................................................................................ 13
– Check control unit ................................................................................................ 13
• Overview of the individual test equipment and control units ..................................... 14
• Locking the control box ........................................................................................... 14
• Cancel the control box lock ..................................................................................... 14
• Important notes (diagnosis of heaters with mini-controller) ....................................... 14
• Testing device for the control device ........................................................................ 15
• Fault diagnosis using the diagnostic unit ........................................................... 15, 16
• Fault diagnosis using the EDiTH diagnostics tool with ISO adapter .......................... 17
• Air pressure sensor diagnosis using EDiTH diagnostics tool and ISO adapter .......... 18
• Fault diagnosis using the EDiTH diagnostics tool with basic adapter ....................... 19
• Fault diagnosis using the module timer .................................................................... 20
• Fault diagnosis using the radio remote control TP5 ................................................. 21
• Fault diagnosis using the EasyStart R+ radio remote control or
the EasyStart T timer ............................................................................................... 22
• Fault code table ...............................................................................................23 – 27
3
Introduction
7
6
5
1
Chapter Title Contents Page
Repair instructions • Repair instructions .................................................................................................. 28
• Always observe the following safety instructions before working on the heater ........ 28
• Special tool, AMP release tool ................................................................................. 28
• Assembly drawing Airtronic / Airtronic M ................................................................. 29
• Repair step 1, remove the heater cover ................................................................... 30
• Repair step 2, dismantle control box, check control box ......................................... 30
• Repair step 3, dismantle glow plug .......................................................................... 31
• Repair step 4, renew lining ...................................................................................... 31
• Repair step 5, dismantle combination sensor (overheating / flame sensor ............... 32
• Repair step 6, install combination sensor (overheating / flame sensor) ..................... 33
• Repair step 7, dismantle heat exchanger /
dismantle combustion air fan ................................................................................... 34
• Repair step 8, dismantle combustion chamber ........................................................ 35
• Check fuel supply .................................................................................................... 36
• Measuring the fuel quantity...................................................................................... 36
Circuit diagrams Overview of the parts lists and circuit diagrams........................................................... 37
• Parts list circuit diagrams Airtronic / Airtronic M ....................................................... 38
• Circuit diagram Airtronic / Airtronic M ..................................................................... 39
This circuit diagram is valid for heaters with one diagnosis cable
and a control box cable loom wich is firmly encapsulated.
• Circuit diagram Airtronic / Airtronic M ..................................................................... 40
This circuit diagram is for heaters with 2 diagnostics cable and whose
control box cable loom is wound with cable tape.
• Parts list circuit diagrams, control units .................................................................... 41
• Circuit diagram control units – part 1 ....................................................................... 42
• Circuit diagram control units – part 2 ....................................................................... 43
• Circuit diagram control units – part 3 ....................................................................... 44
• Circuit diagram control units – part 4 ....................................................................... 45
• Circuit diagram control units – part 5 ....................................................................... 46
• Circuit diagram control units – part 6 ....................................................................... 47
• Circuit diagram control units – part 7 ....................................................................... 48
• Parts list circuit diagram control unit EasyStart R+ / R / T ........................................ 49
• Circuit diagram control unit EasyStart R+ (control box with 1 diagnostics cable) ...... 50
• Circuit diagram control unit EasyStart R+ (control box with 1 diagnostics cable) ...... 51
• Circuit diagram control unit EasyStart R+ (control box with 2 diagnostics cable) ...... 52
• Circuit diagram control unit EasyStart R (control box with 1 / 2 diagnostics cables) . 53
• Circuit diagram control unit EasyStart R (control box with 2 diagnostics cables) ...... 54
• Circuit diagram control unit EasyStart R (control box with 1 diagnostics cables) ...... 55
• Circuit diagram control unit EasyStart T (control box with 1 diagnostics cable) ........ 56
• Circuit diagram control unit EasyStart T (control box with 2 diagnostics cable) ........ 57
• Parts list circuit diagrams Airtronic / Airtronic M – ADR ............................................ 58
• Circuit diagram Airtronic / Airtronic M – ADR .......................................................... 59
1 encapsulated diagnostics cable and control box cable loom firmly encapsulated
• Circuit diagram Airtronic / Airtronic M – ADR .......................................................... 60
2 diagnostics cables and control box cable loom with cable tape
• Parts list circuit diagrams, control units – ADR ......................................................... 61
• Parts list circuit diagrams, control units – EasyStart T – ADR ................................... 61
• Circuit diagram control units – ADR ......................................................................... 62
• Circuit diagram control unit EasyStart T – ADR (control box with 1 diag. cable) ....... 63
• Circuit diagram control unit EasyStart T – ADR (control box with 2 diag. cable) ....... 64
Service • Certification ............................................................................................................. 65
• Disposal .................................................................................................................. 65
• EC Declaration of Conformity .................................................................................. 65
• List of key words ..................................................................................................... 66
• List of abbreviations ................................................................................................ 67
4
Special text structure, presentation and
picture symbols
Special text formats and picture symbols are used in these
instructions to emphasise different situations and subjects.
