Eberspächer AIRTRONIC Series, AIRTRONIC M Series Technical Description And Installation Instructions

AIRTRONIC / AIRTRONIC M
Technical description, installation, operation and maintenance instructions.
Air heater for diesel and petrol operating independently of the engine.
Airtronic Order no.
Airtronic D2, 12 V 25 2069 05 00 00 Airtronic D2, 24 V 25 2070 05 00 00
12 V with mini controller 25 2115 05 00 00 12 V with EasyStart Select 25 2675 05 00 00 24 V with mini controller 25 2116 05 00 00 24 V with EasyStart Select 25 2676 05 00 00
Airtronic M Order no.
Airtronic B3 Plus, 12 V 20 1944 05 00 00 Airtronic B4, 12 V 20 1812 05 00 00
Airtronic D3, 12 V 25 2317 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
20 1944 90 00 01
01.2014
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Introduction
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Contents
Chapter Title Contents Page
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 B3 Plus, B4 ......................................................14
• Main dimensions .................................................................................... 15
Installation • Installation and location .........................................................................16
• 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
Electrical system • Heater wiring .........................................................................................32
• Parts list for the circuit diagrams / Circuit diagrams ....................... 33 – 40
Troubleshooting • In case of faults, please check the following points ...............................41
Maintenance • Troubleshooting ....................................................................................41
Service • Maintenance instructions .......................................................................41
• Service ..................................................................................................41
Environment • Certification ..........................................................................................42
• Disposal ................................................................................................42
• EU Declaration of Conformity .................................................................42
Lists • List of key words ............................................................................43, 44
• List of abbreviations ...............................................................................44
3
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
Here you will find important introductory information about installation of the heater and about the structure of the manual.
Product information
Here you will find information about the scope of supply, the technical data and the dimensions of the heater.
Installation
Here you will find important information and instructions referring to installation of the heater.
Operation and function
Here you will find information about the opera­tion and function of the heater.
Electric system
Here you will find information about the elec­tronic system and electronic components of the heater.
Troubleshooting / maintenance / service
This section contains information on possible faults and malfunctions, troubleshooting, mainte­nance and the service hotline.
Environment
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.
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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 Eberspächer Climate Control Systems 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 cer-
tain 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.
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:
• All types of vehicles (max. 8 seats + driver’s seat)
and their trailers
• Construction machinery
• Agricultural machinery
• Boats, ships and yachts (only diesel heaters)
• Camper vans
• 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 installa-
tion 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.
Please note!
Please note!
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Introduction
1
Statutory regulations
The Federal Motor Transport Authority has issued an “EC type approval”, “EMC type-approval” and the approval for a component according to ECE R122 and ECE-R10 for the heater for installation in motor vehicles with the following official type-approval marks, noted on the heater name plate.
Type-approval marks
Airtronic Airtronic M
EG
00 0025 00 0026
EMV
03 1516 03 1653
ECE
122R-000025 10R-031516
122R-000026 10R-031653
Regulations! Extract from Directive 2001 / 56 / EC Annex VII and ECE Regulation No. 122 of the European Parlia­ment and of the Council
General regulations
• Operating state display
– A clearly visible operating display in the user’s field of
vision must indicate when the heater is switched on and off.
Regulations concerning installation in the vehicle
• Scope
– Subject to differing stipulations in the following
section, combustion heaters must be installed ac­cording to the provisions of Annex VII.
– It is assumed that Class O vehicles with heaters for
liquid fuel conform to the provisions of the directive.
• Arrangement of the heater
– Parts of the structure and other components near
the heater must be protected from excessive heat exposure and possible fuel or oil contamination.
– The heater must not pose a fire hazard even when it
overheats. This requirement is deemed to be fulfilled if adequate clearance is ensured for all parts during installation, sufficient ventilation is provided and fireproof materials or heat shields are used.
– The heater must not be mounted in the passen-
ger compartment of vehicles in class M2 and M3. However, a heater in a hermetically sealed enclosure which also complies with the aforementioned condi­tions 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.
• 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 connec-
tion 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’s combustion chamber must
not be sucked in from the vehicle’s passenger com­partment.
– The air intake must be arranged or protected in such
a way that it cannot be blocked by other objects.
