/ M Technical description Installation instructions Operating instructions Maintenance instructions Eberspächer J. Eberspächer GmbH & Co. KG Eberspächerstr. 24 D - 73730 Esslingen Telefon (zentral) (0711) 939 - 00 Telefax (0711) 939 - 0500 www.eberspaecher.com Air heaters for diesel fuel AIRTRONIC / AIRTRONIC M, operating independently of the engine Air heaters for petrol fuel AIRTRONIC M, operating independently of the engine Heater Order no. Heater Order no.
1 Introduction Contents Chapter Title Contents Page 1 Introduction • • • • • • • Contents ................................................................................................ 2 Concept of this manual .......................................................................... 3 Special text structure, presentation and picture symbols ....................... 4 Important information before starting work ............................................. 4 Statutory regulations .....................
1 Introduction Concept of this manual This manual aims to support the service company installing the heater and to provide the user with all important information about the heater. The manual has been divided into 8 chapters to make it easier to find the corresponding information quickly. 1 Introduction Here you will find important introductory information about installation of the heater and about the structure of the manual.
1 Introduction Special text structure, presentation and picture symbols Important information before starting work 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.
1 Introduction Statutory regulations The Federal Road Transport Directorate has issued an "EC type approval" and an "EMC type approval" for the heater for installation in motor vehicles and with the following official type approval marks, noted on the heater name plate. AIRTRONIC EC- e1 00 0025 • 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.
1 Introduction Statutory regulations Regulation! Mounting the heater in a vehicle for the transport of dangerous goods as per ADR / ADR99 • When the heater is to be installed in vehicles for the transport of dangerous goods, the regulations of ADR / ADR99 must also be observed. Please note! • Compliance with the statutory regulations and safety instructions is prerequisite for guarantee and liability claims.
1 Introduction Safety instructions for installation and operation Caution! Safety instructions for installation and operation! • Repairs by unauthorised 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.
2 Product information Scope of supply for AIRTRONIC Quantity / Designation Order number Parts list for the picture “Scope of supply” on page 9 1 1 25 2069 05 00 00 25 2070 05 00 00 Scope of supply for heater D 2 – 12 V D 2 – 24 V To be ordered separately: 1 Universal installation kit 1 Control unit* Pict.-No.
2 Product information Scope of supply for AIRTRONIC and AIRTRONIC M a) b) a) Only for AIRTRONIC M b) Only for AIRTRONIC 9
2 Product information Scope of supply for AIRTRONIC (Camper-heater) Quantity / Designation Order number 1 25 2326 05 00 00 Parts list for the picture “Scope of supply” on page 11 Scope of supply for heater Pict.-No.
2 Product information Scope of supply for AIRTRONIC and AIRTRONIC M (Camper-heater) 11
2 Product information Technichal data / Heater AIRTRONIC for diesel Version D2 / D2 Camper Heating medium Air Control of the heat flow Stage Power Large Medium Small Heat flow (watt) 2200 1800 1200 850 Heater air flow rate without counterpressure (kg/h) 105 90 60 40 Heater code 6 for outlet hood Ø 60 mm 12 for outlet hood Ø 75 mm Fuel consumption (l/h) 0.28 0.23 34 22 0.15 0.10 12 8 Elektr.
2 Product information Technichal data / Heater AIRTRONIC M for diesel Version D3 Camper / D4 / D4S / D4 Camper / D4 Camper plus Heating medium Air Control of the heat flow Stage Power Large Medium 3000 2200 1600 900 D4 / D4S 4000 / 3500 3000 2000 1000 D4 Camper / D4 Camper plus 4000 / 3500 3000 2000 900 150 120 90 60 D4 / D4S 185 / 160 150 / 140 110 / 100 65 / 60 (kg/h) D4 Camper / D4 Camper plus 185 / 160 150 / 140 110 / 100 60 / 55 Heater code D3 Camper / D4 / D4 Ca
2 Product information AIRTRONIC M für Benzinkraftstoff Technichal data / Heater B4 Version Air Heating medium Stage Control of the heat flow Power Large Medium Small Heat flow (watt) 3800 3200 2100 1300 Heater air flow rate without counterpressure (kg/h) 185 160 120 85 3 for outlet hood Ø 75 mm Heater code Fuel consumption (l/h) 0,54 0,46 0,29 0,18 40 29 15 9 Elektr.
2 Product information Main dimensions AIRTRONIC * Main dimensions AIRTRONIC M * Minimum installation clearance (space) for opening the lid and for dismantling the glow plug and the controller. Minimum installation clearance (space) for intake of heater air.
3 Installation Installation and location The heater is suitable and certified for installation in parts of vehicles used by persons. Installation in the cab or passenger compartments of coaches or buses with more than 9 seats is not allowed. When installing in compartments used by persons, the exhaust, combustion air and fuel pipes in these areas must not have any detachable connections and must be routed splash-waterproof in the breakthroughs.
3 Installation Installation Installation in a car or people carrier Installation in a truck (only diesel heaters) In a car or people carrier, the heater is preferably installed in the passenger compartment or boot. If it is not possible to install the heater in the passenger compartment or boot, the heater can also be mounted under the vehicle floor. In a truck, the heater is preferably installed inside the driver’s cab.
3 Installation Possible installation positions The heater is preferably installed in the normal position as shown in the drawing. Depending on the installation conditions, the heater can be tilted by max. 30° (flow direction to the bottom) or turned by max. 90° around its own longitudinal axis (exhaust connection horizontal, glow plug points upwards!).
