Eberspächer HYDRONIC D 5 W Z, HYDRONIC B 5 W Z, HYDRONIC B 5 W SC, HYDRONIC B 4 W SC, HYDRONIC D 4 W SC Instruction Manual
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J. Eberspächer
GmbH & Co. KG
Eberspächerstr. 24
D - 73730 Esslingen
Telefon (zentral)
(0711) 939 - 00
Telefax
(0711) 939 - 0500
www.eberspaecher.com
Eberspächer
25 2216 90 95 89 EN 10.2010 Subject to changes Printed in Germany © J. Eberspächer GmbH & Co. KG
Technical description
Installation instructions
Operating instructions
Maintenance instructions
Heater (additional heater) for vehicles with
petrol engine
Order no.
HYDRONIC
B 5 W Z – 12 volt 20 1818 05 00 00
Heater (additional heater) for vehicles with
diesel engine
Order no.
HYDRONIC
D 5 W Z – 12 volt 25 2216 05 00 00
Please give this manual to the customer
after installation of the heater.
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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 .............................. 6, 7
• Accident prevention .............................................................................. 7
Product information • Scope of supply ................................................................................. 8, 9
• Technical data petrol heaters .............................................................. 10
• Technical data diesel heaters .............................................................. 11
• Main dimensions .................................................................................. 12
Installation • Installation and location ...................................................................... 13
• Possible installation positions ............................................................. 14
• Mounting and fastening ....................................................................... 14
• Nameplate ........................................................................................... 15
• Connection to the cooling water circuit ......................................... 16, 17
• Exhaust system ................................................................................... 18
• Combustion air system ........................................................................ 19
• Fuel supply ..................................................................................20 – 24
Operation and • Operating instructions / important information for operation ............... 25
function • Initial commissioning ........................................................................... 25
• Description of functions ...................................................................... 25
• Control and safety devices ................................................................. 26
Electrical system • Heater wiring ........................................................................................ 27
• Circuit diagram ..................................................................................... 28
Troubleshooting • In case of faults, please check the following points ........................... 29
Maintenance • Troubleshooting procedure .................................................................. 29
Service • Maintenance instructions .................................................................... 29
• Service ................................................................................................ 29
Environment • Certification ......................................................................................... 30
• Disposal ............................................................................................... 30
• EU Declaration of Conformity ............................................................... 30
Lists • List of key words ........................................................................... 31, 32
• List of abbreviations ............................................................................ 32
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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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4 8
7
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4
Introduction
1
Special text structure, presentation and
picture symbols
This manual uses special text structures and picture
symbols to emphasise different contents.
Please refer to the examples below for the
corresponding meanings and associated actions.
Special structure and presentations
A dot (•) indicates a list which is started by a
heading. If an indented dash (–) follows a dot, this list
is subordinate to the dot.
Picture symbols
Regulation!
This picture symbol with the remark “Regulation”
refers to a statutory regulation. Failure to comply with
this regulation results in expiry of the type permit for
the heater and preclusion of any guarantee and
liability claims on J. Eberspächer GmbH & Co. KG and
its associated companies.
Danger!
This picture symbol with the remark “Danger!” refers
to the risk of a fatal danger to life and limb. Under
certain circumstances, failure to comply with these
instructions can result in severe or life-threatening
injuries
..
..
.
Caution!
This picture symbol with the remark “Caution!” refers
to a dangerous situation for a person and/or the
product.
Failure to comply with these instructions can result in
injuries to people and / or damage to machinery.
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 heater operating independently of an engine is
intended for installation in the following vehicles,
depending on its heating output:
• Vehicles of all kinds
• Construction machinery
• Agricultural machinery
• Boats, ships and yachts
The heater must not be installed in motor vehicles
used to transport dangerous goods according to
ADR / ADR 99.
Purpose of the heater
(using the vehicle heat exchanger)
• Heat up the vehicle's water circuit together with the
vehicle engine for adequate heating of:
– Driver and working cabs
– Freight compartments
– Ship’s cabins
– Passenger and crew compartments
– Vehicle engines and units
On account of its functional purpose, the heater is not
permitted for the following applications:
• Long-term continuous operation, e.g. for pre-heating
and heating of:
– Residential rooms
– Garages
– Work huts, weekend homes and hunting huts
– Houseboats, etc.
