AIRTRONIC / AIRTRONIC M Troubleshooting and Repair Instructions Airtronic Order no. Airtronic M Order no.
1 Introduction Contents This list of contents gives you precise information about the contents of the Troubleshooting and Repair Instructions. Use the index, list of abbreviations, etc, to look for a term, technical word or an explanation for an abbreviation. Chapter Title Contents 1 Introduction • • • • 2 Function and use Cutaway view............................................................................................................. 5 • Description of functions – Switching on............
1 Introduction Chapter Title Contents Page 5 Repair instructions • • • • • • • • • • • 6 Circuit diagrams Overview of the parts lists and circuit diagrams........................................................... 37 • Parts list circuit diagrams Airtronic / Airtronic M........................................................ 38 • Circuit diagram Airtronic / Airtronic M......................................................................
1 Introduction Foreword These Troubleshooting and Repair Instructions are applicable to the heaters listed on the title Page, to the exclusion of all liability claims. Depending on the version or revised status of the heater, there may be differences between it and these troubleshooting and repair instructions. The user must check this before carrying out the repair work and, if necessary, take the differences into account.
2 Function and use Cutaway view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Heater impeller Control box Combustion air fan impeller Glow plug Cover Heat exchanger Combination sensor (overheating / flame sensor) Radio remote control (mobile unit) Radio remote control (stationary unit) Button Temperature sensor (room temperature) Fuse bracket with main fuse and “actuation” fuse Electrical motor Fuel connection Flange seal 16 17 18 19 20 21 22 Combustion chamber Outlet hood Combustion air hose Metering pump Pot-ty
2 Function and use Description of functions Switching on Control in the heating mode When the heater is switched on, the control lamp in the control unit 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.
2 Function and use 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. • If the flame goes off by itself during operation, the heater is restarted.
3 Technichal data Technichal data Airtronic Heater type Heater Airtronic D2 / Airtronic D2 Camper Version D2 / D2 Camper Air Heating medium Stage Control of the heat flow Power Large Medium Small Off Heat flow (watt) 2200 1800 1200 850 – Heater air flow rate without counterpressure (kg/h) with hood Ø 60 mm 105 90 60 40 13 Fuel consumption (l/h) 0.28 0.23 0.15 0.10 – 34 22 12 8 5 Elektr.
3 Technichal data Technichal data Heater type Airtronic M Heater Airtronic B4 Version B4 Heating medium Air Stage Control of the heat flow Power Large Medium Small Off Heat flow (watt) 3800 3200 2100 1300 – Heater air flow rate without counterpressure (kg/h) with hood Ø 90 mm 185 160 120 85 24 Fuel consumption (l/h) 0.54 0.46 0.29 0.18 – 40 29 15 9 5 Elektr.
3 Technichal data Technichal data Airtronic M Heater type Heater Airtronic D3 / Airtronic D4 / Airtronic D4 Plus Version D3 / D4 / D4 Plus Air Heating medium Stage Control of the heat flow Power Large Medium Small Off D3 3000 2200 1600 900 – D4 4000 3000 2000 900 – D4 Plus 4000 3000 2000 900 – Heater air flow rate without counterpressure (kg/h) D3 with hood Ø 90 mm 150 120 90 60 24 D4 with hood Ø 90 mm 185 150 110 60 24 D4 Plus with hood Ø 75 mm 175 140 100 55
3 Technichal data Technichal data Airtronic M Heater type Heater Airtronic D4S / Airtronic D4 Camper / Airtronic D4 Camper Plus Version D4S / D4 Camper / D4 Camper Plus Air Heating medium Control of the heat flow Stage Power Large Medium Small Off 3500 3000 2000 1000 – 4000 / 3500 3000 2000 900 – 160 140 100 60 22 185 / 160 150 / 140 110 / 100 60 / 55 24 / 22 0.44 0.38 0.25 0.13 – 0.51 / 0.44 0.38 0.25 0.
