Eberspächer HYDRONIC D 5 W Z, HYDRONIC B 5 W Z, HYDRONIC B 5 W SC, HYDRONIC B 4 W SC, HYDRONIC D 4 W SC Instruction Manual

1

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

Telefon (zentral)
(0711) 939 - 00
Telefax
(0711) 939 - 0500

www.eberspaecher.com

Eberspächer

25 2216 90 95 89 EN 10.2010 Subject to changes Printed in Germany © J. Eberspächer GmbH & Co. KG

Technical description
Installation instructions
Operating instructions
Maintenance instructions

Heater (additional heater) for vehicles with
petrol engine

Order no.

HYDRONIC

B 5 W Z – 12 volt 20 1818 05 00 00

Heater (additional heater) for vehicles with
diesel engine

Order no.

HYDRONIC

D 5 W Z – 12 volt 25 2216 05 00 00

Please give this manual to the customer
after installation of the heater.

2

Introduction

1

1

8

7

6

5

4

3

Contents

Chapter Title Contents Page

Introduction • Contents ................................................................................................ 2

• Concept of this manual ......................................................................... 3

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

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

• Statutory regulations ......................................................................... 5, 6

• Safety instructions for installation and operation .............................. 6, 7

• Accident prevention .............................................................................. 7

Product information • Scope of supply ................................................................................. 8, 9

• Technical data petrol heaters .............................................................. 10

• Technical data diesel heaters .............................................................. 11

• Main dimensions .................................................................................. 12

Installation • Installation and location ...................................................................... 13

• Possible installation positions ............................................................. 14

• Mounting and fastening ....................................................................... 14

• Nameplate ........................................................................................... 15

• Connection to the cooling water circuit ......................................... 16, 17

• Exhaust system ................................................................................... 18

• Combustion air system ........................................................................ 19

• Fuel supply ..................................................................................20 – 24

Operation and • Operating instructions / important information for operation ............... 25

function • Initial commissioning ........................................................................... 25

• Description of functions ...................................................................... 25

• Control and safety devices ................................................................. 26

Electrical system • Heater wiring ........................................................................................ 27

• Circuit diagram ..................................................................................... 28

Troubleshooting • In case of faults, please check the following points ........................... 29

Maintenance • Troubleshooting procedure .................................................................. 29

Service • Maintenance instructions .................................................................... 29

• Service ................................................................................................ 29

Environment • Certification ......................................................................................... 30

• Disposal ............................................................................................... 30

• EU Declaration of Conformity ............................................................... 30

Lists • List of key words ........................................................................... 31, 32

• List of abbreviations ............................................................................ 32

2

3

Introduction

1

Concept of this manual

This manual aims to support the service company
installing the heater and to provide the user with all
important information about the heater.
The manual has been divided into 8 chapters to make
it easier to find the corresponding information quickly.

Introduction

Here you will find important introductory
information about installation of the heater
and about the structure of the manual.

Product information

Here you will find information about the scope
of supply, the technical data and the
dimensions of the heater.

Installation

Here you will find important information and
instructions referring to installation of the
heater.

Operation and function

Here you will find information about the
operation and function of the heater.

Electric system

Here you will find information about the
electronic system and electronic components
of the heater.

Troubleshooting / maintenance / service

This section contains information on possible
faults and malfunctions, troubleshooting,
maintenance and the service hotline.

Environment

Here you will find information about certification
and disposal of the heater together with the EU
Declaration of Conformity.

Lists

Here you will find the key word list and
abbreviations list.

2

3

4 8

7

6

51

4

Introduction

1

Special text structure, presentation and
picture symbols

This manual uses special text structures and picture
symbols to emphasise different contents.
Please refer to the examples below for the
corresponding meanings and associated actions.

Special structure and presentations

A dot (•) indicates a list which is started by a
heading. If an indented dash (–) follows a dot, this list
is subordinate to the dot.

Picture symbols

Regulation!

This picture symbol with the remark “Regulation”
refers to a statutory regulation. Failure to comply with
this regulation results in expiry of the type permit for
the heater and preclusion of any guarantee and
liability claims on J. Eberspächer GmbH & Co. KG and
its associated companies.

Danger!

This picture symbol with the remark “Danger!” refers
to the risk of a fatal danger to life and limb. Under
certain circumstances, failure to comply with these
instructions can result in severe or life-threatening
injuries

..

..

.

Caution!

This picture symbol with the remark “Caution!” refers
to a dangerous situation for a person and/or the
product.
Failure to comply with these instructions can result in
injuries to people and / or damage to machinery.

These remarks contain application recommendations
and useful tips for installation of the heater.

Important information before
starting work

Range of application of the heater

The heater operating independently of an engine is
intended for installation in the following vehicles,
depending on its heating output:

• Vehicles of all kinds

• Construction machinery

• Agricultural machinery

• Boats, ships and yachts

The heater must not be installed in motor vehicles
used to transport dangerous goods according to
ADR / ADR 99.

Purpose of the heater
(using the vehicle heat exchanger)

• Heat up the vehicle's water circuit together with the
vehicle engine for adequate heating of:
– Driver and working cabs
– Freight compartments
– Ship’s cabins
– Passenger and crew compartments
– Vehicle engines and units

On account of its functional purpose, the heater is not
permitted for the following applications:

• Long-term continuous operation, e.g. for pre-heating
and heating of:
– Residential rooms
– Garages
– Work huts, weekend homes and hunting huts
– Houseboats, etc.

Caution!