• Hot air intake
– The heater’s air supply must consist of fresh air or
circulated air and must be sucked in from a clean area, which cannot be contaminated by exhaust fumes from the engine, 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 ar-
ranged 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.
• Automatic control of the heating system
– If the engine fails, the heating system must be auto-
matically switched off and the fuel supply stopped within 5 seconds. The heater may remain in opera­tion if a manual device has already been activated.
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Introduction
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Statutory Regulations! Additional regulations for certain vehicles named in Directive 94 / 55 / EC of the ADR Agreement
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
The vehicle designations “EX / II”, “EX / III”, “AT”, “FL” and “OX” according to Chapter 9.1 of the ADR Agree­ment Directive 94 / 55 / EC are used for the purposes of this annex.
Technical regulations
General provisions (EX / II, EX / III, AT, FL and OX vehicles)
Avoid heating and ignition
Combustion heaters and their exhaust pipes must be designed, arranged, protected or covered so that any unacceptable risk of heating or ignition of the load is avoided. This regulation is deemed to be complied with if the fuel tank and the exhaust system of the unit con­form to the regulations described in the “Fuel tank” and “Exhaust system and exhaust pipe layout” paragraphs. The complete vehicle must be checked for compliance with these regulations.
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 Eberspächer Climate Control Systems 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.
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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 Eberspächer Climate Control Systems 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.
Introduction
1
• 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.
• Do not operate the heater anywhere where there are readily flammable materials (e.g. dry grass, leaves, paper, etc.) in the area of the exhaust system or where ignitable fumes and dust can form, e.g. near a – 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.
Please note!
Following installation, attach the „Switch off heater before refuelling!“ sticker near the tank filler neck.
Accident prevention
General accident prevention regulations and the cor­responding workshop and operation safety instructions are to be observed.
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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
• with outlet hood Ø 90 mm, heater guide number 30, usable with:
– Airtronic B3 Plus, 12 V 20 1944 05 00 00
Universal installation kit 25 2484 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 B3 Plus, 12 V 20 1944 05 00 00 – Airtronic D4 Plus, 12 V 25 2484 05 00 00 – Airtronic D4 Plus, 24 V 25 2498 05 00 00
Please note!
• Control elements see price list or product information.
• Parts without a figure no. are small parts and packed in a bag.
• If other parts are required for the installation, see product information.
• For notes on the unit ratings, refer to product informa­tion.
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 B3 Plus, 12 V 20 1944 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 Airtronic D2 Order No. package
12 V with mini controller 25 2115 05 00 00 12 V with EasyStart Select 25 2675 05 00 00 24 V with mini controller 25 2116 05 00 00 24 V with EasyStart Select 25 2676 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 EasyStart Select or 4 Mini-controller 5 Tank connection (only in complete
package Airtronic D2, 24 V)
Universal installation kit (all versions)
Included in the scope of supply: No. in figure Name
6 Lead harness, operation 7 Flexible exhaust pipe, 1 m long 8 Combustion air hose, 1 m long 9 Cable tie (10x) 10 Bracket, dosing pump 11 Pipe, 6 x 2, 1.5 m long 12 Pipe, 4 x 1.25, 7.5 m long 13 Hose clip (2x) 14 Air outlet, rotatable 15 Grid 16 Hood 17 Flexible pipe 18 Exhaust silencer
19 Cable harness, heater 20 Lead harness, plus / minus
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Scope of supply: Heater, universal installation kit and complete packages
* Only included in the complete Airtronic D2 package. ** Only included in the installation kit for the Airtronic B3 Plus, D3, B4, D4, D4 Plus. *** Only included in the installation kit for the Airtronic D2 and in the complete Airtronic D2 package. **** Only included in the complete Airtronic D2, 24 volt package.
Product information
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Please note!
• Parts without a figure no. are small parts and packed in a bag.
• If other parts are required for the installation, see product information.
• For notes on the unit ratings, refer to product informa­tion.
• The “Plus” installation kits are particularly suitable for installations in camper vans and boats.