3 Technical data Check values Test speed for the blower Airtronic D2 / D2 Camper (12 volt / 24 volt) • 12 volt 5000 rpm ±25 % at U = 10,0 volt • 24 volt 5000 rpm ±25 % at U = 18,0 volt Airtronic B4 (12 volt) Airtronic D3 / D3 Camper (12 volt) Airtronic D4 (12 volt / 24 volt) Airtronic D4 Camper (12 volt) • 12 volt 4400 rpm ±25 % • 24 volt 4400 rpm ±25 % at U = 10,0 volt at U = 18,5 volt Airtronic D4S / Airtronic D4 Plus (12 volt / 24 volt) Airtronic D4 Camper Plus (12 volt) • 12 volt 4400 rpm ±25 % at U =
4 Troubleshooting What to check first in case of faults • Check – Fuel in the tank? – Fuel pipes leaking? (visual check) – Summer diesel in the fuel pipe? – Combustion air system or exhaust system damaged or blocked? – Hot air system blocked? – Air pressure sensor installed? If yes, refer to „What to do if…?“ chapter of the „Altitude Kit“ installation instructions.
4 Troubleshooting Overview of the test equipment and control units suitable for diagnosis Important notes on diagnosis of heaters with mini-controller control unit The electronic control box can store up to 5 faults, which can be read out and displayed.
4 Troubleshooting Testing device for the control device (Order No.: 22 1509 89 00 00) Prepare for test Connect the correct operating voltage (12 or 24 volt) to the testing device, with plus at the red connector socket and minus at the blue connector socket. • Disconnect socket from the control unit. • Connect cable loom from testing device with the control unit. • Set the rotary knob of the control unit to “Heat”, the corresponding red LED in the testing device must light up.
4 Troubleshooting Connect diagnostic unit • Disconnect the 8-pin connector of the heater’s cable harness and connect the adapter cable. • Connect the diagnostic unit to the adapter cable. Display is as follows: Display of the fault memory F1 – F5 or F5 – F1 • Press the e or f button, or press several times, to display the fault memory. Display is as follows: e.g. fault memory 2 / fault code 10 Please note! Query fault memory • Use the D key to switch on the heater.
4 Troubleshooting EDiTH diagnostic tool with ISO adapter (Order No.: 22 1541 89 00 00) An additional adapter cable is required to connect the ISO adapter (Order No.: 22 1000 31 86 00). Please note! • It is very important to always install in the given order. • Not only the defective component, but also a defective current circuit results in a fault being displayed. • Fault code, fault description, cause / remedial action are described on Pages 23 – 27.
4 Troubleshooting Air pressure sensor diagnosis using EDiTH diagnostics tool and ISO adapter (Order No. 22 1524 89 00 00) An additional adapter cable is required to connect the ISO adapter (Order No.: 22 1000 33 31 00). The air pressure sensor connected to the heater can be diagnosed. If faults occur during the altitude adjustment they are stored in the air pressure sensor.
4 Troubleshooting EDiTH diagnostic tool with basic adapter EDiTH basic adapter (Order No.: 22 1542 89 00 00) An additional extension is required to check the control box (Order No.: 22 1537 89 00 00). Please note! • It is important to always follow the precise connection order as given below! • The Hall sensor integrated in the control box can only be properly tested in the control box is correctly placed on the extension.
4 Troubleshooting Module timer (Order No.: 22 1000 30 34 00) The current fault is displayed as “AF” and is always written in memory position F1. Preceding faults are moved to the memory locations F2 – F5, if necessary the contents of memory position F5 is overwritten. Please note! • Not only the defective component, but also a defective current circuit results in a fault being displayed. • In heaters with connected air pressure sensor the modular timer cannot be used to perform diagnoses.
4 Troubleshooting TP5 radio remote control (Order No: 22 1000 32 01 00) If faults occur while the heater is running, they are displayed with “Err” after the mobile unit is activated. After the diagnostics cable (bl/ws) has been connected and the first logs have arrived at the stationary unit, the diagnose can be carried out using the mobile unit of the TP5 radio remote control. The current fault “F0” is displayed. The stored faults “F1” to “F5” can be queried.
4 Troubleshooting EasyStart R+ radio remote control (Order-No.: 22 1000 32 80 00) EasyStart T timer (Order-No.: 22 1000 32 88 00) If faults occur while the heater is running, they are displayed with “Err” after the mobile unit or timer is activated. The current fault is displayed. The stored faults “F1” to “F5” can be queried.