Please refer to the following examples for their meanings and
appropriate action.
Special text formats and presentations
• A dot (•) indicates a list, which is started by a heading.
– If an indented dash (–) follows a “dot”, this list is a sub-
section of the black dot.
Picture symbols
Danger!
This information points out 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.
Caution!
This information points out 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.
Important information before starting
work
Initial commissioning of the heater or functional test
after a repair
• After installing the heater, the whole fuel supply system must
be carefully vented: please refer to and follow the vehicle
manufacturer’s instructions.
• During the heater trial run, all fuel connections must be
checked for leaks and secure, tight fit.
• If faults occur while the heater is running, use a diagnostic
unit to determine and correct the cause of the fault.
1 Introduction
Foreword
These Troubleshooting and Repair Instructions are applicable
to the heaters listed on the title Page, to the exclusion of all
liability claims.
Depending on the version or revised status of the heater, there
may be differences between it and these troubleshooting and
repair instructions.
The user must check this before carrying out the repair work
and, if necessary, take the differences into account.
Caution!
Safety instructions for installation and repair!
Improper installation or repair of Eberspächer heaters can
cause a fire or result poisonous exhaust entering the inside of
the vehicle. This can cause serious and even fatal risks.
The heater may only be installed according to the specifications in the technical documents or repaired using original
spare parts by authorised and trained persons.
Installation and repairs by unauthorised and untrained persons, repairs using non-original spare parts and without the
technical documents required for installation and repair are
dangerous and therefore are not permitted.
A repair may only be carried out in connection with the respective unit-related technical description, installation instructions, operating instructions and maintenance instructions.
This document must be carefully read through before / during
installation and repair and followed throughout. Particular
attention is to be paid to the official regulations, the safety
instructions and the general information.
Please note!
The relevant rules of sound engineering practice and any
information provided by the vehicle manufacturer are to be
observed during the installation and repair.
Eberspächer does not accept any liability for defects and
damage, which are due to installation or repair by unauthorised and untrained persons.
Compliance with the official regulations and the safety instructions is prerequisite for liability claims. Failure to comply with
the official regulations and safety instructions leads to exclusion of any liability of the heater manufacturer.
Accident prevention
General accident prevention regulations and the corresponding workshop and operating safety instructions are to be
observed.
5
Cutaway view
1 Heater impeller
2 Control box
3 Combustion air fan impeller
4 Glow plug
5 Cover
6 Heat exchanger
7 Combination sensor (overheating / flame sensor)
8 Radio remote control (mobile unit)
9 Radio remote control (stationary unit)
10 Button
11 Temperature sensor (room temperature)
12 Fuse bracket with main fuse and “actuation” fuse
13 Electrical motor
14 Fuel connection
15 Flange seal
16 Combustion chamber
17 Outlet hood
18 Combustion air hose
19 Metering pump
20 Pot-type strainer, installed in the dosing pump
21 Outflow
22 Flexible exhaust pipe
F = Fresh air
W = Hot air
A = Exhaust
B = Fuel
V = Combustion air
Function and use2
6
Description of functions
Switching on
When the heater is switched on, the control lamp in the control unit lights up. The glow plug is switched on and the fan
starts at low speed.
f 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.
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.
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.
The fan then continues running at minimum speed (circulation
mode) until the restart or is switched off (fresh air mode with
external temperature sensor).