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
The scope of supply includes: No. in figure Name
1 Heater 2 Metering pump
“Plus” installation kit 25 2113 81 00 00
• with outlet hood Ø 75 mm, heater guide number 12,
The scope of supply includes: 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 , 6 m long, (included in Item 8) 17 Cable harness, heater 18 Flexible exhaust pipe, 1 m long 19 Grid 20 Bracket metering pump 21 Cable tie (10x) 22 Hood 23 Outlet (2x) 24 Adapter Ø 6 / 4 25 Pipe 4 x 1, 6 m long, (included in Item 8) 26 Pipe clip, Ø 50 mm 27 Flexible pipe for hot air system
Product information
2
11
Product information
2
Scope of supply: Heater and “Plus” installation kit
12
Product information
2
Caution! Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
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.
Technichal data
Heater type
Airtronic
Heater Airtronic D2
Version D2
Heating medium Air
Control of the heat flow Stage
Power Large Medium Small Off
Heat flow (watt) 2200 1800 1200 850
Heater air flow rate without counterpressure (kg/h)
105 87 60 42 13with hood Ø 60 mm
Fuel consumption (l/h) 0,28 0,23 0,15 0,10
Elektr. power consumption (watt)
34 23 12 8 4in operationt
at start 100
Rated voltage 12 or 24 volt
Operating range
• Lower voltage limit: An undervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 10.5 volt resp. 21 volt
Undervoltage protection trigger time: 20 seconds
• Upper voltage limit: An uppervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 16 volt resp. 32 volt
Overvoltage protection trigger time: 20 seconds
Fuel “Fuel quality“ and “Fuel at low temperatures“
see page 28.
Commercially available diesel fuel (DIN EN 590)
Tolarable ambient temperature Operation Not running
Heater –40 °C to +70 °C – 40 °C to +85 °C
Dosing pump –40 °C to +50 °C –40 °C to +125 °C
Maximum air intake temperature +40 °C
Interference suppression Interference suppression class 5 to DIN EN 55 025
Weight approx. 2,7 kg
Ventilation mode possible
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Product information
2
Safety instructions for technical data see page 12.
Please note!
Technichal data
Heater type
Airtronic M
Heater Airtronic D3 / Airtronic D4 / Airtronic D4 Plus
Version D3 / D4 / D4 Plus
Heating medium Air
Control of the heat flow Stage
Power Large Medium Small Off
Heat flow (watt) D3 3000 2200 1600 900
D4 4000 3000 2000 900
D4 Plus 4000 3000 2000 900
Heater air flow rate without counterpressure (kg/h)
150 120 90 60 24D3 with hood Ø 90 mm
D4 with hood Ø 90 mm 185 150 110 60 22
D4 Plus with hood Ø 75 mm 185 140 100 55
Fuel consumption (l/h) D3 0,38 0,28 0,24 0,11
B4 0,51 0,38 0,25 0,11
D4 Plus 0,51 0,38 0,25 0,11
Elektr. power consumption (watt) iin operationt (12 and 24 volt)
D3 24 16 10 7 5
B4 40 24 13 7 5
D4 Plus 55 30 16 7 5
at start (12 and 24 volt) 100
Rated voltage 12 or 24 volt
Operating range
• Lower voltage limit: An undervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 10.5 volt resp. 21 volt
Undervoltage protection trigger time: 20 seconds
• Upper voltage limit: An uppervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 16 volt resp. 32 volt
Overvoltage protection trigger time: 20 seconds
Fuel “Fuel quality“ and “Fuel at low temperatures“
see page 28.
Commercially available diesel fuel (DIN EN 590)
Tolarable ambient temperature Operation Not running
Heater –40 °C to +70 °C – 40 °C to +85 °C
Dosing pump –40 °C to +50 °C –40 °C to +125 °C
Maximum air intake temperature +40 °C
Interference suppression Interference suppression class 5 to DIN EN 55 025
Weight approx. 4,5 kg
Ventilation mode possible
14
Product information
2
Caution! Safety instructions for technical data!
Failure to comply with the technical data can result in malfunctions.
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.
