Eberspächer HYDRONIC 16, HYDRONIC 30, HYDRONIC 24, HYDRONIC 35 Troubleshooting And Repair Instructions

Troubleshooting and Repair Instructions

L

D16WN 25 2395 Rev L
S/N 0612051698
16kW

The Troubleshooting and Repair Instructions are applicable to the
following unit versions:

Normal version Order No. Basic unit No.:

HYDRONIC 16 – 24 volt 25 2165 02 00 00 25 2165 01 00 00
HYDRONIC 24 – 24 volt 25 1817 02 00 00 25 1817 01 00 00
HYDRONIC 30 – 24 volt 25 1818 02 00 00 25 1818 01 00 00
HYDRONIC 35 – 24 volt 25 1819 02 00 00 25 1819 01 00 00

J. Eberspächer GmbH
& Co. KG
Eberspächerstr. 24
D – 73730 Esslingen

Telephone (switchboard)
(0711) 939-00
Facsimile
[phone]

www.eberspaecher.com

Compact version Order No. Basic unit No.:

HYDRONIC 24 – 24 volt 25 1817 05 00 00 25 1817 01 00 00
HYDRONIC 30 – 24 volt 25 1818 05 00 00 25 1818 01 00 00
HYDRONIC 35 – 24 volt 25 2041 05 00 00 25 1819 01 00 00

Normal version

25 1818 95 20 12 09.2008 Subject to change without notice Printed in Germany © J. Eberspächer GmbH & Co. KG

Compact version

Introduction

1

Contents

This list of contents provides precise information about the
contents of these Troubleshooting and Repair Instructions.

Chapter Title Contents Page

Introduction

1

Function

2

Product information

3

Troubleshooting

4

Repair instructions

5

• Contents ................................................................................................... 2 – 3

• Foreword ........................................................................................................ 4

• Safety instructions for installation and repair .................................................... 4

• Accident prevention ........................................................................................ 4

• Special text structure, presentation and picture symbols ................................. 4

• Important information before starting work ...................................................... 4

• Cutaway view .................................................................................................. 5

• Structure of the heater .................................................................................... 6

• Special features of the heater .......................................................................... 6

• Operating instructions ..................................................................................... 6

• Description of functions ................................................................................... 6

• Functional diagram .......................................................................................... 7

• Control diagram .............................................................................................. 7

• Control and safety devices .............................................................................. 8

• Emergency stop (EMERGENCY OFF) .............................................................. 8

• Technical data, heater ..................................................................................... 9

• Technical data, water pump .......................................................................... 10

– Pumping and pressure loss characteristic curves ....................................... 10

• What to check fi rst in case of faults ............................................................... 11

• Locking the control box ................................................................................. 11

• Cancelling the control box lock ...................................................................... 11

• Fault diagnosis – fl ashing code ...................................................................... 12

• Overview of the individual test equipment and control units ........................... 13

• External diagnostic system ............................................................................ 13

• Fault diagnosis using the diagnostic unit ................................................. 14, 15

• Fault diagnosis: EDiTH customer service program with ISO adapter .............. 16

• Fault diagnosis: EDiTH customer service program with basic adapter ........... 17

• Fault diagnosis using the module timer .......................................................... 18

• Fault diagnosis using the radio remote control TP5 ....................................... 19

• Fault diagnosis with EasyStart R+ radio remote control

and EasyStart T timer .................................................................................... 20

• Fault code table .................................................................................... 21 – 24

• Repair instructions ........................................................................................ 25

• Always observe the following safety instructions before working on the heater . 25

• AMP release tool ........................................................................................... 25

• Assembly drawing .................................................................................. 26, 27

– Component parts ..................................................................................... 27

• Removing the hood ....................................................................................... 28

• Dismantling the burner .................................................................................. 28

• Dismantling the control box ........................................................................... 28

• Dismantling the burner motor ........................................................................ 29

• Checking the function and speed of the burner motor

using the burner tester .................................................................................. 29

• Dismantling the ignition electrodes ................................................................ 30

• Dismantling the fuel nozzle ............................................................................ 30

• Dismantling the ignition unit ........................................................................... 31

• Testing the ignition unit using the burner tester .............................................. 31

• Dismantling the solenoid valve ....................................................................... 32

• Testing the solenoid valve using the burner tester .......................................... 32

• Dismantling the nozzle block ......................................................................... 33

– Nozzle block made of brass ....................................................................... 33

– Functional check of the heating cartridge ................................................... 33

• Dismantling the fl ame tube ............................................................................ 34

If you are looking for a specifi c term, use the index at the end
of this document.

2

Introduction

1

Contents

Chapter Title Contents Page

5

Repair instructions

Circuit diagrams

6

Service

7

• Dismantling the temperature and overheating sensor .................................... 35

• Temperature and overheating sensor resistance values ................................. 35

– Table of characteristic values - temperature sensor ................................... 35

– Temperature sensor diagram ..................................................................... 35

– Table of characteristic values - overheating sensor ..................................... 36

– Overheating sensor diagram ...................................................................... 36

• Dismantling the gauze fuel fi lter ..................................................................... 37

• Notes on the fuel fl ow rate and the pressure in the fuel system ...................... 36

• Measuring the CO2 content ........................................................................... 37

• Adjusting the combustion air ......................................................................... 37

• Dismantling the water pump (standard design) .............................................. 39

• "Bus 2000" water pump ................................................................................ 39

• Dismantling the FLOWTRONIC 5000 water pump ......................................... 40

• Heater circuit diagram – Part 1 (HYDRONIC 16 / 24 with temperature switch) .. 41

• Heater circuit diagram – Part 1 (HYDRONIC 16 – 35 without temperature

switch) .......................................................................................................... 42

• Heater circuit diagram – Part 2 with water pump (standard design)

and "Bus 2000" water pump ......................................................................... 43

• Heater circuit diagram – Part 3 with FLOWTRONIC water pump .................. 44

• Circuit diagram / parts list for control units ............................................... 45, 46

• Parts list for circuit diagram - EasyStart control units .................................... 47

• EasyStart R control unit circuit diagram ......................................................... 48

• EasyStart R+ control unit circuit diagram ....................................................... 49

• EasyStart T control unit circuit diagram ......................................................... 50

• Certifi cation ................................................................................................... 51

• Disposal ........................................................................................................ 51

• EC Declaration of Conformity ........................................................................ 51

• Representatives abroad .......................................................................... 52, 53

• List of key words ..................................................................................... 54, 55

3

Introduction

1

Foreword

These Troubleshooting and Repair Instructions are applicable
to the heaters listed on the title page, to the exclusion of all li­ability claims.
Depending on the version or revision status of the heater,
there may be differences between it and these Troubleshoot­ing and Repair Instructions.
The user must check this before carrying out the repair work
and, if necessary, take the differences into account.

Important!
Safety instructions for installation and repair!

Special text structure, presentation and
picture symbols

Special text formats and picture symbols are used in these
instructions to emphasise different situations and subjects.
Please refer to the following examples for their meanings and
appropriate action.

Special text formats and presentations

• A dot (•) indicates a list, which is started by a heading.
– If an indented dash (–) follows a "dot", this list is a sub-

section of the black dot.

Improper installation or repair of Eberspächer heaters can
cause a fi re or result poisonous exhaust entering the inside of
the vehicle. This can cause serious and even fatal risks.

The heater may only be installed according to the specifi ca­tions in the technical documents or repaired using original
spare parts by authorised and trained persons.
Installation and repairs by unauthorised and untrained per­sons, repairs using non-original spare parts and without the
technical documents required for installation and repair are
dangerous and therefore are not permitted.

A repair may only be carried out in connection with the re­spective unit-related technical description, installation instruc­tions, operating instructions and maintenance instructions.
This document must be carefully read through before / dur­ing installation and repair and followed throughout. Particular
attention is to be paid to the offi cial regulations, the safety in­structions and the general information.

Please note!

The relevant rules of sound engineering practice and any in­formation provided by the vehicle manufacturer are to be ob­served during the installation and repair.
Eberspächer does not accept any liability for defects and
damage, which are due to installation or repair by unauthor­ised and untrained persons.
Compliance with the offi cial regulations and the safety instruc­tions is prerequisite for liability claims. Failure to comply with
the offi cial regulations and safety instructions leads to exclu­sion of any liability of the heater manufacturer.

Picture symbols

Danger!

This information points out a potential serious or fatal danger.
Ignoring this information can result in severe injuries.

Important!

This information points out 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.

Important information before starting
work

Initial commissioning of the heater or functional test
after a repair

• After installing the heater, the whole fuel supply system must
be carefully vented: please refer to and follow the vehicle
manufacturer's instructions.

• During the heater trial run, all fuel connections must be
checked for leaks and secure, tight fi t.

• If faults occur while the heater is running, use a diagnostic
unit to determine and correct the cause of the fault.

Accident prevention

General accident prevention regulations and the correspond­ing workshop and operating safety instructions are to be ob­served.

4

Function

2

Cutaway view

Sketch 1

1 Impeller
2 Electric motor
3 Solenoid valve
4 Flame tube
5 Control box
6 Combustion

chamber
7 Heat exchanger
8 Ignition unit
9 Ignition electrodes
10 Fuel nozzle

11 Coupling
12 Temperature sensor
13 Overheating sensor
14 Relay (vehicle blower control)
15 Fuses
16 Module timer
17 Water pump
18 Exhaust pipe
19 Fuel connection
20 Hood (CO
21 Flame detection photocell
22 Nozzle block with integrated heating

element

adjustment)

2

A Exhaust
B Fuel
V Combustion air
WA Water outlet
WE Water inlet

5

Function

2

Structure of the heater

The heater consists of a heat exchanger and a removable
burner. A combustion chamber consisting of a fl ame tube with
integrated mixer is inserted in the heat exchanger. The fl ame
tube can be pulled out of the heat exchanger if necessary.
The control box and electric motor are fi xed to the burner
fl ange under the burner hood. The fuel pump is integrated in
the burner housing.