Ventilating mode
The EasyStart R+ and EasyStart T control units and the minicontroller can be used to activate the „Ventilate“ function.
The „Heat / Ventilate“ switch is also required for the modular
timer and control device whereby, for fan mode, the „Heat /
Ventilate“ switch must be pressed first and then the heater
switched on.
The blower runs at maximum speed in fan mode.
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.
Function and use2
Please note!
7
Forced shut-down for ADR operation
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, petrol station, etc.).
Failure to comply results in the heater automatically switching
off if:
• the vehicle engine is switched off,
• an additional unit is started up (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.
Function and use2
Emergency shutdown – EMERGENCY OFF
If an emergency shutdown –EMERGENCY OFF – is required during operation, execute the following:
• Switch the heater off at the control element or
• remove the fuse or
• disconnect the heater from the battery.
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 restarted 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 if the glow plug or blower motor is defective or if the electric lead to the metering 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 repeat the switching off / on routine more than twice.
8
Technichal data3
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.
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
Technichal data
Heater type
Heater
Version
Heating medium
Control of the heat flow
Heat flow (watt)
Heater air flow rate without counterpressure (kg/h)
with hood Ø 60 mm
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
Tolarable ambient temperature
Heater
Dosing pump
Maximum air intake temperature
Interference suppression
Weight
Ventilation mode
Airtronic
Airtronic D2 / Airtronic D2 Camper
D2 / D2 Camper
Air
Stage
Power Large Medium Small Off
2200 1800 1200 850 –
105 90 60 40 13
0.28 0.23 0.15 0.10 –
34 22 12 8 5
#100
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
Diesel DIN EN 590 (commercially available)
in operation no operation
–40 °C to +70 °C –40 °C to +85 °C
–40 °C to +50 °C –40 °C to +125 °C
max. +40 °C
Interference suppression class 5 to DIN EN 55 025
approx. 2.7 kg
possible
Please note!
9
Technichal data3
Technichal data
Heater type
Heater
Version
Heating medium
Control of the heat flow
Heat flow (watt)
Heater air flow rate without counterpressure (kg/h)
with hood Ø 90 mm
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
Tolarable ambient 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
#100
12 volt
approx. 10.5 volt
Undervoltage protection trigger time: 20 seconds
16 volt
Overvoltage protection trigger time: 20 seconds
Petrol DIN EN 228 (commercially available)
in operation no operation
–40 °C to +50 °C –40 °C to +85 °C
–40 °C to +20 °C –40 °C to +125 °C
max. +40 °C
Interference suppression class 5 to DIN EN 55 025
ca. 4.5 kg
possible
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.
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
Please note!
10
Technichal data3
Technichal data
Heater type
Heater
Version
Heating medium
Control of the heat flow
Heat flow (watt) D3
D4
D4 Plus
Heater air flow rate without counterpressure (kg/h)
D3 with hood Ø 90 mm
D4 with hood Ø 90 mm
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
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
#100
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
Diesel DIN EN 590 (commercially available)
in operation no operation
–40 °C to +70 °C –40 °C to +85 °C
–40 °C to +50 °C –40 °C to +125 °C
max. +40 °C
Interference suppression class 5 to DIN EN 55 025
approx. 4.5 kg
possible
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.
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
Please note!
11
Technichal data3
Technichal data
Heater type
Heater
Version
Heating medium
Control of the heat flow
Heat flow (watt) D4S
D4 Camper / D4 Camper Plus
Heater air flow rate without counterpressure (kg/h)
D4S
D4 Camper / D4 Camper Plus
Fuel consumption (l/h)) D4S
D4 Camper / D4 Camper Plus
Elektr. power consumption (watt) D4S
in operation (12 and 24 v) D4 Camper / D4 Camper Plus
at start (12 and 24 v)
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
Tolarable ambient temperature
Heater
Dosing pump
Maximum air intake temperature
Interference suppression
Weight
Ventilation mode
Airtronic M
Airtronic D4S / Airtronic D4 Camper /
Airtronic D4 Camper Plus
D4S / D4 Camper / D4 Camper Plus
Air
Stage
Power Large Medium Small Off
3500 3000 2000 1000 –
4000 / 3500 3000 2000 900 –
160 140 100 60 22
185 / 160 150 / 140 110 / 100 60 / 55 24 / 22
0.44 0.38 0.25 0.13 –
0.51 / 0.44 0.38 0.25 0.11 –
40 30 16 8 5
40 24 / 30 13 / 16 7 / 8 5
#100
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
Diesel DIN EN 590 (commercially available)
in operation no operation
–40 °C to +70 °C –40 °C to +85 °C
–40 °C to +50 °C –40 °C to +125 °C
max. +40 °C
Interference suppression class 5 to DIN EN 55 025
approx. 4.5 kg
possible
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.