Technichal data
Heatertyp
Airtronic M
Heater Airtronic B3 Plus / Airtronic B4
Version B3 Plus / B4
Heating medium Air
Control of the heat flow Stage
Power Large Medium Small Off
Heat flow (watt) B3 Plus 3000 2300 1700 1200
B4 3800 3200 2100 1300
Heater air flow rate without counterpressure (kg/h)
175 143 115 85 24B3 Plus with hood Ø 90 mm
B4 with hood Ø 90 mm 185 160 120 85 24
Fuel consumption (l/h) B3 Plus 0,43 0,33 0,24 0,16
B4 0,54 0,46 0,29 0,18
Elektr. power consumption (watt) in operation
B3 Plus 33 20 13 8 5
B4 40 29 15 9 5
at start 100
Rated voltage 12 volt
Operating range
• Lower voltage limit: An undervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 10.5 volt
Undervoltage protection trigger time: 20 seconds
• Upper voltage limit: An uppervoltage protection in the controller
switches off the heater when the voltage limit is reached.
approx. 16 volt
Undervoltage protection trigger time: 20 seconds
Fuel “Fuel quality“ and “Fuel at low temperatures“
see page 28.
Commercially available petrol fuel (DIN EN 228)
Tolarable ambiet temperature Operation Not running
Heater –40 °C to +50 °C – 40 °C to +85 °C
Dosing pump –40 °C to +20 °C –40 °C to +125 °C
Maximum air intake temperature +40 °C
Interference suppression Interference suppression class 5 to DIN EN 55 025
Weight approx. 4,5 kg
Ventilation mode possible
15
Main dimensions Airtronic
A = Exhaust B = Fuel V = Combustion air
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.
Main dimensions Airtronic M
* 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 B3 Plus, 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
Product information
2
**
*
Please note!
Installation of spherical reduction hood is not permitted in the Airtronic D4 Plus.
16
Installation
3
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 in living space 5 Heater in the boot
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 pas-
senger compartment or boot, the heater can also be mounted, protected against splashing water, under
the vehicle floor.
The „Plus“ installation kits are intended for installation
in a camper van.
Please note!
Installation and mounting position
The heater is suitable and approved for installation in vehicle interiors used by people. The heater, together with its heater flange and the mounted flange seal, is fixed directly onto the floor of the vehicle or in a suitable position in the rear panel of the vehicle.
• If installed inside the vehicle, detachable connections
of exhaust gas, combustion air and fuel lines are not allowed.
• The flange seal must be mounted on the heater, in order to seal off the openings for the exhaust gas, combustion air and fuel lines.
• Installation in the driver’s cab or passenger compart­ment of commercial buses with more than 9 seats (8 seats + driver’s seat) is not allowed.
• The ADR regulations must also be complied with for installation of the heater in vehicles used to transport dangerous goods.
For information on the ADR regulations, see page 6,
31 and in the information sheet with Print No. 25 2161 95 15 80.
• When installing the heater, ensure sufficient open space is allowed for intake of the heating air and for the dismantling of glow plugs and control box (see page 15 “main dimensions”).
• Observe the regulations and safety instructions for this chapter, given on pages 4 – 7.
Please note!
17
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 pas-
senger 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 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.
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.
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
• 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.
Installation
Please note!
3
18
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 bot-
tom) 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
Cable harness connection, optionally 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 semi­circular 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.
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.
Installation
3
Please note!
19
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, for Order No. see
above) 6 Spring washer 7 Hexagon nut M6 (torque 5
+1 Nm
)
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.
Picture hole
Special tool
If the sheet metal of the support surface is <1.5 mm
thick, an additional reinforcement must be installed.
Order no: reinforcement plate 20 1577 89 00 03 Order no: special tool 99 1201 46 53 29
Fastening the unit on the vehicle floor
Installation
3
Fastening the heater horizontally to the vehicle wall
1 Contour of the bearing surface
20
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.
The regulations and safety instructions to be ob­served for this chapter are stated on page 5.
1 Original nameplate 2 2
nd
nameplate (duplicate)
Installation
3
Please note!
21
Heater air system (example)
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 contain any exible pipes, these must be ordered separately. Refer to the
product information for the Order No.
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.
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.
Installation
3
1 Safety grid 2 Outflow hood 3 Hose clip 4 Flexible hose
5 Rotating outflow 6 Connection fitting 7 Safety grid
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.
22
Installation
3
Exhaust system
Mounting the exhaust system
The “Universal” and “Plus” installation kits include a exible 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.
Use a pipe clip to x a short exhaust pipe end (with end sleeve) to the exhaust silencer (Anzugsdrehmo-
ment 7
+0.5
Nm).