4 Troubleshooting Fault code Fault description Display Comments • Remedial action 000 No faults —— 004 Warning: Short circuit in control box, fresh air output • Disconnect connector S1 / B1 at the heater and at the connector B1, PIN 16 check the cable up to the fresh air fan relay for short circuit to negative, if ok —> replace control box.
4 Troubleshooting Fault code Fault description Display Comments • Remedial action 015 Operating lock-out The fault code 015 is displayed, if the heater was switched back on after the fault code display 017. The hardware threshold value for the overheating sensor has been exceeded —> the control box is locked. • Replace control box.
4 Troubleshooting Fault code Fault description Display Comments • Remedial action 034 * Blower motor, outlet (+) short circuit after UB (battery voltage) • Check that the lead harness of the blower motor has been correctly laid and check for damage, if ok —> remove lead harness at control box and check for continuity, if ok —> replace control box.
4 Troubleshooting Fault code Fault description Display Comments • Remedial action 061 External temperature sensor – short circuit • Disconnect connector S4 / B4 of the external temperature sensor, if fault code 060 is displayed —> check external temperature sensor, diagram and table of values, see Page 32. If temperature sensor ok —> check connection cables 0.5 gr and 0.5 br/ws for short circuit, if ok, reassemble the connector S2 / B2.
4 Troubleshooting Fault code Fault description Display Comments • Remedial action 094 Control box defective (EEPROM-Fehler) • Replace control box. 095 * Control box defective • Replace control box. 096 Internal temperature sensor defective • Replace control box or use an external room temperature sensor.. 097 Control box defective • SReplace control box. 098 * Control box defective • Replace control box.
5 Repair instructions Repair instructions Special tool The permitted repair work to the heater is described in the “Repair Instructions” chapter. If extensive repairs are necessary, it makes sense to dismantle the heater. AMP release tool The heater is assembled in the reverse order, if applicable not additional instructions. This release tool can be ordered directly from AMP. Please note! The AMP release tool is used to release plug-in contacts in a connector housing.
5 Repair instructions Assembly drawing Airtronic / Airtronic M Parts list 1 2 3 4 5 6 7 Combustion air fan Seal – combustion air fan / heat exchanger Combustion chamber Seal – combustion chamber / heat exchanger Heat exchanger Control box Combination sensor (overheating / flame sensor) with assembly tool 8 9 10 11 12 13 14 Bracket Glow plug, with special tool (SW 12) Lining – glow plug socket, with assembly tool Cover Outer shell (bottom section) Flange seal Sleeve (for petrol only) 29
5 Repair instructions Repair step 1 Remove the heater’s cover (see Figure 1) 1. Unlock both fastening clips, lift the cover and remove from the front. 2. Please note! The heater’s cover must be removed for all repair steps. If necessary, wait until the unit has cooled down. Cable harness outlet from the housing optionally on left or right-hand side. Figure 1 Cover Fastening clips Repair step 2 Dismantle control box (see Figure 2) • • • • • Repair step 1.
5 Repair instructions Repair step 3 Dismantle glow plug (see Figure 3) • Repair step 2. • Disconnect connector from “glow plug” cable loom on control box. • Remove rubber grommet and unscrew the glow plug using the special tool (SW 12). (The special tool is included with the glow plug). Tightening torque for glow plug: 6 +0.5 Nm Special glow plug tool Please note! With the glow plug dismantled, visually check the socket lining of the installed glow plug for dirt.
5 Repair instructions Repair step 5 Dismantle combination sensor (overheating / flame sensor) (see Figure 5) • Repair step 2. • Remove both connectors from the “combination sensor” cable loom at the control box. • Unlock bracket from combination sensor. • Remove the combination sensor. Figure 5 a “Combination sensor” cable loom b Bracket, unlocked Check combination sensor The external temperature sensor must be checked with a digital multimeter.
5 Repair instructions Repair step 6 Install combination sensor (overheating / flame sensor) (see Figure 6, 7 and Sketch 2 – 4) • Repair step 2. • For Airtronic (assembly with special tool, see Sketch 2) Push the special tool a onto the combination sensor b. Use the special tool to position the combination sensor on the heat exchanger, the special tool slides on the heat exchanger until the combination sensor hits the collar (installation position of the combination sensor).