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!
5
Introduction
1
Statutory regulations
The Federal Road Transport Directorate has issued an
"EC type approval" and an "EMC type approval" for the
heater for installation in motor vehicles and with the
following official type approval marks, noted on the
heater name plate.
HYDRONIC
EC- e1 00 0023
EMC- e1 023971
Regulation!
Directive 2001 / 56 / EU of the European
Parliament and the Council
• Arrangement of the heater
– Parts of the structure and other components near
the heater must be protected from excess heat
exposure and possible contamination from fuel or
oil.
– The heater must not pose a fire hazard even when
it overheats.
This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and
fire-proof materials or heat plates are used.
– The heater must not be located in the passenger
compartment in vehicles of class M
1
, M2, M3 and N.
A unit may however be used in a hermetically sealed
housing which also corresponds to the conditions
stated above.
– 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
connection indicating that the heater must be
switched off before refuelling.
• Exhaust system
– The exhaust outlet must be arranged so as to
prevent any penetration of exhaust fumes into the
vehicle interior through the ventilation system,
warm air intakes or open windows.
• Combustion air intake
– The air for the heater combustion chamber must
not be sucked in from the passenger compartment
of the vehicle.
– The air intake must be arranged or protected in
such a way that it cannot be blocked by other
objects.
• Operating status display
– A clearly visible operating display in the user’s
field of vision must indicate when the heater is
switched on and off.
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Introduction
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Statutory regulations
• Compliance with the statutory regulations and
safety instructions is prerequisite for guarantee
and liability claims.
Failure to comply with the statutory regulations and
safety instructions and incorrect repairs even when
using original spare parts make the guarantee null
and void and preclude any liability for
J. Eberspächer GmbH & Co. KG.
• Subsequent installation of this heater must comply
with these installation instructions.
• The statutory regulations are binding and must also
be observed in countries which do not have any
special regulations.
• 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.
Safety instructions for installation
and operation
Danger!
Risk of injury, fire and poisoning!
• Disconnect the vehicle battery before starting any
kind of work.
• Before working on the heater, switch the heater off
and let all hot components cool down.
• The heater must not be used in closed rooms, e.g.
in the garage or in a multi-storey car park (do not
leave the engine running when the vehicle is at a
standstill).
Caution!
Safety instructions for installation and operation!
• 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.
• Repairs by non-authorised third-parties or with not
original spare parts are dangerous and therefore not
allowed. They result in expiry of the type permit of
the heater; consequently, when installed in motor
vehicles they can cause expiry of the vehicle
operating licence.
• The following measures are not allowed:
– Changes to components relevant to the heater.
– Use of third-party components not approved by
J. Eberspächer GmbH & Co. KG.
– 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.
Please note!
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Introduction
1
Accident prevention
General accident prevention regulations and the
corresponding workshop and operation safety
instructions are to be observed.
Safety instructions for installation
and operation
Caution!
Safety instructions for installation and operation
• Only the controls approved by Eberspächer may be
used to operate the heater.
The use of other controls can result in malfunctions.
• Only when upgrading the additional heater:
Before the heater is installed again in another
vehicle, rinse the heater parts carrying water with
clear water.
• Before the heater is installed again in another
vehicle, rinse the heater parts carrying water with
clear water.
• When carrying out electric welding on the vehicle,
the plus pole cable at the battery should be
disconnected and placed at ground to protect the
controller.
• The heater must not be operated where there is a
risk of an accumulation of flammable vapours or
dust, for example close to
– fuel depot
– coal depot
– wood depot
– grain depots etc.
• The heater must be switched off when refuelling
(vehicle engine).
• 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.
• When topping up the coolant, only use the coolant
permitted by the vehicle manufacturer, see the
vehicle operating manual. Any blending with
unpermitted coolant can cause damage to the
engine and heater.
• 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.
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• Please consult the additional parts catalogue for
any other parts required for installation, e.g. hose
clips.
• The heater can be upgraded from additional heater
to pre-heater with a mod kit. Please consult the
sales documents for the order number for vehiclespecific mod kits.
Recommendation:
Starting the heater can be limited with an outside
temperature switch, i.e. the heater switches on at a
temperature <5 °C or <10 °C.
In addition, an ON / OFF switch should be fitted for
vehicles frequently used for short distances.
