Air heaters B1LC compact /D1LC compact
Technical Description Eberspacher '
Operating Instructions
Installation Instructions
J. Eberspa-sher
GmbH & Co.
Eoerspachersr.r 24
D-7373Q Esslingen
Tole-fon (2entral)
(0711)9 39-03
Telefax
(0? 11)939-0500
vwrt.cberspaechw.dQ
Engine-independent air heaters
B 1 LC compact for gasoline
D 1 LC compact for diesel fuel
with integrated control unit
Specifications (margin of error ± 10%)
Heating medium
Fuel
Heating capacity
control
Heating capacity”
Air
Gasoline
(commercially available) or
diesel fuel
(commercially available)
High / Medium / Low / Off
Power High Medium Low
2200 1800 1200 850 W
Hot air throughput4* 110 95 65 65 kg/h
Fuel consumption
B 1 L C compact 0,30 0,24 0,16 0,12 l/h
D 1 L C compact 0,27 0,21 0,14 0,10 l/h
Rated voltage
Operating range
Minimum voltage21
Maximum voltage31
12 Vo r 24 V
10,5V or 21 V
16 Vo r 32 V
Air heater
B 1 L C compact
D 1 L C compact
D 1 L C compact
Cat. No.
12V 20 1766050000
12V 25 197 6050 000
24 V 25 1977 05 00 00
Universal installation kit, operating and unit and heater
timers must be ordered separately as additional parts
(see page 2).
01 L C compact, complete 12V 25 1979 05 00 00
D 1 L C compact, complete 24 V 25 1978 05 00 00
with universal installation kit and opening unit.
See Additional Parts Catalog for further accessories.
Electric power
consumption11
gt start
B 1 L C compact 12 V = 250 W
D1 L C compact 12 V = 250 W
24 V = 210 W
in operation
Power / High
30 22
/ Medium 10/ Low
10W
Radio interference
suppression level 3
Weight
Ambient temperature
D 1 L C compact
B 1 L C compact
Additional radio inter
ference suppression
measures possible
approx. 3.5 kg
in operation
- 40 °C to + 70 °C
- 40 °C to 4- 50 °C
not in operation
- 40°C to + 85 °C
1) at rated voltage.
an undervoltage safety device built into the control
unit switches off the heater at about 10.5 V. or 21 V.
3) an overvoltage safety device built into the control
unit switches off the heater at about 16 V or 32 V.
4) without backpressure.
25 1976 90 94 C6 07.2030 Subject to change Printed In Germany © J. Eberspacher GmbH & Co.
B39
Contents Page
Scope of delivery / Cat Nos.................................................2
Government regulations......................................................4
Safety instructions
................................................................4
Typical installation / Installation position
..........................
5
Installing the heater
.............................................................5
Principal dimensions...........................................................6
Permissible installation positions / Fastening methods ... 6
Running the heating a ir.......................................................7
Running the combustion a ir................................................8
Running the exhaust............................................................8
Fuel supply......................................................................9, 10
Electrics / Wiring diagrams....................................... 11-15
Function description..................................................16-17
Scope of supply
Quantify / Designation Order No.
1 Air heater B 1 L C compact - 12 V 20 1766 05 00 00
To be additionally ordered:
1 Universal mounting kit 25 1976 80 00 00
1 Air heater D 1 L C compact - 12 V 25 1976 05 00 00
To be additionally ordered:
1 Universal mounting kit 25 1976 30 00 00
or
1 Air heater D 1 L C compact -1 2 V 25 1979 05 00 00
As a complete package*
1 Air heater D 1 L C compact - 24 V 25 1977 05 00 00
To be additionally ordered:
1 Universal mounting kit 25 1976 80 00 00
or
1 Air heater D 1 L C compact - 24 V 25 1978 05 00 00
As a complete package’
* The complete package consists of:
1 Air heater
1 Universal mounting kit
Optional accessories
1 Temperature sensor, external 25 1774 89 03 00
with line tract, 2 m long
1 Line tract. 4 m long 25 1688 89 09 00
for the temperature sensor, external
1 Cable harness, ADR / TRS 003
3 m long 25 1226 39 50 00
For further accessories, please refer to the accessories
catalogue.
Control elements, optional
Quantity / Designation Order No.
1 Control unit 12 volt 25 1395 71 00 00
24 volt 25 1896 71 00 00
Rotary switch lor ON / OFF
and to adjust the heat flow.
1 Mini-clock - 12 / 24 volt 22 1000 31 31 00
Tbs mini-cock can fce combined
with the TP 41 / TP 41 i 'adio remoie control.
Additionally required
The contra! unit to adjust the heat flow
and the change-over switch ’heating /
ventilating' fcr ventilation rrn de.
