Eberspächer Airtronic B5 Operating Instructions Manual
Heater Order number
AIRTRONIC B5, 12 volt 20 1859 05 00 00
Heater Order number
AIRTRONIC D5, 12 volt 25 2361 05 00 00
AIRTRONIC D5, 24 volt 25 2362 05 00 00
AIRTRONIC L
Technical description, installation,
operation and maintenance instructions.
Air heater for diesel and petrol
operating independently of the engine.
25 2361 90 97 67
09.2008
Contents
Chapter Title Contents Page
2
Introduction
8
7
6
5
4
3
2
1
1
Introduction
Product information
Installation
Operation and
function
Electrical system
Faults
Maintenance
Service
Environment
Lists
• 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
• Scope of supply ..................................................................................... 8, 9
• Technical data .......................................................................................... 10
• Main dimensions ...................................................................................... 11
• Installation and mounting position ........................................................... 12
• Installing the 24 volt heater in a vehicle for the transport of
dangerous goods according to ADR ........................................................ 12
• Installation location .................................................................................. 13
• Possible mounting positions ..................................................................... 14
• Installation and fixing................................................................................ 15
• Nameplate ................................................................................................ 16
• Hot air system .......................................................................................... 17
• Exhaust system ......................................................................................... 18
• Combustion air system .............................................................................. 19
• Fuel supply ...................................................................................... 20 – 24
• Operation instructions / important information for operation .................... 25
• Initial commissioning ................................................................................ 25
• Description of functions ........................................................................... 26
• Control and safety devices / EMERGENCY OFF ..................................... 27
• Heater wiring ........................................................................................... 28
• Parts list for the circuit diagrams / circuit diagrams ....................... 28 – 41
• If any faults occur, please check the following items ............................... 45
• Troubleshooting ........................................................................................ 45
• Maintenance instructions ......................................................................... 45
• Service ..................................................................................................... 45
• Certification .............................................................................................. 46
• Disposal .................................................................................................... 46
• EU Declaration of Conformity .................................................................... 46
• List of key words ............................................................................... 47, 48
• List of abbreviations .................................................................................. 48
3
Introduction1
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.
1
2
3
4
5
6
7
8
Introduction
This section contains important introductory
information about installing 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.
Electrical system
Here you will find information about the electronic
system and electronic components of the heater.
Troubleshooting / maintenance / service
Here you will find information about possible
faults, troubleshooting, servicing / 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.
4
Introduction1
Special text structure, presentation and
picture symbols
This manual uses special text structures and picture
symbols to emphasize 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 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 recommendations for use and
useful tips for installation of the heater.
Please note!
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:
• All types of motor vehicles and their trailers
• Construction machinery
• Agricultural machinery
• Boats, ships and yachts
• The heater is approved for installation inside vehicle
spaces used by people (max. 9 seats), subject to
compliance with the statutory requirements and
notes given in the contents of these instructions.
• The AIRTRONIC L – D5 (24 volt) heater is approved
for installation in vehicles used for the transport of
dangerous goods according to ADR.
Intended use of the heater
• Pre-heating, de-misting windows
• Heating and keeping the following warm:
– Driver and working cabs
– Freight compartments
– Ship’s cabins
– Passenger and crew compartments
On account of its intended functional use, the heater is
not approved for the following applications:
• Long-term continuous operation, e.g. for heating of:
– Residential rooms
– Garages
– Work huts, weekend homes and hunting lodges
– Houseboats, etc.
• Heating or drying of:
– Living creatures (people or animals) by blowing hot
air directly at them
– Objects
– Blowing hot air into containers
Caution!
Safety instructions for the range of application
and proper, intended use!
• The heater must only be used and operated for the
range of application stated by the manufacturer and
in compliance with the “Operation instructions“
included with every heater.
Please note!
5
Introduction1
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.
AIRTRONIC L EC- e1 00 0105
EMC- e1 03 3971
• 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’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
arranged 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.
Regulation!
