* 16/24/30/35 HYDRONIC Eberspächer ® Technical Description Troubleshooting and Repair Manual J. Eberspächer GmbH & Co. Eberspächerstr. 24 D - 73730 Esslingen Telephone (switchboard) +49 (0)711 939 - 00 Fax +49 (0)711 939 - 0500 www.eberspaecher.com This Troubleshooting and Repair Manual is valid for the following heater models: Standard Model Cat. No. Basic Heater No.
1 / Introduction Table of Contents This table of contents provides detailed information on the contents of this Technical Description, Troubleshooting and Repair Manual. To find a term, use the index at the end of this document. Technical Description Chapter No.
1 / Introduction Troubleshooting and repair instructions Chapter No.
1 / Introduction Special notation, pictures and pictograms Liability claims / warranty This document uses special notation and pictograms to give emphasis to different types of information. Their meaning and how you should respond to them are explained in the examples below. Adherence to the official regulations and the safety instructions is essential if any liability claims are to be accepted.
1 / Introduction Important information prior to commencing work Applications in which the HYDRONIC may be used The engine-independent “HYDRONIC 16 / 24 / 30 / 35” water heaters are intended for installation in the following vehicles (in each case, the heater output should be appropriate to the application): • motor vehicles, especially buses • building machinery • trailers • ships and yachts Important! • The heater may only be used and operated for the applications specified by the manufacturer and in compl
1 / Introduction Statutory requirements To install the heater in a vehicle subject to the German regulations governing the registration of motor vehicles (StVZO), a “General Type Approval” has to be issued by the Federal Motor Vehicle Office (Kraftfahrtbundesamt) and the appropriate official test symbol must be indicated on the heater rating plate.
1 / Introduction Safety instructions for installation and repair of the HYDRONIC Danger of injury, fire and poisoning! • Disconnect the vehicle battery prior to starting work. • Prior to starting any repair work, switch off the HYDRONIC and allow all hot components to cool down.
2 / Product Information Cat. No. HYDRONIC and additional equipment Fig. No. / Designation Cat. No. 1 HYDRONIC 16 - 24 V 25 2165 02 00 00 1 2 HYDRONIC 24 - 24 V HYDRONIC 24 - 24 V Compact model 25 1817 02 00 00 25 1817 05 00 00 1 2 HYDRONIC 30 - 24 V HYDRONIC 30 - 24 V Compact model 25 1818 02 00 00 25 1818 05 00 00 1 2 HYDRONIC 35 - 24 V HYDRONIC 35 - 24 V Compact model 25 1819 02 00 00 25 2041 05 00 00 Quantity / Designation Cat. No.
2 / Product Information 5 Control elements 10 9 12 8 5 4 7 11 5 6 3 5 28 30 18 29 25 27 24 26 25 18 23 22 18 21 1 18 17 19 20 16 13 14 2 15 31 35 33 32 Drawing 1 34 9
2 / Product Information Construction of the HYDRONIC Special features of the HYDRONIC The HYDRONIC consists of a heat exchanger and a removable burner. The heat exchanger is a combustion chamber, consisting of a flame pipe with integrated mixer. If required, the flame pipe can be removed from the heat exchanger. The control unit and electric motor are attached under the burner hood on the burner flange. The fuel pump forms an integral part of the burner casing.
2 / Product Information Sectional view Drawing 2 1 2 3 4 5 6 7 8 9 10 11 Hood (CO2 setting) Coupling Control unit Ignition spark generator Flame monitor Solenoid valve Temperature sensor Ignition electrodes Combustion chamber Safety thermal cutout sensor Relay (vehicle blower control) 12 13 14 15 16 17 18 19 20 21 22 Fuses Modular timer Fan wheel Electric motor Fuel connection Nozzle holder heater Fuel atomizer nozzle Flame pipe Heat exchanger “Bus 2000” water pump Exhaust pipe connection A Exhaust g
2 / Product Information Functional diagram HYDRONIC ON HYDRONIC OFF Operation Component test Delayed shutoff Nozzle holder heater (On at temp. < 5 °C) From control unit 25 1818 53 00 00, switching on and off the nozzle holder heater is temperature-controlled Water pump Solenoid valve From control unit 25 1818 53 00 00 Ignition spark generator Electric Motor 3 10 60 180 Sec.