5 Repair instructions Repair step 7 Dismantle heat exchanger (see Figure 8 and Sketch 5) Dismantle combustion air fan (see Figure 8 and Sketch 5) • Repair step 2. • Remove flange seal. Remove heater from the outer shell (bottom section). Unscrew the 4 fixing screws from the combustion air fan. Remove the combustion air fan and the seal from the heat exchanger. Caution! When installing the combustion air fan the seal must always be renewed.
5 Repair instructions Repair step 8 Dismantle combustion chamber (see Figure 9 and Sketch 6) • Repair step 3. • Repair step 7. • Unscrew the fixing screws. In the Airtronic = 3 fixing screws, in the Airtronic M = 4 fixing screws. • Pull out the combustion chamber from the front and remove the heat exchanger’s seal. Caution! When assembling the combustion chamber, always renew the seal, which is included with the spare part.
5 Repair instructions Check fuel supply 2. Measurement Before measuring the fuel quantity, check the following points in the fuel supply. • • • • • Check the screen in the metering pump. Check the laying of the fuel pipes. Check fuel pipes for leaks. Check and tighten the hose connections. Is the fuel removal installed according to the details in the technical description? The fuel begins to be pumped approx. 60 sec after switching on the heater.
6 Circuit diagram Overview of the parts lists and circuit diagrams Parts list circuit diagram Airtronic / Airtronic M................................................................................................................................. 38 Circuit diagram Airtronic / Airtronic M...............................................................................................................................................
6 Circuit diagram Parts list circuit diagrams Airtronic / Airtronic M 1.1 1.2 1.5 2.1 2.2 2.7 Burner engine Glow plug Overheating and flame sensor Control box Metering pump Main fuse 12 volt = 20 A 24 volt = 10 A 2.7.1 Fuse, actuation 5 A 5.
6 Circuit diagram Circuit diagram – Airtronic / Airtronic M Please note! This circuit diagram is for heaters with a diagnostics cable and whose control box cable loom which is firmly encapsulated.
6 Circuit diagram Circuit diagram – Airtronic / Airtronic M Bitte beachten! This circuit diagram is for heaters with 2 diagnostics cable and whose control unit cable loom is wound with cable tape.
6 Circuit diagram Parts list circuit diagrams, control units 2.15.1 2.15.9 3.1.9 3.1.11 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 Circuit diagram Circuit diagram, control units – part 1 Parts list Page 41 42 25 2069 00 97 01 C
6 Circuit diagram Circuit diagram, control units – part 2 Parts list Page 41 25 2069 00 97 01 C 43
6 Circuit diagram Circuit diagram, control units – part 3 Parts list Page 41 44 25 2069 00 97 02 A
6 Circuit diagram Circuit diagram, control units – part 4 Parts list Page 41 25 2069 00 97 02 A 45
6 Circuit diagram Circuit diagram, control units – part 5 Parts list Page 41 46 25 2069 00 97 04 A
6 Circuit diagram Circuit diagram, control units – part 6 Parts list Page 41 25 2069 00 97 04 A 47
6 Circuit diagram Circuit diagram, control units – part 7 Parts list Page 41 48 25 2069 00 97 03 B
6 Circuit diagram Parts list circuit diagram control units – EasyStart R+ / R / T 2.15.1 2.15.9 Temperature sensor (room temperature) (included in scope of supply for EasyStart R+, optional for EasyStart R / T) Outside temperature sensor (optional) 3.1.7 3.1.9 3.1.11 3.1.16 3.1.17 “OFF” button “Heat / ventilate” switch “Round” control unit Radio remote control button “Mini controller” control unit 3.2.15 EasyStart T timer 3.3.9 3.3.