3 Installation Mounting and fastening Make the necessary breakthroughs for exhaust, combustion air and fuel as shown in the hole diagram. The support surface for the heater foot must be flat. An appropriate tool can be purchased from the manufacturer for drilling the breakthroughs and also smoothing the support surface. The hole Ø 10.5 mm for the cable harness “dosing pump” is not included in the picture drawing and must be drilled after installation.
3 Installation 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. Please note! The regulations and safety instructions to be observed for this chapter are stated on page 5.
3 Installation Heater air system The universal installation kit includes a flexible pipe, an outflow and a safety grid for the heater air system. The flexible pipe is not included in the installation kits for the camper heaters. It has to be ordered separately. The order number is stated in the Accessories Catalogue.
3 Installation Exhaust system Mounting the exhaust system 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.
3 Installation Combustion air system Mounting the combustion air system The universal installation kit includes a flexible combustion air hose, inner Ø 25 mm , 100 mm long. If necessary the flexible combustion air hose can be shortened by 20 cm or lengthened by max. 2 m depending on the installation conditions. Fasten the combustion air hose to the heater with a pipe clip and at suitable points with hose clips or cable ties.
3 Installation 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! • Route the fuel pipes so that any distortion of the vehicle, engine movements etc.
3 Installation Fuel supply 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 Fuel return pipe to the tank connection Dosing pump T-piece, 8 - 6 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.
3 Installation Fuel supply Fuel feed point with tank connection – ascending pipe, integrated in the vehicle tank or in the tank fitting Tank connection for metal tank – di = Ø 2 mm, da = Ø 6 mm Tank connection for tank fitting – di = Ø 2 mm, da = Ø4 mm dosing pump Fuel filter – only required for contaminated fuel. Fuel hose, 5 x 3 (di = Ø5 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.
3 Installation 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.
3 Installation Fuel supply Fuel quality for petrol heaters Operation with biodiesel (PME) The heater runs smoothly on standard commercial quality petrol in accordance with DIN EN 228, which you use to run your vehicle engine. AIRTRONIC The heater is not certified for operation with biodiesel. Biodiesel can be added to the fuel to up to 10%.
4 Operation and function Operating instructions Initial commissioning The heater is operated by a control unit. The control unit is accompanied by detailed operating instructions which you will receive from the company installing the heater. The following points are to be checked by the company installing the heater during initial commissioning. Please note! The control elements (e.g.
4 Operation and function Description of functions Switching on Control in the heating mode When the heater is switched on, the control lamp in the control element lights up. The glow plug is switched on and the fan starts at low speed. During the heating mode, the room temperature or the temperature of the sucked in heating air is constantly measured. If the temperature is higher than the temperature selected on the control element, the heater starts to regulate its output.
4 Operation and function 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 of pumping fuel, the heater is switched off, i.e. the fuel supply is off and the fan runs on for approx. 4 minutes. 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.
5 Electrical system Heater wiring Parts list for the circuit diagrams AIRTRONIC and AIRTRONIC M 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: 1.1 1.2 1.5 2.1 2.2 2.7 • Ensure that the insulation of electrical cables is not damaged. Avoid: chafing, kinking, jamming or exposure to heat. 2.7.1 5.1 5.2.
5 Electrical system Parts list circuit diagrams control elements 2.15.1 2.15.9 Temperature sensor (room temperature) Temperature sensor (outside temperature) 3.1.9 3.1.16 3.1.17 3.1.18 3.2.8 3.2.12 3.2.14 3.3.6 3.3.7 3.3.8 3.8.3 3.9.
6 Troubleshooting / Maintenance / Service 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.
7 Environment Certification EU Declaration of Conformity 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.
8 Lists List of key words A – Z Keyword Page A Accident prevention ................................................... 7 ADR / ADR99 ..................................................... 16, 31 Altitude ..................................................................... 29 Ambient temperature ........................................ 12 – 14 C Cable harness connection ........................................ 18 Certificates ...............................................................
8 Lists List of key words A – Z Keyword List of abbreviations Page T Technical data .................................................. 12 – 14 Temperature selection .............................................. 30 Test symbol ................................................................ 5 Text structure ............................................................. 4 T-piece ...................................................................... 25 Transport .............................................
AIRTRONIC / AIRTRONIC M EN Parts list page 31, 32 Liste des pièces, pages 31, 32 25 2069 00 98 01 B 1 FR
Control elements Eléments de commande EN FR Parts list page 31, 32 Liste des pièces, pages 31, 32 2 25 2069 00 97 02 A
Control elements Eléments de commande EN Parts list page 31, 32 Liste des pièces, pages 31, 32 25 2069 00 97 02 A 3 FR
Control elements Eléments de commande EN FR Parts list page 31, 32 Liste des pièces, pages 31, 32 4 25 2069 00 97 04 A
Control elements Eléments de commande EN Parts list page 31, 32 Liste des pièces, pages 31, 32 25 2069 00 97 04 A 5 FR
Control elements Eléments de commande 25 2069 00 97 01 C EN FR Parts list page 31, 32 Liste des pièces, pages 31, 32 6 25 2069 00 97 03 B
AIRTRONIC / AIRTRONIC M – ADR / ADR 99 EN Parts list page 31, 32 Liste des pièces, pages 31, 32 25 2069 00 96 01 C 7 FR
Control elements – ADR / ADR 99 Eléments de commande – ADR / ADR 99 EN FR Parts list page 31, 32 Liste des pièces, pages 31, 32 8 25 2069 00 99 01 B