1 Module clock -12/24 volt 22 1000 30 38 00
with temperature preselection
*
The modulo c'ock can be combined
wilh ibs TP 4 / TP 4i radio remote control
1 Mounting parts ‘module clock' 25 1482 70 01 00
only required when installing with parol.
1 Radio remote control TP 4 22 1000 30 63 00
/ 24 volt TP 4i* 22 1000 30 99 00
The radio remote control TP 4 / TP 4i
can only be used in combination
with too module clock.
1 Radio remote control TP 41 22 1000 31 35 00
124 volt TP 41 i* 22 1000 31 39 00
The radio remote control TP -11 / TP 41 j
can be used on its own or in combination
with the mini-clock, order No. 22 10C0 31 31 03
* Outside Germany, only the i-version radio remote
controls may be permissible.
Please note!
Control elements must be selected in accordance with
the intended use of the heater, distinguishing between air
or water heater, simple switching on and off. programme
preselection and / or remote control.
The control elements are supplied with operating
instructions. These are intended for the customer together
with the “Technical Description”.
%■ ic>
5 •: .1 0. J
2
Scope of delivery D 1 L C compact complete
Version 25 1978 05 00 00 as shown without Pos. Z
Version 25 1979 05 00 00 as shown without Pos. Y
Parts without item no.
= universal installation kit
without additional parts X and Y
vv\
Government regulations concerning installation
For installation in motor vehicles that are subject to the Regulations Authorising
the Use of Vehicles for Road Traffic (StVZO), the air heater has been approved by
the (German) Federal Office for Motor Traffic in keeping with the "General Model
Approval” (ABG), and the official test symbol is marked on the type plate of the air
heater.
B 1 L C compact
D 1 L C compact
m S 237
-WV S 221
The mounting requirements associated with the General Model Approval (ABG)
have been printed in the corresponding sections of these mounting instructions.
When the air heater is installed in special vehicles, then the regulations governing
such vehicles must be taken into account (e.g. TRS 003 for vehicles used to trans
port dangerous substances).
The year in which the air heater was operated for the first time must be perma
nently recorded on the type plate. The works must print 3 years in the correspond
ing field c>f the type plate. The valid year is identified by removing those years that
are not applicable.
Subsequent installation of the heater must be completed in conformity with these
mounting instructions and must be accepted by an officially approved vehicle
specialist or inspector (Section 7.4a of Annex VIII relating to StVZO) in conformity
with § 19 Section 4 StVZO. The specialist / inspector must issue a corresponding
written certificate. The effectiveness of model acceptance (ABG) for the heater
depends upon this certificate.
The vehicle owner can choose the kind of certificate to be issued:
* A separate "Acceptance Confirmation” must always be kept in the vehicle. Neu
tral acceptance confirmations of the motor vehicle specialist are also permissi
ble. The vehicle manufacturer, the vehicle type and the vehicle identification
number must all be entered in both cases.
• Entry in the vehicle registration book (by the assessing agency) and in the motor
vehicle certificate (by the approving agency).
For vehicles that are not subject to StVZO (e.g. ships), it is necessary to observe
the specific rules and mounting instructions applicable to the given vehicle; these
can differ regionally.
The heater must be installed in keeping with these mounting nstructions or possi
bly other special installation recommendations by a workshop approved by the
manufacturer.
The installation points suggested in these mounting instructions are examples.
Alternative installation points are permissible provided they conform with the gen
eral installation requirements and, possibly, after consulting the manufacturer. This
applies particularly to the electrical wiring (circuit diagram), the fuel supply, con
ducting the combustion air and exhaust gas and the use of alien operating and
controlling elements. This is only permissible with the written approval of the manu
facturer.
The sticker "Turn off the heater prior to refuelling", included with the heater, must
be applied at an appropriate point on the vehicle (near the fuel tank cap).
Further mounting information (e.g. for boats and ships) can be requested from the
manufacturer.
Safety instructions concerning installation
Every combustion process produces exhaust gas that contains toxic substances.
Consequently, and on account of the high temperatures, the exhaust gas must be
conducted in conformity with the requirements specified in these mounting in
structions.
Fuel pipes and exhaust pipes must be safely fastened, to avoid damage from
vibrations (recommendation: at intervals of approx. 50 cm).
The hot-air emitter (possibly adjustable) must always be arranged in such a man
ner that the hot air is not directly blown onto heat-sensitive parts of the vehicle.
People and loose objects must not be directly exposed to the blown hot air. To
avoid damage and burns, people and loose objects must no: be directly exposed
to the blowing hot air.
If there is no suction hose, then the suction side of the heater must be covered
with a protective grille to prevent injury from the hot-air blower.
The heater may only be started up when the maintenance flap is closed.
The maintenance flap may not be open during operation.
Ensure that the insulation of electrical lines cannot be damaged due to abrasion,
kinking, squeezing or by exposure to heat.