6 Circuit diagram EasyStart R+ control unit circuit diagram (Control box with one diagnostics cable) Parts list Page 49 50 25 2069 00 97 06 B
6 Circuit diagram EasyStart R+ control unit circuit diagram (Control box with one diagnostics cable) Parts list Page 49 25 2069 00 97 06 B 51
6 Circuit diagram EasyStart R+ control unit circuit diagram (Control box with two diagnostics cables) Parts list Page 49 52 25 2361 00 97 01 B
6 Circuit diagram EasyStart R control unit circuit diagram (Control box with one or two diagnostics cables) Parts list Page 49 25 2361 00 97 05 B 53
6 Circuit diagram EasyStart R control unit circuit diagram (Control box with two diagnostics cables) Parts list Page 49 54 25 2361 00 97 02 B
6 Circuit diagram EasyStart R control unit circuit diagram (Control box with one diagnostics cable) Parts list Page 49 25 2069 00 97 07 B 55
6 Circuit diagram EasyStart T control unit circuit diagram (Control box with one diagnostics cable) Parts list Page 49 56 25 2069 00 97 08
6 Circuit diagram EasyStart T control unit circuit diagram (Control box with two diagnostics cables) Parts list Page 49 25 2361 00 97 03 57
6 Circuit diagram Parts list circuit diagrams Airtronic / Airtronic M – ADR 1.1 1.2 1.5 2.1 2.2 2.7 Burner engine Glow plug Overheating and flame sensor Control box Metering pump Main fuse 12 volt = 20 A 24 volt = 10 A 2.7.1 Fuse, actuation 5 A 5.1 Battery 5.2.1 Operating switch battery d) (operation controlled e.g. via ignition lock) Emergency off function for ADR – Item 5.2.2 – 5.5 5.2.2 Isolating switch battery d) 5.3 Auxiliary drive HA+ 5.3.1 Switch, auxiliary drive 5.
6 Circuit diagram Circuit diagram – Airtronic / Airtronic M – ADR Bitte beachten! This circuit diagram is for heaters with one diagnostics cable and whose control box cable loom is firmly encapsulated.
6 Circuit diagram Circuit diagram – Airtronic / Airtronic M – ADR Bitte beachten! This circuit diagram is for heaters with 2 diagnostics cable and whose control box cable loom is wound with cable tape.
6 Circuit diagram Parts list circuit diagram control units – ADR 2.15.1 Temperature sensor, external (room temperature) 3.1.11 3.1.17 Control unit, round Mini controller Airtronic 3.2.8 Module timer (ADR – potentiometer) 3.9.
6 Circuit diagram Circuit diagram, control units – ADR Parts list Page 61 62 25 2069 00 99 01 B
6 Circuit diagram Circuit diagram, control unit EasyStart T – ADR (Control box with one diagnostics cable) Parts list Page 61 25 2069 00 97 09 63
6 Circuit diagram Circuit diagram, control unit EasyStart T – ADR (Control box with two diagnostics cables) Parts list Page 61 64 25 2361 00 97 04
7 Service Certification EC 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.
7 Service Representatives abroad Argentina Champion S. A. Mejico 3941 Villa Matelli RA -1603 Buenos Aires Tel. 0054 / 11 49 43 99 00 Fax. 0054 / 11 47 09 02 24 for boat heaters Trimer S. A. Del Area San Fernando RA -1000 Buenos Aires Tel. 0054 / 11 45 80 04 44 Fax. 0054 / 11 45 80 04 40 Belgium & Luxemburg Eberca bvbal Research Park Haasrode Esperantolaan 2 B-3001 Leuven Haasrode Tel. 0032 / 16-40 25 00 Fax. 0032 / 16-40 05 15 Chile for boat heaters Nauticentro Ltda.
7 Service Representatives abroad Austria Eberspächer GmbH IZ NÖ-Süd 2, Hondastraße 2, Obj. M47 A-2351 Wiener Neustadt Tel. 0043 / 2236 677 144-0 Fax. 0043 / 2236 677 144-42 Poland Eberspächer Sp.zo.o Wysogotowo K. Poznania ul. Okrezna 17 PL- 62081 Przezmierowo Tel. 0048 / 61-816 18 50 Fax. 0048 / 61-816 18 60 Sales partners in Austria Russia JSC OTEM Верхняя Красносельская улица 2 RUS107140 Moscow Tel. 007 (495) 645 59 79 Fax. 007 (495) 647 13 24 Bulgaria ProMobile 13, Iskarsko Chaussee Blvd.
7 Service List of key words / A – Z index Keyword Page Keyword Page A Accident prevention................................................................4 ADR...........................................................................7, 59, 69 Always observe the following safety instructions before working on the heater..................................................................28 AMP release tool..................................................................28 Assembly drawing..................
7 Service List of abbreviations ADR European agreement about the international transport of dangerous goods on the road. 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-Partners J. Eberspächer partner. FAME (biodiesel) FAME for diesel engines according to DIN EN 14 214.
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