Safety instructions for application and
proper purpose

• The heater must only be used and operated for the
range of application stated by the manufacturer in
compliance with the “Operating instructions”
included with every heater.

Please note!

Please note!

5

Introduction

1

Statutory regulations

The Federal Road Transport Directorate has issued an
"EC type approval" and an "EMC type approval" for the
heater for installation in motor vehicles and with the
following official type approval marks, noted on the
heater name plate.

HYDRONIC

EC- e1 00 0023

EMC- e1 023971

Regulation!

Directive 2001 / 56 / EU of the European
Parliament and the Council

• Arrangement of the heater

– Parts of the structure and other components near

the heater must be protected from excess heat
exposure and possible contamination from fuel or
oil.

– The heater must not pose a fire hazard even when

it overheats.
This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and
fire-proof materials or heat plates are used.

– The heater must not be located in the passenger

compartment in vehicles of class M

1

, M2, M3 and N.
A unit may however be used in a hermetically sealed
housing which also corresponds to the conditions
stated above.

– The factory nameplate or duplicate must be affixed

so that it can still be easily read when the heater
is installed in the vehicle.

– All appropriate precautions must be taken when

arranging the heater to minimise the risk of injuries
to persons or damage to other property.

• Fuel supply

– The fuel intake connection must not be located in

the passenger compartment and must be sealed
with a properly closing lid to prevent any fuel leaks.

– In heaters for liquid fuel where the heater fuel is

separate from the vehicle fuel, the type of fuel and
intake connection must be clearly identified.

– A warning sign is to be fixed to the intake

connection indicating that the heater must be
switched off before refuelling.

• Exhaust system

– The exhaust outlet must be arranged so as to

prevent any penetration of exhaust fumes into the
vehicle interior through the ventilation system,
warm air intakes or open windows.

• Combustion air intake

– The air for the heater combustion chamber must

not be sucked in from the passenger compartment
of the vehicle.

– The air intake must be arranged or protected in

such a way that it cannot be blocked by other
objects.

• Operating status display

– A clearly visible operating display in the user’s

field of vision must indicate when the heater is
switched on and off.

6

Introduction

1

Statutory regulations

• Compliance with the statutory regulations and
safety instructions is prerequisite for guarantee
and liability claims.
Failure to comply with the statutory regulations and
safety instructions and incorrect repairs even when
using original spare parts make the guarantee null
and void and preclude any liability for
J. Eberspächer GmbH & Co. KG.

• Subsequent installation of this heater must comply
with these installation instructions.

• The statutory regulations are binding and must also
be observed in countries which do not have any
special regulations.

• Installation of the heater in special vehicles must
comply with the regulations applying to such
vehicles.

• Other installation requirements are contained in the
corresponding sections of this manual.

Safety instructions for installation
and operation

Danger!

Risk of injury, fire and poisoning!

• Disconnect the vehicle battery before starting any
kind of work.

• Before working on the heater, switch the heater off
and let all hot components cool down.

• The heater must not be used in closed rooms, e.g.
in the garage or in a multi-storey car park (do not
leave the engine running when the vehicle is at a
standstill).

Caution!

Safety instructions for installation and operation!

• The heater must only be installed by a JE partner
authorised by the manufacturer according to the
instructions in this manual and possibly according to
special installation recommendations; the same
applies to any repairs to be carried out in the case
or repairs or guarantee claims.

• Repairs by non-authorised third-parties or with not
original spare parts are dangerous and therefore not
allowed. They result in expiry of the type permit of
the heater; consequently, when installed in motor
vehicles they can cause expiry of the vehicle
operating licence.

• The following measures are not allowed:
– Changes to components relevant to the heater.
– Use of third-party components not approved by

J. Eberspächer GmbH & Co. KG.

– Nonconformities in installation or operation from

the statutory regulations, safety instructions or
specifications relevant to safe operation as stated
in the installation instructions and operating
instructions. This applies in particular to the
electrical wiring, fuel supply, combustion air
system and exhaust system.

Please note!

7

Introduction

1

Accident prevention

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

Safety instructions for installation
and operation

Caution!

Safety instructions for installation and operation

• Only the controls approved by Eberspächer may be
used to operate the heater.
The use of other controls can result in malfunctions.

• Only when upgrading the additional heater:
Before the heater is installed again in another
vehicle, rinse the heater parts carrying water with
clear water.

• Before the heater is installed again in another
vehicle, rinse the heater parts carrying water with
clear water.

• When carrying out electric welding on the vehicle,
the plus pole cable at the battery should be
disconnected and placed at ground to protect the
controller.

• The heater must not be operated where there is a
risk of an accumulation of flammable vapours or
dust, for example close to
– fuel depot
– coal depot
– wood depot
– grain depots etc.

• The heater must be switched off when refuelling
(vehicle engine).

• When the heater is mounted in a safety housing
etc., the installation compartment of the heater is
not a stowage compartment and must be kept clear.
In particular fuel canisters, oil cans, spray cans,
gas cartridges, fire extinguishers, cleaning rags,
items of clothing, paper etc. must not be stored or
transported on or next to the heater.

• Defect fuses must only be replaced by fuses with
the prescribed rating.

• If fuel leaks from the heater fuel system, arrange
for the damage to be repaired immediately by a
JE service partner.

• When topping up the coolant, only use the coolant
permitted by the vehicle manufacturer, see the
vehicle operating manual. Any blending with
unpermitted coolant can cause damage to the
engine and heater.