The following additional parts are required for operation of the
heater:

• Water pump

• Additional parts for connection to the water circuit

• Additional parts for the fuel supply

• Additional parts for the exhaust system

• Control unit

Order No. see technical description, for further additional parts
see additional parts catalogue.

Special feature of the heater

Description of functions

Switching on the heater

When the heater is switched on, a component test is carried
out (3 seconds) and then the water pump is started up.

Note:

If the water temperature is < 5 °C the nozzle pre-heater is
switched on for 60 seconds; the burner start is delayed by
this length of time.

Burner start

The electric motor starts and drives the combustion air impel­ler and the fuel pump.
After approx. 10 seconds, the ignition is switched on and then
the fuel solenoid valve opens. Within these 10 seconds a ro­tational check of the electric motor is carried out. The fuel and
combustion air in the combustion chamber form an ignitable
mixture.
The mixture is ignited by a high-voltage ignition spark. The
fl ame detection photocell detects the fl icker frequency of the
fl ame and switches off the ignition unit. The hot fuel gases
fl ow through the heat exchanger and transfer the heat to the
heating medium.

• If the water fl ow rate is too low, the water outlet temperature
is limited by premature correction.

• The temperature rise of the heating medium is monitored
over time. If it rises too fast (water fl ow rate too low) the
heater automatically switches "OFF" and begins the after­run, the cycle then begins again.

• Constant comparison of the measured temperature sensor
and overheating sensor values provides additional heater
safety. If the difference between the measured values is
too large (water fl ow rate too low) the heater prematurely
switches "OFF".

Operating instructions

The heater is operated by a control unit. Detailed operating in­structions are supplied with the control unit.

Please note!

The operating instructions are issued to you by the garage /
workshop that installs the heater.

Please note!

• The heater operates depending on the heat requirement,
therefore the length of the burner's on-time and off-time
periods differ.

• The water pump continues to run throughout the whole op­erating period, even during pause mode periods and during
the after-run.

Options

• When the temperature drop is activated the "ON / OFF"
control temperatures are lowered by approx. 8K.

For connection of the ON / OFF switch for temperature

drop, see circuit diagram on pages 43 and 44.

• The water pump can also be operated independently of the
heater, if an appropriate control is installed. For connec­tion of the additional "ON / OFF" switch for separate water
pump control, see circuit diagram on pages 43 and 44.

• For vehicle blower control, the vehicle blower is switched on
and off at the following water temperatures.
– Water temperature > 55 °C —>Vehicle blower "ON"
– Water temperature < 50 °C —>Vehicle blower "OFF"

Switching off the heater

If the heater is switched off, the fuel solenoid valve closes and
at the same time the approx. 3 minute after-run begins.
After the after-run has fi nished the heater is automatically
switched off.

Please note!

Until it is switched off, including during the after-run, the fuel is
circulated.

6

Function

2

Functional diagram

Heater ON

Components test

Heating mode

Heater OFF

Nozzle block heating

(ON at temperature <5 °C)

Water pump

Solenoid valve

Ignition unit

Electric motor

Sketch 2

Control diagram

60 sec.

3 sec.

From control box 25 1818 53 00 00,
switching "OFF / ON" of the nozzle block
heating is temperature controlled

From control box 25 1818 53 00 00

10 sec.

10 sec.

After running

180 sec.

Vehicle blower ON

Vehicle blower OFF

Sketch 3

Heater ON NORMAL OPERATION Heater OFF

ON ONOFF OFF

After-run – 3 min.

Control – Normal
Control – Temperature drop

7

Function

2

Control and safety devices

The heater is equipped with the following control and safe­ty devices.

• If the heater does not ignite the control box* is locked after
an impermissible number of failed start attempts.

• If the water fl ow rate is too low, the water outlet temperature
is limited by premature correction.

• The temperature rise of the heating medium is monitored
over time. If it rises too fast (water fl ow rate too low) the
heater automatically switches "OFF" and begins the after­run, the cycle then starts again.

• Constant comparison of the measured values for the tem­perature sensor and overheating sensor provides additional
heater safety, as a premature lockout (shutdown on faults)
occurs if the difference between the measured values is too
high (the water fl ow rate is too low).

After an impermissible number of lockouts, the control box

is locked.*

• If the lower or upper voltage limit is reached, a lockout
(shutdown on faults) occurs.

• If the fl ame sensor detects a fl ame during the heater's after­run a lockout occurs (shutdown on faults).

After an impermissible number of lockouts, the control box

is locked.*

* The lock can be cancelled and the faults read out:

• with the module timer / EasyStart T timer

• with the radio remote control TP5 / EasyStart R+.

For other control units by connecting:

• the diagnostic unit

• the customer service program KD2000 / EDiTH.

For details of operation and fault list, see these Trouble-

shooting and Repair Instructions from page 13.

Emergency shutdown – EMERGENCY
OFF

If an emergency shutdown –
EMERGENCY OFF – is required during operation, execute
the following:

• Switch the heater off at the control unit or

• remove the fuse or

• disconnect the heater from the battery.

8

Product information

0.53 Gal/Hr

6 GPM

3

Technical data, heater

Type

Heating medium Mixture of water and refrigerant (max. 50 % refrigerant fraction)

Heat fl ow in watt (at ambient temperature 20 °C) 16 000 24 000 30 000 35 000

Temperature values – at water inlet ON 73 °C / OFF 78 °C

Temperature values – at water outlet ON 85 °C / OFF 118 °C

Fuel Diesel – standard commercial (DIN EN 590) Heating oil EL (DIN 51603)

Fuel consumption (at ambient temperature –10 °C) 2.0 l/h 2.9 l/h 3.65 l/h 4.2 l/h

Rated voltage 24 volt

Operating range

• Lower voltage limit:
An undervoltage protector installed in the control box

switches off the heater if the voltage limit is reached.

• Upper voltage limit:
An overvoltage protector (surge suppressor) installed

in the control box switches off the heater if the voltage
limit is reached.

Electrical power consumption
(in combustion mode / without circulating pump)

D 16 W N D 24 W N D 30 W N D 35 W N

60 watt 80 watt 105 watt 120 watt

HYDRONIC L

19 volt

30 volt

Water content of the heat exchanger approx 2 l

Water content of the water circuit min. 10 l

Minimum heating medium fl ow rate (±200 l/h) 1400 l/h 2000 l/h 2600 l/h 3000 l/h

Permissible ambient temperature in operation:

during transport / storage:

for the combustion air:

Pumped medium:

Operating pressure (water circuit) < 2.5 bar

values (% vol) 9 – 11 9 – 11 9 – 11 9.5 – 11.5

CO

2

CO in the exhaust < 0.04

Smoke spot no. (Bacherach) < 4

Weight approx 18 kg

Interference suppression class VHF 4 / SW 3 / MW 5 / LW 3 according to DIN 57879 / Part 1

Protection IP 64

–40 °C to +85 °C
–40 °C to +100 °C
< 60 °C
–40 °C to +90 °C,
short-term up to +120 °C

VDE 0879

Important!
Safety instructions for technical data!

Failure to comply with the technical data can result in malfunc­tions.

Please note!

If no limit values are given, the technical data listed is with the
usual heater tolerances of ± 10 % at nominal voltage, 20 °C
ambient temperature and Esslingen reference altitude.

9

Product information

3

Technical data, water pump

Heating medium Mixture of water and refrigerant (max. 50 % refrigerant fraction)

Delivery rate 5200 l/h ±10 % at 0.2 bar discharge pressure

Water circuit operating pressure max. 2 bar

Weight (without bracket, clamp and refrigerant) 2.14 kg

Rated voltage 24 volt

Operating range 20 – 28 volt

Power consumption at 5200 l/h and 0.2 bar discharge pres­sure

Interference suppression class 3 according to DIN 57879 / Part 1 VDE 0879

Protection IP 54A according to DIN 40 050 Sheet 1

Electrical fusing for third party control 15 A

Temperature conditions Heating medium –40 °C to + 90 °C [short-term (15 min.) +115 °C]

Ambient, operation

Dry running No

Blocking Within a period of max. 6 seconds the motor is undamaged.

Shaft - impeller connection Mechanical seal

FLOWTRONIC 5000

104 watt ±10 %

–40 °C to 90 °C [short-term (15 min.) +115 °C]

Pumping and pressure loss characteristic curves

Sketch 4

Please note!

• If no limit values are given, the technical data listed is with
the usual heater tolerances of ± 10 % at nominal voltage,
20 °C ambient temperature and Esslingen reference alti­tude.

• The FLOWTRONIC 5000 water pump is installed in com-
pact design heaters.

• If water pumps are ordered separately, please refer to the
documentation supplied with them for the relevant technical
data, installation positions, etc.

Flow resistance (when pump at rest)Volumetric fl ow rate (with water at 20 °C)

Important!
Safety instructions for technical data!

Failure to comply with the technical data can result in malfunc­tions.

10

Troubleshooting

4

What to check fi rst in case of faults

• Faulty wiring (short circuits, interruption).

• Visual inspection for
– corroded contacts
– defective fuses
– damaged electrical leads, connections and terminals
– damaged exhaust and combustion air circuit.

• Battery voltage when heater started <19 Volt (measure volt­age at control box).

• Check fuel supply.

• On changeover to winter service: Is summer diesel still in
the line?

• Delayed start –> nozzle block heating switched on for
60 seconds.

• The Bus 2000 water pump and the HYDRONIC are auto­matically switched off shortly after the start if there is no
refrigerant or if the pump impeller is blocked.

Locking the control box

The control box is locked if the following faults occur:

• Overheating

If the heater overheats 3x in succession – fault code 012, is

displayed as AF 015 –> the control box is locked.

• Flame in after-run

If the fault "fl ame in after-run" is signalled 3x in succession

– fault code 058, is displayed as AF 016 –> the control box
is locked.

• Too many attempted starts

If the heater carries out ten failed start attempts in succes-

sion – fault code 052, is displayed as AF 050 –> the control
box is locked.

Cancelling the control box lock

Cancellation of the control box lock is described on pages 15
to 20.

Cancelling control box lock without diagnostic equip-
ment

If the heater is switched on, apply plus at 18-pin cable har­ness connector, pin 13, cable 1
control) for approx. 3 sec. –> the control box is unlocked.