This allows for the heater to be switched off with the
ON / OFF switch when used for short distances and
during the summer months.
The ON / OFF switch can be bought from a good parts
dealer.
Order number:
Outside temperature switch <5 °C 201 00 121
Outside temperature switch <10 °C 201 00 122
ON / OFF switch, 12 volt 201 00 123
Product information
2
Please note!
Scope of supply for petrol heaters
Picture No.
Quantity / Designation Order number
–1
HYDRONIC
B 5 W Z – 12 V 20 1818 05 00 00
–1
HYDRONIC
D 5 W Z – 12 V 25 2216 05 00 00
As complete package:
1 1 Heater --- 2 1 Dosing pum ----
To be ordered separately:
3 1 Heater bracket 25 2220 80 00 01
4 1 Central screw 100 10 258
5 4 Metal-rubber puffer 20 1185 00 00 01
6 1 Water hose Ø 20 25 1917 80 00 01
7 2 Connector Ø 20 mm 20 1534 88 00 01
8 p.m. Pipe 3,5 x 3 360 75 300
9 p.m. Pipe 4 x 1,25 090 31 118
10 1 Pipe clip 22 1000 50 05 00
11 1 Hose clip 10 2064 01 60 25
12 1 Flexible exhaust pipe 25 1774 80 02 00
13 1 Combustion air hose 360 00 099
14 1 End sleeve 25 1688 80 12 01
15 1 Plug 22 1000 30 10 21
16 1 Receptacle housing 22 1000 31 87 00
17 1 Bracket 22 1000 50 03 00
18 1 T-piece 8-6-8 262 31 151
19 2 Support sleeve 22 1000 20 02 00
20 p.m. Hose 7,5 x 2,5 360 31 070
21 p.m. Hose 5 x 3 360 75 350
22 p.m. Pipe 6 x 2 090 31 125
23 1 Fuse holder 22 1000 31 06 00
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Scope of supply
Product information
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Product information
2
Caution!
Safety instructions for technical data!
Failure to comply with the technical data
can result in malfunctions.
Technical data for petrol heaters
Heater B 5 W Z
Heating medium Water, cooling fluid
Control of the heat flow Large Small
Heat flow (watt) 5000 1500
Fuel consumption (l/h) 0.69 0.2
Mean electr. power (watt) in operation 37 10
at start 110
after-running 8
Rated voltage 12 volt
Operating range
• Lower voltage limit: An undervoltage protection 10.2 volt
in the controller switches the heater off on
reaching approx 10 volt.
• Upper voltage limit: An overvoltage protection
in the controller switches the heater off on 16 volt
reaching approx 16 volt.
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow rate of the heater 250 l/h
Fuel commercially available petrol
(see also fuel supply, page 24). (DIN EN 228)
Tolerable operating temperature operation heater –40 °C to +80 °C
operating, dosing pump –40 °C to +20 °C
storage –40 °C to +105 °C
Interference suppression class 5 for VHF, SW, MW, 2 for LW
Weight
• without controller and cooling fluid ca. 2.3 kg
• with dosing pump and water pump ca. 2.5 kg
All technical data ±10 %
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Product information
2
Technical data for diesel heaters
Heater D 5 W Z
Heating medium Water, cooling fluid
Control of the heat flow Large Small
Heat flow (watt) 5000 2400
Fuel consumption (l/h) 0.62 0.27
Mean electr. power (watt) in operation 37 10
at start 110
after-running 8
Rated voltage 12 volt
Operating range
• Lower voltage limit: An undervoltage protection 10.2 volt
in the controller switches the heater off on
reaching approx 10 volt.
• Upper voltage limit: An overvoltage protection
in the controller switches the heater off on 16 volt
reaching approx 16 volt.
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow rate of the heater 250 l/h
Fuel commercially available diesel
(see also fuel supply, page 24). (DIN EN 590)
Tolerable operating temperature operation heater –40 °C to +80 °C
operating, dosing pump –40 °C to +80 °C
storage –40 °C to +105 °C
Interference suppression class 5 for VHF, SW, MW, 2 for LW
Weight
• without controller and cooling fluid ca. 2.3 kg
• with dosing pump and water pump ca. 2.5 kg
Caution!
Safety instructions for technical data!
Failure to comply with the technical data
can result in malfunctions.
All technical data ±10 %
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