2 / Product-Information Technical Data Test symbol HYDRONIC 16 S 329 Heating medium Heating capacity (at ambient temperature of 20ºC) HYDRONIC 24 HYDRONIC 30 HYDRONIC 35 S 297 S 295 296 Mixture of water and refrigerant (Max 50% proportion of refrigerant 16,000 W 24,000 W 30,000 W 35,000 W Temperature control values - at water inlet ON 73 °C / OFF 78 °C Temperature control values - at water outlet ON 85 °C / OFF 118 °C Fuel Fuel consumption (at ambient temperature of -10ºC) S Commercial gr
2 / Product Information Principal dimensions HYDRONIC - standard model Please note! • If there is enough space, the burner can be swung out for routine checks - see drawing. • The principal dimensions are the same when a hood with hose connection is mounted. 320 ca. 335 82 ca. 140 70 150 M8 29 130 min. ø 38 230 50 244 ø 220 110 190 222 2 Min.
3 / Installation Installation position The heater should be installed as low down as possible in the vehicle, e.g. in the engine compartment or in a stowage area. This will ensure that the heater and water pump are automatically ventilated. Other installation positions are also permitted as long as they comply with the installation requirements stated in these Installation Instructions.
3 / Installation Installation of the HYDRONIC in a case If installation in the engine compartment or stowage compartment of the vehicle is not possible, than the HYDRONIC can also be installed in a case. The case containing the installed HYDRONIC is then affixed to the vehicle at a suitable location, e.g. to the longitudinal chassis frame. It is recommended that a hood with a hose connection is mounted for the combustion air intake.
3 / Installation Permissible installation positions and attachment of the HYDRONC The HYDRONIC should if possible be installed in the normal position. To do this, transfer the 4 fastening holes and the through-hole for the exhaust outlet - as shown in the diagram - to the mounting surface and drill. Fasten the HYDRONIC to the vehicle with the two mounting supports. Please note! • The support surface for the two mounting supports of the HYDRONIC must be flat.
3 / Installation Installation of the water pump The water pump must be installed at the lowest point in the water circulation system, taking into account the installation position - see diagrams. Transfer the four fastening holes for the water pump holder to the mounting surface - as shown in the diagram - and drill. Attach the water pump to the vehicle with the holder. Please note! • No shutoff valves may be inserted in the water hose for the water pump (intake side).
3 / Installation Exhaust gas piping Regulation! • The outlet must be implemented in such a way that insertion of a 16 mm dia. ball is not possible. • Exhaust pipes must be laid in such a way that there is no likelihood of any exhaust gases entering the vehicle interior. • The functioning of parts of the vehicle which are important for its operation must not be impaired. • It must not be possible for condensate or water to collect in the exhaust gas line. Drain holes are permitted.
3 / Installation Examples of exhaust gas piping 1 HYDRONIC 2 Exhaust pipe connection 3 Exhaust pipe connection, 60° 4 Exhaust pipe bend 5 Exhaust pipe 6 End sleeve 7 Flex. exhaust pipe Please note! Items 5-8 are not included in the Eberspächer scope of supply. Drawing 14 Combustion air piping Regulation! • The necessary combustion air must be drawn from the outside. • The combustion air inlet must be implemented in such a way that insertion of a 16 mm dia. ball is not possible.
3 / Installation Coolant circuit Warning: contact with hot parts could cause burning. • The coolant and the coolant circuit components can get very hot. - Lay and attach water-carrying parts in such a way that there is no danger of burning to humans, animals or any temperature-sensitive material from either heat radiation or direct contact. - Prior to working on the coolant circuit, switch off the HYDRONIC and wait until all components have cooled down completely, if necessary wearing gloves.
3 / Installation Fuel supply Regulation! • When laying fuel lines and installing an additional fuel tank, §§45 and 46 StVZO (regulations governing the registration of motor vehicles) must be adhered to. Excerpt from §§45 and 46 StVZO: - Fuel tanks may not be contained in passenger compartments or driver‘s cabs of buses. They must be positioned in such a way that in the event of a fire the exits are not directly endangered. - Fuel lines may not be contained in compartments or driver‘s cabs of buses.
3 / Installation Permissible fuel line dimensions Fuel quality Inner diameter of the intake pipe = 6 mm dia. to 8 mm dia. All commercial grade diesel which complies with DIN 51 601 may be used as fuel. Any heating oils which comply with class EL, DIN 51 603 can also be used. At temperatures below 0°C diesel must be used as specified in the table below. Inner diameter of the return pipe = 6 mm dia. to 8 mm dia. Permitted intake head and length of intake pipe: • Where intake head is up to 1.5 m ---> max.
4 / Troubleshooting In the event of faults, start by checking… Test equipment • Defective wiring (short-circuits, open circuit). The following test equipment can be used for troubleshooting and repair. • Visual inspection for - corroded contacts - defective fuses - damaged electric lines, joints and connections - damaged exhaust gas and combustion air piping • Battery voltage on starting up the heater <19 V (measure voltage on control unit). • Check fuel supply.