Additional option from control box
25 1818 53 00 00 with Bus 2000 water pump fault

Apply plus at 18-pin cable harness connector, pin 9, cable 1
bl/sw for approx. 3 sec. –> the control box is unlocked.

2

ge/rt (water pump third party

2

11

Troubleshooting

Too many attempted
starts

4

Fault diagnosis – fl ashing code
(LED with series resistor)

The electronic control box can store up to 5 faults.
The defective component and type of fault are output by the
control box as a fl ashing code and are displayed by an LED
with series resistor (approx. 1 kΩ / 1W).
The LED with series resistor is connected to the 8-pin con­nector of the heater cable harness (chamber 2, cable 12 bl/ws
and chamber 5, cable 1

2

ge).
The fl ashing codes of the defective components and the cor­responding fault codes are described on page 12.
Possible causes and remedial action are explained in the fault
code tables (pages 21 – 24).

Flashing code

400 ms pause at the start
of the fl ashing code

Operation without faults

Flame detection photocell,

Fault code 16, 51, 58

Safety time exceeded,

Fault code 50, 52

LED and series resistor

Sketch 5

8 sec. 16 sec.

resistor

LED

connector B2

chamber 5

chamber 2

8
64

2

1753

connector B1

1

4

5

2

3

6

Flame cutout

Fault code 54

Overheating

Fault code 12, 15

Burner engine

Fault code 32, 33

Undervoltage cut-off

Fault code 11

Overvoltage cut-off

Fault code 10

Temperature sensor

Fault code 14, 60, 61, 71, 72

Connection error

Fault code 20, 21, 25, 37 – 39, 44 – 49, 80 – 83

Control box

Fault code 90 – 97

Short pulse – fl ash duration: 0.4 sec.
Long pulse – fl ash duration: 2.0 sec.

Pause between the pulses: 0.4 sec.
Period of a fl ashing sequence: 8.0 sec.

Sketch 6

12

Troubleshooting

4

Overview of the individual test equipment
and control units

The electronic control box can store up to 5 errors, which can
be read out and displayed. The following test equipment can
be used to query the fault memory in the control box and if
necessary to delete the control box locking:

Test equipment Order No.:

• Diagnostic unit 22 1529 89 00 00
additionally required:
Adaptor cable 22 1000 31 66 00

• EDiTH customer service program
– Basic adapter with software 22 1532 89 00 00

additionally required:

HYDRONIC L extension 22 1539 89 00 00

– ISO adapter 22 1524 89 00 00
additionally required:
Adaptor cable 22 1000 31 66 00

• Burner tester 22 1527 89 00 00

If a diagnostics cable is connected, the following control units
can also be used to query the fault memory in the control box
and if necessary to delete the control box locking:

Control units Order No.:

• Module timer 22 1000 30 34 00

• TP5 radio remote control 22 1000 32 01 00

• EasyStart T 22 1000 32 88 00

• EasyStart R+ 22 1000 32 80 00

Please note!

If the fault memory cannot be read out, check the diagnostics
cable for correct laying and possible damage.

External diagnostic system

With an external, vehicle-specifi c diagnostic system
–> contact the vehicle manufacturer.

13

Troubleshooting

4

Diagnostic unit

(Order No.: 22 1529 89 00 00)

To connect the diagnostic unit, an additional
adapter cable is required (Order No.: 22 1000 31 66 00).

The current fault is displayed as "AF“ and a 2-digit number
and is always written in the memory location F1.
Preceding faults are moved to the memory locations F2 – F5,
if necessary the contents of memory location F5 is overwrit­ten.

Please note!

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

Connect diagnostic unit

• Disconnect the 8-pin connector of the heater's cable har­ness and connect the adapter cable.

• Connect the diagnostic unit to the adapter cable.

Display is as follows:

Query fault memory

• Use the D key to switch on the heater.

Display is as follows:

• After 8 sec the following is displayed:

Display is as follows:

Sketch 7

– Delete fault memory

l

– Delete fault memory

l

– Switch heater on / off, request diagnosis

d

– Return, F5 – F1

e

– Flow, F1 – F5, current fault (AF)

f

Display of the fault memory F1 – F5 or F5 – F1

• Press the
display the fault memory.

Display is as follows:

e.g. fault memory 2 / fault code 10

Please note!

Only the fault memory locations with an error assigned to
them are displayed.

Delete fault memory

• Press both L buttons simultaneously until the following ap­pears in the display:

Display is as follows:

or f button again, or press several times, to

e

Heater has no malfunction

or

e.g. current error / fault code 64

or

Fault diagnosis not possible

Possible causes:

– Adapter cable is not properly connected.
– Control box is defective or is not capable of diagnosing

(not a universal control box).

14

• If the fault memory has been deleted the most recent cur­rent fault is displayed. The current fault is not reset to 00
until the heater is restarted – provided there is no new, more
recent fault.

Display is as follows:

Heater has no faults



Troubleshooting

4

Cancel the control box lock

• Delete the fault memory as described and switch off the
heater using the d key.

• The control box lock is cancelled and the diagnosis closed.

Display is as follows:

Sketch 8

 Diagnostic unit with connection cable
 Adaptor cable

15

Troubleshooting

4

EDiTH customer service program
with ISO adapter

(Order No.: 22 1524 89 00 00)

An additional adapter cable is required to connect the ISO
adapter (Order No.: 22 1000 31 66 00).

Please note!

• It is very important to always install in the given order.

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

• The EDiTH customer service program software is not in­cluded in the scope of supply, it must be downloaded from
the service portal.

• Faults 1 – 5 only are displayed in heaters up to serial No.
12 000.

In addition to faults 1 –5, measured values are also dis-

played in heaters from serial No. 12 001.

Connect ISO adapter

• Disconnect the heater's cable harness.

• Connect the adapter cable to the cable harness – as shown
in the sketch.

• Connect the adapter cable to the ISO adapter.

• Connect the SUB-D connection cable with the PC and the

ISO adapter.

Installing software on the PC

• Double-click "setup.exe" fi le to start and
follow the SETUP program instructions.

Query / delete fault memory F1 – F5
or cancel the control box lock

• Start the software at the PC:
– on the desktop —> double-click the "EDiTH" icon
– Select heater type
– Press the "GO" button.

• Delete fault memory or cancel the control box lock:
– Press the "Delete fault memory" button
—> the stored faults F1 – F5 are deleted and the control

box is unlocked.

Quit diagnosis

• Press the "STOP" button —> fault memory query is ended.

Sketch 9

 ISO adapter
 Adaptor cable
 SUB-D connection cable

16

Troubleshooting

4

EDiTH customer service program
with basic adapter

EDiTH basic adapter
(Order No.: 22 1532 89 00 00)

An additional extension is required to check the control box
(Order No.: 22 1539 89 00 00).

Please note!

• It is important to always follow the precise connection order
as given below!

• The fl ame failure safeguard integrated in the control box can
only be tested properly if the corresponding mating connec­tor (a) is connected.

• Only push or pull on the connectors, not on the cables!

• Only use the network cable and RS232 cable with snap
ferrites included in the scope of supply. Use original acces­sories with snap ferrites only to connect the test equipment.

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

Important!
Magnetic fi eld!

During the test operation a magnetic fi eld develops at the
adapter. Therefore, do not place any objects such as data
media, credit cards, etc. on the adapter or in its immediate vi­cinity.

Connect basic adapter

• Start computer and wait until the system has successfully
booted.

• Start PC software.

• Insert the unit connector of the mains cable in the basic
adapter and connect the mains connection to the mains.

• Connect the SUB-D connection cable with the PC and
basic adapter.

Connect extension and test control box

• Connect the extension to the basic adapter.

• Connect extension and basic adapter to control box.

• Switch on basic adapter at mains switch.

• Select the control box version and operating voltage
(12 V / 24 V) in the PC software.

• Start the control box test with the PC software.

A more detailed description of how to operate the basic

adapter is given in the EDiTH online help.

(A) Basic adapter
(B) SUB-D connection cable
(C) Mains connection
(D) Mains switch
(E) Control box
(F) Extension

Sketch 10

17

Troubleshooting

4

Module timer

(Order No.: 22 1000 30 34 00)

The current fault is displayed as "AF" and is always written in
the memory location F1.
Preceding faults are moved to the memory locations F2 – F5,
if necessary the contents of memory location F5 is overwrit­ten.

Please note!

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

Sketch 11

– Time

a

– Preset

p

– Heat

c

– Return

e

– Flow

f

Query fault memory F1 – F5

Condition:
The heater is switched off.

• Press c key –> the heater is switched on.

• Press a key and keep pressed,

then press p key within 2 seconds.
Display is as follows:
AF = current fault
3 digit number = fault code
c fl ashes.

• Press the f key or press it several times,

Fault memory F1 – F5 are displayed.

Cancel the control box lock and simultaneously delete
the fault memory

Condition:
An electrical connection exists from terminal 15 (ignition) to
the module timer, 12-pin connector, chamber 10.

• Press c key
Display is as follows:
the current fault, e.g. F15.

• Press a key, keep pressed and
press p key within 2 seconds.

The module timer is now in the "Query fault memory"
program.

• Switch off ignition (terminal 15).

• Simultaneously press button a and button p, in addition,
switch on the ignition (terminal 15) and wait until the follow­ing appears in the display.

After ignition "ON" the following appears in the display:

Display fl ashes,
Heater symbol does not fl ash

18

• Switch the heater off and on –> the control box is unlocked,
the heater restarts.

After switching the heater off and on and renewed query of

the fault memory, the following appears in the display:

Display fl ashes,
Heater symbol does not fl ash

Troubleshooting

4

TP5 radio remote control

(Order No.: 22 1000 32 01 00)

If faults occur while the heater is running, they are displayed
with "Err" after the mobile unit is activated.

The current fault "F0" is displayed. The stored faults "F1" to
"F5" can be queried.

Please note!

• In order to carry out the diagnosis, the diagnostics cable
(bl/ws) must be connected to the stationary unit and the
heater cable harness. To this end, please refer to and follow
the circuit diagram for the TP5 radio remote control and the
heater.