As a result of their concept for mobile service, the heaters are not suitable as
permanent heating installations (for instance to heat living rooms).
Government regulations concerning operation
Subsequent installation of the heater must be completed in conformity with these
mounting instructions and must be accepted by an officially approved vehicle
specialist or inspector (TOV, DEKRA) in conformity with § 19 Section 4 StVZO (Regu
lations Authorising the Use of Vehicles for Road Traffic), who must issue a corre
sponding written certificate, either by entry in the vehicle papers (vehicle registra
tion book or motor vehicle certificate), or as a separate “Acceptance Confirma
tion” that must always be kept in the vehicle. The effectiveness of model accept
ance for the heater (ABG) depends upon this certificate.
The heater must only be used for the purpose specified by the manufacturer with
due consideration of the “Technical Description / Mounting Instructions" and the
"Operating Instructions” included with each heater.
It is not permissible to operate the heater where combustible vapours or dusts can
be formed, e.g. in the vicinity of fuel, coal, wood and grain stores and similar
facilities.
The heater must not be used in closed rooms, e.g. in a garage or car park build
ing. This is because of the danger of poisoning since all combustion processes
produce exhaust gases that contain toxic constituents.
The heater must be turned off when refuelling.
With vehicles subject to TRS regulations (transport of dangerous products, e.g.
road tankers), the heater must be switched off before entering the hazardous area
(refinery, petrol statior, etc.).
In conformity with StVZO, the heater must be exchanged for an original replace
ment heater by the manufacturer or an authorised workshop 10 years after the
heater was first used. The vehicle owner / operator of the heater is responsible for
ensuring replacement. A plate must then be mounted (not detachable) on the
replacement heater indicating the date when the replacement heater was installed,
together with the designation "Original Part" (the plate is supplied with the re
placement heater).
D.I.Y. repairs (on your own and without using original spare parts) are dangerous
and therefore not permitted. The General Model Approval (ABG) for the heater
and the General Operating Permit (ABE) for the vehicle will both become :nvalid.
The manufacturer's guarantee for the entire heating system will become invalid if
the above instructions are not observed. The Eterspacher Guarantee Conditions
are exclusively applicable.
The observance of the pertinent regulations and safety instructions is a precondi
tion for liability claims. The Eberspacher company cannot be held liable if the
''Operating Instructions” have not been observed and If repairs have not been
competently completed, even if original spares were used.
I^ l Safety instructions concerning operation
As a result of its concept for mobile service, the heaters are not suitable as perma
nent heating installations (for instance to heat living rooms).
The installation space of the heater must remain tree and cannot be used as stor
age space. Reserve fuel tanks, oil cans, spray cans, gas cartridges, fire extin
guishers, cleaning cloths, clothes, paper, etc., must not be stored or transported
on or alongside the heater.
The protective grille over the suction side should be occasionally inspected, but
particularly before the heating period, and cleaned should this prove to be neces
sary.
An adjustable hot-air emitter must always be arranged in such a manner that hot
air is not directly blown onto heat-sensitive parts of the vehicle. People and loose
objects must not be directly exposed to the stream of hot air. To avoid carnage
and burns, people and loose objects must not be directly exposed to the stream
of hot air.
Defective fuses must only be replaced by fuses with the prescribed fuse rating.
Should fuel leak out of the heater's fuel system, then the damage must be immedi
ately rectified by an authorised servicing workshop.
The heater should be tested before the beginning of the heating period. The heater
must be turned off, and the fuse removed so that it is inoperable, should intense
smoke develop for an extended period, if unusual burner noises can be heard, if
there is a distinct smell of fuel or if electric / electronic parts become overheated.
Renewed operation of the heater is only permissible after it has been checked by
trained specialist Eberspacher personnel.
Damage to the actual heater or the heating installation must only be remedied by
an authorised servicing workshop which will only use original spare parts
4
Installation Instructions
The suggestions put forward in these installation instruc
tions are only examples. Possibilities other than those illu
strated (e.g. in the selection of the installation position or
means of running air) are also permissible provided they
meet the requirements of the West German road traffic re
gulations (StVZO), and if necessary after consultation with
the manufacturer.
Typical installations/installation position
in the cab of the excavator
in the truck cab
1. on the rear panel of the cab
2. under the driver's seat
inside a passenger car
1. under the back seat, inside or underfloor
2. in front of the passenger seat
3. on the center console
Installing the heater
The B 1 L C com pact! D 1 L C compact heaters are suitable
and approved for installation in vehicle areas used by per
sons. Installation in the driver or passenger areas of motor
buses* is not permitted.
The electronic control device is integrated in the heater. This
facilitates wiring during installation
The heaters are suitable for installation in cabins of vehicles
transporting hazardous goods and, if wired with the appro
priate cable harness (see wiring diagram), meet TRS 003.
