Eberspächer D5L, B5LC, D5LC Troubleshooting And Repair Manual

Air

heaters

B5L/D5L

/

B5LC/D5LC

'.

Trouble.hooting and repair manual

The Troubleshooting and Repair Manual Is valid

for

the

following

heaters:

BOL

201707

05

00

00 -

12

Volt

20 1708 05

00

00 - 24 Vol1

D5L

2517290500

00 -

12

Volt

25 1730

05

00

00 -24 Volt

Contents

sectional view

___

_ ,

..... , ...... " .............

. ,

......................

,

Description

of

operation.

In the event

of

fault

s,

first

check

the following point

s",

Function and fault test...

Wiring diagrams

Repair instructions .

................

..........

. .

Measuring

the

fuel quantity" ..

Using the test adapter

25186195086

2 04.1995

ModifIca

tion

reserved.

BOLC

2017350500

00 -12

Vc>1

20

1736 05

00 00 -24

Volt

D5LC

251861

05 00

00

-12

VoI1

25

1862

05 00

00 -24

van

Page

2

3

4
4

.5

6. 7

8-13

14
15, 16

Printed

In

GIIrmany. C Copyright J. Eb6'spAchef

J. Ebersp

ilc

her

GmbH

&Co

Ebersp:tcherst

r.

24

0·73130

Esslinge

n

Telefon (

zentla

l)

(011 1) 939-00

TelelllJ(

(0111 ) 93>1

{)500

http:lt-w

.

eberspaec

he,-de

C29/C3O

Sectionlil dl'llwtng 0

SL

ID 5 L C

Parts list

1 Heating air blower wheel

2

PCB

wi

th

temperature contrOl sensor

3 Combusti

on

air blower wheel

4 Glow plug

5 Safety thermal cutout switch

6 Combustion chamber

7 Rame sensor

8 Heat exchanger

9 Outer casing

10 Flange seal

11 Fuel line

Wi

12 Blower motor

13 Combustion air intake silencer

14 Exhaust line
15 Fuel metering pump
16 Fuel filter

17 Main

fu

se, 25 A

18 Gl

ow

plug relay

19 Control unit
20 Actuating unit

21

Healing timer

2

F

~

Fresh air

V

~

Combustion air

B

~

Fuel

W-

Hot air

A -

Exhaust

_01

___

_---on

,

=;

Switch-on: green pilot light

in

the operating unit

~ON·.

After about 1 s&cond: healing coil of glow plug

NON-.

Blower 'ON" at full speed.
After

33 -

70

seconds: fuel

pump

·OW.

Once a stable llame has been obtained. the

glow

plug is

switched

off.

To

reach

the

operating temperature

of

the heat exchanger

quickly, the healer

is

operated

at

an

increased heating ca-

pacily

of

5.5

kW

after being switched

on.

Once

the

heat exchanger operating temperature

has

been

reached,

the

heating capacity is reduced

10

4.8

1NoI.

The

duration of heater operation

with

Increased capacity

depends

on

the

ambient temperature.

Reguldon

In heatlna opention

Once the intakelroom temperature as set at the operating

unit has been reached,

the

heater switches

to

the

"lOW"

setting and then continues to

run

at low blower motor

speed.

If

the

heating capacity

In

the

NLOW"

control setting

is

in-

sufficient,

the

heater switches to

the

"MEDIUM~

setting.

The

blower continues to operate

at

low speed.

In

most cases,

the

LOW/MEDIUM/LOW

settings

at

low

speed will provide

the

required heal.

If

the

heat

ing

capacity

in

lhe Q

MEDIUM"

sening

is

insuffi-

cient. the heater switches back to

the

-HIGW setling. This

entails full speed

tor

the

blower motor again. _

If

in

some cases

even

less heating capacity is needed

than

the

heater supplies in

the

"LOW' sening. the heater

switches to

the

·OFf" setting.

The

heater continues to

run

after shutdown, followed

by

constant after-ventilation prior to

restart.

The

constant after-ventilation applies only lor heaters

In

reci

rculated air mode.

The

subsequent restart is

in

the

-MEDIUMM setting

at

low

blower motor speed.

When

the

heater

is

finally switched

off.

the

green pilot light

goes out and

the

blower continues to

run

until

II

coots

down. During continued operation,

the

glow plug is

switched on

for

approx.

30

sees

. to dean it

of

combustion

residues.

Th

is continued operation will always

end

after about 4

to

5 minutes

at

low speed.

3

Control_nd

ufety

equipment

The

flame

is

monitored

by

the

flame sensor

(7).

the

maxi­mum permitted temperature by the safety thermal cutout
switch (5).
Both

of

them affect the control unit

(19),

which switches off

the

heater in

the

event

of

fauNs

.

. 1.

If

the healer does not ignite wtthin 90 seconds of

the

start

of

fuel

pumping, starting is repealed as described.

If

the healer still does not ignite after a further 90 se-

conds,

fauN

shutdown follows.

2.

If

lhe flame goes out

by

itself during operation, a restart

follows

first.

If

the heater does

not

ignite within 90 seconds

of

fuel

pumping being switched

on.

or

It

does Ignite but then

goes out within

10

minutes, fault shutdown follows.

The fault shutdown can be cancelled out

by

briefly

switching

the

heater

off

and back

on

again.

3. In the event

of

overheating, the safety thermal cutout

switch (5)

leacts

,

the

fuel

supply is interrupted, and fault

shutdown follows.

If

overheating

is

the cause of a fault shutdown,

the

switch-on pilot light

(green)

in

the

operating unit flashes
steadily.
Once

the

cause

of

the overheat

has

been remedied,

the

heater

can

be restarted

by

switching

it

off

and then

back

on

again.