• If the diagnostics cable (bl/ws) is not connected, the "Diag­nosis" menu is blocked.

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

Sketch 12

Button to activate / deactivate the mobile unit

Next control key

Back control key

Button for activating the possible settings

Button for switching heat / ventilate ON / OFF;
Activate / deactivate preselected time and
open fault memory.

Enquire / delete fault memory

Use the key to activate the mobile unit.
Switch on the heater with the key.
Press the key twice to open the Time setting menu –
the time fl ashes in the display.

Press the key for approx. 2 sec – until the following ap­pears in the display:

Further key sequence:

Press key.
Press key.
Press key twice.
Press key.

Display
Heater with fault or heater without fault:

Delete fault memory /
Cancelling the control box lock

Use the key to delete the fault memory.

To confi rm, press the key for approx. 2 sec until
lights up in the display – fault memory is deleted.

Please note!

If the fault memory is to be deleted later or the control unit
lock cancelled later, the whole procedure must be repeated.

Use the and keys to open the fault memory loca­tions 1 to 5.

19

Troubleshooting

4

EasyStart R+ radio remote control

(Order No.: 22 1000 32 80 00)

EasyStart T timer

(Order No.: 22 1000 32 88 00)

If faults occur while the heater is running, they are displayed
with "Err" after the mobile unit or timer is activated.

The current fault is displayed. The stored faults "F1" to "F5"
can be queried.

Please note!

• Prerequisite for carrying out the diagnosis is that the diag­nostic cable bl/ws is connected. To this end, please refer to
and follow the circuit diagram for the radio remote control
and / or the timer.

• If the diagnostics cable is not connected the "Diagnosis"
menu is blocked.

• Not only the defective component, but also a defective cur­rent circuit results in a fault being displayed.

• Fault code, fault description, cause / remedial action are
described on Pages 21 – 24.

Enquire / delete fault memory

Activate mobile part / timer
(see EasyStart R+ / EasyStart T operating instructions)

Confi rm symbol with .

Heater is switched on.

Confi rm operating time with .

Sketch 13

Back control key

Next control key

ON / OFF activation key mobile unit / timer

OK key (symbol selection / confi rm input)

The following actions are possible

• Call up fault memory.

Open the fault memory locations F1 – F5 with or ..

• Call up fault memory again.

Briefl y press and simultaneously.

• Delete fault memory
(display dEL)
Press .

Briefl y press and
simultaneously.

20

Press again.

The diagnosis is completed.

Switch off heater.

Troubleshooting

4

Fault code table

Fault code
display

000

010

011

012

014

015

016

020

021

Cause

Fault description

No fault – –

Overvoltage cut-off Overvoltage (> 30 volt) applied to control box for at least 20 seconds without inter-

Undervoltage cut-off Under voltage (< 19 volt) applied to control box for at least 20 seconds without inter-

Overheating Temperature at overheating sensor >130 °C

Difference between the over­heating and temperature sen­sor is too large

Operating lock-out – Control
box is locked

Operating lock-out – control
box is locked

Ignition unit interruption

Danger!
High voltage!

Ignition unit earth short

Danger!
High voltage!

• Remedial action

ruption – heater not working.

• Disconnect 18-pin connector at control box, start the vehicle's engine.
Measure the voltage between PIN 15 (cable 2.5

voltage > 30 volt –> check generator controller.

ruption – heater not working.

• Disconnect 18-pin connector at control box, start the vehicle's engine.
Measure the voltage between PIN 15 (cable 2.5
The measured value and the voltage at the battery should be the same.
In case of a voltage drop, check the fuses, the supply cables, the negative con-

nections and the positive support point on the battery for correct contact.

• Check water circuit:
– Check all hose connections for leaks
– Vent water circuit
– Check valves in water circuit, replace if necessary
– Temperature difference between water inlet and water outlet must be <10 K, if

not –> check minimum fl ow rate of the heating medium, for values see technical
data.

• Check water pump, replace if necessary

• Check overheating sensor, replace if necessary, see diagram on page 36

Difference between measured values of the temperature sensor and overheating
sensor impermissibly high for a lengthy time.

• Check installation of both sensors, tighten sensor if necessary, tightening torque
for both sensors 2.5 Nm + 0.5 Nm.

• Check temperature sensor and overheating sensor, see diagram on pages 35 and

36.

• Check minimum fl ow rate of the heating medium, see technical data for values.

Fault code 012 "Overheating" three times in succession –> fault code 015 is dis­played.
Unlock the control box by deleting the fault memory, see pages 15 to 20.

• For remedial action see fault code 012.

Fault code 058 "fl ame in after-run" three times in succession –> fault code 016 is
displayed.
Unlock the control box by deleting the fault memory, see pages 15 to 20.

• For remedial action see fault code 058.

Control lead from ignition unit to control box is interrupted or short-circuited.

• Check cable loom from ignition unit to control box, if necessary remove interrup­tion or short circuit.

• Check function of ignition unit only using burner tester, replace ignition unit if
necessary.

• If faults are not corrected by the remedial action listed above –> replace control
box.

Earth short in control lead from ignition unit to control box.

• Check cable loom from ignition unit to the control box, if necessary remove earth
short.

• Check function of the ignition unit only using the burner tester, replace ignition
unit if necessary.

• If faults are not corrected by the remedial action listed above –> replace control
box.

2

rt) and PIN 16 (cable 2.52 br), if

2

rt) and PIN 16 (cable 2.52 br).

21

Troubleshooting

4

Fault code table

Fault code
display

025

032

033

037

039

044

045

Cause

Fault description

Diagnosis output short circuit Cable 1

Burner motor does not rotate
at start

Burner motor does not rotate
during operation

Apply max. 12 volt at burner
motor

Water pump fault Check fi rst:

Vehicle blower control short
circuit

Water pump
Relay coil interruption

Water pump
Relay coil short circuit

• Remedial action

2

bl/ws from 18-pin control box connector, chamber 12 to 8-pin cable har-

ness connector, chamber 2 has short circuit with + UB.

• Check cable and connections, if necessary remove short circuit.
Impeller chafes or is blocked.

Burner motor is defective.
Generator voltage is too low.

• Check impeller for free running.

• Check cables and connections to burner motor.

• Check function of installed burner motor only using burner tester, replace burner
motor if necessary.

• If faults are not corrected by the remedial action listed above –> replace control
box.

Fuel pump is blocked.

• Check fuel pump for free running, replace burner if necessary.

• Water pump Bus 2000 / FLOWTRONIC 6000 S is installed?

• "Diagnosis" cable loom from the Bus 2000 water pump is connected?

• Voltage applied to the Bus 2000 water pump?

If yes

– Disconnect plug-in connector from "Diagnose" cable loom. Heater start
– If fault code 037 is no longer displayed, then check Bus 2000 water pump for

dry running or blocking.

– If fault code 037 is still displayed, then use remedial action as described for the

water pump (standard design).

• Water pump (standard design / FLOWTRONIC 5000 / 5000 S) is installed?

If yes

– Disconnect plug-in connector from "water pump" cable loom , apply voltage to

2-pin connector of the "water pump" connector and check function.

If the water pump is functioning ok, then check fuse (15 A), cable loom and

connections of the water pump –> if fault code 037 still displayed, then replace
the control box.

2

Cable 1
connector, chamber 7, on to blower relay is short-circuited.

• Check cable and connections, if necessary remove short circuit.

• Check installation of the relay.

• Replace relay.

• If faults are not corrected by the remedial action listed above, then replace con-

• Check installation of the relay at the control box.

• Replace relay.

• If faults are not corrected by the remedial action listed above, then replace con-

sw from 18-pin control box connector, chamber 6 to 8-pin cable harness

trol box.

trol box.

22

046

047

Solenoid valve interruption "Solenoid valve" cable loom from control box (connector position "D") to solenoid

valve is interrupted or has earth short.

• Check cables and connections from solenoid valve, remove earth short if neces­sary.

• Replace solenoid valve coil.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

Solenoid valve short circuit "Solenoid valve" cable loom from control box (connector position "D") to solenoid

valve has earth short.

• Check cables and connections from solenoid valve, remove earth short if neces­sary.

• Replace solenoid valve coil.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

Troubleshooting

4

Fault code table

Fault code
display

048

049

050

051

052

054

058

060

061

071

072

081

Cause

Fault description

Nozzle block heating
Relay coil interruption

Nozzle block heating
Relay coil short circuit

Operating lock-out
Control box is locked

Flame detection photocell sig­nals "Flame before fuel"

Safety time exceeded, no start

Danger!
High voltage!
Note when checking the
ignition unit

Flame cutout during operation Heater has ignited, the fl ame is detected and signals fl ame cutout twice within an

Flame does not extinguish dur­ing after-run

Temperature sensor interruption Temperature value outside operating range.

Short circuit in temperature
sensor

Overheating sensor interrup­tion

Short circuit in overheating
sensor

Combustion indicator light
short-circuit

• Remedial action

• Check installation of the relay at the control box.

• Replace relay.

Control box locked by 10 start attempts without fl ame detection.
Unlock the control box by deleting the fault memory, see pages 15 to 20.

• For remedial action see fault code 052.

• Replace burner.

No fl ame detected within the ignition phase.

• Check combustion air inlet and exhaust system.

• Check fuel supply (fl ow and return).

• Check fl ame tube for correct installation in heat exchanger.

• Check function of ignition unit only using burner tester, replace ignition unit if
necessary.

• Check distance between ignition electrodes, if necessary renew ignition elec­trodes.

• Check electric cables and connections.

• Check fl ame detection photocell for dirt, clean if necessary.

• Replace fuel nozzle.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

operating time of 60 minutes.

• Check fuel supply (fl ow and return).

• Carry out CO

• Replace fuel nozzle.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

Flame detection photocell signals that fl ame has not extinguished 30 seconds after
after-run "ON".

• Check heat exchanger, clean if necessary, then carry out CO

• Test the solenoid valve using the burner tester, replace if necessary.