• After-running of the heater must not be interrupted
prematurely e.g. by pressing the battery
disconnecting switch, apart from in the case of an
emergency stop.

8

• Please consult the additional parts catalogue for
any other parts required for installation, e.g. hose
clips.

• The heater can be upgraded from additional heater
to pre-heater with a mod kit. Please consult the
sales documents for the order number for vehicle­specific mod kits.

Recommendation:

Starting the heater can be limited with an outside
temperature switch, i.e. the heater switches on at a
temperature <5 °C or <10 °C.
In addition, an ON / OFF switch should be fitted for
vehicles frequently used for short distances.
This allows for the heater to be switched off with the
ON / OFF switch when used for short distances and
during the summer months.
The ON / OFF switch can be bought from a good parts
dealer.

Order number:

Outside temperature switch <5 °C 201 00 121

Outside temperature switch <10 °C 201 00 122

ON / OFF switch, 12 volt 201 00 123

Product information

2

Please note!

Scope of supply for petrol heaters

Picture No.

Quantity / Designation Order number

–1

HYDRONIC

B 5 W Z – 12 V 20 1818 05 00 00

–1

HYDRONIC

D 5 W Z – 12 V 25 2216 05 00 00

As complete package:

1 1 Heater ---­ 2 1 Dosing pum ----

To be ordered separately:

3 1 Heater bracket 25 2220 80 00 01
4 1 Central screw 100 10 258
5 4 Metal-rubber puffer 20 1185 00 00 01
6 1 Water hose Ø 20 25 1917 80 00 01
7 2 Connector Ø 20 mm 20 1534 88 00 01
8 p.m. Pipe 3,5 x 3 360 75 300
9 p.m. Pipe 4 x 1,25 090 31 118
10 1 Pipe clip 22 1000 50 05 00
11 1 Hose clip 10 2064 01 60 25
12 1 Flexible exhaust pipe 25 1774 80 02 00
13 1 Combustion air hose 360 00 099
14 1 End sleeve 25 1688 80 12 01
15 1 Plug 22 1000 30 10 21
16 1 Receptacle housing 22 1000 31 87 00
17 1 Bracket 22 1000 50 03 00
18 1 T-piece 8-6-8 262 31 151
19 2 Support sleeve 22 1000 20 02 00
20 p.m. Hose 7,5 x 2,5 360 31 070
21 p.m. Hose 5 x 3 360 75 350
22 p.m. Pipe 6 x 2 090 31 125
23 1 Fuse holder 22 1000 31 06 00

9

Scope of supply

Product information

2

10

Product information

2

Caution!

Safety instructions for technical data!

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

Technical data for petrol heaters

Heater B 5 W Z

Heating medium Water, cooling fluid

Control of the heat flow Large Small

Heat flow (watt) 5000 1500

Fuel consumption (l/h) 0.69 0.2

Mean electr. power (watt) in operation 37 10

at start 110

after-running 8

Rated voltage 12 volt

Operating range

• Lower voltage limit: An undervoltage protection 10.2 volt
in the controller switches the heater off on
reaching approx 10 volt.

• Upper voltage limit: An overvoltage protection
in the controller switches the heater off on 16 volt
reaching approx 16 volt.

Tolerable operating pressure up to 2.5 bar overpressure

Minimum water flow rate of the heater 250 l/h

Fuel commercially available petrol
(see also fuel supply, page 24). (DIN EN 228)

Tolerable operating temperature operation heater –40 °C to +80 °C

operating, dosing pump –40 °C to +20 °C

storage –40 °C to +105 °C

Interference suppression class 5 for VHF, SW, MW, 2 for LW

Weight

• without controller and cooling fluid ca. 2.3 kg

• with dosing pump and water pump ca. 2.5 kg

All technical data ±10 %

11

Product information

2

Technical data for diesel heaters

Heater D 5 W Z

Heating medium Water, cooling fluid

Control of the heat flow Large Small

Heat flow (watt) 5000 2400

Fuel consumption (l/h) 0.62 0.27

Mean electr. power (watt) in operation 37 10

at start 110

after-running 8

Rated voltage 12 volt

Operating range

• Lower voltage limit: An undervoltage protection 10.2 volt
in the controller switches the heater off on
reaching approx 10 volt.

• Upper voltage limit: An overvoltage protection
in the controller switches the heater off on 16 volt
reaching approx 16 volt.

Tolerable operating pressure up to 2.5 bar overpressure

Minimum water flow rate of the heater 250 l/h

Fuel commercially available diesel
(see also fuel supply, page 24). (DIN EN 590)

Tolerable operating temperature operation heater –40 °C to +80 °C

operating, dosing pump –40 °C to +80 °C

storage –40 °C to +105 °C

Interference suppression class 5 for VHF, SW, MW, 2 for LW

Weight

• without controller and cooling fluid ca. 2.3 kg

• with dosing pump and water pump ca. 2.5 kg

Caution!

Safety instructions for technical data!

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

All technical data ±10 %

12

Main dimensions

Product information

2

Fuel
inlet

Water: inlet / outlet

Combustion
air inlet

Exhaust outlet

13

Installation example
Diesel heater in a truck and in a delivery van

 Heater
 Exhaust silencer
 Combustion air hose
 Fuse holder
 Dosing pump
 Fuel suction pipe
 T-piece

Installation location

The installation location for the heater is the engine
compartment. The heater must be mounted below the
min. cooling water level (compensation tank, cooler,
vehicle heat exchanger) for automatic venting of the
heat exchanger of the heater.