For this reason the heater must be fitted by its base on an
outside panel of the vehicle or on the vehicle floor, using the
seal seated on the base.
The factory plate must be clearly visible when the heater is
installed. If necessary a second plate (duplicate) with the
same information as the original can be affixed to a point on
the heater clearly visible after installation or to a cover loca
ted in front of the heater. A second plate is not necessary if
the original is visible after removal of a cover without the aid
of tools.
* Vehicles with more than 9 seats.
Principal Dimensions
360
Permissible installation positions
%
rar
The heater should be installed in the standard position as
shown. See sketch for maximum permissible deviations.
Please consult the manufacturer if further differences are re
quired.
During starting and thermostatic operation a heater installed
in the standard position may deviate, due to the inclination
of the vehicle during motion, up to ± 15° in both axes from
the standard position.
Continuous heating operation after starting is possible at a
deviation of up to ± 30° from the standard position. With
deviations exceeding ± 30° reliable heating operation is no
longer possible. However, this does not lead to damage of
the heater if the changes in the operating position are only
for brief periods.
Important; the plug connection must always point
upwards.
Fastening to the vehicle wall/floor
Make penetrations in accordance with the template pattern.
The hoie for the cable leading to the metering pump is not in
cluded in the template and must be drilled to suit the installa
tion method.
The mating surface for the heater base must be smooth. To
drill the penetrations and if necessary to smooth the mating
surface a special tool is available from the manufacturer un
der Cat. No. 99 1 201 46 53 29.
Special tool
Check for free
turning of
fan wheel.
i\ .
- \ r
This must be smooth
* This must be kept free
Heater base
Seal
If the mating surface sheet is too thin (criterion: thinner than
1.5 mm), a reinforcing plate, Cat. No. 20 1 577 89 00 03 can
be installed additionally on the outside.
Spring
washer
Vehicle panel
Running the Heating Air - Parts for running the heating air included in the scope of delivery for the universal
installation kit
1 Protective grid
2 Reducing piece
3 Hose clip, dia. 50 mm to dia. 70 mm
When checking an installation the average output tempera
ture should not significantly exceed 100°C at the output
point with an intake temperature of 20°C. This will ensure
that the safety thermal cutout switch will not respond under
normal operating conditions.
4 Flexible pipe, dia. 60 mm (1 m + 1 m)
5 Air outlet, rotatable
6 Connection piece, dia. 60 mm
Heating air intake openings shall be arranged in such a man
ner that exhaust from the vehicle's engine and from the hea
ter cannot be expected to be sucked in under normal opera
ting conditions, and the heating air cannot be contaminated.
When operating as a recirculating heater, locate the inlet for
the heating air in such a way that the outflowing hot air can
not be sucked directly in again.
7
Running the combustion air/Running the exhaust
Permissible diameters, lengths, bends of combustion air and exhaust lines.
Silencer (optional)
r t f
min. 0,2-max.2m
Protect from
slipstream, snow,
dirt and water.
Combustion air
Silencer (optional)
r t t
min. 0,2 -max. 2m
Exhaust
■©.
r f
Protect from
slipstream, snow,
dirt and water.
Permissible diversions - exhaust line: max. 180°; combustion air line: max. 180°.
The scope of delivery includes a flexible exhaust pipe,
24 mm internal dia., 1 m long. This can be shortened as re
quired. For longer pipes see the Additional Equipment Cata
log.
The scope of delivery includes a flexible combustion air
pipe, 20 mm internal dia., 1 m long. This can be shortened
as required. For longer pipes see the Additional Equipment
Catalog.
Additional noise suppression is possible by installing an ex
haust silencer or combustion air silencer (see Additional
Equipment Catalog). The permissible overall length, inclu
ding silencer, remains unchanged.
The combustion air must be sucked in from the outside, not
from the passenger compartment or trunk.
Do not install the intake opening facing the slipstream, but
run it in such a manner that dirt and snow cannot enter and
that any water which does enter can flow out.
Exhaust lines must not project beyond the sides of the
vehicle. They must be laid either with a slight slope or with
5 mm dia. holes at the lowest points for draining off conden
sate.
Arrange the exhaust outlet and the combustion air opening
such that the exhaust cannot be sucked back in directly.
The exhaust outlet must be on the outside. Exhaust lines
must be laid in such a way that neither the penetration of
exhaust into the vehicle interior nor the intake of exhaust
through the vehicle or heater blowers need be expected^
.and that the operation of essential vehicle parts is not affec
ted (ensure adequate clearance). Place the outlet opening of
the exhaust line in such a way that it cannot be clogged by
dirt and snow and that any water which does enter can run
off. Do not install facing the slipstream.
15 This requirement is deemed met when the outlet of the
exhaust pipe points upwards or to the side, or — when
the exhaust is run under the vehicle floor — is positioned
close to the side or rear edge of the cab or vehicle.