• If fuel continues to be pumped during after-run –> replace fuel pump.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

• Check plug-in connection with temperature sensor and cable to the control box.

• Check temperature sensor, see diagram on page 35.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

Temperature value outside operating range.

• Check plug-in connection with overheating sensor and cable to the control box.

• Check overheating sensor, see diagram on page 36.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

Cable 1
ness connector, chamber 3, on up to combustion indicator light is short-circuited.

• Check cable and connections, if necessary remove short circuit.

• Check combustion indicator light, replace if necessary.

2

measurement.

2

measurement.

2

ge/ws from 18-pin control box connector, chamber 8 to 8-pin cable har-

23

Troubleshooting

4

Fault code table

Fault code
display

083

090

091

092

093

094

097

Cause

Fault description

Fault indicator light short circuit Cable 1

Control box defective • Replace control box

External interference voltages Possible causes:

Control box defective • Replace control box

• Remedial action

2

gr from 18-pin control box connector, chamber 5 to 8-pin cable harness

connector, chamber 6, on to fault indicator light is short-circuited.

• Check cable and connections, if necessary remove short circuit.

• Check fault indicator light, replace if necessary

• Distance between ignition electrodes not ok –> check distance between ignition
electrodes, if necessary renew ignition electrodes.

• Interference voltages from charger or other sources of interference –> Remove
interference voltages.

• If faults are not corrected by the remedial action listed above, then replace con­trol box.

24

Repair instructions

5

Repair instructions

The permitted repair work on the heater is described in the
"Repair Instructions" chapter. If extensive repairs are neces­sary, it makes sense to dismantle the heater.

The heater is assembled in the reverse order, if applicable not
additional instructions.

Please note!

After completing all the work on the heater, you must carry out
a functional check.

Always observe the following safety in­structions before working on the heater

Danger!

• Always switch off the heater beforehand and leave it to cool.

• Disconnect the battery.

• Relieve the overpressure in the cooling water circuit by
opening the radiator screw cap.

• Do not switch on the heater if burner is dismantled.

• Before removing the ignition unit, disconnect plug-in con­nections in cable harness.

• The heater must not be operated in closed rooms such as
garages or workshops.

Exception:
Exhaust suction available directly at the entry to the exhaust

pipe.

AMP release tool

The AMP release tool is used to unclip push-on sleeves from
a connector housing.

This release tool can be ordered directly from
Eberspächer GmbH & Co. KG.

• For Micro Timer Order No. 206 00 205

• For Junior Power Timer Order No. 206 00 215

Sketch 14
AMP release tool

Important!

• The seals of dismantled components must be renewed.

• During repair work, check all components for damage and if
necessary replace.

• Check connector contacts, plug-in connections and cables
for corrosion and damage and if necessary repair.

• Only ever use Eberspächer spare parts if replacements are
necessary.

• After working on the cooling water circuit the level of the
cooling water must be checked and if necessary the refrig­erant must be topped up according to the vehicle manufac­turer's instructions.

The cooling water circuit must then be vented.

• Operation or the after running of the heater may only be
stopped in an emergency (see "EMERGENCY OFF" Page 8)
by interrupting the battery current (risk of heater overheat­ing).

25

Repair instructions

5

Assembly drawing

(

)

(

)

Sketch 15

26

Repair instructions

5

19

26*

16

17

20

24

23

Sketch 16–

18

10

22

21

22

14

15

11

25

12

16

13

Component parts

1 Heat exchanger
2 Flame tube, complete
2a Flame tube, complete

(unit version 25 1817 and 25 2165)

3 Burner
4 Hood
5 Impeller
6* Controlling system

(unit version 25 1817 and 25 2165;

however, not installed in all heaters)

7 Grommet
8 Temperature sensor
9 Overheating sensor
10 Fuel pump

(integrated in burner housing)

11 Solenoid valve
12 Electric motor, 24 volt
13 Coupling
14 Ignition unit, 24 volt
15 Ignition electrode
16 Baffl e plate
17 Fuel nozzle
18 Screen insert/strainer
19 Heating cartridge
20 KL fuse
21 Control box, 24 volt
22 Relay
23 Wiring harness
24 Nozzle block made of brass
25 Nozzle block made of plastic with

integrated heating element

26* Temperature switch for nozzle

block made of brass

(unit version 25 1817 and 25 2165)

27

Repair instructions

5

Removing the hood (see Sketch 17)

• Loosen both of the hood's retaining screws.

• Remove hood.

Risk of injuries!

• The impeller has sharp edges.
– Avoid touching the impeller or if necessary wear safety

gloves.

 Retaining screw

Dismantling burner (see Figure 1)

1

Sketch 17

• Remove hood.

• Disconnect "temperature sensor" cable loom and "over­heating sensor" cable loom at control box.

• Remove grommet from burner housing.

Please note!

The fuel lines should remain connected,
if necessary extend the fuel lines.

 Burner
 Heat exchanger
 Grommet
 "Temperature sensor" cable loom and "overheating

sensor" cable loom"

Dismantle control box (see Figure 2)

• Remove hood.

• Dismantle the burner.

• Undo impeller in anti-clockwise direction, at the same time
pressing against the motor shaft with a screwdriver.

• Disconnect all connectors at the front and rear of the con­trol box.

• Unlock and remove control box with 4 clamps.

Figure 1

















 Control box
 Clamps
 Motor shaft (thread)

28





Figure 2

Repair instructions

5

Dismantling the burner motor (see Figure 3 and 4)

• Remove hood.

• Dismantle the burner.

• Undo impeller in anti-clockwise direction, at the same time
pressing against the motor shaft with a screwdriver.

• If necessary, use the burner tester to test the burner motor
(see below).

• Disconnect "burner motor" cable loom at control box, slot
"B".

• Undo three retaining screws of burner motor.

• Remove burner motor.

 







Please note!

When assembling, tighten the impeller with 1 Nm +0.5 Nm.





Figure 3

 Electric motor
 Retaining screws
 Motor shaft (thread)

Check function and speed of the burner motor using the
burner tester (see Sketch 18)

• Disconnect all connectors from the control box.

• Connect burner tester.

• Make a mark on the impeller.

• Keep "Heating ON" pressed for 4 seconds –> the heater
starts, the electric motor must run for 180 seconds (after­run) –>
– if yes, measure speed using non-contact tachometer.
– if no, replace the electric motor.

Speed of the electric motor

HYDRONIC 16 3800 ±350 rpm
HYDRONIC 24 4200 ±350 rpm
HYDRONIC 30 4800 ±350 rpm
HYDRONIC 35 5200 ±350 rpm

Figure 4

 Electric motor
 Coupling



Sketch 18

 Impeller with mark



Risk of injuries!

• The impeller has sharp edges.
– Avoid touching the impeller or if necessary wear safety

gloves.

Please note!

Read and follow the burner tester operating instructions.
Let the electric motor to run for 180 seconds.

29

Repair instructions

5

Dismantle ignition electrodes (see Figure 5 and Sketch 19)

• Remove hood.

• Dismantle the burner.

• Disconnect ignition electrodes from ignition unit.

Please note!

• If the Ignition spark generator, ignition electrodes or pump
housing is replaced it is necessary to check the distance
between the ignition electrodes with a check gauge.

The check gauge is included with the spare parts.

• Place the check gauge on the fuel nozzle and push up to
the limit stop. The electrode tips must lie against the square
surfaces of the check gauge, if not –> renew ignition elec­trodes.

• If the insulation body of the ignition electrodes is damaged
–> renew ignition electrodes.

• Do not touch the fuel nozzle opening when measuring the
electrode spacing.

• The check gauge is solely for checking and not for setting
the distance between the electrode tips.

• If the distance between the ignition electrodes differs from
what it should be –> renew ignition electrodes.

• Bending the ignition electrodes is not allowed.



Figure 5

 Ignition electrodes



Dismantle fuel nozzle (see Figure 6)

• Remove hood.

• Dismantle the burner.

• Dismantle the ignition electrodes.

• Undo fuel nozzle from the nozzle block, press against the
nozzle block with wrench.

Please note!

• When installing the fuel nozzle do not touch the nozzle
opening.

• After installing the fuel nozzle, check the position of the igni­tion electrodes, adjust if necessary.

• Tightening torque for fuel nozzle:
– for nozzle block made of brass 16 +1 Nm.
– for nozzle block made of plastic 2 +0.5 Nm.



Sketch 19

 Ignition electrodes
 Check gauge









Figure 6

 Fuel nozzle
 Ignition electrodes
 Baffl e plate
 Flame detection photocell

30

Repair instructions

5

Dismantle ignition unit (see Figure 7 – 9)

• Remove hood.

• Dismantle the burner.

• Dismantle the ignition electrodes.

• Pull fuse clip (KL fuse) off nozzle block and remove baffl e
plate.

• If necessary, use the burner tester to test the ignition unit
(see below).

• Disconnect ignition unit cable loom at control box, slot "E".

• Undo both retaining screws of ignition unit.

• Remove ignition unit.

Please note!

• When installing insert the ignition unit in the burner housing
holders.

• Check distance between ignition electrodes, if necessary
renew ignition electrodes.

• Lay the cable harnesses as shown in Figure 8 and 9.









Figure 7

 Ignition electrodes
 Fuse clip (KL fuse)
 Baffl e plate





Figure 8

 Ignition unit
 Connection of the "ignition unit" cable loom at control

box, slot "E"

Testing the ignition unit using the burner tester

Danger!

• A spark gap with a voltage of approx. 20 000 volt forms
between the electrodes.
– Test the ignition unit only using the burner tester.
– Do not test ignition unit without ignition electrodes.



Figure 9

 Ignition unit
 Holders for the ignition unit

Functional check

• Disconnect all connectors from the control box.

• Connect burner tester.

• Press "ZFG" button –> a spark gap must form between the
electrodes
– if not, replace the ignition unit.

High voltage!

Always note when testing the igni­tion unit!

31

1

2

3

Repair instructions

5

Dismantling the solenoid valve (see Figure 10 and
Sketch 20)

• Remove hood.

• Dismantle the burner.

• If necessary, use the burner tester to test the solenoid valve
(see below).