4 / Troubleshooting Diagnosis The HYDRONIC electronic control unit can store up to five faults. The faults can be read from the control unit and displayed by one of the following means: • Flashing code After connection of an LED and a series resistor (approx. 1 kΩ / 11 W) the function / fault is displayed as a flashing code. For details of the flashing code signals and the corresponding faults, see table on page 26.
4 / Troubleshooting Fault diagnosis - flashing code (LED with series resistor) Release of control unit when locked The electronic control unit can store up to five faults. The function or type of fault is output by the control unit as a flashing code and displayed by an LED (with series resistor). The LED with series resistor is connected to the cable harness of the HYDRONIC, using the 8-pin connector, pin 12, blue / white cable 1 mm² (see wiring diagram page 25).
4 / Troubleshooting Fault diagnosis with the diagnostic unit Diagnostic unit Cat. No. 22 1512 89 00 00 ~ Ä Å Ç É Ñ= To connect the diagnostic unit, an adapter cable is required. Adapter cable Cat. No. 22 1000 31 66 00 The electronic control unit can store up to 5 faults, which can be read out and displayed with the timer. The current error is shown as “AF” and is always written to memory location F1.
4 / Troubleshooting Fault diagnosis with the ISO adapter and the KD 2000 software ISO adapter and KD-2000 software Cat. No. 22 1524 89 00 00 To connect the ISO adapter, an adapter cable is required. Adapter cable Cat. No. 22 1000 31 66 00 Installing KD 2000 software on the PC • Place CD-ROM in the CD drive. • Double click on the file "setup.exe" and follow the instructions of the SETUP program.
4 / Troubleshooting Fault diagnosis with the modular timer Modular timer Cat. No. 22 1000 30 34 00 The electronic control unit can store up to 5 faults, which can be read out and displayed with the timer. The current error is shown as “AF” and is always written to memory location F1. Previous faults are transferred to memory locations F2 - F5; if necessary, the content of memory location F5 is overwritten. Retrieve fault memories F1 to F5 • Press key c ---> HYDRONIC is switched on.
4 / Troubleshooting Fault code Fault Description Cause • Remedial measures 000 No fault ----------------- 010 Overvoltage --> disconnection Overvoltage (>30 V) exists for a minimum of 20 seconds without interruption at the control unit - HYDRONIC not working. • Unplug 18-pin connector on the control unit and start up vehicle engine. Measure the voltage between PIN 15 (red 2.5 mm² cable) and PIN 16 (brown 2.5 mm² cable) if the voltage >30 V --> check alternator controller.
4 / Troubleshooting Fault code Fault Description Cause • Remedial measures 020 Ignition spark generator - open circuit Control line from ignition spark generator to the control unit has open circuit or short circuit. • Check cable section from the ignition spark generator to the control unit and, if necessary, eliminate open circuit or short circuit. • Check functioning of the ignition spark generator only with the test unit for burner head; if necessary ,replace the ignition spark generator.
4 / Troubleshooting Fault code Fault Description Cause • Remedial measures 039 Vehicle blower control - short circuit Black 1 mm² cable from the 18-pin control unit connector, compartment 6 to the 8-pin cable harness connector, compartment 7, and from there to the blower relay has short-circuit. • Check lead and connections and, if necessary, eliminate short circuit. • Check mounting of the relay. • Replace relay.
4 / Troubleshooting Fault code Fault Description Cause • Remedial measures 054 Flame loss during operation HYDRONIC has ignited, detected the flame and reports flame loss twice within an operating period of 60 minutes. • Check fuel supply (supply and return). • Measure the amount of CO2. • Replace fuel atomizer nozzle. • If the fault could not be eliminated by taking the remedial measures listed above, then replace control unit.
5 / Repair Instructions Assembly drawing 3 8 7 2 4 6 1 5 1 2 3 4 5 6 7 8 9 10* 11 12 13 14* 15 16 17 18 19 20* 21 22 23 Hood with hose connection Flexible hose Protective grille Hose clip Hood Fan wheel Control unit Electric motor Cable section Baffle plate Burner casing with integrated fuel pump Ignition spark generator Cartridge heater Temperature switch Nozzle holder Baffle plate Fuel atomizer nozzle Ignition electrodes Solenoid valve Flame pipe Heat exchanger Temperature sensor Safety thermal c
5 / Repair Instructions 17 14* 12 13 16 18 15 19 11 10* 23 22 20* 21 20 * Only with heater models HYDRONIC 16 - 25 2165 01 00 00 HYDRONIC 24 - 25 1817 01 00 00 35
5 / Repair Instructions Repair Instructions The “Repair Instructions” chapter describes the approved repair work for the HYDRONIC 16 / 24 / 30 / 35. Where extensive repair work is to be carried out, it is sensible to dismantle the HYDRONIC. Mounting of the HYDRONIC involves the reverse sequence of steps, but there may be some additional instructions which need to be heeded. Once all work on the HYDRONIC has been completed, a functional test should be performed (see page 5).
