-
Airtronic M Orderno.
AirtronicD3,12V 252317050000
AirtronicB4,12V 201812050000
AirtronicD4,12V 252113050000AirtronicD4,24V 252114050000
AirtronicD4Plus,12V 252484050000AirtronicD4Plus,24V
252489050000
AirtronicD4S,12V 252144050000AirtronicD4S,24V 252145050000
AirtronicD3Camper,12V(seeAirtronicD3)
AirtronicD4Camper,12V 252318050000
AirtronicD4Camperplus,12V 252327050000
AIRTRONIC / AIRTRONIC MTroubleshooting and Repair
Instructions
25211595190104.2009
Airtronic Orderno.
AirtronicD2,12V 252069050000AirtronicD2,24V
252070050000AirtronicD2Camper,12V 252326050000
Completepackage
AirtronicD2,12V 252115050000AirtronicD2,24V 252116050000
Air heater for diesel and petroloperating independently of the
engine.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
www.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.comwww.butlertechnik.com
-
2
4
3
1
2
1Contents
ThislistofcontentsgivesyoupreciseinformationaboutthecontentsoftheTroubleshootingandRepairInstructions.
Introduction
Usetheindex,listofabbreviations,etc,tolookforaterm,technicalwordoranexplanationforanabbreviation.
Chapter Title Contents Page
Introduction •
Foreword..................................................................................................................
4•
Accidentprevention..................................................................................................
4•
Specialtextstructure,presentationandpicturesymbols...........................................
4•
Importantinformationbeforestartingwork................................................................
4
Function and use
Cutawayview............................................................................................................
5• Descriptionoffunctions–
Switchingon..........................................................................................................
6–
StartingtheAirtronic..............................................................................................
6–
StartingtheAirtronicM..........................................................................................
6–
Temperatureselectionwiththecontrolelement......................................................
6–
Controlinheatingmode.........................................................................................
6–
Ventilatingmode....................................................................................................
6–
Switchingoff..........................................................................................................
6
•
Controlandsafetydevices........................................................................................
7–
Forcedshut-downforADRoperation.....................................................................
7–
Emergencyshutdown–EMERGENCYOFF...........................................................
7
Technical data •
Airtronic(fordiesel)...................................................................................................
8•
AirtronicM(forpetrol)................................................................................................
9•
AirtronicM(fordiesel)........................................................................................
10,11• Checkvalues–
Testspeedfortheblower.....................................................................................
12–
Resistan\cevalues...............................................................................................
12–
Switchingvalue....................................................................................................
12–
Exhaustemissionspecification.............................................................................
12–
Check“externaltemperaturesensor”...................................................................
12–
Tableofvalues:“Externaltemperaturesensor”.....................................................
12
Troubleshooting • Whattocheckfirstincaseoffaults–
Check..................................................................................................................
13–
Electricalcomponents..........................................................................................
13–Measurebatteryvoltage.......................................................................................
13–Measuresvoltagesupply.....................................................................................
13–
Checkswitch-onsignal........................................................................................
13–
Checkcontrolunit................................................................................................
13
•Overviewoftheindividualtestequipmentandcontrolunits.....................................
14•
Lockingthecontrolbox...........................................................................................
14•
Cancelthecontrolboxlock.....................................................................................
14•
Importantnotes(diagnosisofheaterswithmini-controller).......................................
14•
Testingdeviceforthecontroldevice........................................................................
15•
Faultdiagnosisusingthediagnosticunit...........................................................
15,16•
FaultdiagnosisusingtheEDiTHdiagnosticstoolwithISOadapter..........................
17•
AirpressuresensordiagnosisusingEDiTHdiagnosticstoolandISOadapter..........
18•
FaultdiagnosisusingtheEDiTHdiagnosticstoolwithbasicadapter.......................
19•
Faultdiagnosisusingthemoduletimer....................................................................
20•
FaultdiagnosisusingtheradioremotecontrolTP5.................................................
21•
FaultdiagnosisusingtheEasyStartR+radioremotecontrolortheEasyStartTtimer...............................................................................................
22
•
Faultcodetable...............................................................................................23–27
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
3
Introduction
7
6
5
1
Chapter Title Contents Page
Repair instructions •
Repairinstructions..................................................................................................
28•
Alwaysobservethefollowingsafetyinstructionsbeforeworkingontheheater........
28•
Specialtool,AMPreleasetool.................................................................................
28•
AssemblydrawingAirtronic/AirtronicM.................................................................
29•
Repairstep1,removetheheatercover...................................................................