• Disconnect "solenoid valve" cable loom at control box, slot
"D".

• Loosen hexagon nuts from solenoid valve.

• Remove solenoid valve coil.

• Undo magnet.

Please note!





When installing lay the cable looms as shown in Figure 10.

Testing the solenoid valve using the burner tester

• Disconnect all connectors from the control box.

• Connect burner tester.

• Press "MV" button –> solenoid valve must click
– if not, replace solenoid valve.

Figure 10

 Solenoid valve
 Connection of the "solenoid valve" cable loom at control

box, slot "D"

Sketch 20

 Magnet
 Solenoid valve coil

32

Repair instructions

5

Dismantling the nozzle block (see Figure 11 and 12)

• Remove hood.

• Dismantle the burner.

• Disconnect ignition electrodes from ignition unit.

• Undo fuel nozzle from the nozzle block, press against the
nozzle block with a wrench.

• Pull fuse clip (KL fuse) from nozzle block.

• Remove baffl e plate.

• Disconnect cable loom from control box, slot "F".

• Dismantle nozzle block.

Only for nozzle block made of brass

• Remove split rivet from the nozzle block (heating cartridge
holder).

• Pull heating cartridge out of the nozzle block.

• Undo temperature switch (if installed) from the nozzle block.

• If necessary check the heating cartridge (see below).

Please note!

• When installing the heating cartridge, insert the split rivet
back in the nozzle block.

• Tightening torque for temperature controller 2.8 +1 Nm.

• When installing the fuel nozzle do not touch the nozzle
opening.

• After installing the fuel nozzle, check the position of the igni­tion electrodes, adjust if necessary.

• Tightening torque for fuel nozzle:
– for nozzle block made of brass 16 +1 Nm.
– for nozzle block made of plastic 2 +0.5 Nm.

Nozzle block made of brass without temperature switch







Figure 11

 Heating cartridge – installed in nozzle block
 Split rivet for heating cartridge
 Connection of the "heating cartridge" cable loom at

control box, slot "F"

Nozzle block made of brass with temperature switch

(in HYDRONIC 24 only)









Functional check of the heating cartridge

• Connect ohmmeter at 2-pin push-on sleeve housing and
behind the temperature switch (if installed) –> if measured
value 5 – 10 Ω, heating cartridge is ok, if not replace heating
cartridge.

Figure 12

 Heating cartridge – installed in nozzle block
 Split rivet for heating cartridge
 Connection of the "heating cartridge" cable loom at

control box, slot "F"

 Temperature switch

Nozzle block made of plastic (with integrated heating element)

Sketch 21

 Nozzle block made of plastic

33

Repair instructions

5

Dismantling the fl ame tube (see Figure 13 and Sketch 22)

• Remove hood.

• Dismantle the burner.

• Remove fl ame tube from the heat exchanger.

Please note!

When installing insert the detent of the fl ame tube in the
groove of the heat exchanger.



Figure 13

 Flame tube
 Detent on fl ame tube
 Heat exchanger





Sketch 22

 Flame tube
 Detent on fl ame tube
 Heat exchanger

21 3

34

Repair instructions

5

Dismantling the temperature sensor and overheating
sensor (see Figure 14 and Sketch 23)

• Remove hood.

• Dismantle the burner.

• Undo impeller in anti-clockwise direction, at the same time
pressing against the motor shaft with a screwdriver.

2

1

Sketch 23

 Temperature sensor
 Overheating sensor

• Disconnect temperature and overheating sensor connectors
at control box.

• Undo temperature sensor and overheating sensor from the
heat exchanger.



Figure 14

 Control box – slot "G" for temperature sensor
 Control box – slot "C" for overheating sensor



Resistance values for temperature sensor and over­heating sensor (see Sketches 29 and 30)

Test the temperature sensor and the overheating sensor with
a digital multimeter and compare the values with the diagram
or the characteristic values table.
If the measured values do not match the diagram or the char­acteristic values table, then replace the temperature sensor or
the overheating sensor.

Check for earth short:
There must be no electrical connection between the sensor
connections and the housing.
Resistance value must be ∞.

Characteristic values table – temperature sensor (PTC)

Temp. [°C] Resistance value [Ω] all. deviation [±Ω]

- 40 567 18
0 815 15

25 1000 12
40 1122 16
60 1299 23

80 1490 30
100 1696 44
120 1915 52
130 2023 62

Diagram - temperature sensor (section)

Resistance [Ω]

Temperature [°C]

Sketch 24

35

Repair instructions

5

Characteristic values table – overheating sensor (NTC)

Temp. [°C] Resistance value [Ω] all. deviation [±Ω]

- 40 3 492 000 324 600
0 337 933 21 560

25 103 517 5 000
40 55 143 3 130
60 25 950 1 727

80 13 118 995
100 7 099 597
120 4 069 374
130 3 135 300
150 1 917 199
180 981 115
200 668 85

Diagram - overheating sensor (section)

Resistance [kΩ]

Temperature [°C]

Sketch 25

36

Repair instructions

5

Dismantling the gauze fuel fi lter (see Figure 15)

• Remove hood.

• Dismantle the burner.

• Undo the banjo bolt and the ring connector from the fuel
fl ow line at the burner.

• Undo the gauze fuel fi lter from the burner housing, clean or
replace.

Danger!
Risk of fi re, explosion and poisoning!

• Caution when handling fuel.

• Avoid naked fl ames when handling fuel.

• Do not smoke, this also applies where fuel is only noticed
by its characteristic odour.

• Do not inhale fuel fumes.

• When dismantling the fuel fl ow line, collect any escaping
fuel.

Notes on the fuel fl ow rate and the pressure in the fuel
system

Precise checking of the fuel fl ow rate is not possible.
If necessary the combustion can be checked by checking the

content in the exhaust.

CO

2

If it is necessary to change the combustion air set in the fac­tor (CO2 content), this can be achieved by turning the adjust­ing cap (see page 38).
To ensure perfect function of the fuel pump you must ensure
that the partial vacuum in the fuel system does not become
too large (see diagram).

Figure 15

 Banjo bolt and ring connector of the fuel fl ow line
 Gauze fuel fi lter

Functional performance of the heater depending on the
underpressure in the fuel system

In order to ensure the fuel pump works properly, it is
necessary to ensure that the underpressure in the fuel system
is not too high (see table).

Fuel pressure (P)

Heater inlet

Preferred range * min –0.3 bar min –0.2 bar
Allowable range ** –0.45 bar to –0.3 bar
Critical range *** –0.55 bar to –0.45 bar
Heating mode not possible < –0.55 bar <
* Range for design of the fuel supply
** Over the operating period the counterpressure in the fuel supply can increase as a result of deposits (filter clogs up).
*** Heater becomes susceptible to faults (gas bubble formation / fault code 52, 54)

Fuel pressure (P)

Filter inlet

–0.35 bar to –0.2 bar

–0.45 bar to –0.35 bar

–0.45 bar

37

Repair instructions

5

Measuring the CO2 content in the exhaust

Danger!
Risk of injury, fi re and poisoning!

• The heater must not be operated in closed rooms such as
garages or workshops without an exhaust extraction sys­tem.

• Do not operate the heater if the burner is dismantled.

Please note!

• It is necessary to measure the CO
adjust the combustion air:
– after repairs to heater (functional check).
– if combustion is not working properly.
– after replacing the fuel nozzle.

Measurement

Measure the CO2 content of the heater in the vehicle ready for
service.
In order to carry out a correct measurement of the CO2 con­tent the heater must have reached its operating temperature.
Measure the CO2- content using a CO2 indicator, to this end,
read and follow the manufacturer's instructions.

Adjusting the combustion air (see Figure 16)

• Undo the adjusting cap screws.
– If the CO2 content is less than 9 % by vol, turn the adjust-

ing cap to the left (CO2 +).

– If the CO2 content is higher than 11 % by vol, turn the

adjusting cap to the right (CO2 –).

• Retighten the adjusting cap.

• If proper adjustment of the CO2 content is no longer pos­sible:
– Check the burner for damage.
– Check the speed of the electric motor.
– Replace fuel nozzle.

content, if necessary

2



Figure 16

 Adjusting cap

38

Repair instructions

6

5

Dismantling the water pump (standard design)

(see Sketch 27)

• Undo screws from pump housing and remove the pump
housing.

• Undo locknut and remove the impeller.

• Pull the mechanical seal and stationary seal ring off the mo­tor shaft.

• Undo screws from pump fl ange and remove the pump
fl ange.

• Replace defective parts.

1

2

6

4

5

Please note!

• Before installation, clean mechanical seal and stationary
seal ring with a dry cloth.

• The sliding surfaces must be free of grease and dust.

• Always renew the O-ring.

• Component part No. see spare parts list.

3

10

8

7

9

1 Water pump
2 Bracket
3 Clamp
4 Pump housing
5 Impeller
6 Washer
7 Mechanical seal
8 O-ring
9 Stationary seal ring
10 Pump fl ange

Sketch 27

"Bus 2000" water pump (see Sketch 28)

The "Bus 2000" water pump is maintenance free. If damaged,
replace the complete water pump.

5

4

1

Please note!

Component part No. of attachments, see spare parts list.

2

3

1 Water pump
"Bus 2000"
2 Cover, top
3 Cover, rear
4 Bracket
5 Clamp
6 Metal - rubber buffer

Sketch 28

39

Repair instructions

5

Dismantling the FLOWTRONIC 5000 water pump

(see Sketch 29)

• Undo screws on pump cover.

• Remove the pump cover and check for damage.

• Undo nut while holding on to the impeller, unscrew from the
motor shaft and dispose of the nut.

• Pull the impeller and spacer off the motor shaft and dispose
of them.

• Undo and dispose of screws with spring lock washers on
pump housing.

• Pull the pump housing with mechanical seal and station­ary seal ring and O-ring off the motor shaft and dispose of
them.

• Remove the washer and if applicable splash guard off the
motor shaft and dispose of the washer.

• Check motor for smooth and easy movement and examine
for damage, unbalance and noise generation.

Please note!