Use a pipe clip (tightening torque 7
+0.5
Nm) to fix a short exhaust end pipe (with end sleeve) to the exhaust silencer.
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.
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.
• Comply with the regulations and safety instructions
for this chapter on page 4 – 7.
• If a silencer is tted, 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 ow have
been cast into the fittings to differentiate between the combustion air and the exhaust fittings at the
heater (see diagram page 23).
• To prevent contact erosion, the clips used to fix the exhaust pipe must be made of stainless steel. The order No. for the stainless steel fixing clips is given in the product information.
Please note!
23
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.
Combustion air system
Mounting the combustion air system
The universal installation kit includes a flexible combus­tion air hose, inner Ø 25 mm , 1000 mm long. If necessary the flexible combustion air hose can be shortened to 20 cm or lengthened to max. 2 m depend­ing on the installation conditions. Use a pipe clip (tightening torque 3
+0.5
Nm) to fix the flexible combustion air hose to the heater and use hose clips or cable ties to fix in suitable positions. 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). Use a pipe clip (tightening torque 3
+0.5
Nm) to fix the flexible connection hose to the heater and use hose clips or cable ties to fix in suitable positions. Fit an end sleeve after completing the installation.
1 Combustion air hose, di = 25 mm 2 Combustion air silencer, – Included in the “Plus” installation kit 3 Exhaust pipe, di = 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
Installation
3
Please note!
For Airtronic and Airtronic M heaters a combustion air
intake silencer can be fitted instead of the combustion air hose to reduce the noise level. Order No. see spare parts list or product information.
• Comply with the regulations and safety instructions
for this chapter on page 4 – 7.
max. 2 m
min. 0.2 m
min. 0.2 – max. 2 m
24
Installation
3
1 Correct connection 2 Incorrect connection – bubble formation
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. can not have any lasting effect on the service life.
• Use hose clips to secure all hose connections in the fuel supply (tightening torque 1
+0.2
Nm).
• 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. of protective hose, see product information).
• 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.
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.
25
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.
* If necessary, a fuel pipe 4 x 1 (di = Ø 2 mm) can be
used for diesel heaters instead of the fuel pipe 4 x
1.25 (di = Ø 1.5 mm), Item (8).
The details regarding the pipe lengths remain un-
changed. The fuel pipe, 4 x 1 must be order separately. Order
No. see spare parts list or product information.
Installation
3
• 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 product information.
Please note!
Installation position of the T-piece
Use the installation positions shown in the diagram
when inserting a T-piece.
1 Direction of flow from the fuel tank 2 Direction of flow to the vehicle engine
Possible pipe lengths
Intake side
Airtronic a = max. 5 m
Airtronic M a = max. 2 m
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
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
* If necessary, a fuel pipe 4 x 1 (di = Ø 2 mm) can be
used for diesel heaters instead of the fuel pipe 4 x
1.25 (di = Ø 1.5 mm), Item (8).
The details regarding the pipe lengths remain un-
changed.
The fuel pipe, 4 x 1 must be order separately. Order
No. see spare parts list or product information.
Fuel supply
• 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. The order no. is given in the product information.
• 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.
• Consult the vehicle manufacturer before installing the tank connection in a metal tank.
Installation
3
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.
• 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.
Please note!
Possible pipe lengths Intake side
Airtronic a = max. 5 m
Airtronic M a = max. 2 m
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
27
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
Check tank venting.
1 Connection to heater 2 Max. fuel level 3 Min. fuel level
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.
1 Installation position between 0° and 15° is not al-
lowed. 2 Preferred installation position in range 15° to 35°. 3 Installation position in range 35° to 90° is allowed.
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.
Please note!
28
Installation
3
Fuel supply
Caution! Fuel supply safety information
It is not permitted to operate the heater with unap­proved fuel / fuel mixtures or the addition of used oil. Failure to comply with this can lead to personal injuries as well as a malfunction or damage to the heater. Only the fuel approved by the manufacturer or by the vehicle manufacturer is to be used.
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!
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.
• Bio diesel fuel (FAME) according to DIN EN 14 214 – during the winter months is adapted to low tem-
peratures 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.
Please note!
29
Operation and function
4
Operating instructions
The heater is operated by a control element. Detailed operating instructions are enclosed with the control unit.