• The regulations and safety instructions to be
observed for this chapter are stated on page 4 – 7.

• The installation suggestions made in the
installation instructions are examples. Other
installation locations are possible if they
correspond to the installation requirements stated
in these installation instructions.

• Other installation information (e.g. for boats and ships)
is available from the manufacturer on request.

• Observe the tolerable installation position together
with the operating and storage temperatures.

Installation

3

 Heater
 Exhaust pipe
 Combustion air intake silencer
 Fuse bracket
 Dosing pump
 Fuel suction pipe

Installation example
Petrol heater / diesel heater in a car

Please note!

14

Installation

3

Mounting and fastening

Position the heater in the holding clips of the heater
bracket and fasten with fastening screw, M6 x 97
(torque 6

0.5

Nm). Mount the heater bracket in a suitable
position in the engine compartment, possibly using
anti-vibration pads if necessary.

Depending on the installation space available, the
heater can be moved sideways in the bracket and
screwed in one of the two fastening threads.

Possible installation positions

The heater should preferably be installed in the normal
position, horizontal with the exhaust connection down
to the bottom. Depending on the installation
conditions, the heater can also be mounted in the
permitted swivel range, see diagram.

Heater in normal position with
permitted swivel range

Swivel range from the normal position
up to max. 90° swivel upwards.

Swivel range from the normal position to
max. 90° swivel around the longitudinal axis.

When the heater is operating, the shown normal or
maximum installation positions can be varied briefly
by up to +15° in all directions. Such deviations
caused by the inclined position of the vehicle do not
impair the heater functions in any way.

Please note!

 Heater
 Bracket clips
 Bracket holder

 Fastening screw
 fastening thread

15

Nameplate

The nameplate is fastened to the front of the heater.
The second nameplate (duplicate) is included in the
scope of supply of the heater.
If required, the duplicate nameplate can be adhered
in a clearly visible position on the heater or near to
the heater.

The regulations and safety instructions to be
observed for this chapter are stated on page 5.

Installation

3

 Original nameplate
 2nd nameplate (duplicate)

Please note!





16

Installation

3

Connection to the cooling water circuit

The heater is connected to the cooling water circuit
in the water feed pipe from the vehicle engine to the
heat exchanger. There are four possible alternative
installations here.

Danger!

Risk of injuries and burns!

It is possible for the coolant and components of the
coolant circuit to get very hot.

• Parts conveying water must be routed and fastened

in such a way that they pose no temperature risk to
man, animals or material sensitive to temperature
from radiation / direct contact.

• Before working on the coolant circuit, switch the

heater off and wait until all components have cooled
down completely, if necessary where safety gloves.

• When installing the heater and the water pump,
please note the direction of flow of the coolant
circuit.

• Fill the heater and water hoses with coolant before
connecting to the coolant circuit.

• Route the water hoses without any kinks, and in a
rising position if possible.

• When routing the water pipes, observe a sufficient
clearance to hot vehicle parts.

• Protect all water hoses / water pipes from chafing
and from extreme temperatures.

• Secure all hose connections with hose clips
(tightening torque = 1.5 Nm).

• After the vehicle has been operating for 2 hours or
travelled 100 km, tighten the hose clips again.

• The minimum water flow rate is only guaranteed if
the temperature difference of the heating medium
does not exceed 10 K between water inlet and water
outlet during heating.

• Only overpressure valves with an opening pressure
of min. 0.4 – max. 2 bar may be used in the coolant
circuit.

• The coolant liquid must contain at least 10 %
antifreeze all year round as corrosion protection.

• The cooling liquid must contain sufficient antifreeze
for low temperatures.

• Before commissioning the heater or after changing
the cooling liquid, the whole coolant circuit including
heater must be vented free of bubbles according to
the instructions issued by the vehicle manufacturer.

• Only top up with coolant approved by the vehicle
manufacturer.

Please note!

17

Installation

3

Heating characteristics

The heater starts in the "LARGE" setting.
Once the cooling water temperature has reached
approx. 80 °C, depending on the selected fan
setting, the heater switches to the "SMALL" setting.
If the heating output is inadequate in the "SMALL"
setting, the cooling water temperature falls to 75 °C:
the heater then switches back to the "LARGE"
settings.
If the heating output is sufficient in the "SMALL"
setting, the cooling water temperature increases to
85 °C: the heater switches to the pause setting.
Once the cooling water has cooled down to 75 °C in
the pause setting, the cycle starts up again in the
"LARGE" setting.

Connection to the cooling water circuit

Integrate the heater in the water feed pipe from
the vehicle engine to the heat exchanger “inline
connection”

Disconnect the water feed pipe from the vehicle engine
to the vehicle heat exchanger. Connect up the heater
with connection pieces and water hoses to the water
feed pipe.
Route and connect a water hose from the pressure
connection of the water pump to the water intake
connection of the heater.
Secure both connection parts with hose clips.

 Heater
 Connection piece
 Heat exchanger
 Vehicle engine

18

Installation

3

Exhaust system

(Exhaust diagram see page 19).

Mounting the exhaust system

The scope of supply of the universal installation kit
includes a flexible exhaust pipe, inner Ø 24 mm,
1000 mm long and an exhaust silencer.
The flexible exhaust pipe can be shortened to 20 cm
or lengthened to max. 2 m, depending on the
installation conditions.
Fasten the exhaust silencer to a suitable position in
the vehicle. Route the flexible exhaust pipe from the
heater to the exhaust silencer and fasten with pipe
clips. If necessary, also fasten the flexible exhaust
pipe with pipe clips at suitable positions in the vehicle.
Connect the exhaust end pipe to the exhaust silencer
with an end sleeve and fasten with a pipe clip.