5 / Repair Instructions Removing the hood (see Drawing 24) • Undo the two fixing screws on the hood. • Take off the hood. 1 Beware danger of injury! • The fan wheel has sharp edges. - Avoid contact with the fan wheel and, if necessary, wear protective gloves. ~ Fixing screw 1 Drawing 24 Removing the burner (see Figure 1). • Take off the hood. • Pull out “Temperature sensor” and “Safety thermal cutout sensor” cable sections on the control unit. • Take grommet out of burner casing.
5 / Repair Instructions Removing the burner motor (see Figures 3 and 4) • Take off the hood. • Unscrew the fan wheel in an anti-clockwise direction, counter-restraining the motor shaft with screwdriver. • If necessary, check the burner motor with the test unit for burner head (see below). • Pull out “Burner motor” cable section at the control unit, slot “B”. • Undo 3 fastening screws from the burner motor. • Remove burner motor. Ä Please note! When mounting the fan wheel, tighten with 1 Nm +0.5 Nm.
5 / Repair Instructions Removing the ignition electrodes (see Figure 5 and Drawing 26) • Take off the hood. • Remove burner. • Remove ignition electrodes from ignition spark generator. Following installation, check the position of the ignition electrodes and adjust as necessary. • Attach the reference gauge to the nozzle and push as far as the limit stop. • Check the electrode position. The points of the electrodes should be touching the square-shaped surfaces of the reference gauge.
5 / Repair Instructions Removing the ignition spark generator (see Figures 7-9) • • • • • • • • Take off the hood. Remove burner. Remove ignition electrodes. Remove securing clip (retaining spring) from the nozzle holder and take off the baffle plate. If necessary, check the ignition spark generator with the test unit for burner head (see below). Pull out “ignition spark generator” cable section at the control unit, slot “E”. Undo the two fastening screws from the ignition spark generator.
5 / Repair Instructions Removing the solenoid valve (see Figure 10 and Drawing 26) • Take off the hood. • Remove burner. • If necessary, check the solenoid valve with the test unit for burner head (see below). • Pull out “Solenoid valve” cable section at the control unit, slot “D”. • Loosen hexagonal nut from the solenoid valve. • Remove solenoid valve coil. • Unscrew magnet. ~ Ä Please note! During installation of the heater, lay the cable sections as shown in Figure 10.
5 / Repair Instructions Removing the heating cartridge for the nozzle holder heater (see Figures 11 and 12) • • • • • • • • • • Heating cartridge without temperature switch Take off the hood. Remove burner. Remove ignition electrodes from ignition spark generator. Remove securing clip (retaining spring) from the nozzle holder. Remove baffle plate. Pull out “Heating cartridge” cable section at the control unit, slot “F”. Remove securing pin from the nozzle holder (which holds the heating cartridge).
5 / Repair Instructions Removing the flame pipe (see Figure 13 and Drawing 27) • Take off the hood. • Remove burner. • Take flame pipe out of the heat exchanger. ~ Ä Please note! During installation, insert the catch of the flame pipe into slot on the heat exchanger.
5 / Repair Instructions Removing the temperature sensor and safety thermal cutout sensor (see Figure 14 and Drawing 28) • Take off the hood. • Unscrew the fan wheel in an anti-clockwise direction, counter-restraining the motor shaft with screwdriver. • Remove plug connector from the temperature sensor / safety thermal cutout sensor on the control unit. • Unscrew temperature sensor / safety thermal cutout sensor from the heat exchanger.
5 / Repair Instructions Characteristic value table - safety thermal cutout sensor (NTC) Temp.
5 / Repair Instructions Measuring the CO2 content in the exhaust gas Danger of injury, fire and poisoning! • The HYDRONIC must not be operated in enclosed spaces such as garages or workshops without exhaust-gas extraction. • Do not switch on HYDRONIC with the burner dismantled.