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
• up to 1500 m altitude, heating mode is possible wit­hout altitude adjustment.
• from 1500 m – 3000 m, heating mode for short stays (e.g. if crossing a pass or stopping for a break) is possible without adjusting the heater altitude.
In case of a lengthy stay, e.g. winter camping, it is
necessary to adjust the heater‘s altitude.
The heater‘s altitude is adjusted by installing an air
pressure sensor; this is included in the altitude kit – Order No. 22 1000 33 22 00.
Please note!
Heaters suitable for high altitudes are labelled with “HKit” on the side nameplate.
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!
30
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, rstly 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 (ame sensor) has de­tected the ame, 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 ame sensor has detected the ame, 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.
Operation and function
4
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 (circula-
tion mode) or is switched off (fresh air mode) until the
heater is started again.
Ventilating mode
In the ventilating mode, rst the changeover switch
“heating / venting” has to be activated and then the heater is switched on.
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.
31
Forced shutdown in ADR mode (only for diesel heaters 24 volt)
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 (renery, 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.).
The fan then runs on for max. 40 seconds.
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.
Operation and function
4
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.
32
Electrical system
5
Heater wiring
The electronic control box is integrated in the heater, which considerably simplifies the wiring required during installation.
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:
• With the appropriate electrical wiring, the heater fulfils the ADR regulations; please refer to the circuit diagrams at the end of this document.
• 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 (plus cable
+ minus cable): – up to 5 m = cable cross section 4 mm² – from 5 to 8 m = cable cross section 6 mm²
• f 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.
33
-A1 Airtronic / Airtronic M control box
-A30 Fuse holder, 3 pin
-B1 Control sensor, internal
-B6 Flame and overheating sensor
-F1 Fuse 12 V = 20 A / 24 V = 10 A
-M4 Burner motor
-R1 Glow plug
-Y1 Fuel metering pump
Optional b Activation of vehicle blower and / or separate
fresh air fan
Please note!
• The plus signal is only applied in „Low“ control stage (PIN 16, plus signal for relay, Imax = 200 mA)
ADR function Wiring for ADR mode (dangerous goods in utility or commercial vehicles, e.g. fuel tanker) - wire yourself according to vehicle circumstances
m Battery isolating switch n Auxiliary drive NA+ o Generator D+
Please note!
• It must be ensured that if the battery isolating switch is pressed due to EMERGENCY STOP, all the heater‘s electric circuits are disconnected from the battery immediately (without any consideration of the heater‘s status).
• If the battery isolating switch is pressed to disconnect the battery from all electric circuits, the heater must be switched off first and if applicable you must wait until the heater’s afterrun has finished.
a to the heater c to the control unit x Insulate and tie back any cable ends that are not
needed.
Parts list for the circuit diagrams Airtronic / Airtronic M and Airtronic / Airtronic M – ADR mode
Electrical system
5
Please note!
Circuit diagram for Airtronic / Airtronic M see Page 34 and 35. Circuit diagram for Airtronic / Airtronic M in ADR mode ¬ see also Page 36.
For circuit diagrams for other control units, e.g. EasyStart T, R and R+, refer to the installation instruc­tions of the control unit concerned.