Caution!

Safety instructions!

The whole exhaust system gets very hot during and
immediately after the heater has been working in the
heating mode. This is why the exhaust system must
be routed according to these installation instructions.

• The exhaust outlet must end in the open air.

• The exhaust pipe must not protrude beyond the
lateral limits of the vehicle.

• Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm at
the lowest point to drain off condensation.

• Important functional parts of the vehicle must not be
impaired (keep sufficient clearance).

• Mount the exhaust pipe with sufficient clearance to
heat-sensitive parts. Pay particular attention to fuel
pipes (plastic or metal), electrical cables and brake
hoses etc.!

• Exhaust pipes must be fastened safely
(recommended clearance of 50 cm) to avoid damage
from vibrations.

• Route the exhaust system so that the emitted fumes
are not sucked in with the combustion air.

• The mouth of the exhaust pipe must not get clogged
by dirt and snow.

• The mouth of the exhaust pipe must not point in the
direction of travel.

• Always fasten the exhaust silencer to the vehicle.

Danger!

Risk of injuries and burns!

Every type of combustion produces high temperatures
and toxic exhaust fumes. This is the reason why the
exhaust system must be installed according to these
instructions.

• Do not perform any work on the exhaust system
while the heater is working.

• Before working on the exhaust system, first switch
the heater off and wait until all parts have cooled
down completely, wear safety gloves if necessary.

• Do not inhale exhaust fumes.

• Comply with the regulations and safety instructions

for this chapter on page 4 – 7.

• If a silencer is fitted, the exhaust end pipe must be
much shorter than the flexible exhaust pipe bet­ween the heater and the exhaust silencer.

Please note!

19

Installation

3

 Heater
 Combustion air pipe
 Exhaust pipe
 End sleeve

Caution!

Safety instructions for the combustion air system

• The combustion air opening must be free at all
times.

• Position the combustion air intake to be sure that
exhaust fumes cannot be sucked in with the
combustion air.

• Do not arrange the combustion air intake to
pointing against the wind blast.

• The combustion air intake must not get clogged
with dirt and snow.

• Install the combustion air intake system sloping
slightly downwards. If necessary, make a drain
hole approx. Ø 5 mm at the lowest point to drain
off condensation.

Combustion air system

Mounting the combustion air system

The heater is mounted in the engine compartment, as
described in these instructions.
If the intake connection for combustion air is in a
position where the combustion air can be expected to
be no warmer than 25°C and whether neither splashed
water nor dust / dirt are expected, then no combustion
air hose is required.
Otherwise a flexible combustion hose must be
mounted with an inner Ø 20 mm and up to 1.5 m long,
to ensure that the intake of combustion air comes
from an area which complies with the above
conditions.
After completing all work, push an end sleeve over
the intake silencer / flexible pipe.

Comply with the regulations and safety instructions
for this chapter on page 4 – 7.

Please note!







min. 20 cmmax. 1.5 m to max. 2 m

20

Installation

3

 Correct connection
 Incorrect connection – bubble formation





Fuel supply

Mounting the dosing pump, routing the fuel pipes
and mounting the fuel tank

The following safety instructions must be observed
when mounting the dosing pump, routing the fuel pipes
and mounting the fuel tank.
Deviations from the instructions stated here are not
allowed.
Failure to comply can result in malfunctions.

Danger!

Risk of fire, explosion, poisoning and injuries!

Caution when handling fuel.

• Switch off the vehicle engine and heater before
refuelling and before working on the fuel supply.

• No naked lights when handling fuel.

• Do not smoke.

• Do not inhale petrol fumes.

• Avoid any contact with the skin.

Caution!

Safety instructions for routing the fuel pipes!

• Only use a sharp knife to cut off fuel hoses and
pipes.
Interfaces must not be crushed and must be free
of burrs.

• The fuel pipe from the dosing pump to the heater
should be routed at a continuous rise.

• Fuel pipes must be fastened safely to avoid any
damage and / or noise production from vibrations
(recommended clearance of approx. 50 cm).

• Fuel pipes must be protected from any mechanical
damage.

• Route the fuel pipes so that any distortion of the
vehicle, engine movements etc. cannot have any
lasting effect on the service life.

• Parts carrying fuel must be protected from
interfering heat.

• Never route or fasten the fuel pipes to the heater or
vehicle exhaust system. When the systems cross,
always ensure there is a sufficient heat clearance.
If necessary, install heat deflection plates.

• Dripping or evaporating fuel must never be allowed
to collect on hot parts or ignite on electric systems.

• When connecting fuel pipes with a fuel hose, always
mount the fuel pipes in a butt joint to prevent any
bubbles from forming.

Safety instructions for fuel pipes and fuel tanks
in buses and coaches

• In buses and coaches, fuel pipes and fuel tanks
must not be routed through the passenger
compartment or driver’s cab.

• Fuel tanks in buses and coaches must be
positioned in such a way that the exits are not in
direct danger from a possible fire.

Comply with the regulations and safety instructions
for this chapter on page 4 – 7.

Please note!

21

a

8

b

Installation

3

Fuel feed point with T-piece from the fuel supply line
from the tank fitting to the vehicle engine

 Fuel feed pipe from tank connection – insert

T-piece before the fuel pump in the fuel feed pipe.