5 / Repair Instructions Taking the water pump apart (standard model) (see Drawing 31) • Unscrew screws from the pump housing and take out the pump housing. • Unscrew locknut and take out the impeller wheel. • Remove axial face seal and ring from the motor shaft. • Unscrew screws from the pump flange and take out the pump flange. • Replace any faulty parts. Please note! • Clean axial face seal and ring with a dry cloth prior to installation. • Slide surfaces must be free of grease and dust.
6 / Wiring diagram Wiring diagram for the basic heater models HYDRONIC 16 - 24 V HYDRONIC 24 - 24 V HYDRONIC 30 - 24 V HYDRONIC 35 - 24 V 25 2165 01 00 00 25 1817 01 00 00 25 1818 01 00 00 25 1819 01 00 00 25 1818 00 96 01 C Parts list 1 1.1 1.2 1.3 1.4.1 1.5 1.11 1.13 48 HYDRONIC Burner motor Ignition electrode Ignition spark generator Temperature switch - only on HYDRONIC 16 / 24 Safety thermal cutout sensor Fuel solenoid valve Temperature sensor 1.14 Heating cartridge for nozzle holder heater 2.
6 / Wiring diagram Cablecolours sw ws rt ge gn vi br gr bl li black white red yellow green violet brown grey blue lilac 25 1818 00 97 01 E Parts list 2.5.7 2.7 2.7.1 2.7.2 2.12.1 2.12.2 Relay for control, e.g. of vehicle blower Main fuse 15 A 5A fuse for control switch 15A fuse for water pump Bus 2000 water pump Water pump 3.1.4 3.1.5 3.4.1 3.4.3 3.4.6 Switch, temperature reduction Switch, water pump Pilot light / flame indicator Fault code indicator Combustion indicator light 5.1 5.
6 / Wiring diagram Wiring diagram, control elements 25 1818 00 97 01 E Parts list 2.15.9 Sensor, external temperature b) Connect to terminal +15 3.1.1 Universal switch c) Illumination, terminal 58 3.1.2 Switch, heat, continuous operation e) External ON/OFF key (optional) 3.1.12 Fault code inquiry i) Radio remote control connection 3.2.6 Mini-timer 3.2.9 Modular timer 3.2.
7 / Environment Certification The Eberspächer company accepts the challenge and takes active steps to avoid and eliminate ecological problems. The HYDRONIC heater is designed for environmentally friendly operation. ISO 9000 / ISO 14001 Our production process is certified to ISO 9000 (quality management) and ISO 14001 (environmental management).
8 / Service / Index Regional offices - Germany Postcode Town Company Road Telephone 17358 Torgelow Eberspächer Heizgeräte GmbH Wilhelmstraße 47 Tel. +49 (0)3976 23 50 - 0 20539 Hamburg J. A. Schlüter Söhne Industrie-Vertriebs-GmbH Ausschläger Billdeich 62–64 Tel. +49 (0)40 7 88 16 86 44139 Dortmund Eugen Boss GmbH & Co. KG Rosemeyerstr. 14 Tel. +49 (0)231 91 14 - 236 65936 Frankfurt Dipl. Ing. B. Schmitt GmbH Technikhaus Westerbachstr. 124 Tel.
8 / Service / Index Representative offices abroad Country Company Town Telephone Poland Eberspächer Sp.zo. PL- 62081 Przezmierowo Tel. 061 - 81 6 18 50 Russia Company OKMA RUS - 105023 Moscow Tel. 095 - 111 90 95 Sweden Svenska Eberspächer AB S - 12830 Skarpnäck Tel. 0 8 - 683 11 00 Switzerland Technomag AG Ch - 4127 Birsfelden Tel. 061 - 378 9152 Spain Portugal Pedro Sanz Clima S. L E - 28022 Madrid Tel. 91 - 748 07 85 Czech Republic Eberspächer spol. sr. o.
8 / Service / Index Index A-M Keyword Page Keyword Page A F Accident prevention --------------------------------------- 2, 4 Additional equipment ----------------------------- 2, 8, 10, 22 ADR --------------------------------------------------------5, 54 ADR99 -----------------------------------------------------5, 54 Ambient temperature ----------------------------------- 13, 16 Applications --------------------------------------------- 2, 5, 6 Assembly drawing ---------------------------------------
8 / Service / Index Index N-Z Keyword Page Keyword Page M T Minimum throughput ----------------------------------- 13, 30 Mini-timer --------------------------------------------------8, 50 Modular timer ------------------------3, 8, 11, 25, 29, 32, 50 Mounting surface --------------------------------------- 17, 18 Table of contents---------------------------------------------- 2 Technical data ---------------------------------------------2, 13 Technical description ------------------------ front cove