Fuel supply
Divergences from the instructions set forth here are not permitted, as they can iead to malfunctions.
1. For cars w ith diesel engines, and for cars with petrol engines having mechanical pump.
Fuel tapped from the fuel supply line to the engine.
Precondition: The fuel line from the fuel tank to the engine must be leak-free, so that there is no break in the fuel column
when the engine is not running.
Fuel connection to heater
Dimension a = max. 2 m with petrol
max. 5 m with diesel
Dimension b= 50 mm
Dimension c — max. 300 mm
Dimension d= max. 4 m with petrol
max. 6m with diesel
2. For cars with petrol injection engines and for trucks with diesei engines.
Tapping fuel from the supply line downstream of the delivery pump is prohibited in cars, since pressures of up to 10 bars can
occur.
The following possibilities are available:
2.1 Tapping fuel - where possible - using a separate riser pipe, fitted to the fuel tank fitting in the case of cars, an directly into
the fuel tank in the case of trucks.
Fuel connection to heater
Dimension a = max. 2 m with petrol
max. 5 m with diesel
Dimension d= max. 4 m with petrol
max. 6 m with diesel
2.2 If it is not possible to fit a separate riser pipe in the case of cars with petrol injection engines, the return line can be tapped
using a T-piece.
Conditions:
1. There must be no valve installed in the return line of the fuel tank.
2. The pressure in the return line must not exceed 2 bars. For pressures greater than 0.3 bars and up to 2 bars, a pressure
reducing valve {additional equipment Cat. No. 201645 89 30 00} must be provided upstream of the metering pump.
2.3 If it is not possible to fit a separate riser pipe in the case of trucks with diesel engines, the fuel supply line can be
tapped (as shown under 1.).
1 Fuel tank (vehicle tank or separate tank)
2 Fuel branch
3 Fuel hose, internal dia. 5 mm
Cat No. 360 75 350
4 Fuel pre-filter
(only necessary when contaminated fuel is used)
Cat. No. 25 1226 89 00 37
5 Fuel metering pump (15° to vertically upwards)
6 Fuel hose, internal dia.3.5 mm
Cat. No. 360 75 300
7 Fuel pipe, plastic, internal dia. 1.5 mm
Cat. No. 090 31118
For D1 L C compact also permissible: Fuel pipe, plastic,
internal dia. 2 mm, Cat. No. 090 31117
8 Riser pipe, internal dia. 2 mm
external dia. 4 mm
9 Connection socket
external dia. 4 mm
10 Riser pipe, internal dia. 2 mm Cat. No. 25 1226 89 50 00
external dia. 6 mm
11 Fuel pipe, internal dia. 2 mm
Cat. No. 090 31125
Cat. No.
20 1645 89 35 00
3. Permissible suction and pressure heads for installation per 1„and 2.;
permissible positioning of metering pump
max. fuel level
Fuel line connection to heater
Metering pump
min.fuel level
Supply pressure from tank to metering pump:
e= max. 3000 mm suction head:
tank at zero pressure
f = max. 500 mm with gasoline
f = max. 1000 mm with diesel oil
Check whether tank ventilation works properly
intake from tank when underpressure occurs during
(operation vaive 0.03 bar in tank cap)
f = max. 150 mm with gasoline
f — max. 400 mm with diesel oil
Pressure head metering pump to heater:
g = max, 2000 mm
Fuel line metering pump to heater should not have a slope
if at all possible.
2. Important
Protect fuel lines, filter and metering pump from overhea
ting; do not install near silencers and exhaust pipes. Tempe
ratures above 30°C lead to gas bubbles and problems with
gasoline.
When installing the fuel line, fuel filter and fuel metering
pump near the rear axle, be sure to takte the spring deflec
tion of the rear axle into consideration.
Cut fuel tubes and pipes to length only with a sharp knife.
Cuts may not be indented and must be burr-free.
For connection of the fuel branches, always use rubber
tuhing, never plastic pipe.
Fuel pipes connected by means of a fuel tube.
Fuel pipe sections must abut.
bubble
right
Do not let fuel tube sag.
wrong
wrong
D 1 L C compact
Fuel grades/Fuel at low temperatures
The heater can take without problem the same fuel you use
in your tank. In the USA diesel fuel no. 1 and no. 2.
Admixture of used oil is not permitted.
The refineries automatically adapt their fuels to normal win
ter temperatures (Winter Diesel).
Therefore difficulties can only arise at extremely-low tempe
rature (as in the engine - see the vehicle's instruction
manual).
If the heater is operated from a separate tank, the foltowing
rules must be observed: at temperatures above 0°C any type
of diesel fuel can be used.
If no special cold-weather diesel fuel is available at low
temperatures, mix kerosine or gasoline according to the
adjacent table.
