Hydronic D 4 W SC – 12 V, D 5 W SC – 12 V Technical Description, Installation, Operating And Maintenance Instructions
HYDRONIC
Technical Description, Installation,
Operating and Maintenance Instructions.
Heater Order No.
Hydronic D 4 W SC – 12 V 25 2096 05 00 00
Hydronic D 4 W SC – 12 V 25 2097 05 00 00
as a complete package
Heater Order No.
Hydronic D 5 W SC – 12 V 25 2098 05 00 00
Hydronic D 5 W SC – 12 V 25 2099 05 00 00
as a complete package
Hydronic D 5 W SC – 24 V 25 2147 05 00 00
Engine-independent water heater
for diesel and petrol.
25 2096 90 95 33
11.2014
Introduction1
Contents
Chapter Title Content Page
1
2
3
4
5
6
7
8
Introduction
Product information
Installation
Operation and function
Electrics
Troubleshooting
Maintenance
Service
Environment
Lists
• Contents .................................................................................................... 2
• Concept of this manual .............................................................................. 3
• Special text structure, presentation and picture symbols ......................... 4
• Important information before starting work ............................................... 4
• Statutory regulations ............................................................................. 5, 6
• Safety instructions for installation and operation ...................................... 7
• Accident prevention .................................................................................. 7
• Scope of supply ..................................................................................... 8, 9
• Technical data ..........................................................................................10
• Main dimensions .......................................................................................11
• Installation and mounting position ............................................................ 12
• Permissible installation positions ..............................................................13
• Installation and fixing................................................................................ 13
• Nameplate ................................................................................................ 14
• Connection to the cooling water circuit ......................................... 15 – 18
• Exhaust system .........................................................................................19
• Combustion air system .............................................................................. 20
• Fuel supply ...................................................................................... 21 – 27
• 12 volt heater fuel supply .................................................................. 22, 23
• 24 volt heater fuel supply ................................................................ 24 – 26
• Operating instructions / important instructions for operation .................. 28
• Initial commissioning ................................................................................. 28
• Functional description .............................................................................. 28
• Control and safety devices ....................................................................... 29
• Wiring of the heater.................................................................................. 30
• Parts list for circuit diagram, 12 volt heater ............................................. 31
• Circuit diagram for 12 volt heater ............................................................ 32
• Parts list for circuit diagram, 24 volt / 24 volt ADR heater ...................... 33
• Circuit diagrams for 24 volt / 24 volt ADR heater ............................. 24, 35
• Parts list for circuit diagrams, EasyStart R+ / R / T and
EasyStart T – ADR control units .............................................................. 36
• Circuit diagrams for EasyStart R+ / R / T and EasyStart T –
ADR control units ............................................................................ 37 – 40
• If any faults occur, please check the following items ...............................41
• Troubleshooting ........................................................................................ 41
• Maintenance instructions ......................................................................... 41
• Service ..................................................................................................... 41
• Certifications ............................................................................................ 42
• Disposal .................................................................................................... 42
• EC Declaration of Conformity .................................................................... 42
• List of abbreviations ..................................................................................43
2
Introduction1
Concept of this manual
This manual aims to support the service company
installing the heater and to provide the user with all
important information about the heater.
The manual has been divided into 8 chapters to make
it easier to find the corresponding information quickly.
Introduction
1
This section contains important introductory
information about installing the heater and
about the structure of the manual.
Product information
2
Here you will find information about the scope of
supply, the technical data and the dimensions of
the heater.
Installation
3
Here you will find important information and
instructions referring to installation of the
heater.
Operation and function
4
Here you will find information about the operation and function of the heater.
Electrics
5
Here you will find information about the electronic system and electronic components of the
heater.
Troubleshooting / maintenance / service
6
Here you will find information about possible
faults, troubleshooting, servicing / maintenance
and the service hotline.
Environment
7
Here you will find information about certification
and disposal of the heater together with the EC
Declaration of Conformity.
Lists
8
Here you will find the list of abbreviations.
3
Introduction
1
Special text structure, presentation and
picture symbols
This manual uses special text structures and picture
symbols to emphasize different contents.
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 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-approval for the heater and preclusion of
any guarantee and liability claims on J. Eberspächer
GmbH & Co. KG.