• Before installation, clean mechanical seal and stationary
seal ring with a dry cloth.

• The sliding surfaces must be free of grease and dust.

• Always renew the O-ring.

• Component part No. see spare parts list.

Sketch 29

1 Screw (4)
2 Pump cover
3 Nut
4 Impeller
5 Washer
6 Mechanical seal
7 O-ring
8 Screw (4)
9 Spring lock washer (4)
10 Pump housing
11 Washer
12 Spray guard
13 Stationary seal ring

40

Circuit diagram

6

Heater circuit diagram – part 1

HYDRONIC 16 – 24 volt 25 2165 01 00 00 (with temperature switch Item 1.4.1)
HYDRONIC 24 – 24 volt 25 1817 01 00 00 (with temperature switch Item 1.4.1)

Parts list

1 Heater

1.1 Burner engine

1.2 Ignition electrode

1.3 Ignition unit

1.4.1 Temperature switch in
HYDRONIC 16 / 24 only

1.5 Overheating sensor

1.11 Fuel solenoid valve

1.13 Temperature sensor

1.14 Heating cartridge for
nozzle block heating

2.1 Control box

2.5.1 Relay, heating cartridge

2.5.6 Relay, water pump

25 1818 96 01 00 C

a) Heater connection
X Graphic illustration of the control box

from the impeller side

Connectors and bush housings are shown
from the cable inlet side.

41

Circuit diagram

6

Heater circuit diagram – part 1

HYDRONIC 16 – 24 volt 25 2165 01 00 00 (without temperature switch)
HYDRONIC 24 – 24 volt 25 1817 01 00 00 (without temperature switch)
HYDRONIC 30 – 24 volt 25 1818 01 00 00
HYDRONIC 35 – 24 volt 25 1819 01 00 00

Parts list

1 Heater

1.1 Burner engine

1.2 Ignition electrodes

1.3 Ignition unit

1.5 Overheating sensor

1.11 Fuel solenoid valve

42

1.13 Sensor, internal control tempe­rature

1.14 Heating element for fuel nozzle

2.1 Control box

2.5.6 Relay, water pump

2.5.10 Relay, heating cartridge

25 1818 00 96 01 D

a) Connection, control unit
X Graphic illustration of the control

box from the impeller side

Connectors and bush housings are
shown from the cable inlet side.

Circuit diagram

6

Heater circuit diagram – part 2

with water pump (standard design) and Bus 2000 water pump

Parts list

2.5.7 Relay for control
e.g. vehicle blower

2.7 Main fuse 15 A

2.7.1 Fuse, actuation 5 A

2.7.2 Fuse, water pump 15 A

2.12.1 Bus 2000 water pump

2.12.2 Water pump (standard design)

3.1.4 Switch, temperature drop

3.1.5 Switch, water pump

3.4.1 Operating display / fl ame indicator

3.4.3 Fault code display

3.4.6 Combustion indicator light

5.1 Battery

5.2 Battery disconnector

25 1818 97 01 00 E

a) Heater connection
d) optionally 2.12.1 or 2.12.2
f) If using 3.2.6
optionally terminal 15 or
terminal 30 - otherwise start

positive (cable 1² yellow)

43

Circuit diagram

6

Heater circuit diagram – part 3

with FLOWTRONIC water pump

Parts list

2.5.7 Relay for control, vehicle blower

2.7 Main fuse 15 A

2.7.1 Fuse, actuation 5 A

2.7.3 Fuse, water pump 15 A

2.12.1 FLOWTRONIC 6000S water pump

2.12.2 FLOWTRONIC 5000 / 5000S water pump

3.1.4 Switch, temperature drop

3.1.5 Switch, water pump

44

25 1818 00 97 01 F

3.4.1 Switch on check

3.4.3 Fault indicator light

3.4.6 Combustion indicator light

5.1 Battery

5.2 Battery disconnector
a) Heater connection
d) optionally 2.12.1 or 2.12.2
f) If using 3.2.6 optionally terminal 15 or terminal 30

– otherwise start positive (cable 1² yellow)

Circuit diagram

6

Circuit diagram for control units

25 1818 00 97 01 E

Parts list

2.15.1 Temperature sensor (room temperature)

2.15.9 Temperature sensor (outside temperature)

3.1.1 Universal switch

3.1.2 Switch, heat, continuous operation

3.1.12 Fault code query

3.1.16 Button, radio remote control

3.2.9 Module timer

3.2.12 Timer, mini (12 / 24 volt)

3.3.7 TP5 radio remote control

3.8.3 Antenna

3.9.1 Diagnostic unit, JE diagnosis

25 1818 00 97 02 A

b) Connect to +15
c) Lighting, terminal 58
e) External "ON / OFF" key (optional)
i) Connection, radio remote control

Insulate unused cable ends.

Connectors and bush housings are shown
from the cable inlet side.

45

Circuit diagram

6

Circuit diagram for control units

25 1818 00 97 01 F

Parts list

2.15.9 Temperature sensor (outside
temperature)

3.1.1 Universal switch

3.1.2 Switch, heat, continuous operation

3.1.12 Fault code query

3.2.9 Module timer

3.2.12 Timer, mini (12 / 24 volt)

3.2.14 Timer, mini, lighting

(12 / 24 volt

3.9.2 Diagnostic unit

b) Connect to +15
c) Lighting, terminal 58
e) External "ON / OFF" key (optional)
i) Connection, radio module
k) Not included in scope of supply of

3.9.2

z) Terminal 58 (lighting)

Insulate unused cable ends.

Connectors and bush housings are shown
from the cable inlet side.

46

Circuit diagram

6

Parts list for circuit diagram - EasyStart
control units

2.15.1 Temperature sensor (room temperature)
(included in scope of supply for EasyStart R+,
optional for EasyStart T and EasyStart R)

2.15.9 Outside temperature sensor (optional)

3.1.7 "OFF" button

3.1.9 "Heat / Ventilate" switch
(included in scope of supply for EasyStart T,
optional for EasyStart R)

3.1.16 Radio remote control button

3.2.15 Timer EasyStart T

3.3.9 Radio remote control EasyStart R (stationary unit)

3.3.10 Radio remote control EasyStart R+ (stationary unit)

3.6.1 Lead harness

3.8.3 Antenna

c) Terminal 58 (lighting)
d) Parking ventilation with vehicle fan (optional)
e) Connection, EasyStart T timer
g) External "ON / OFF" key (optional)

Cable colours circuit diagrams

sw = black
ws = white
rt = red
ge = yellow
gn = green
vi = violet
br = brown
gr = grey
bl = blue
li = purple

Connectors and bush housings are shown from the cable in­let side.

Please note!

Circuit diagrams, see pages 48 – 50.

47

Circuit diagram

6

Circuit diagram, EasyStart R control units

Parts list Page 47 25 1818 00 97 04 B

48

Circuit diagram

6

Circuit diagram, EasyStart R+ control units

Parts list Page 47 25 1818 00 97 03 B

49

Circuit diagram

6

Circuit diagram, EasyStart T control units

Parts list Page 47 25 1818 00 97 05 B

50

Service

7

Certifi cation

The high quality of Eberspächer's products is the key to our
success.
To guarantee this quality, we have organised all work proc­esses in the company along the lines of quality management
(QM). Even so, we still pursue a large number of activities for
continuous improvement of product quality in order to keep
pace with the similarly constantly growing requirements made
by our customers.
All the steps necessary for quality assurance are stipulated in
international standards. This quality is to be considered in a
total sense.
It affects products, procedures and customer / supplier rela­tionships.
Offi cially approved public experts assess the system and the
corresponding certifi cation company awards a certifi cate.

Eberspächer has already qualifi ed for the following standards:

Quality management in accordance with
DIN EN ISO 9001:2000 and ISO/TS 16949:1999

Environmental management system in accordance with
DIN EN ISO 14001:1996

EC Declaration of Conformity

With regard to the following products

Heater type HYDRONIC L

we herewith confi rm that it conforms with the prime safety re­quirements stipulated in the directives of the EU Council for
harmonisation of the legal regulations of the member states
with regard to electromagnetic compatibility (89 / 336 / EEC).
This declaration applies to all heaters produced according to
the production drawings HYDRONIC L which are an integral
part of this declaration.
The following standards / directives have been used to assess
the product with regard to electromagnetic compatibility:

• EN 50081 – 1 Basic form interference emission

• EN 50082 – 1 Basic form of interference immunity

• 72 / 245 / EEC – Modifi cation status 2005 / 83 / EC inter­ference suppression in motor vehicles.

Disposal

Disposal of materials

Old devices, defect components and packaging material can
all be separated and sorted into pure-grade factions so that all
parts can be disposed of as required in an environment-friend­ly manner recycled where applicable. Electric motors, control
boxes and sensors (e.g. temperature sensors) are deemed to
be "electronic scrap".

Dismantling the heater

The heater is dismantled according to the repair stages in the
current troubleshooting / repair instructions.

Packaging

The packaging of the heater can be kept in case it has to be
sent back.