Installing the heater in a vehicle for the transport of
dangerous goods according to ADR
• The ADR regulations must also be observed for
installation of the heater in vehicles for the transport
of dangerous goods. Detailed information about the
ADR regulations is given in the information leaflet
no. 25 2161 95 15 80 (see also pages 12 and 27).
Regulation!
Extract from the EC Directive 2001 / 56 EC
Annex VII
• 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.
• 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 passenger
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 of it 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 rist of injuries
to persons or damage to other property.
6
Regulations
Additional regulations for certain vehicles named in
Directive 94 / 55 / EC (ADR Framework Directive)
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
For the purposes of this appendix, the vehicle
designations "EX / II", "EX / III", "AT", "FL" and "OX"
according to Chapter 9.1 of Annex B of Directive 94 /
55 / EC are used.
Technical regulations
General provisions (EX / II, EX / III, AT, FL and OX
vehicles)
Avoid heating and ignition
The combustion heaters and their exhaust gas routing
shall be designed, located, protected or covered so
as to prevent any unacceptable risk of heating or
ignition of the load. This requirement shall be
considered as fulfilled if the fuel tank and the exhaust
system of the appliance conform to provisions in
3.1.1.1 and 3.1.1.2. Compliance with these
regulations shall be checked in the complete vehicle.
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.
• 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
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.
• 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.
Introduction1
Please note!
7
Safety instructions for installation and
operation
Danger!
Risk of injury, fire and poisoning!
• The heater must only be started up if the intake and
outflow hoods have been fitted.
• 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-story car park.
• Adjustable hot air outlets must always be adjusted
so that they cannot blow hot air directly at living
creatures (people, animals) or object 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 the initial commissioning of
the heater.
In addition, the installation date must be entered on
the plate “original spare part“ enclosed with the
heat exchanger. 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 documentation and any special
installation recommendations. The same applies to
any necessary repairs or in case of guarantee
claims.
• Only the control elements approved by
J. Eberspächer GmbH & Co. KG must be used to
operate the heater.
Use of other control elements can cause
malfunctions.
• 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.
Introduction1
• The following measures are not allowed:
– Changes to components relevant to the heater.
– Use of third-party components not approved by
Eberspächer.
– Departures from the statutory regulations, safety
instructions and / or functional specifications given
in these documents with regard to installation or
operation. This applies in particular to the
electrical wiring, fuel supply, combustion air
system and exhaust system.
• Only original accessories and spare parts may be
used for 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.
• 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.
• If the heater is fitted in a safety casing, etc., the
heater’s installation box must not be used as
storage space 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.
• Defective fuses must only be replaced by fuses with
the prescribed fuse value.
• If fuel escapes from the heater’s fuel system (leak),
arrange for immediate repair of the damage by a
JE service partner.
• The after-running of the heater must not be
prematurely interrupted e.g. by pressing the battery
disconnector switch, except for an emergency stop.
Accident prevention
General accident prevention regulations and the
corresponding workshop and operating safety
instructions are to be observed.
8
Product information2
Scope of supply for AIRTRONIC L – B5
Quantity / Designation Order no.
1 AIRTRONIC L – B5, 12 V 20 1859 05 00 00
To be ordered separately:
1 Universal installation kit 25 2361 80 00 00
1 Control element* –
Scope of supply for AIRTRONIC L – D5
Quantity / Designation Order no.
1 AIRTRONIC L – D5, 12 V 25 2361 05 00 00
1 AIRTRONIC L – D5, 24 V 25 2362 05 00 00
To be ordered separately:
1 Universal installation kit 25 2361 80 00 00
1 Control element* –
* Control elements see price list / accessories
catalogue.