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.
Please note!
These remarks contain recommendations for use and
useful tips for installation of the heater.
Important information before starting
work
Range of application of the heater
The water heater operating independently of an engine
is intended for installation in the following vehicles:
• All kinds of vehicles
• Construction machinery
• Agricultural machinery
• Boats, ships and yachts
Please note!
Only the Hydronic D5 W SC – 24 volt heater is approved for installation in vehicles used for the transport
of dangerous goods according to ADR.
For installation of the heater in vehicles used for
the transport of dangerous goods, the ADR regulations
must also be observed.
Detailed information on the ADR regulations is given in
the information sheet, Print No. 25 2161 95 15 80.
Intended purpose of the heater
(via the vehicle’s own heat exchanger)
• Pre-heating, de-misting windows
• Heating and keeping the following warm:
– Driver and working cabs
– Freight compartments
– Ships cabins
– Passenger and crew compartments
– Vehicle engines and units
On account of its functional purpose, the heater is not
approved for the following applications:
• Long-term continuous operation, e.g. for heating of:
– Residential rooms
– Garages
– Work huts, weekend homes and hunting huts
– Houseboats, etc.
Caution!
Safety instructions for the range of application and
proper, intended use!
• The heater may only be used and operated for the
range of applications stated by the manufacturer in
compliance with the “Operation instructions” included
with every heater.
4
Introduction
1
Statutory regulations
The Federal Motor Transport Authority has issued an
"EC type approval", "EMC type-approval" and the approval for a component according to ECE R122 and
ECE-R10 for the heater for installation in motor vehicles
with the following official type-approval marks, noted on
the heater name plate.
Heater type: Hydronic
Test mark:
EC 00 0023
EMC 031075
122 R - 000023
ECE
Regulations
Extract from Directive 2001 / 56 / EC Annex VII and
ECE Regulation No. 122 of the European Parliament
and of the Council
General regulations
• Operating state display
– A clearly visible operating display in the user's
field of vision must indicate when the heater is
switched on and off.
Regulations concerning installation in the vehicle
• Scope
– Subject to differing stipulations in the following
section, combustion heaters must be installed
according to the provisions of Directive 2001 / 56
/ EC Annex VII.
– It is assumed that Class O vehicles with heaters
for liquid fuel conform to the provisions of Directive
2001 / 56 / EC.
• Arrangement of the heater
– Parts of the structure and other components near
the heater must be protected from excessive heat
exposure and possible fuel or oil contamination.
– The heater must not pose a fire hazard even when
it overheats. This requirement is deemed to be
fulfilled if adequate clearance is ensured for all
parts during installation, sufficient ventilation is
provided and fireproof materials or heat shields are
used.
– The heater must not be mounted in the passenger
compartment of vehicles in class M2 and M3.
However, a heater in a hermetically sealed
enclosure which also complies with the aforementioned conditions may be used.
10 R - 041075
– 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's combustion chamber must
not be sucked in from the vehicle's passenger
compartment.
– The air intake must be arranged or protected in
such a way that it cannot be blocked by other
objects.
• Automatic control of the heating system
– If the engine fails, the heating system must be
automatically switched off and the fuel supply
stopped within 5 seconds. The heater may remain
in operation if a manual device has already been
activated.
Please note!
The heater is not approved for installation in the interior of Class M1 vehicles (vehicles for passenger transport
/ cars) and N vehicles (vehicles for the transport of
goods).
5
Introduction
1
Statutory regulations
Please note!
• Compliance with the statutory regulations, the
additional regulations and the safety instructions is
prerequisite for guarantee and liability claims.
Failure to comply with the statutory regulations and
safety instructions and incorrect repairs, even if
original spare parts are used, make the guarantee
null and void and preclude any liability for J.
Eberspächer GmbH & Co. KG.
• Subsequent installation of this heater must comply
with these installation instructions.
• The statutory regulations are binding and must also
be observed in countries which do not have any
special regulations.
• When installing the heater in vehicles not subject to
the German Road Traffic Licensing Regulations
(StVZO), for example ships, the respective specially
valid regulations and installation instructions must be
observed.
• Installation of the heater in special vehicles must
comply with the regulations applying to such vehicles.