30•
Repairstep2,dismantlecontrolbox,checkcontrolbox.........................................
30•
Repairstep3,dismantleglowplug..........................................................................
31•
Repairstep4,renewlining......................................................................................
31•
Repairstep5,dismantlecombinationsensor(overheating/flamesensor...............
32•
Repairstep6,installcombinationsensor(overheating/flamesensor).....................
33•
Repairstep7,dismantleheatexchanger/dismantlecombustionairfan...................................................................................
34
•
Repairstep8,dismantlecombustionchamber........................................................
35•
Checkfuelsupply....................................................................................................
36•Measuringthefuelquantity......................................................................................
36
Circuit diagrams
Overviewofthepartslistsandcircuitdiagrams...........................................................
37•
PartslistcircuitdiagramsAirtronic/AirtronicM.......................................................
38•
CircuitdiagramAirtronic/AirtronicM.....................................................................
39Thiscircuitdiagramisvalidforheaterswithonediagnosiscableandacontrolboxcableloomwichisfirmlyencapsulated.
•
CircuitdiagramAirtronic/AirtronicM.....................................................................
40Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
•
Partslistcircuitdiagrams,controlunits....................................................................
41•
Circuitdiagramcontrolunits–part1.......................................................................
42•
Circuitdiagramcontrolunits–part2.......................................................................
43•
Circuitdiagramcontrolunits–part3.......................................................................
44•
Circuitdiagramcontrolunits–part4.......................................................................
45•
Circuitdiagramcontrolunits–part5.......................................................................
46•
Circuitdiagramcontrolunits–part6.......................................................................
47•
Circuitdiagramcontrolunits–part7.......................................................................
48•
PartslistcircuitdiagramcontrolunitEasyStartR+/R/T........................................
49•
CircuitdiagramcontrolunitEasyStartR+(controlboxwith1diagnosticscable)......
50•
CircuitdiagramcontrolunitEasyStartR+(controlboxwith1diagnosticscable)......
51•
CircuitdiagramcontrolunitEasyStartR+(controlboxwith2diagnosticscable)......
52•
CircuitdiagramcontrolunitEasyStartR(controlboxwith1/2diagnosticscables).
53•
CircuitdiagramcontrolunitEasyStartR(controlboxwith2diagnosticscables)......
54•
CircuitdiagramcontrolunitEasyStartR(controlboxwith1diagnosticscables)......
55•
CircuitdiagramcontrolunitEasyStartT(controlboxwith1diagnosticscable)........
56•
CircuitdiagramcontrolunitEasyStartT(controlboxwith2diagnosticscable)........
57•
PartslistcircuitdiagramsAirtronic/AirtronicM–ADR............................................
58•
CircuitdiagramAirtronic/AirtronicM–ADR..........................................................
591encapsulateddiagnosticscableandcontrolboxcableloomfirmlyencapsulated
•
CircuitdiagramAirtronic/AirtronicM–ADR..........................................................
602diagnosticscablesandcontrolboxcableloomwithcabletape
•
Partslistcircuitdiagrams,controlunits–ADR.........................................................
61•
Partslistcircuitdiagrams,controlunits–EasyStartT–ADR...................................
61•
Circuitdiagramcontrolunits–ADR.........................................................................
62•
CircuitdiagramcontrolunitEasyStartT–ADR(controlboxwith1diag.cable).......
63•
CircuitdiagramcontrolunitEasyStartT–ADR(controlboxwith2diag.cable).......
64
Service •
Certification.............................................................................................................
65•
Disposal..................................................................................................................
65•
ECDeclarationofConformity..................................................................................
65•
Representativesabroad....................................................................................
66,67•
Listofkeywords...............................................................................................
68,69•
Listofabbreviations................................................................................................
69
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
4
Special text structure, presentation and picture symbols
Specialtextformatsandpicturesymbolsareusedintheseinstructionstoemphasisedifferentsituationsandsubjects.Pleaserefertothefollowingexamplesfortheirmeaningsandappropriateaction.
Special text formats and presentations•
Adot(•)indicatesalist,whichisstartedbyaheading.–
Ifanindenteddash(–)followsa“dot”,thislistisasub-sectionoftheblackdot.
Picture symbols
Danger!Thisinformationpointsoutadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.
Caution!Thisinformationpointsoutadangeroussituationforapersonand/ortheproduct.Failuretocomplywiththeseinstructionscanresultininjuriestopeopleand/ordamagetomachinery.
Important information before starting work
Initial commissioning of the heater or functional test after a
repair
•
Afterinstallingtheheater,thewholefuelsupplysystemmustbecarefullyvented:pleaserefertoandfollowthevehiclemanufacturer’sinstructions.