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
Please note!
12
Check values
Test speed for the blower
Airtronic D2 / D2 Camper (12 volt / 24 volt)
• 12 volt 5000 rpm ±25 % at U = 10,0 volt
• 24 volt 5000 rpm ±25 % at U = 18,0 volt
Airtronic B4 (12 volt)
Airtronic D3 / D3 Camper (12 volt)
Airtronic D4 (12 volt / 24 volt)
Airtronic D4 Camper (12 volt)
• 12 volt 4400 rpm ±25 % at U = 10,0 volt
• 24 volt 4400 rpm ±25 % at U = 18,5 volt
Airtronic D4S / Airtronic D4 Plus (12 volt / 24 volt)
Airtronic D4 Camper Plus (12 volt)
• 12 volt 4400 rpm ±25 % at U = 10,5 volt
• 24 volt 4400 rpm ±25 % at U = 19,0 volt
Resistance values
at 20 °C
12 volt 24 volt
Glow plug 0.42 – 0.70 1.2 – 2.0
Dosing pump 9.5 ±0.50 36.0 ±1.8
Control unit
resistance values
Switch position,
left limit stop
Switch position,
right limit stop
Control device
12 volt / 24 volt
min. 1720
max. 1760
min. 2096
max. 2216
Modular timer and
mini-controller
12 volt / 24 volt
min. 1730
max. 1780
min. 2120
max. 2240
Switching value
Overheating sensor 140 °C – 170 °C
measured in the “High” control stage
and at a distance of 300 mm downstream
from the hot air outlet
Exhaust emission specification
CO
2
in exhaust
in control stage “high” 7,5 – 12,5 Vol. %
Smoke spot number according to Bacharach < 4
Temperature (°C)
Resistance (ohm)
2200
2000
1800
1600
1400
1200
1000
±40
±20
02040±10
±30
10 30
2400
50
Technical data3
Check “external” temperature sensor
(Order No.: 25 1774 89 03 00)
The “external” temperature sensor test must be carried out
using a digital multimeter. If the resistance value is not the
same as the curve in the diagram or the table of values, replace the temperature sensor.
Table of values – “external” temperature sensor
Temperature °C Resistance
min. max.
0 1600 1660
5 1670 1730
10 1745 1800
15 1820 1870
20 1895 1950
25 1970 2030
30 2050 2110
35 2130 2190
40 2210 2280
45 2295 2370
13
Troubleshooting4
What to check first in case of faults
• Check
– Fuel in the tank?
– Fuel pipes leaking? (visual check)
– Summer diesel in the fuel pipe?
– Combustion air system or exhaust system damaged or
blocked?
– Hot air system blocked?
– Air pressure sensor installed? If yes, refer to „What to do
if…?“ chapter of the „Altitude Kit“ installation instructions.
– New generation control box installed?
Features:
> Cable loom of control box wound with cable tie
> Temperature sensor mounted on the side of the control
box (visible when cover removed)
• Electrical components
– Cables, connections damaged?
– Contacts corroded?
– Fuses defective?
– Incorrect wiring? (short circuits, interrupted / broken)
• Measure battery voltage
– Battery voltage < 10.5 volt, the undervoltage protection of
the 12 volt heater has triggered.
– Battery voltage < 21 volt, the un
• Measure voltage supply (Cl 30)
Disconnect the 16-pin connector S1 / B1 and measure the
voltage applied at connector B1 between chamber 1 (cable
2.5
2
rt) and chamber 10 (cable 2.52 br).
If it differs from the battery voltage, check the fuses, the
supply cables, the negative connection and the positive
support point on the battery for voltage drop (corrosion /
interruption).