• Other installation requirements are given in the
relevant sections of these installation instructions.
6
Introduction
1
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 parts cool down.
• The heater may not be operated in enclosed spaces,
e.g. in the garage or in a multi-storey car park.
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 of
repairs or guarantee claims.
• Repairs by non-authorised third-parties and / or with
non-original spare parts are dangerous and are
therefore not allowed. They result in expiry of the
type-approval of the heater; consequently, when
installed in motor vehicles they can cause expiry of
the vehicle’s 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.
– Installation or operation not conforming to the
statutory regulations, safety instructions or
specifications relevant for 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.
• Original accessories and original spare parts only may
be used for installation or repairs.
• Only the control units approved by Eberspächer may
be used to operate the heater. Use of other control
units can cause malfunctions.
• 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 positive cable at the battery should be disconnected and placed at ground to protect the control
box.
• The heater must not be operated where there is a
risk of an accumulation of flammable vapours or dust,
e.g. close to
– Fuel depot
– Coal depot
– Wood depot
– Grain depot, etc.
• The heater must be switched off when refuelling.
• If the heater is installed in a safety casing or similar,
its installation box must not be used as storage space
and must be kept clear. In particular fuel canisters, oil
cans, spray cans, gas cartridges, fire extinguishers,
cleaning rags, items of clothing, paper etc. must not
be stored or transported on or next to the heater.
• Defective fuses may be replaced by fuses with the
prescribed rating only.
• 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
unapproved coolant can cause damage to the engine
and heater.
• The after-running of the heater must not be
prematurely interrupted e.g. by pressing the battery
isolating switch, except for an emergency stop.
Accident prevention
General accident prevention regulations and the corresponding workshop and operating safety instructions
are to be observed.
7
Product information
2
Scope of supply
Quantity / Designation Order No.
1 Hydronic D 4 W SC – 12 V
To be ordered separately:
1 Universal installation kit 25 1917 80 00 00
1 Control unit** –
or
1 Hydronic D 4 W SC – 12 V
as a complete package*
To be ordered separately:
1 Control unit** –
or
1 Hydronic D 5 W SC – 12 V
To be ordered separately:
1 Universal installation kit 25 1917 80 00 00
1 Control unit** –
or
1 Hydronic D 5 W SC – 12 V
as a complete package*
To be ordered separately:
1 Control unit** –
25 2096 05 00 00
25 2097 05 00 00
25 2098 05 00 00
25 2099 05 00 00
Parts list for the picture “Scope of supply” on page 9
Scope of supply for petrol heater
Figure No. Designation
1 Heater
2* Metering pump
* with Hydronic D 5 W SC-24 V only
Scope of supply for universal installation kit
Figure No. Designation
3 Exhaust silencer
4 Cable harness, heater
5 Lead harness, positive
6 Bracket, heater
7 Water hose
8 Flexible exhaust pipe
9 Cable tie
10* Bracket, metering pump
11* Pipe, 6 x 2
12 Combustion air hose
13* Hose, 5 x 3
14* Pipe, 4 x 1
15* Tank connection
16* Fuel filter
17 Hose, 3.5 x 3
* Included in installation kit 25 2009 80 00 00 only.
1 Hydronic D 5 W SC – 24 V
25 2147 05 00 00
To be ordered separately:
1 Universal installation kit 25 2009 80 00 00
1 Control unit** –
* The complete package contains:
1 Heater
1 Universal installation kit
**Control units, see price list / accessories catalogue.
8
Cable harnesses
(A) Lead harness, “control units”
(B) Lead harness, “fan activation”
Please note!
• Parts without a figure No. are small parts and are
packed in a bag.
• Please consult the additional parts catalogue if any
other parts are required for the installation.
Product information
2
Scope of supply
7
1
6
12
17
13*
11*
16*
2*
14*
15*
10*
8
3
4
9
5
9
Product information
2
Technical data / diesel heaters
Heating medium
Control of the heat flow
Heat flow (watt)
Fuel consumption (l/h)
Average elec. power consumption (watt)
during operation
while starting
Rated voltage
Operating range
• Lower voltage limit:
An undervoltage protection installed in the
control box switches off the heater if the
voltage limit is reached.