 Fuel return pipe to the tank connection.
 Dosing pump
 T-piece, 8-6-8
 Fuel filter – only necessary for contaminated fuel.
 Fuel hose, 5 x 3 (di = Ø 5 mm)
 Fuel pipe, 6 x 2 (di = Ø 2 mm)
 Fuel pipe, 4 x 1.25 (di = Ø 1.5 mm)
 Fuel hose, 5 x 3 (di = Ø 5 mm),

approx. 50 mm long

 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm),

approx. 50 mm long

 To the engine, mechanical fuel or injection pump.

Possible pipe lengths

Intake side Pressure side

a = max. 2 m b = max. 4 m for petrol

b = max. 6 m for diesel

Fuel supply for petrol heaters

Installation position of the T-piece

Use the installation positions shown in the diagram
when inserting a T-piece.

 Direction of flow from the fuel tank
 Direction of flow to the vehicle engine



22

a

10

b

Installation

3

Fuel feed point with tank connection –
ascending pipe, integrated in the vehicle tank

 Tank connection for metal tank –

di = Ø 2 mm, da = Ø 6 mm

 Tank connection for tank fitting –

di = Ø 2 mm, da = Ø 4 mm

 Dosing pump
 Fuel filter – only required for contaminated fuel.
 Fuel hose, 5 x 3 (di = Ø 5 mm)
 Fuel pipe, 6 x 2 (di = Ø 2 mm)
 Fuel hose, 4 x 1 (di = Ø 2 mm)
 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm),

approx. 50 mm long

 Fuel hose, 5 x 3 (di = Ø 2 mm),

approx. 50 mm long

 Fuel pipe, 4 x 1.25 (di = Ø 1.5 mm)
 Connection fitting, da = Ø 4 mm

Possible pipe lengths

Intake side Pressure side

a = max. 2 m b = max. 4 m for petrol

b = max. 6 m for diesel

Items    are included in the “tank connection “ kit
(order no. 22 1000 20 07 00).

Fuel supply for petrol heaters

Caution!

Safety instructions for the fuel supply!

• The fuel must not be conveyed by gravity or
overpressure in the fuel tank.

• Withdrawal of fuel after the vehicle’s fuel pump is
not allowed.

• When the pressure in the fuel pipe is more than

0.2 bar to max. 2 bar, use a pressure reducer
(order no. 22 1000 20 08 00) or separate tank
connection.

• When the pressure in the fuel pipe is more than
2 bar or there is a non-return valve in the return pipe
(in the tank), a separate tank connection must be
used.

• When using a T-piece in a plastic pipe, always use
support sleeves in the plastic. Connect the T-piece
and the plastic pipe with corresponding fuel hoses
and secure with hose clips.

Please note!

23

Possible suction and pressure height
of the dosing pump

Pressure height from vehicle tank to dosing pump:
a = max. 3000 mm

Intake height in pressure-less vehicle tank:
b = max. 500 mm for petrol
b = max. 1000 mm for diesel

Intake height in vehicle tanks with withdrawal by
negative pressure (valve with 0.03 bar in tank cap):
b = max. 150 mm for petrol
b = max. 400 mm for diesel

Pressure height of the dosing pump to the heater:
c = max. 2000 mm

Check tank venting.

 Connection to heater
 Max. fuel level
 Min. fuel level

Installation

3

Fuel supply

Installation position of the dosing pump

Always mount the dosing pump with the pressure side
rising upwards. Every installation position over 15° is
allowed, although an installation position between 15°
and 35° is preferable.

 Installation position between 0° and 15°

is not allowed.

 Preferred installation position in range 15° to 35°.
 Installation position in range 35° to 90° is

allowed.

Caution!

Safety instructions for installing
the dosing pump

• Always mount the dosing pipe with the pressure
side rising upwards – minimum incline 15°.

• Protect the dosing pump and filter from intolerable
heat, do not mount near to the silencers and
exhaust pipes.

Please note!







24

Installation

3

Fuel supply

Fuel quality for petrol heaters

The heater can run on commercially available fuel
as per DIN EN 228, as used in the vehicle tank.

Fuel quality for diesel heaters

The heater can run on commercially available fuel
as per DIN EN 590, as used in the vehicle tank.

Fuel for special cases

In special cases (above 0°C), the heater can also
run on fuel oil EL or paraffin.

Fuel for low temperatures

Refineries and fuel service stations automatically
adjust the fuel to normal winter temperatures (winter
diesel). This means that difficulties are only to be
expected for extreme drops in temperature, as also
apply to the vehicle engine. Please also refer to the
vehicle manual.

If the heater is run from a separate tank, please
comply with the following rules:
For temperatures above 0°C, any kind of diesel fuel
as per DIN EN 590 can be used.

If no special diesel fuel is available for low
temperatures, then paraffin or petrol should be mixed
with the fuel according to the following table:

Temperature Winterdiesel Addition
0 °C to –25 °C 100 % –––
–25 °C to –40 °C 50 %* 50 % paraffin

or petrol

* or 100% special cold diesel fuel (Arctic diesel)

Please note!

• Mixtures with used oil are not allowed!

• After refuelling with winter or cold diesel or the listed
blends, the fuel pipes and the dosing pump must be
filled with the new fuel by letting the heater run for
15 mins.!

Operation with biodiesel (PME)
The heater is not certified for operation with biodiesel.