• Check switch-on signal
Disconnect the 16-pin connector S1 / B1 and then switch
on the heater at the control unit.
Check whether voltage is applied in the connector B1
between chamber 4 (cable 0.5
2
ge) and chamber 10 (cable
2.5
2
br).
If no voltage is measured, then check the supply cable (ca-
ble 0.5
2
ge), the 5 A fuse (item 2.7.1 in the circuit diagram)
and the control unit.
• Check control unit
Control device, mini-timer, mini-controller
and modular timer
Disconnect the connector at the control unit; install a jumper
between the red 0.5² rt cable and the yellow 0.5² ge cable.
If a voltage is measured in connector B1 between cham-
ber 4 (cable 0.5² ge) and chamber 10 (cable 2.5² br), then
replace the control unit.
EasyStart R+ / EasyStart R / EasyStart T
Disconnect the connector at the control unit; install a jumper
between the yellow 0.5² ge cable and the red 0.5² rt cable.
If a voltage is measured in connector B1 between cham-
ber 8 (cable 0.5² ge) and chamber 10 (cable 2.5² br), then
replace the control unit.
14
Troubleshooting4
Overview of the test equipment and
control units suitable for diagnosis
The electronic control box can store up to 5 faults, which can
be read out and displayed. The following test equipment and/
or control units can be used to query the fault memory in
the control box and if necessary to delete the locking of the
control box:
Test equipment Order No.:
• Testing device
for the control device 22 1509 89 00 00
• Diagnostic unit 22 1529 89 00 00
additionally required:
Adapter cable 22 1000 31 86 00
• EDiTH diagnostic tool
– Basic adapter with software 22 1542 89 00 00
additionally required:
Airtronic extension 22 1537 89 00 00
– ISO-adapter 22 1541 89 00 00
additionally required:
Adapter cable 22 1000 31 86 00
– „Air pressure sensor“ adapter cable 22 1000 33 31 00
Only for heaters with connected air pressure sensor for
reading out the „air pressure sensor“ fault memory.
If a diagnostics cable is connected, the following control units
can also be used:
Control units Order No.:
• Module timer 22 1000 30 34 00
• TP5 radio remote control 22 1000 32 01 00
• EasyStart T 22 1000 32 88 00
• EasyStart R+ 22 1000 32 80 00
Please note!
If the fault memory cannot be read out, check the diagnostics
cable for correct laying and possible damage.
Important notes on diagnosis of heaters
with mini-controller control unit
Caution!
When checking the heater with the diagnostics unit or the
EDiTH diagnostics tool the order given in the following notes
must always be followed as otherwise the heater detects Error
62 (control unit – interruption) and switches to emergency
operation.
Mini-controller in stand-alone operation
• Connect adapter cable 22 1000 31 86 00 as described in
the operating instruction.
• Select operating mode (Heat / Ventilate) at the mini-controller
• Perform diagnosis using the diagnostics unit or the EDiTH
diagnostics tool.
• Switch off the mini-controller after finishing the diagnosis
• Remove the adapter cable
Mini-controller in combination with mini-timer
• Connect adapter cable 22 1000 31 86 00 as described in
the operating instruction.
• Press the m button of the mini-timer
• Select operating mode (see mini-timer operating instructions)
• Perform diagnosis using the diagnostics unit or the EDiTH
diagnostics tool.
• Switch off the mini-timer after finishing the diagnosis
• Remove the adapter cable
Mini-controller in combination with TP5
• Connect adapter cable 22 1000 31 86 00 as described in
the operating instruction.
• Press the
button of the TP5 radio remote control
• Select operating mode (see TP5 radio remote control operating instruction)
• Perform diagnosis.
• Switch off TP5 radio remote control after finishing the diagnosis
• Remove the adapter cable
Please note!
If the operating mode is to be changed during the test the
heater must be switched off first using the diagnostics unit or
the EDiTH diagnostics tool, otherwise the heater detects Error
62 (control unit – interruption) and switches to emergency
operation.
Test mini controller
The mini-controller must be connected to the heater for testing. The setpoint value can be displayed using the EDiTH
diagnostics tool. If the rotary knob is at the left limit stop the
setpoint value is 8 °C, at the right limit stop it is 34 °C.
Please note!