• Upper voltage limit:
An overvoltage protection installed in the
control box switches off the heater if the
voltage limit is reached.
Allowable operating pressure
Water volume in the heater
Water flow rate of the water pump against
0.1 bar
Minimum water flow rate of the heater
Fuel – see also “Diesel Heater Fuel Quality”
page 30
Allowable ambient temperature
Heater
Control box
Metering pump
Interference suppression class
Weight – without coolant and attachments
Hydronic D 4 W SC Hydronic D 5 W SC
Water, coolant
High Low High Low
4300 2400 5000 2400
0.53 0.27 0.62 0.27
48 23 50 23
120
12 volt 12 volt 24 volt
10.2 volt 10.2 volt 20.4 volt
16 volt 16 volt 32 volt
up to 2.5 bar overpressure
0.18 l
500 l/h ±70 l/h 900 l/h ±100 l/h
250 l/h 300 l/h
Diesel – commercially available (EN 590)
FAME for diesel engines according to EN 14 214
– for Hydronic D 5 W SC – 24 volt only
in operation without operation
–40 °C to +80 °C –40 °C to +105 °C
–40 °C to +80 °C –40 °C to +105 °C
–40 °C to +20 °C –40 °C to +105 °C
5
to DIN 57879 / Part 1 VDE 0879
approx. 2.7 kg approx. 2.9 kg
with metering pump
approx. 2.7 kg
without metering pump
Caution!
Safety instructions for technical data!
Failure to comply with the technical data can result in
malfunctions.
10
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.
Product information
2
Main dimensions D 4 W SC
Main dimensions D 5 W SC
WE Water inlet
WA Water outlet
A Exhaust
BFuel
V Combustion air
WE Water inlet
WA Water outlet
A Exhaust
BFuel
V Combustion air
11
Installation
3
Installation and mounting position
The heater is installed in the engine compartment. The
heater must be installed below the min. cooling water
level (header tank, radiator, vehicle’s heat exchanger)
so that the heat exchanger of the heater and water
pump can vent independently.
Installation example
10
Please note!
• Observe the regulations and safety instructions for
this chapter, given on page 4 – 7.
• The positions suggested in the installation instructions
are examples. Other installation locations are possible
if they comply with the installation requirements
stated in these installation instructions.
• Further installation information (e.g. for boats and
ships) is available from the manufacturer on request.
• Note and observe the permissible installation positions
as well as the operating and storage temperatures.
7
8
9
2
4
5
6
1
3
1 Heater
2 Exhaust pipe with exhaust silencer
3 Combustion air hose
4 Non-return valve
5 T-piece (water circuit)
12
7
4
10
8
1
3
2
6 Thermostat
7 Vehicle heat exchanger with blower
8 Tank connection / T-piece (fuel)
9 Metering pump (24 volt version only)
10 Module timer
Installation3
Permissible installation positions
The heater should preferably be installed in the normal
position, horizontally with the exhaust connection
facing downwards.
Depending on the installation conditions, the heater
can be installed within the permissible swivel ranges,
see sketch.
Normal position with permissible swivel ranges
• Swivel range swung by up to max. 90° downwards
from the normal position – the water pipe sockets are
pointing downwards.
1 Vent screw – must always be at the top
2 Fuel connection
In heating mode, the normal and maximum installation
positions shown can differ by up to +15° in all directions for a short time. These differences, caused by
tilted positions of the vehicle, do not have any negative
effects on the heater’s function.
• Swivel range swung from the normal position by up to
max. 90° about the longitudinal axis – the water pipe
sockets are horizontal.
Installation and fixing
Insert the heater in the heater bracket and fasten with
fixing screws (tightening torque 6
bracket with the installed heater in a suitable position
in the engine compartment, if possible with rubber
buffer.
+0.5
Nm). Fix the heater
13
Installation
3
Nameplate
The nameplate and the 2nd nameplate (duplicate) is
fixed to the side, on the lower jacket shell. The 2nd
nameplate (duplicate) is attached to the lower jacket
shell; it is removable and, if necessary, can be stuck
onto a clearly visible place on the heater or in the area
of the heater.
Please note!
The regulations and safety instructions to be observed
for this chapter are stated on page 5.
1 Original nameplate
2 2nd nameplate (duplicate)
14
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