Temperature
From 0°C to - 1 5°C*
From -1 5°C to -25° C
From -25°C to -4 0 °C
Winter
diesel oil
100%
50%
Additive
50% kerosine or
gasoline
100% kerosine*
* or special winter diesel oils
** or in accordance with fuel manufacturer's specifications
The fuel line and the fuel pump must be filled with new fuel
by operation for 15 minutes.
Fuel for special cases
In special cases, the heaters can also be operated on extra
light fuel oil (above 0°C) or kerosine. If in doubt consult the
manufacturer.
10
Heating operation at high altitudes:
up to 1500 m: Unrestricted heating operation,
above 1 500 m: Heating operation is possible during a short
stay (e.g. crossing a mountain pass, taking
a rest). If a longer stay is planned (e.g. winter
camping), the fuel has to be adapted to the
altitude. In this case, please consult the
heater manufacturer for advice.
Elektrics:
Arrange electric cables, switches and control units in the
vehicle in such a way that their correct functioning cannot
be impaired under normal operating conditions.
The pilot light (built into the operation unit) should be within
the field of vision of the driver, or at least be visible to him
without great effort.
When carrying out electric welding work on the vehicle,
disconnect the positive terminal from the battery and earth
it in order to protect the control unit.
Operating unit and Mini-timer
The operating unit (see page 2 for Cat. No.) comprises the
On-Off switch with controller for the heating capacity, a red
light for illumination, and a green operation pilot light. Two
scale discs are supplied with the operating unit.
Scale disc 1 is fitted if operation is exclusively with the
operating unit. The operating unit then serves as an On-
switch and temperature controller.
Scale disc 2 is fitted if a Mini-timer is used for actuation.
Switch-on is then exclusively with the Mini-timer, and the
temperature is selected with the rotary knob. See wiring
diagram for connection.
Remove the protective film before fitting.
Permissible clearance
for operating button
0,5 to max. 1. mm.
The following cable cross-sections must be observed
between battery and heater, in order that the maximum per
missible voltage losses in the cables (0.5 at 12V rated volta
ge and 1 V at 24 V) are not exceeded.
Length + and — < 5 m -*• cross-section 4 mm2
Length + and — 5 to 8 m -> cross-section 6 mm2
If the positive cable is to be connected to the fuse box (e. g.
terminal 30), the vehicle's cable too from the battery to the
fuse box must be included in the calculation of the total line
length, and if necessary redimensioned in accordance with
the above.
Smear plug and earth connections with contact protection
grease outside the vehicle interior.
Temperature control
The >High/Medium/Low/Off< settings are provided for tem
perature control.
A temperature sensor is arranged on the intake side of the
heater, and - in conjunction with the controller of the operat
ing unit - switches the heater to "High", "Medium" or "Low"
or "Off" depending on intake temperature and controller
setting.
This type of temperature sensor is only suitable for recireu-
lated-air operation (heating air intake from the space being
heated).
If the heater is operated with fresh air, an external tempera
ture sensor (for Cat. No. see page 2) must be fitted in the in
terior and connected according to the wiring diagram. The
sensor must not be attached to uninsulated outer panels, and
must be protected from draughts and direct sunlight. See wi
ring diagram for connection.
11
Wiring diagram heater, normal version
Parts list
Cable colours
sw = black
ws = white
rt = red
ge =
yellow
gn = green
vi = violet
br = brown
gr =
grey
bl = blew
li =
purple
25 1976 00 96 01 B
1.1
1.2
1.5
1.12
2.1
2.2
2.7
2.7.1
5.1
Burner motor
Glow plug
Overheating sensor
Flame sensor
Controller
Dosing pump
Main fuse
12 volt = 25 A
24 volt = 15 A
Fuse, actuation 5 A
Battery
a) Connect the control elements and
external sensors according to the
“Control Elements” circuit diagram
• rt Supply plus terminal 30
• ge Switch-on signal S+
• gr Temperature - actual value
• wsrt Switch off theft warning
system
• br Supply minus terminal 31
• blws Diagnosis
• grrt Temperature - target value
• brws Sensor reference signal
b) Optional
• Fresh-air blower
and / or
• separate fresh air fan
12
Circuit diagram, control elements
(Tip
QlM?|3Ml5|t|?T7iro
Parts list
2.15.1 Sensor, room temperature
2.15.9 Sensor, outside temperature
3.1.11 Operating unit
3.1.16 Momentary-contact switch
3.2.8 Module clock
3.2.12 Timer
3.3.6 Radio receiver
3.9.1 Diagnosis unit, JE diagnosis
a) Connect the control elements to the heater
• rt Supply plus terminal 30
• ge Switch-on signal S+
• gr Temperature - actual value
• wsrt Switci off theft warning system
• br Supp y minus terminal 31
• blws Diagnosis
• grrt Temperature - target value
• brws Connection to earth for external temperature
sensor and temperature target value
b) Terminal 15 - necessary when connecting TP 4
c) Lighting terminal 58
d) Connection for diagnosis unit
e) Connection for external temperature sensor
g) Connection for external heater key ®
h) Connection for TP4 remote control
j) Connection for outside temperature sensor
k) When connecting an automatic switch or radio
receiver - cut open wire at this point
I) Connection change-over switch ‘heating /
ventilating’ (optional). How to start: operate
change-over switch ‘heating / ventilating’,
then switch on the heater.