The resistance of the setpoint value potentiometer cannot be
measured directly. The measured values are not meaningful.
15
Troubleshooting4
Testing device for the control device
(Order No.: 22 1509 89 00 00)
Prepare for test
Connect the correct operating voltage (12 or 24 volt) to the testing device, with plus at the red connector socket and minus
at the blue connector socket.
• Disconnect socket from the control unit.
• Connect cable loom from testing device with the control
unit.
• Set the rotary knob of the control unit to “Heat”, the corresponding red LED in the testing device must light up.
• Set control unit to “0”, then press the “LED – red” button,
the red control lamp in the control unit must light up.
• Set control unit to “Heat”, then press the “LED – green”
button, corresponding red control lamp in the testing device
and the green control lamp in the control unit must light up.
Caution!
Safety instructions for checking the control unit!
Ensure you use the correct operating voltage, otherwise the
connected components can be severely damaged.
Check the setpoint potentiometer of the control unit
Set the “Temperature sensor / Potentiometer” switch in the
testing device to the “Potentiometer” setting and slowly turn
the rotary knob of the control unit.
The green LED – temperature sensor / potentiometer must
light up continuously.
In case of a fault, replace the control unit.
1 Testing device
2 Control device
Diagnostic unit
(Order No.: 22 1529 89 00 00)
An additional adapter cable is required to connect the diag-
nostic unit (Order No.: 22 1000 31 86 00).
The current fault is displayed as “AF” and a 2-digit number
and is always written in the memory position F1.
Preceding faults are moved to the memory locations F2 – F5,
if necessary the contents of memory position F5 is overwritten.
• Not only the defective component, but also a defective current circuit results in a fault being displayed.
• In heaters with connected air pressure sensor the diagnostics unit can be used to read out the fault memory of the
heater only.
The fault memory of the „air pressure sensor“ can be read
out using the EDiTH diagnostics tool only.
• Fault code, fault description, cause / remedial action are
described on Pages 23 – 27.
l
–Delete fault memory
l
– Delete fault memory
d
– Switch heater on / off, request diagnosis
e
– Reverse, F5 – F1
f
– Forward, F1 – F5, current fault (AF)
Connect diagnostics unit, see page 16.
Please note!
16
Connect diagnostic unit
• Disconnect the 8-pin connector of the heater’s cable harness and connect the adapter cable.
• Connect the diagnostic unit to the adapter cable.
Display is as follows:
Query fault memory
• Use the D key to switch on the heater.
Display is as follows:
• After 8 sec the following is displayed:
Display is as follows:
Heater has no malfunction
or
e.g. current error / fault code 64
or
Fault diagnosis not possible
Possible causes:
– Adapter cable is not properly connected.
– Control box is defective or is not capable of diagnosing
(not a universal control box).
Display of the fault memory F1 – F5 or F5 – F1
• Press the e or f button, or press several times, to display
the fault memory.
Display is as follows:
e.g. fault memory 2 / fault code 10
Only the fault memory positions with an error assigned to
them are displayed.
Delete fault memory
• Press both L buttons simultaneously until the following appears in the display:
Display is as follows:
• If the fault memory has been deleted the most recent current fault is displayed. The current fault is not reset to 00
until the heater is restarted – provided there is no new, more
recent fault.
Display is as follows:
Heater has no malfunction
Cancel the control box lock
• Delete the fault memory as described and switch off the
heater using the d key.
• The control box lock is cancelled and the diagnosis closed.
Display is as follows:
Troubleshooting4
1 Heater
2 Adapter cable
3 Diagnostic unit
1
2
3
Please note!
17
Troubleshooting4
EDiTH diagnostic tool with ISO adapter
(Order No.: 22 1541 89 00 00)
An additional adapter cable is required to connect the ISO
adapter (Order No.: 22 1000 31 86 00).
• It is very important to always install in the given order.
• Not only the defective component, but also a defective current circuit results in a fault being displayed.
• Fault code, fault description, cause / remedial action are
described on Pages 23 – 27.
• The EDiTH diagnostics tool scope of supply does not
include the software; this must be downloaded from the
Service Portal.
Connect ISO adapter
• Disconnect the heater’s cable harness.
• Connect the adapter cable to the cable harness – as shown
in the sketch.