34
Airtronic / Airtronic M
Parts list page 33 25.2069.0089.02.0A
X:58
Light (+)
X:15
Ign (+)
X:30
Bat (+)
-XS16 1
2
3
4
5
6
7
8
1,5 RD
0,5 BUWH
0,5 YE
1,0 GNRD
0,5 BNWH
0,5 GYRD
-A1
9
10
0,5 BUYE
1,5 BN
11
12
13
14
15
16
0,5 GY
0,5 BU
0,5 BUBK
0,5 PK
0,5 BKGY
a
-R1
-XS2/1 1
2
1
2
2,0 WH
2,0 BN
-XS2/2 1
2
1
2
-XS2/3 1
2
1
2
-XS2/4 1
2
1
2
Θ
-B6
Θ
M
-M4
Θ
-B1
0,75 BN
0,75 BK
0,5 BU
0,5 GN
0,5 BNWH
0,5 YE
0,5 YE
X:31
Bat (-)
Electrical system
5
35
Airtronic / Airtronic M
Parts list page 33 25.2069.0089.03.0A
b
2 1
-XB2
-Y1
12
X:58
Light (+)
X:15
Ign (+)
X:30
Bat (+)
X:31
Bat (-)
1
2
3
4
5
6
7
8
9
10
-XB16
11
12
13
14
15
16
a
1
2
-F1
-A30
1
2
-F2 5A
1
2
-F3
c
0,5 RD
0,5 BN
0,5 BUWH
0,5 YE
0,5 GY
0,5 WHRD
0,5 GYRD
0,5 BNWH
2,5 RD
0,5 YE
1,0 GNRD
0,5 BNWH
0,5 GYRD
0,5 BUWH
2,5 BN
0,5 GY
0,5 BU
0,5 BUVT
0,5 WHRD
4,0 RD 4,0 BN
4,0 RD 1,0 RD
1,0 GNRD 1,0 BN
0,5 BUVT0,5 BU0,5 WHRD
x
x
x
x x
x
/ / /
Electrical system
5
36
b
2 1
-XB2
-Y1
12
X:58
Light (+)
X:15
Ign (+)
X:30
Bat (+)
X:31
Bat (-)
1
2
3
4
5
6
7
8
9
10
-XB16
11
12
13
14
15
16
a
1
2
-F1
-A30
1
2
-F2 5A
1
2
-F3
c
0,5 RD
0,5 BN
0,5 BUWH
0,5 YE
0,5 GY
0,5 WHRD
0,5 GYRD
0,5 BNWH
2,5 RD
0,5 YE
1,0 GNRD
0,5 BNWH
0,5 GYRD
0,5 BUWH
2,5 BN
0,5 GY
0,5 BU
0,5 BUVT
0,5 WHRD
4,0 RD 4,0 BN
4,0 RD 1,0 RD
1,0 GNRD 1,0 BN
0,5 BUVT0,5 BU0,5 WHRD
m n o
x
x
Circuit diagram Airtronic / Airtronic M – ADR mode
Electrical system
5
Parts list page 33 25.2069.0089.04.0A
37
g
0,5 BNWH
0,5 GYRD
c
y
X:58
Light (+)
X:15
Ign (+)
-E3
0,5 RD
0,5 BUWH
0,5 BN
1
2
3
4
5
6
7
8
-XB10
9
10
1
2
3
4
5
6
7
8
-XS10
9
10
0,35 RD
0,22 GYBK
0,22 BN
0,22 BUWH
0,22 VT
0,35 YE
0,22 BNYE
0,22 WHRD
0,22 BNWH
0,22 GY
0,5 GYBK
-XB10
-XS10
Circuit diagram EasyStart Timer
Electrical system
5
E3 EasyStart Timer Timer c to the heater g to the heater y Connect cables and insulate
22 1000 34 97 20
Please note!
• For heater circuit diagrams see page 34, 35 and 36.
• Further circuit diagrams for the EasyStart Timer are printed in the Installation Instructions Plus, these are available to view and download from the Service Portal.
Cable colours
RD = red BU = blue WH
= white GY = grey YE = yellow
VT = violet BK = black GN = green BN = brown
38
25 2361 00 97 01 C
g
0,5 BNWH
0,5 GYRD
c
y
X:58
Light (+)
X:15
Ign (+)
-E5
1
-XB12
2
12
3
4
5
6
7
8
9
10
11
-H2
0,5 RD
0,22 RDYE
0,5 BUWH
0,22 BNWH
0,22 GY
0,22 BNYE
-W2
0,5 BN
Θ
-B8
0,22 BN
-XB12
Circuit diagram EasyStart Remote
+
Electrical system
5
B8 Room temperature sensor E5 EasyStart Remote+ radio remote control H2 Button W2 Antenna c to the heater g to the heater y Connect cables and insulate
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Remote+ are printed in the Installation Instructions Plus, the­se are available to view and download from the Ser­vice Portal.
Cable colours
RD = red BU = blue WH
= white GY = grey YE = yellow
VT = violet BK = black GN = green BN = brown
39
25 2361 00 97 05 B
g
0,5 BNWH
0,5 GYRD
c
y
X:58
Light (+)
X:15
Ign (+)
0,5 RD
0,5 BUWH
0,5 BN
0,5 GYBK
-E2
1
2
3
4
-XB4 1
2
3
4
-XS4 0,35 RD
0,35 GYBK
0,35 BN
0,35 BUWH
-XB4 -XS4
Circuit diagram EasyStart Select
Electrical system
5
E2 EasyStart Select c to the heater g to the heater y Connect cables and insulate
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Select are printed in the Installation Instructions Plus, the­se are available to view and download from the Ser­vice Portal.