25

Operation and function

4

Operating instructions

If the vehicle engine is not providing enough heat in
the warming-up phase, in city traffic or in traffic
congestion, the heater switches on automatically and
supports the vehicle's own heating system.

Important instructions for operation

Safety checks before the start

After a longer interval in operations (after the summer
months) the fuse must be put in position and / or the
heater connected up to the battery. Check that all
parts fit firmly (tighten screws where necessary).
Check the fuel system visually for any leaks.

Heating at high altitudes

When using the heater at high altitudes, please note:

• Heating at altitudes up to 1500 m:
– Unlimited heating possible.

• Heating at altitudes over 1500 mm:
– Heating is possible for short periods at this

altitude (e.g. driving over a mountain pass or
taking a break in a journey).

– Heating is not possible for longer periods at this

altitude (e.g. winter camping).

Initial commissioning

• After installation of the heater, the coolant circuit
and the whole fuel supply system must be vented
carefully. Comply with the instructions issued by the
vehicle manufacturer.

• Open the coolant circuit before the trial run (se the
temperature control to “OPEN”).

• During the trial run of the heater, check all water and
fuel connections for leaks and firm fitting.

• If the heater shows a fault during operation, find
and eliminate the cause of the fault using a
diagnosis unit.

Description of functions

Switching on (additional heating mode)

After a certain program sequence, the heater starts
the combustion air fan, glow plug and fuel dosing
pump. Once a stable flame has formed in the
combustion chamber, the glow plug switches off again
under time control.

Heating mode

Depending on heating requirements, the heater is
adjusted in the following stages:
LARGE – SMALL – OFF (pause).
The temperature limits are permanently programmed in
the electronic controller.
If the heating requirements in the “SMALL” stage are
so small that the cooling water temperature reaches
85 °C, the heater goes into the pause mode.
The heater continues to run on for approx. 130
seconds, then it switches off (pause mode).
The control lamp lights up and the water pump
continues to run, even in the pause mode.

26

Operation and function

4

Control and safety devices

• If the heater does not ignite within 90 seconds
after starting the fuel pump, the start is repeated.
If the heater still does not ignite after another
90 seconds, the heater is switched off. After an
unacceptable number of failed start attempts, the
controller is locked.*

• If the flame goes off by itself during operation, the
heater is restarted.
If the heater does not ignite within 90 seconds
after the fuel pump has started again, the heater is
switched off.
The fault shutdown can be cancelled by switching
off and on again briefly (ignition ON / OFF).

• In the case of overheating (e.g. lack of water, poorly
vented coolant circuit), the overheating sensor
triggers, the fuel supply is interrupted and the heater
switched off.
Once the cause of overheating has been eliminated,
the heater can be started by switching off and on
again (ignition ON / OFF), on condition that the
heater has cooled down again sufficiently, cooling
water temperature <70 °C.
After the heater has been switched off for
overheating an unacceptable number of times,
the controller is locked.*

• The heater is switched off if the upper or lower
voltage limit is reached.

• The heater does not start up when the glow plug is
defect or when the electric lead to the dosing pump
is interrupted.

• The speed of the fan motor is monitored continuously.
If the fan motor does not start up, if it is blocked or if
the speed falls below 40 % of the nominal speed, the
heater is switched off after 60 sec.

* The controller can be enabled again and the faults

read off:

• by connecting up a diagnosis unit

• using the customer service program KD2000.

For operation and fault list, please refer to the
enclosed operating instructions or the troubleshooting
and repair instructions for the heater.

Do not switch the heater off and on again more than
twice.

Emergency shutdown – EMERGENCY OFF

If an emergency shutdown – EMERGENCY OFF –
is necessary during operation, proceed as follows:

• Switch heater off (ignition OFF)

• pull the fuse out or

• disconnect the heater from the battery.

Please note!

27

Electrical system

5

Heater wiring

Caution!

Safety instructions for wiring the heater!

The heater is to be connected up electrically
according to the EMC directives.
EMC can be affected if the heater is not connected up
correctly. For this reason, comply with the following
instructions:

• Ensure that the insulation of electrical cables is not
damaged. Avoid: chafing, kinking, jamming or
exposure to heat.

• In waterproof connectors, seal any connector
chambers not in use with filler plugs to ensure they
are dirt-proof and water-proof.

• Electrical connections and ground connections must
be free of corrosion and firmly connected.

• Lubricate connections and ground connections
outside the heater interior with contact grease.

Comply with the following when wiring the heater and the
control element:

• Electrical leads, switchgear and controllers must be
arranged in the vehicle so that they can function
perfectly under normal operating conditions
(e.g.heat exposure, moisture etc.).

• The following cable cross sections are to be used
between the battery and heater. This ensures that
the max. tolerable voltage loss in the cables does
not exceed 0.5 V for 12 V or 1 V for 24 V rated
voltage.

Cable cross sections for a cable length of:
– up to 5 m (plus cable + minus cable) =

cable cross section 4 mm²

– from 5 to 8 m (plus cable + minus cable) =

cable cross section 6 mm²

• If the plus cable is to be connected to the fuse box
(e.g. terminal 30), the vehicle cable from the battery
to the fuse box must be included in rating the overall
cable length and possibly re-dimensioned if
necessary.

• Insulate unused cable ends.

Please note!