51

Service

7

Representatives abroad

Argentine

Champion S. A.
Av. Cordoba 2756 al 58
RA - 1187 Buenos Aires
Tel. 0054 / 1 - 962 16 21
Fax. 0054 / 1 - 962 16 27

for boat heaters
Trimer S. A.
P.O. Box 1772
Correo Central
RA - 1000 Buenos Aires
Tel. 0054 / 11 45 80 04 44
Fax. 0054 / 11 45 80 04 40

Belgium & Luxembourg

Eberca bvbal
Research Park Haasrode
Esperantolaan 2
B - 3001 Leuven Haasrode
Tel. 0032 / 16 - 40 25 00
Fax. 0032 / 16 - 40 05 15

Chile

for boat heaters
Nauticentro Ltda.
Tomas Moro 135
Las Condes - Santiago
Tel. 0056 / 2 - 201 49 66
Fax. 0056 / 2 - 201 56 35

People's Republic of China

Eberspaecher Automotive Technology
(Beijing) Co., Ltd.
B1-1 Xincheng Industrial Park
Kechuang Street No. 2, BDA
Beijing 100023
People‘s Republic of China
Tel. [phone]
Fax. [phone]

Denmark

Eberspächer Danmark
Literbuen 9
DK - 2740 Skovlunde
Tel. 0045 / 44 - 85 30 30
Fax. 0045 / 44 - 85 30 39Estland

Estonia

Hesyco Group OÜ
Lüli 1
EE - 10112 Tallinn
Tel. 00372 / 38 48 890/891
Fax. 00372 / 38 48 892

Finland

Wihuri Oy Autola
Manttaalitie 9
SF - 01510 Vantaa 51
Tel. 0035 / 89 - 82 58 51
Fax. 0035 / 89 - 82 58 52 07

France

Eberspächer S. A. S.
Z.A.C. la Clé Saint Pierre
3 rue Blaise Pascal
F - 78996 Elancourt Cedex
Tel. [phone]
Fax. [phone]

Greece

MARCONI HELLAS S. A.
Souliou 2 – 4
GR 143 43 N. Halkidona Athen
Tel. 0030 / 210 25 13 500
Fax. 0030 / 210 25 28 854

Great Britain

Eberspächer UK Ltd.
Headlands Business Park
Salisbury Road, Ringwood
GB - Hampshire BH 243 PB
Tel. 0044 / 1425 - 48 01 51
Fax. 0044 / 1425 - 48 01 52

Italy

Eberspaecher S.r.l.
Via del Canneto 45
I - 25010 Borgosatollo (BS)
Tel. 0039 / 030 25076-1
Fax. 0039 / 030 2500307

Japan

White House Co., Ltd.
10-4 Obata-Miyanokoshi
Moriyama-Ku
Nagoya 463-0052 JP
Tel. 0081 / 5 27 76 38 11
Fax. 0081 / 5 27 76 38 55

Canada

Espar Products Inc.
6099A Vipond Drive
CDN Mississauga
Ontario L5T 2B2
Tel. 001 / 905 6 70 09 60
Fax. 001 / 905 6 70 07 28

Latvia

Trans Baltic Trading Corporation
Maskavas iela 449
LV - 1063 Riga
Tel. 00371 / 7-26 63 23
Fax. 00371 / 7-18 79 67

Lithuania

UAB Leopolis
Paneriu 51
LIT - 2055 Vilnius
Tel. [phone]
Fax. [phone]

Republic of Moldova

TC - IUSTINIAN
140 Hinchesti Str., of.9
MD - 2070 Kishinev
Tel. 003732 / 727883, 738710
Fax. 003732 / 727883

Netherlands

Eberca B. V.
Marconistraat 2
NL - 3281 NB Numansdrop
Tel. 0031 / 1866 - 2 19 55
Fax. 0031 / 1866 - 2 18 18

Norway

Eberspächer Norge
Trollåsveien 34
N 1414 Trollåsen
Tel. 0047 / 66 82 30 50
Fax. 0047 / 66 82 30 58

Austria

Eberspächer Ges.m.b.H.
IZ NÖ-Süd 2, Hondastraße 2, Obj. M47
A - 2351 Wiener Neustadt
Tel. 0043 / (0) 2236 677 144-0
Fax. 0043 / (0) 2236 677 144-42

Poland

Eberspächer Sp.zo.o
Wysogotowo K. Poznania
ul. Okrezna 17
PL- 62081 Przezmierowo
Tel. 0048 / 61 - 816 18 50
Fax. 0048 / 61 - 816 18 60

52

Service

7

Representatives abroad

Russia

JSC OTEM
Верхняя Красносельская улица 2
RUS - 107140 Moskau
Tel. 007 / 49 56 45 59 79
Fax. 007 / 49 56 47 13 24

Sweden

Eberspächer AB
Box 2103
S - 12823 Skarpnäck
Tel. 0046 / 86 83 11 34
Fax. 0046 / 87 24 90 40

Switzerland

Technomag AG
Fischermättelistr. 6
Ch - 3000 Bern - 5
Tel. 0041 - 31 379 81 21
Fax. 0041 - 31 379 82 50

Slovakian Republic

Molpir, spol.s.r.o.
Hrachova 30
SK-821 05 Bratislawa
Tel. 00421 / 243 19 12 18
Fax. 00421 / 243 19 12 20

Turkey

ASCA Otomotiv Ltd. Sti.
Ikitelli Organize Sanayi Bölgesi
Dolapdere Sanayi Sitesi 1. Ada No. 38
TR - 34760 Ikitelli / Istanbul
Tel. [phone]
Fax. [phone]

Hungary

Austropannon KFT
Fö ut 96
H - 9081 Györujbarat
Tel. 0036 / 96 - 54 33 33
Fax. 0036 / 96 - 45 64 81

Liberatus
Hungary Trade and Services Ltd.

Roźalia park 6
H - 2051 Biatorbágy

Tel. [phone]
Fax. [phone]

Ukraine

Geruk+K
ul. Dobrovolskogo 3/4
UA - 18006 Tscherkassy
Tel. 0038 / 0472 310800
Fax. 0038 / 0472 310801

Slovenia

Eberspaecher Gesellschaft m. b. H.
Podružnica SLO
Celovška cesta 228
1000 Ljubljana
Tel. 00386 / 1 518 70 52
Fax. 00386 / 1 518 70 53

Spain – Portugal

Pedro Sanz Clima S.L
Avda. Ingeniero
Torres Queredo, 6
E - 28022 Madrid
Tel. 00349 / 1-761 38 30
Fax. 00349 / 1-329 42 31

Czech Republic

Eberspächer Praha s r.o.
AREÁL ZÁLESÍ
Pod Višňovkou 29
CZ 140 00 Praha 4 – Krč
Tel. 00420 / 234 035 800
Fax. 00420 / 234 035 810 und 820

Belarus

Belvneshinvest
Per. 1-yi Izmajlowskij. 51/2
BY - 220 131 Minsk
Tel. 00375 / 172 371 437
Fax. 00375 / 172 371 716

Dated 03/2007

53

Service

7

List of key words

Keyword Page

A

Accident prevention .............................................................. 4

Ambient temperature ...................................................... 9, 10

AMP release tool ................................................................ 27

Assembly drawing ........................................................ 25, 26

B

Burner engine ..................................................................... 29

Burner start .......................................................................... 6

Burner tester ...................................................................... 13

Burner ................................................................................ 26

C

Cancelling the control box lock ................... 11, 15, 16, 18, 19

Certifi cation ........................................................................ 51

Characteristic values table ............................................ 35, 36

Circuit diagram ............................................................41 – 50

CO in the exhaust ................................................................. 9

CO2 value ....................................................................... 9, 38

Contents .......................................................................... 2, 3

Control box ........................................................................ 26

Control diagram .................................................................... 7

Control unit ........................................................................... 6

Cutaway view ....................................................................... 5

D

Declaration of conformity .................................................... 51

Delivery rate ........................................................................ 10

Description of functions ........................................................ 6

Diagnostic system, external ................................................ 13

Diagnostic unit ........................................................ 13, 14, 15

Disposal ............................................................................. 51

E

EasyStart R+ radio remote control ...................................... 20

EDiTH customer service program ................................. 16, 17

Electrical power consumption ......................................... 9, 10

Electromagnetic compatibility ............................................. 55

Emergency shutdown ........................................................... 8

Environmental protection .................................................... 51

F

Fault code ...................................................................21 – 24

Fault description ..........................................................21 – 24

Faults ................................................................................. 11

Flame tube ................................................................... 26, 34

Flashing code ............................................................... 11, 12

FLOWTRONIC water pump .......................................... 10, 40

Fuel consumption ........................................................... 9, 10

Fuel nozzle ......................................................................... 30

Fuel quantity ....................................................................... 37

Fuel supply ......................................................................... 37

Fuel ................................................................................ 9, 10

Function ..........................................................................5 – 8

Functional check ................................................................ 27

Functional diagram ............................................................... 7

G

Gauze fuel fi lter ................................................................... 37

Keyword Page

H

Heat fl ow ........................................................................ 9, 10

Heating cartridge .......................................................... 26, 33

Heating element ....................................................... 5, 26, 33

Heating medium ............................................................. 9, 10

Hood ............................................................................ 26, 28

I

Ignition electrodes ........................................................ 26, 30

Ignition unit ................................................................... 26, 31

Initial commissioning ............................................................. 4

Interference suppression class ........................................ 9, 10

Introduction .....................................................................2 – 4

ISO adapter ........................................................................ 16

L

Locking the control box ...................................................... 11

M

Minimum fl ow rate .......................................................... 9, 10

Module timer ...................................................................... 18

N

Nozzle block - heating cartridge ......................................... 33

O

Operating instructions ........................................................... 6

Operating pressure ......................................................... 9, 10

Overheating sensor ...................................................... 35, 36

P

Packaging .......................................................................... 51

Permissible ambient temperature .................................... 9, 10

Picture symbols .................................................................... 4

Power consumption ....................................................... 9, 10

Pressure loss characteristic curve ....................................... 10

Product information ........................................................ 9, 10

Protection ....................................................................... 9, 10

Pumping characteristic curve .............................................. 10

R

Radio remote control TP 5 .................................................. 19

Rated voltage ................................................................. 9, 10

Remedial action ...........................................................21 – 24

Repair instructions .......................................................25 – 40

Representatives abroad ................................................ 52, 53

S

Safety devices ...................................................................... 8

Safety Instructions ................................................................ 4

Solenoid valve .................................................................... 32

Spare parts list ................................................................... 26

Structure of the heater .......................................................... 6

Switching off ......................................................................... 6

Switching on ......................................................................... 6

T

Technical data ................................................................ 9, 10

Temperature control values ................................................... 7

Temperature sensor ............................................................ 35

Temperature switch ...................................................... 26, 33

Test equipment ................................................................... 13

Troubleshooting ...........................................................11 – 24

54

Service

7

List of key words

Keyword Page

V

Voltage limit .................................................................... 9, 10

Voltage ........................................................................... 9, 10

W

Water pump, Bus 2000 ..................................................... 39

Water pump, normal design ................................................ 39

Weight ............................................................................ 9, 10

55