Parts list for the picture “Scope of supply“ on
page 9
Scope of supply for heater
No. in figure Designation
1 Heater
2 Dosing pump
Scope of supply for universal installation kit
No. in figure Designation
3 Grid, Ø 90 mm
4 Outflow
5 Hose clip, Ø 90 mm – 110 mm (2x)
6 Flexible pipe, Ø 90 mm
7 Support (3x)
8 Pipe clip, Ø 50 mm
9 Intake silencer
10 Flexible exhaust pipe, Ø 24 mm
11 Cable tape 200 (2x 10 pcs)
12 Fuel pipe, 4 x 1.25, 7.5 m long
13 Fuse-switch
14 Plus cable, 1
2
rt
15 Plus cable, 42 rt
16 Wiring harness
17 Bracket dosing pump
18 Fuel pipe, 6 x 2, 1.5 m long
19 Hose connector 8 / 6 / 8
20 Hose connector 10 / 6 / 10
Please note!
• Parts without a figure no. are small parts and packed
in a bag.
• Please consult the additional parts catalogue if any
other parts are required for installation.
9
Product information2
Scope of supply
10
Product information2
Technical data
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can
result in malfunctions.
Heatertype
Heater
Version
Heating medium
Control of the heat flow
Heat flow (watt)
Heater air flow rate without counterpressure (kg/h)
Heater code
Fuel consumption (l/h)
Elec. power consumption (watt)
in operation
while starting
Rated voltage (volt)
Operating range
Lower voltage limit:
An undervoltage protector installed in the
control box switches off the heater when the
voltage limit is reached.
Upper voltage limit:
An overvoltage protector installed in the
control box switches off the heater when the
voltage limit is reached.
Fuel
“Fuel quality“ and “fuel at low temperatures“
see operating instructions page 24.
Permissible ambient temperature
Operation
Storage
Maximum air intake temperature
Interference suppression
Weight
Ventilation mode
AIRTRONIC L
AIRTRONIC B5 AIRTRONIC D5
B5 D5
Air Air
Stage Stage
Power High Medium Low Power High Medium Low
5500 4800 2700 2000 5500 4800 2700 1600
280 275 180 125 280 275 190 155
10 10
0.75 0.65 0.37 0.27 0.66 0.58 0.34 0.20
85 80 30 15 85 80 35 25
< 250 < 250
12 12 / 24
ca. 10.5 volt resp. ca. 21 volt
Undervoltage protection response time: 20 seconds
ca. 16 volt resp. ca. 32 volt
Overvoltage protection response time: 20 seconds
Petrol – standard Diesel fuel – standard
commercial quality commercial quality
(DIN EN 51600 / DIN EN 228) (DIN EN 590)
Heater Controller Dosing Heater Controller Dosing
pump pump
–40 °C to –40 °C to –40 °C to –40 °C to –40 °C to –40 °C to
+50 °C +75 °C +20 °C +70 °C +75 °C +50 °C
–40 °C to –40 °C to –40 °C to –40 °C to –40 °C to –40 °C to
+85 °C +85 °C +85 °C +85 °C +85 °C +85 °C
+40 °C
Suppression class 5 to DIN 55025
ca. 9.3 kg
possible
Provided no limit values are given, the technical data
listed is subject to the tolerances usually applicable
to heaters of ±10% for nominal voltage, ambient
temperature 20 °C and reference altitude Esslingen.
Please note!
11
Product information2
Main dimensions
1 Minimum installation space (clearance) required for
hot air intake and for dismantling the intake hood.
2 Minimum installation space (clearance) required for
dismantling the glow plugs and controller.
3 Wiring harness connection, right or left-hand
possible (see “Wiring harness connection, right or
left-hand“).
A = Exhaust
B = Fuel
V = Combustion air
Cable harness connection, right or
left-hand
If necessary, the cable harness can be changed over
to the opposite side of the heater. The controller can
be removed after the intake hood has been
dismantled.
Unclip the semi-circular cable harness cover on the
controller and relay the cable harness. Then fit the
semi-circular cable harness cover back onto the
controller. Install the controller.
Push the grommet of the cable harness and the
dummy grommet in the corresponding holes of the
upper sleeve casing. Refit the intake hood.
12
Installation3
Installation and mounting position
The heater is suitable and approved for installation in
vehicle interiors used by people.
Installation in the driver’s cab or passenger
compartments of coaches or buses with more than
9 seats is not allowed.
When installing in compartments used by persons, the
exhaust, combustion air and fuel pipes in these areas
must not have any detachable connections and must
be laid splash-proof in the penetrations.