•
Duringtheheatertrialrun,allfuelconnectionsmustbecheckedforleaksandsecure,tightfit.
•
Iffaultsoccurwhiletheheaterisrunning,useadiagnosticunittodetermineandcorrectthecauseofthefault.
1 IntroductionForeword
TheseTroubleshootingandRepairInstructionsareapplicabletotheheaterslistedonthetitlePage,totheexclusionofallliabilityclaims.Dependingontheversionorrevisedstatusoftheheater,theremaybedifferencesbetweenitandthesetroubleshootingandrepairinstructions.Theusermustcheckthisbeforecarryingouttherepairworkand,ifnecessary,takethedifferencesintoaccount.
Caution!Safety instructions for installation and repair!
ImproperinstallationorrepairofEberspächerheaterscancauseafireorresultpoisonousexhaustenteringtheinsideofthevehicle.Thiscancauseseriousandevenfatalrisks.
Theheatermayonlybeinstalledaccordingtothespecifica-tionsinthetechnicaldocumentsorrepairedusingoriginalsparepartsbyauthorisedandtrainedpersons.Installationandrepairsbyunauthorisedanduntrainedper-sons,repairsusingnon-originalsparepartsandwithoutthetechnicaldocumentsrequiredforinstallationandrepairaredangerousandthereforearenotpermitted.
Arepairmayonlybecarriedoutinconnectionwiththere-spectiveunit-relatedtechnicaldescription,installationinstruc-tions,operatinginstructionsandmaintenanceinstructions.Thisdocumentmustbecarefullyreadthroughbefore/duringinstallationandrepairandfollowedthroughout.Particularattentionistobepaidtotheofficialregulations,thesafetyinstructionsandthegeneralinformation.
Please note!
Therelevantrulesofsoundengineeringpracticeandanyinformationprovidedbythevehiclemanufactureraretobeobservedduringtheinstallationandrepair.Eberspächerdoesnotacceptanyliabilityfordefectsanddamage,whichareduetoinstallationorrepairbyunauthor-isedanduntrainedpersons.Compliancewiththeofficialregulationsandthesafetyinstruc-tionsisprerequisiteforliabilityclaims.Failuretocomplywiththeofficialregulationsandsafetyinstructionsleadstoexclu-sionofanyliabilityoftheheatermanufacturer.
Accident prevention
Generalaccidentpreventionregulationsandthecorrespond-ingworkshopandoperatingsafetyinstructionsaretobeobserved.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
5
Cutaway view
1 Heaterimpeller 2 Controlbox 3 Combustionairfanimpeller 4
Glowplug 5 Cover 6 Heatexchanger 7
Combinationsensor(overheating/flamesensor) 8
Radioremotecontrol(mobileunit) 9
Radioremotecontrol(stationaryunit)10 Button11
Temperaturesensor(roomtemperature)12
Fusebracketwithmainfuseand“actuation”fuse13 Electricalmotor14
Fuelconnection15 Flangeseal
16 Combustionchamber17 Outlethood18 Combustionairhose19
Meteringpump20 Pot-typestrainer,installedinthedosingpump21
Outflow22 FlexibleexhaustpipeF= FreshairW= HotairA= ExhaustB=
FuelV= Combustionair
Functionanduse2
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
6
Description of functions
Switching on
Whentheheaterisswitchedon,thecontrollampinthecon-trolunitlightsup.Theglowplugisswitchedonandthefanstartsatlowspeed.
fthereisstilltoomuchresidualheatintheheatexchangerfromwhentheheaterwaslastused,firstlyonlythefanstartsup(coldblowing).Oncetheresidualheathasbeencleared,theheaterstarts.
Starting Airtronic
Afterapprox.65secondsthefuelsupplystartsandthefuel/airmixtureinthecombustionchamberignites.Oncethecombinedsensor(flamesensor)hasdetectedtheflame,theglowplugisswitchedoffafter60seconds.Theheaterisnowinstandardoperation.
Starting Airtronic M
Afterapprox.60secondsthefuelsupplystartsandthefuel/airmixtureinthecombustionchamberignites.Aftertheflamesensorhasdetectedtheflame,theglowplugisswitchedoffafterapprox.90sec.Theheaterisnowinstandardoperation.Afteranother120seconds,theheaterhasreachedthe“POWER”stage(maximumfuelquantity,maximumfanspeed).