Cable ends that are not being used must be insulated.
Plug and socket case are shown from the cable entry
side.
Cable colours
sw = black
25 1 895 00 97 02 A _ vvhite
rt = red
ge = yellow
gn - green
vi = violet
br - brown
gr = grey
bl = blew
li = purple
13
Wiring diagram heater, version ADR / TRS 003 / TMD
T ~ rr m ~ n rr r T T i~ T i
1 2 3 4 5 6 7 8 9 10 !! 12 13 14
Parts list
GD
1.1
Burner motor
1.2
Glow plug
1.5
Overheating sensor
1.12
Flame sensor
2.1 Controller
2.2 Dosing pump
2.7 Main fuse
12 volt = 25 A; 24 volt = 15 A
2.7.1 Fuse, actuation 5 A
4.5.1
Diode TRS
5.1
Battery
5.2.1
Battery operating switch d)
(operation e.g. controlled via
ignition lock)
Cable colours
sw = black
ws - white
rt = red
ge -
yellow
gn = green
V! - violet
br = brown
gr = grey
bl -
blew
li = purple
a)
Emergency-shutclown function in
the case of ADR / TRS 003 / TMD -
item 5.2.2-5.5
5.2.2 Battery separating switch d)
5.3 Accessory drive HA+
5.3.1 Switch auxiliary drive
5.5 Generator D+
Connect the control elements and
external sensors according to the
“Control Elements" circuit diagram
• rt Supply plus terminal 30
• ge Switch-on signal S+
• gr Temperature - actual value
• wsrt Switch off theft warning
system; Feedback to ADR /
TRS 003 / TMD switch clock
• br Supply minus terminal 31
• blws Diagnosis
• grrt Temperature - target value
• brws Sensor reference signal
b) Optional
• Fresh-air blower
and / or
. • Vehicle fan control
25 1976 00 96 02 B
c) Wiring if operated subject to ADR /
TRS 003 / TMD (transporters
carrying dangerous substances in
the utility vehicle sector, e.g. road
tanker)
d) If only one control element is used
for items 5.2.1 and 5.2.2, it must be
ensured that, if the function
opening of battery separating
switch’ is actuated (emergency
shutdown-function in the case of
ADR, TRS 003, TMD and similar),
the switch always breaks contact
without delay (without
consideration for the heater mode)
and breaks all of the heater’s
circuits from the battery.
14
Circuit diagram, control elements - ADR / TRS 003 / TMD
r rt0.5
ge 0. 5
gr 0.5
I
----------------------------------
kC
=7
I
T l
< br 0.5
I
4
a |
grrt 0.5 I
brws fl. 5 \r
i - t t S " * £
(3. 1.11)
rt 0. 5
ge 0.5
gr 0.5
wsrt 0.5
Jjr 0J__
,bl*Sj)J5_
grrt 0.5
br*s 0.5
~ T '
.-U
i_ .
B6
K[-Ff
—k U 4
O-
"1 t!:!d z zr
B5
^ i
10 !
s 58II
i 36912 1
86
Oil I | 2 | 3 I * I S iTTfTn-p
Cable colours
sw = black
ws = white
rt = red
ge = yellow
gn =
green
vi = violet
br = brown
gr =
grey
bl = blew
li = purple
Parts list
25 2069 00 99 01 A
2.15.1 Sensor, room temperature
3.1.11 Control unit, round
3.2.8 Module clock (ADR / TRS 003 / TMD -
potentiometer)
3.9.1 Diagnosis, JE-diagnosis
a) Connect the control elements to the heater
• rt Supply plus terminal 30
• ge Switch-on signal S+
• gr Temperature - actual value
• wsrt Feedback to ADR / TRS 003 / TMD switch clock
Switch off theft warning system
• br Supply minus terminal 31
• blws Diagnosis
• grrt Temperature - target value
• brws Connection to earth for external temperature
sensor and temperature target value
b) Terminal 15
c) Lighting terminal 58
d) Connection for diagnosis unit
e) Connection for external temperature sensor
g) Connection for external heater key GD
Cable ends that are not being used must be insulated.
Plug and socket case are shown from the cable entry
side.
15
Functional description
Controls
1. Operating unit
The operating unit is for switching the heater on and off
and for setting the desired cabin temperatures (intake air
temperature between 10 °C and 30 °C). The integrated
green LED indicates wheter the heater is on.