For this reason, the heater can be fitted onto the
vehicle floor or an outer panel of the vehicle using the
flange seal in the heater’s base.
The electronic control is integrated in the heater, which
makes wiring during installation much easier.
• When installing the heater, always make sure there is
sufficient clearance left for intake of the heater air and
for dismantling the glow plug and controller.
• Observe the regulations and safety instructions for
this chapter, given on pages 4 – 7.
Please note!
Installing the 24 V heater in a vehicle for
the transport of dangerous goods
according to ADR
The heater can be installed in vehicles used for the
transport of dangerous goods according to
ADR.
If installed with the appropriate electrical wiring, the
heater fulfills the ADR regulations, see circuit
diagrams at the end of this manual.
Detailed information about the ADR regulations is
given in the leaflet no. 25 2161 95 15 80.
For installation of the heater in vehicles for the
transport of dangerous goods, the regulations of
ADR must also be observed.
Please note!
13
Installation3
Installation location
Installation location in a delivery truck or van
In a delivery truck or van, the heater should preferably
be installed in the vehicle interior or cargo area.
If it is not possible to install the heater in the vehicle
interior or cargo area, the heater can also be fitted
under the vehicle floor.
Installation location in a trailer
In a trailer, the heater is preferably installed in a box in
the upper part of the end panel of the trailer.
In this case, for recirculation mode, select hot air intake
in the lower part of the trailer and hot air outflow in the
lower area.
1 Heater in the vehicle interior or cargo area
2 Heater fitted under the vehicle floor
1 Heater
2 Battery
3 Flexible pipe for hot air
4 Outlet for hot air
5 Additional fuel tank
6 Exhaust pipe
7 Combustion air hose
8 Fuel dosing pump
• The positions suggested in the installation
instructions are examples.
Other mounting positions 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 permissible mounting positions as well
as the operating and storage temperatures.
Please note!
14
Installation3
Permitted mounting positions
The heater should preferably be installed in the
standard position as shown in the drawing.
Depending on the installation conditions, the heater
can be tilted by max. 30° (flow direction downwards!)
or turned by max. 90° around its own longitudinal axis
(exhaust connection horizontal, glow plug points
upwards!), as shown in the drawing.
In heating mode, the standard or maximum installation
positions shown can differ by up to +15° in all
directions, due to tilted vehicle or boat positions,
without impairing the heater’s function.
Normal horizontal position (exhaust connection
facing downwards) with permissible swivel ranges
1 Hot air intake opening (fan wheel)
2 Direction of flow
3 Position of the glow plug
15
1
1
1
1
1
1
Installation3
Installation and fixing
Make the through-holes for exhaust, combustion air
and fuel as shown in the drilling hole pattern.
The support surface for the heater base must be flat.
The Ø 10.5 mm hole for the “dosing pump“ cables is
not included in the drilling hole pattern and must be
drilled depending on the installation.
If the sheet metal of the support surface is thinner than
1.5 mm, an additional reinforcing plate will have to be
fitted.
Order no: reinforcing plate 25 1729 89 00 03
Drilling hole pattern
Fixing the heater to the vehicle floor Fixing the heater horizontally to the vehicle wall
(panel)
1 There must be sufficient clearance between the
heater and the vehicle floor – in addition, check
that the fan wheel runs freely.
2 The mounting surface must be flat and smooth.
3 The flange seal must be fitted.
4 The vehicle wall must be flat and smooth.
5 Spring washer
6 4 x M8 hexagonal nut (tightening torque 11
+1
Nm)
7 Reinforcing plate (if needed, Order no.
25 1729 89 00 03)
1 Contour of the bearing surface.
16
Installation3
Nameplate
The nameplate is fixed onto the upper jacket shell. A
2nd nameplate (duplicate) is available as an additional
part.
• Observe the regulations and safety instructions for
this chapter given on page 5.
• For further information about the 2nd nameplate
(duplicate) see the additional parts catalogue.
Please note!
1 Original nameplate
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