• Connect the adapter cable to the ISO adapter.
• Connect the SUB-D connection cable with the PC and the
ISO adapter.
Installing the software on your PC
• Double click the “setup.exe” file to start the installation and
following the SETUP program instructions.
Query / delete fault memory F1 – F5
or cancel the control box lock
• Start the software on your PC:
– on the desktop —> double click the “EDiTH” icon
– Select heater type
– Press the “GO” button.
• Delete fault memory or cancel the control box lock:
– press the “Delete fault memory” button
—> the stored faults F1 – F5 are deleted and the control
box is unlocked.
Quit diagnosis
• Press the “STOP” button —> fault memory query is ended.
1 Heater
2 Adapter cable
3 ISO adapter
4 SUB-D connection cable
5 USB to Serial RS-232 adapter
Please note!
18
Troubleshooting4
Air pressure sensor diagnosis using
EDiTH diagnostics tool and ISO adapter
(Order No. 22 1524 89 00 00)
An additional adapter cable is required to connect the
ISO adapter (Order No.: 22 1000 33 31 00).
The air pressure sensor connected to the heater can be diagnosed. If faults occur during the altitude adjustment they are
stored in the air pressure sensor. If necessary, faults can be
read out using the ISO adapter in conjunction with the EDiTH
diagnostics tool – from Version S3V7-F – and the additionally
necessary adapter cable.
Please note!
• It is very important to always install in the given order.
• Not only the defective component, but also a defective current circuit results in a fault being displayed.
• Fault code, fault description, cause / remedial action are
described on pages 27.
• The EDiTH diagnostics tool scope of supply does not
include the software; this must be downloaded from the
Service Portal.
Perform diagnosis of the air pressure sensor
Disconnect the connector between the air pressure sensor /
heater, control unit, connect the ISO adapter with the adapter
cable (see sketch).
Start the diagnosis of the air pressure sensor.
• Double-click the >>EDiTH<< icon on the desktop.
• Select the air pressure sensor in the »Heater and Test Selection«.
The following actions are possible:
– Read out the current fault and the fault memory.
– Delete the fault memory.
– Query the current measured air pressure.
– Query the operating state.
– Query the general data.
– Print out the fault memory and / or the general data
• Exit the diagnosis with the »Stop« button or by closing all
windows.
– Selection: Save analysis / Do not save analysis
• Remove ISO adapter and adapter cable from the lead harness and reconnect the air pressure sensor / heater, control
unit connector.
1 Air pressure sensor
2 Adapter cable
3 Cable loom from heater
4 Cable loom to control unit
5 ISO adapter
6 SUB-D connection cable
7 USB to Serial RS-232 adapter
19
Caution!
Magnetic field!
During the test operation a magnetic field develops at the
adapter. Therefore, do not place any objects such as data
media, credit cards, etc. on the adapter or in its immediate
vicinity.
Troubleshooting4
(A) Basic adapter
(B) SUB-D connection cable
(C) Mains connection
(D) Mains switch
(E) USB to Serial RS-232 adapter
(F) Adapter
(G) Control box
Cable colours
sw = black
gn = green
bl = blue
EDiTH diagnostic tool with basic adapter
EDiTH basic adapter (Order No.: 22 1542 89 00 00)
An additional extension is required to check the control box
(Order No.: 22 1537 89 00 00).
• It is important to always follow the precise connection order
as given below!
• The Hall sensor integrated in the control box can only be
properly tested in the control box is correctly placed on the
extension.
• Only push or pull on the connectors, not on the cables!
• Only use the network cable and RS232 cable with snap
ferrites included in the scope of supply. Use original accessories with snap ferrites only to connect the test equipment.
• Not only the defective component, but also a defective
current circuit results in a fault being displayed.
• Fault code, fault description, cause / remedial action are
described on Pages 23 – 27.
Connect basic adapter
• Start computer and wait until the system has successfully
booted.
• Start PC software.
• Insert the unit connector of the mains cable in the basic
adapter (A) and connect the mains connection (C) to the
mains.
• Connect the SUB-D connection cable (B) with the PC and
basic adapter (A).
Connect extension and test control box
• Connect the extension to the basic adapter (A).
• Connect the control box (E) to the extension and the adapter (F).