28

Electrical system

5

Parts list

1.1 Burner motor

1.2 Glow plug

1.5 Overheating sensor

1.12 Flame sensor

1.13 Temperature sensor

2.1 Control unit

2.2 Dosing pump

2.7 Main fuse 25 A

5.1 Battery

a) Diagnosis
b) +15

Option: a temperature switch and / or an
ON / OFF switch can be fitted in this line.

c) Alternator (AC)

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

Cable colours

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

Circuit diagram

25 1988 00 96 01 C

29

Troubleshooting / Maintenance / Service

6

In case of faults, please check the following
points

• If the heater does not start after being switched on:
– Switch the heater off and on again.

• If the heater still does not start, check whether:
– There is fuel in the tank?
– The fuses are OK?
– The electrical cables, connections etc. are OK?
– Anything is clogging the combustion air supply
or exhaust system?

Troubleshooting

If the heater remains faulty even after these points
have been checked, or another malfunction occurs
in your heater, please contact:

• For installation ex works, your contract workshop.

• For subsequent installation, the workshop who
installed your heater.

Please note that warranty claims can be become void
if the heater is changed by a third party or by this
installation of third party parts.

Maintenance instructions

• Before the heating period starts, the heater should
undergo a trial run. If persistent extreme smoke
develops, unusual burning noises or a clear fuel
smell can be perceived or if electric / electronic
parts heat up, the heater must be switched off and
put out of service by removing the fuse.
In this case, the heater should not be started up
again until it has been checked by qualified staff
who have been trained on Eberspächer heaters.

• Check the openings of the combustion air supply
and exhaust system after longer standstill periods,
clean if necessary!

Service

If you have any technical queries or problems with your
pre-heater, dial the following service phone number:

Hotline
Phone. 0800 / 12 34 300

Fax hotline
Fax 01805 / 26 26 24

Please note!

30

Environment

7

EU Declaration of Conformity

With regard to the following products

heater type

HYDRONIC

we herewith confirm 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

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 interference resistance.

• 72 / 245 / EEC – Modification status 95 / 54 / EU
interference suppression in motor vehicles.

Certification

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.
Officially approved public experts assess the system
and the corresponding certification company awards
a certificate.

Eberspächer has already qualified for the following
standards:

Quality management as per
DIN EN ISO 9001:2000 and ISO/TS 16949:1999

Environment management system as per
DIN EN ISO 14001:1996

Disposal

Disposal of materials

Old devices, defect components and packaging
material can all be separated and sorted into pure­grade factions so that all parts can be disposed of as
required in an environment-friendly manner or recycled
where applicable.
Electric motors, controllers 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.

31

Lists

8

List of key words A – Z

Keyword Page

A

Accident prevention ................................................... 7

Arrangement of the heater ......................................... 5

B

Biodiesel (PME) ......................................................... 24

Bubble formation ...................................................... 24

C

Cable colours ........................................................... 28

Certification .............................................................. 30

Circuit diagram .......................................................... 28

Combustion air system ............................................. 19

Concept of this manual .............................................. 3

Connection cooling water circuit ........................ 16, 17

Control and safety devices ...................................... 26

D

Description of functions ........................................... 25

Disposal .................................................................... 30

Dosing pump ............................................................. 23

E

Electrical system .............................................. 27 – 28

Electronic components ...................................... 33, 34

Emergency shutdown ................................................ 26

Environment .............................................................. 30

EU Decleration .......................................................... 30

EU Type Permit ............................................................ 5

Exhaust system ........................................................ 18

F

Fastening .................................................................. 16

Fuel supply ....................................................... 20 – 24

Fuel quality ............................................................... 24

G

Guarantee ................................................................ 31

H

Heater wiring ............................................................. 27

Heating operation ..................................................... 31

Heating mode ........................................................... 25

I

Initial commissioning ................................................ 25

Installation ........................................................ 13 – 24

Installation example ................................................. 13

Installation location .................................................. 13

Introduction ......................................................... 2 – 7

Keyword Page

L

Liability ..................................................................... 31

List of abbrevations ................................................. 32

M

Main dimensions ....................................................... 12

Maintenance instructions ......................................... 29

Mounting and fastening ............................................ 14

Mounting the exhaust system .................................. 18

N

Nameplate ................................................................ 15

O

Operating instructions .............................................. 25

Operation and function ..................................... 25 – 26

Operating status display ............................................ 5

P

Parts list ................................................................... 28

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

Place of jurisdiction .................................................. 31

Possible pipe lengths ......................................... 21, 22

Power consumption ............................................ 10, 11

Presentations ............................................................. 4

Product information ............................................ 8 – 12

Proper use .................................................................. 4

Protection .......................................................... 10, 11

Purpose ...................................................................... 4

R

Rated voltage .................................................... 12, 13

Regulation ............................................................. 5, 6

S

Safety checks .......................................................... 25

Safety instructions ................................................ 6, 7

Scope of supply ..................................................... 8, 9

Service ..................................................................... 29

Special text structure ................................................. 4

Statutory regulations ............................................. 5, 6

Storage temperature .......................................... 10, 11

Switching on ............................................................. 25

32

Lists

8

List of key words A – Z

Keyword Page

T

Technical data ................................................... 10, 11

Text structure ............................................................. 4

T-piece ...................................................................... 21

Troubleshooting ........................................................ 29

V

Voltage .............................................................. 10, 11

Voltage limit ....................................................... 10, 11

W

When faults occur .................................................... 29

List of abbreviations

EC type approval

Permit awarded by the Federal Vehicle Office for the
production of a heater for installation in motorised
vehicles.

EMC directive

Electromagnetic compatibility.

JE partner

J. Eberspächer partner.

PME

Biodiesel as per DIN V 51606.