2. Heater timer (optional)
With the heater timer, the heater can be switched on or off
immediately or the switch-on time preset (between 24 h
and 7 days depending on version).
Mode of operation
Switch-on
The green pilot light comes on when the heater is switched
on. The glow plug is switched on and the blower starts up at
a low speed.
Note: If the heat exchanger still contains residual heat, only
the blower runs (cold-blowing phase). The start-up procedure
commences after residual heat has dissipated.
Start-up procedure
Fuel feed starts after approx. 15 seconds. The fuel/air mixture
ignites. Blower speed and fuel feed are increased continuosly.
Once a flame has been detected and the combustion process
has stabilized, the glow plug is switched off. The heater is
heated up rapidly in the >P0WER< setting at maximum heat
flow until the heat exchanger reaches its operating tempera
ture.
Note: The duration of max. heat flow is temperature-
dependent.
Control during heating
During heating, the cabin temperature or the intake heating
air temperature is measured constantly and compared with
the temperature set at the operating unit. If the measured
temperature exceeds the desired cabin temperature, the
heater switches to the >LOW< setting and continues to run at
low blower motor speed. If the heating capacity in the >LOW<
setting is insufficient, the heater switches to the >MEDlUM<
setting. The blower continues to run at low speed. In most
cases, the LOW-MEDIUM-LOW control sequence at low
blower speed will supply the required heat.
If the >MEDIUM< setting is not sufficient, the heater switches
back to >HIGH<. This again entails full blower speed. If, in spe
cial cases, an even lower heating capacity is required than the
heater delivers in the >LOW< setting, the heater switches to
the >OFF( setting. Restart is generally in the >MEDIUM< setting
at low blower motor speed.
Switch-off
When the heater is switched off, the green pilot light goes
out and the fuel feed is shut off. The blower continues to run
to cool down the heater.
The glow plug remains switched on for another 15 seconds to
clear the heater of combustion residues.
Note: If no fuel feed took place during the start-up procedure
or if the heater is in the >OFF< setting, the heater is switched
off immediately without afterrun.
Once the normal afterrun period has elapsed, the heater is
constantly after-ventilated at minimum blower speed (in re-
circulated-air operation only) until the heater is restarted.
Controls and safety equipment
The flame is monitored by the flame sensor, and the max.
permissible temperature by the safety thermal cutout switch.
Both affect the control unit, which shuts down the heater in
the event of faults.
1. If the heater fails to ingnite within 90 seconds of fuel
starting to be pumped, starting is repeated as described.
If the heater still fails to ignite after 90 seconds of fuel
pumping, fault shutdown takes place.
2. If the flame goes out spontaneously during operation, a
restart is first attempted.
If the heater fails to ignite within 90 seconds of fuel
pumping, or if it does ignite but goes out again within 10
minutes, fault shutdown takes place.
The heater can be reset by switching it off and then back
on again.
3. In the event of overheating the safety thermal cutout
switch is operated, the fuel supply is interrupted, and fault
fault shutdown takes place.
If the fault shutdown is due to overheating, the switch-
on pilot light (green) in the operating unit flashes at a
steady rate. Further fault indication signals can be called
using an additional unit - also see Troubleshooting and
Repair Manual.
Once the cause of the overheat has been removed, the
unit can be restarted by switching it off and then back
on again.
4. If the voltage drops below 10.5 or 21 V or rises above
16 or 32 V as the case may be, fault shutdown takes
place.
5. If the glow plug is defective and the electric cable to the
metering pump is interrupted, the heater will not start.
6. When the heater starts the operation of the blower mo
tor is checked once. If it does not start, the heater reacts
as for fault.
During operation, the blower motor is monitored in cyc
lic manner (every 4 minutes). If the motor speed is below
the allowed limit, fault shutdown follows.
7. When the heater is switched off the glow plug is swit
ched on during the delayed shutdown for about 30 se
conds (after-glow) to clear the heater of combustion
residues.
Please note:
When carrying out electric welding work on the vehicle, dis
connect the positive terminal from the battery and earth it in
order to protect the control unit.
The heater must always be switched off when the tank is
being filled.
The heater must not be operated in garages.
16
Sectional drawing
12V 25A
1 Hot air blower wheel
11 Ouiercasing
F = fresh air
2 Blower motor
12 Exhaust line
3 Comb usti on ai r blowe r whee I 13 Flange seal V = combustion air
4 Glow plug 14 Fuel line
5 Control unit 15 Main fuse 8 = fuel
6 Safety thermal cutout switch
16 Combustion air intake line
7 Combustin chamber
17 Fuel metering pump
W = hot air
8 Flame monitor
18 Fuel strainer
9 Heat exchanger A = exhaust
10 Heater timer
17
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