Temperature selection with the control element
Thecontrolcanbeusedtopreselectaninteriortemperature.Theresultingtemperaturecanbewithintherangeof+10°Cto+30°Canddependsontheselectedheater,onthesizeofthespacetobeheatedandontheprevailingoutdoortem-perature.Thesettingtobeselectedatthecontrolisanempiricalvalue.
Control in the heating mode
Duringtheheatingmode,theroomtemperatureorthetem-peratureofthesuckedinheatingairisconstantlymeasured.Ifthetemperatureishigherthanthetemperatureselectedonthecontrolelement,theheaterstartstoregulateitsoutput.Thereare4controlstagessothattheoutflowofheatpro-ducedbytheheatercanbeadjustedfinelytotheheatingrequirements.Fanspeedandfuelquantitycorrespondtotheparticularcontrolstage.Ifthesettemperatureisstillexceededinthesmallestcontrolstage,theheatergoestothe“OFF”stagewiththefanrunningonforapprox.4minutestocooloff.Thefanthencontinuesrunningatminimumspeed(circulationmode)untiltherestartorisswitchedoff(freshairmodewithexternaltemperaturesensor).
Ventilating mode
TheEasyStartR+andEasyStartTcontrolunitsandthemini-controllercanbeusedtoactivatethe„Ventilate“function.The„Heat/Ventilate“switchisalsorequiredforthemodulartimerandcontroldevicewhereby,forfanmode,the„Heat/Ventilate“switchmustbepressedfirstandthentheheaterswitchedon.Theblowerrunsatmaximumspeedinfanmode.
Switching off
Whentheheaterisswitchedoff,thecontrollampgoesoffandthefuelsupplyisswitchedoff.Thefanrunsonforapprox.4minutestocooldown.Whilethefanisrunningon,theglowplugisswitchedonforapprox.40secondstoclean.Specialcase:Ifnofuelhasbeensuppliedoriftheheaterisinthe“OFF”stageuntilitisswitchedoff,theheaterisstoppedwithoutanyafterrunning.
Functionanduse2
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
7
Forced shut-down for ADR operation
Invehiclesforthetransportofdangerousgoods(e.g.tankertrucks),theheatermustbeswitchedoffbeforethetruckdrivesintoadangerarea(refinery,petrolstation,etc.).Failuretocomplyresultsintheheaterautomaticallyswitchingoffif:•
thevehicleengineisswitchedoff,•
anadditionalunitisstartedup(auxiliarydriveforunloadingpump,etc.),
•
avehicledoorisopened(ADR99regulation,onlyinFrance).Thefanthenrunsonformax.40seconds.
Functionanduse2
Emergency shutdown – EMERGENCY
OFFIfanemergencyshutdown–EMERGENCYOFF–isre-quiredduringoperation,executethefollowing:•
Switchtheheateroffatthecontrolelementor• removethefuseor•
disconnecttheheaterfromthebattery.
Control and safety devices
•
Iftheheaterdoesnotignitewithin90secondsafterstartingthefuelpump,thestartisrepeated.Iftheheaterstilldoesnotigniteafteranother90secondsofpumpingfuel,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4minutes.
•
Iftheflamegoesoffbyitselfduringoperation,theheaterisrestarted.Iftheheaterdoesnotignitewithin90secondsafterthefuelpumphasstarted,orignitesandgoesoffagainwithin15minutes,theheaterisswitchedoff,i.e.thefuelsupplyisoffandthefanrunsonforapprox.4minutes.Thisstatuscanberemediedbybrieflyswitchingoffandonagain.Donotrepeattheswitchingoff/onroutinemorethantwice.
•
Inthecaseofoverheating,thecombinedsensor(flamesensor/overheatingsensor)triggers,thefuelsupplyisinterruptedandtheheaterswitchedoff.Oncethecauseoftheoverheatinghasbeeneliminated,theheatercanbere-startedbyswitchingoffandonagain.
•
Iftheloweroruppervoltagelimitisreached,theheaterisswitchedoffafter20seconds.
•
Theheaterdoesnotstartupiftheglowplugorblowermo-torisdefectiveoriftheelectricleadtothemeteringpumpisinterrupted.
•
Ifthecombinedsensor(flamesensor/overheatingsensor)isdefectortheelectricleadinterrupted,theheaterstartsupandisthenswitchedoffagainduringthestartphase.
•
Thespeedofthefanmotorismonitoredcontinuously.Ifthefanmotordoesnotstartuporifthespeeddeviatesbymorethan10%,theheaterisswitchedoffafter30sec.
•Whentheheaterisswitchedoff,theglowplugis
switchedonfor40seconds(after-glowing)whilethe
fanrunsontocleanoffanycombustionresidues.