4. Further

fauN

indicating signals cen be obtained

with

additional equipment, and

are

described in

the

trouble-

shooting and repair Instructions

on

pages

4 and 5.

5.

If

the voltage drops

below about

10.5

or

21

V.

Of

rises

above

15

or

30 V as

the

cese may be, fault shutdown

follows.

6.

If

the glow plug

is

defective and the electric line to the

metering pump

has a break,

the

heater will

not

start.

7. When

the

heater

is

started

the

functioning of

the

blower

motor is checked

once.

11

it

does not

start,

the

heater

will undergo fault shutdown.

During operation,

the

blower motor

is

monitored

in

cyc-

les

(4

mlns.).

If

the molor speed

Is

below the permitted

limit,

lauN

shutdown follows.

PIe8

..

not.:

For

electric welding work

on

the

vehicle, the positive ter-

minal

of

the battery must

be

disconnected and earthed

in

order to protect

the

control

unit.

I

e

Fuel

in

the tank?

eFusesOK?

e Electrical

lines

and

connecttons OK?

·

c.

• Combustion air and exhaust piping

!'Iystems

tree?

When

combustion produces

soot,

check

the

following:

Combustion air and exhaust piping systems clogged?

.........

Remove cause of clogging.

Fuel

metering pump conveying too much?

.........

Measure fuel quantity, replacing

fuel

metering pump

if

necessary.

Deposits

in

the

heat exchanger?

.........

Clean heat exchanger, or replace

illf

necessary,

Cliling

of

dIIlftOdc

......

18

Connec1

a switch to terminals 4 and 6 of

the

operating

unil.

Turn

on

the switch

and

compare the diagnostic signal

displayed

by

the

operating unit

with

the

list

on

page 5,

Deal

with

lhe Irouble

as

descnbed

under

'Remedy".

Checkweluee

Speed

of

blower

motof

in

HIGH

set1ing

: 5000

rpm

±10%

in

MEDIUM

and

LON

settlng5: 3000 rpm ± 10%

in continued

operation:

3000 rpm ± 10%

in

after

ventilation:

850

rpm

(

only

In

recirculated

air

mode)

4

I

DIopIojod

by

......

LID o 1

2

31

r n r

SOCS.

A-.dy

Operation
Warning of olJer-lundelVoltage

•••

Check controller, charge battery

Overvoltage cutout

••

Check

controller, jf

necessary

test

charger.

Heater must be connected directly to

the

battery.

Undervollage cutout

•

Charge

battery,

check

control~r

.

Check

glow plug.

glow

plug

series

resistor(for B 5

LI

Glow

plug break

••••

05L

24

V),

replace. Check connecting lines

and

connection, check connection

to

glow

plug

relay.

Burner

motor

does

not

turn,

Check

mdtor

speed

(test

adapter),

If

necessary

speed changeover relay does nol

replace

blower.

Check

speed

changeover

function

(tast

adapter),

if

necessary

replace

PCB.

Rated speed: high =

4500±

10%rpm,

medlumJlow - 3000 ±

10

% rpm

ShOf1-circuit

at

glow-plug

~I

Replace glow-plug relay

relay

contacts

Saf~ty

time exceeded

•••

Check

fuel

supply, test glow plug 0nterrupted coil,

no start

yet

sooty

connection),

replace

if

necessary.

I

,

Check heating air lines inlet and outlet

for

clogging,

Overheat

~

.....

---

if necessary remove clog. Check electrical lines,
contacts to metering pump. Check safety thermal
cutout switch

(test

adapter).

Short circuil

of

fuel

~

..

Check metering pump and supply lines,

metering pump replace

if

necessary.

Plug

connection to temperature sensor

in

cable

harness made internally/externally? Check

PCB,

Temperature sensor defective

~.

internal temperature sensor

(test

adapter).

If

neces-

sary test

the

external temperature sensor directly.

Check connection

to

operating device, and check

the latter (test equipment

for

operating device).

Flame

sensor defective

~.

•

Check flame sensor or connection,
and

also

PCB

(test

adapter).

•

Rame goes out

at

"Low"

or

••

Check fuel quantity

-Medium" stage

Check blower speed

Heater

goes

out

by

Itself

Rame goes out

at

"

High~

stage

•••

Check

fuel

quantity

Heater goes out

by

Itself Check blower speed

Control unit defective

Replace control unit

External

disturbing voltages

•

••

Remove

cause

Er

roneous

flame reoognition

•

Check flame sensor.

5

'"

·UD

,

I"

.

.......

. ,

..

c ....... . ,_

, I

~ t~=, ·~·'

......

"

1.1 Burner

motor

1,2 Glow plug

1.5 Safety thermal

cutout

switch

1.7

PCB

with temperature control

sensor, speed change and

multiple-blade

connector

1.12

Aameaenaor

1.13 Tcmperaturesensor

2.1 Control unit

2.2

Fuel metering

pump

2.5.1 Glow plug relay

2.7 Main fuse.

25

A

IUD

,O!

,

i

~

<

~

i

:.a

(ill

3.1.11 Actuating unit

3.1.12 Fauhcodeenquiry

3.2.3

Timer, digitel

.•

quare

3.2.4

Timer, digital. rectangular

5.1 Battery

,
,
,

1$,""-

~

f-

•

I i] I

25172900

96

01

C

_)

test

(wOfbhopl

digital

timer

b)

to terminlll15

c)

lighting, terminel58

dl

if

timer

Is connected,

break

lin.

here

81

If

tempenltlire sensor is connected.

<M1ach

existing socket housing and fit

todc:et

houlirtg

of

tempenture

sentor

:;;

s:

,s

I

~

.

I

..

..

r-

,

o

'"

r-

I

-

'"

R