Cable colours
RD = red BU = blue WH
= white GY = grey YE = yellow
VT = violet BK = black GN = green BN = brown
40
25 2361 00 97 02 B
Circuit diagram EasyStart Call
X:58
Light (+)
X:15
Ign (+)
-E1
1
-XB12
2
12
3
4
5
6
7
8
9
10
11
-H1
0,22 RDYE
0,22 BNWH
0,22 GY
0,22 BNYE
-W1
Θ
-B8
0,22 BN
g
0,5 BNWH
0,5 GYRD
y
1
2
3
4
5
6
7
8
-XB9
9
1
2
3
4
5
6
7
8
-XS9
9
RD
YE
BN
VT
BUWH VT
BUWH
BN
RD
YE
0,5 RD
0,5 BUWH
0,5 BN
c
Electrical system
5
B8 Room temperature sensor E1 EasyStart Call radio remote control H1 EasyStart Call button W1 EasyStart Call antenna c to the heater g to the heater y Connect cables and insulate
Please note!
• For heater circuit diagrams see page 34 and 35.
• Further circuit diagrams for the EasyStart Call are printed in the Installation Instructions Plus, these are available to view and download from the Service Por­tal.
Cable colours
RD = red BU = blue WH
= white GY = grey YE = yellow
VT = violet BK = black GN = green BN = brown
41
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 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 on 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.
Please note!
42
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
The manufacturer:
Eberspächer Climate Control Systems GmbH & Co. KG.
Address: Eberspächerstraße 24 D-73730 Esslingen
herewith declares that the following product:
Product name
Vehicle heater
Type
Airtronic Airtronic M
Version
D2 B3 Plus
B4 D3 D4 D4 Plus
fulfils the requirements of the following EC Directives: a) Heating systems directive 2001/56/EC Revision status 2006/119/EC
b) Radio interference (EMC) of vehicles 72/245/EEC, Revision status 2006/28/EC
c) Heater control ECE-R 122, Revision status 00
d) EMC of vehicles ECE-R 10, Revision status 03
The following EC Directives and UN regulations have been used to assess the product: 2001/56/EC; 72/245/EEC; ECE-R 122; ECE-R 10
43
List of key words A – Z
Keyword Page
A
Accident prevention ................................................... 7
ADR .......................................................................... 16
Altitude ..................................................................... 29
Ambient temperature ........................................ 12 – 14
C
Cable harness connection ....................................... 18
Certificates ............................................................... 42
Circuit diagrams ............................................... 34 – 40
Combustion air system ............................................. 23
Control devices ........................................................ 31
Control in heating mode ........................................... 30
Contents ..................................................................... 2
D
Dangerous goods ............................................... 16, 31
Declaration of conformity ......................................... 42
Description of functions ............................................ 30
Disposal .................................................................... 42
Dosing pump .................................................... 24 – 27
E
Electronic components ....................................... 33, 36
Emergency off .......................................................... 31
Environment management ....................................... 42
EU Declaration of Conformity ................................... 42
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 ...................................................................... 41
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 ................................................. 44
M
Maintenance ............................................................. 41
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
Lists
8
44
Lists
8
Keyword Page
T
Technical data .................................................. 12 – 14
Temperature selection .............................................. 30
Test symbol ................................................................. 5
Text structure .............................................................. 4
T-piece ...................................................................... 25
Transport .................................................................. 16
Troubleshooting ........................................................ 41
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
Eberspächer partner.
FAME
Biodiesel according to DIN V 14 214.
List of key words A – Z
Subject to changes Printed in Germany © Eberspächer Climate Control Systems GmbH & Co. KG
www.eberspaecher.com
Eberspächer Climate Control Systems GmbH & Co. KG Eberspächerstraße 24 D-73730 Esslingen Telefon 0800 1234300 Telefax 01805 262624 info@eberspaecher.com www.eberspaecher.com
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