• Switch on the basic adapter (A) at the mains switch (D).
• Select the control box version and operating voltage
(12 V / 24 V) in the PC software.
• Start the control box test with the PC software. A more detailed description of how to operate the basic adapters (A) is
given in the EDiTH online help.
Please note!
20
Troubleshooting4
Module timer
(Order No.: 22 1000 30 34 00)
The current fault is displayed as “AF” and is always written in
memory position F1.
Preceding faults are moved to the memory locations F2 – F5,
if necessary the contents of memory position F5 is overwritten.
• Not only the defective component, but also a defective current circuit results in a fault being displayed.
• In heaters with connected air pressure sensor the modular
timer cannot be used to perform diagnoses. The diagnostics unit or the EDiTH diagnostics tool must be used to
perform the diagnosis.
The fault memory of the „air pressure sensor“ can be read
out using the EDiTH diagnostics tool only.
• Fault code, fault description, cause / remedial action are
described on Pages 23 – 27.
Query fault memory F1 – F5
Condition:
The heater is switched off.
• Press c key –> the heater is switched on.
• Press a key and keep pressed,
then press p key within 2 seconds.
Display is as follows:
AF = current fault
3 digit number = fault code
c flashes.
• Press f key once or several times,
fault memory positions F1 – F5 are displayed.
Cancel the control box lock and simultaneously delete
the fault memory
Condition:
An electrical connection exists from terminal 15 (ignition) to
the module timer, 12-pin connector, chamber 10.
• Press c key
Display is as follows:
the current fault F15 or F50.
• Press button a, keep it depressed and then press button p
within 2 seconds.
The module timer is now in the “Query fault memory” pro-
gram.
• Switch off ignition (terminal 15).
• Simultaneously press button a and button p, in addition,
switch on the ignition (terminal 15) and wait until the following appears in the display.
After ignition “ON” the following appears in the display:
Display flashes,
Heater symbol does not flash
• Switch the heater off and on –> the control box is unlocked,
the heater restarts.
After switching the heater off and on and renewed query of
the fault memory, the following appears in the display:
Display flashes,
Heater symbol does not flash
a
– Time
p
– Preset
c
– Heat
e
– Reverse
f
– Forward
Please note!
21
Troubleshooting4
TP5 radio remote control
(Order No: 22 1000 32 01 00)
If faults occur while the heater is running, they are displayed
with “Err” after the mobile unit is activated.
After the diagnostics cable (bl/ws) has been connected and
the first logs have arrived at the stationary unit, the diagnose
can be carried out using the mobile unit of the TP5 radio
remote control.
The current fault “F0” is displayed. The stored faults “F1” to
“F5” can be queried.
• In order to carry out the diagnosis, the diagnostics cable
(bl/ws) must be connected to the stationary unit and the
heater cable harness. To this end, please refer to and follow
the circuit diagram for the TP5 radio remote control and the
heater.
• If the diagnostics cable (bl/ws) is not connected, the “Diagnosis” menu is blocked.
• Not only the defective component, but also a defective current circuit results in a fault being displayed.
• In heaters with connected air pressure sensor the TP5 radio
remote control cannot be used to perform diagnoses. The
diagnostics unit or the EDiTH diagnostics tool must be used
to perform the diagnosis.
The fault memory of the „air pressure sensor“ can be read
out using the EDiTH diagnostics tool only.
• Fault code, fault description, cause / remedial action are
described on Pages 23 – 27.
Button to activate / deactivate the mobile unit
Button for forward time setting
Button for backward time setting
Button for activating the possible settings
Button for switching heat / ventilate ON / OFF;
Activate / deactivate preselected time
Enquire / delete fault memory
Use the
key to activate the mobile unit.
Switch on the heater with the
key.
Press the
key twice to open the Time setting menu –
the time flashes in the display.
Press the
key for approx 2 sec – until the following ap-
pears in the display:
Press
key.
Press
key.
Press
key twice.
Press
key.
Malfunction in heater: Heater has no malfunction:
Use the
and buttons to call up the fault memory posi-
tions 1 to 5.
Delete fault memory /
Cancel the control box lock
Use the
key to delete the fault memory.
To confirm, press the
key for approx 2 sec until lights
up in the display – fault memory is deleted.
Please note!
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