Please note!
Donotrepeattheswitchingoff/onroutinemorethantwice.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
8
Technichaldata3
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical
data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt)
Heaterairflowratewithoutcounterpressure(kg/h) withhoodØ60mm
Fuelconsumption(l/h)
Elektr.powerconsumption(watt)
inoperation(12and24volt)
atstart(12and24volt)
Ratedvoltage
Operatingrange
Lowervoltagelimit:Anundervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit:
Anuppervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic
AirtronicD2/AirtronicD2Camper
D2/D2Camper
Air
Stage
Power Large Medium Small Off
2200 1800 1200 850 –
105 90 60 40 13
0.28 0.23 0.15 0.10 –
34 22 12 8 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.2.7kg
possible
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
9
Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt)
Heaterairflowratewithoutcounterpressure(kg/h) withhoodØ90mm
Fuelconsumption(l/h)
Elektr.powerconsumption(watt)
inoperation(12and24volt)
atstart(12and24volt)
Ratedvoltage
Operatingrange
Lowervoltagelimit:Anundervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit:
Anuppervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicB4
B4
Air
Stage
Power Large Medium Small Off
3800 3200 2100 1300 –
185 160 120 85 24
0.54 0.46 0.29 0.18 –
40 29 15 9 5
#100
12volt
approx.10.5voltUndervoltageprotectiontriggertime:20seconds
16voltOvervoltageprotectiontriggertime:20seconds
PetrolDINEN228(commerciallyavailable)
inoperation nooperation
–40°Cto+50°C –40°Cto+85°C
–40°Cto+20°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
ca.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical
data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
10
Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt) D3
D4
D4Plus
Heaterairflowratewithoutcounterpressure(kg/h)
D3withhoodØ90mm
D4withhoodØ90mm
D4PluswithhoodØ75mm
Fuelconsumption(l/h) D3
D4
D4Plus
Elektr.powerconsumption(watt) D3
inoperation(12and24volt) D4
D4Plus
atstart(12and24volt)
Ratedvoltage
Operatingrange
Lowervoltagelimit:Anundervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit:
Anuppervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicD3/AirtronicD4/AirtronicD4Plus
D3/D4/D4Plus
Air
Stage
Power Large Medium Small Off
3000 2200 1600 900 –
4000 3000 2000 900 –
4000 3000 2000 900 –
150 120 90 60 24
185 150 110 60 24
175 140 100 55 22
0.38 0.28 0.2 0.11 –
0.51 0.38 0.25 0.11 –
0.51 0.38 0.25 0.11 –
24 16 10 7 5
40 24 13 7 5
55 30 16 7 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical
data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
11
Technichaldata3Technichal data
Heatertype
Heater
Version
Heatingmedium
Controloftheheatflow
Heatflow(watt) D4S
D4Camper/D4CamperPlus
Heaterairflowratewithoutcounterpressure(kg/h) D4S
D4Camper/D4CamperPlus
Fuelconsumption(l/h)) D4S
D4Camper/D4CamperPlus
Elektr.powerconsumption(watt) D4S
inoperation(12and24v) D4Camper/D4CamperPlus
atstart(12and24v)
Ratedvoltage
Operatingrange
Lowervoltagelimit:Anundervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Uppervoltagelimit:
Anuppervoltageprotectioninthecontrollerswitchesofftheheaterwhenthevoltagelimitisreached.
Fuel
Tolarableambienttemperature
Heater
Dosingpump
Maximumairintaketemperature
Interferencesuppression
Weight
Ventilationmode
Airtronic M
AirtronicD4S/Airtronic D4Camper/AirtronicD4CamperPlus
D4S/D4Camper/D4CamperPlus
Air
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 0.11 –
40 30 16 8 5
40 24/30 13/16 7/8 5
#100
12or24volt
approx.10.5voltresp.21voltUndervoltageprotectiontriggertime:20seconds
approx.16voltresp.32voltOvervoltageprotectiontriggertime:20seconds
DieselDINEN590(commerciallyavailable)
inoperation nooperation
–40°Cto+70°C –40°Cto+85°C
–40°Cto+50°C –40°Cto+125°C
max.+40°C
Interferencesuppressionclass5toDINEN55025
approx.4.5kg
possible
Providednolimitvaluesaregiven,thetechnicaldatalistedissubjecttothetolerancesusuallyapplicabletoheatersof±10%fornominalvoltage,ambienttemperature20°CandreferencealtitudeEsslingen.
Caution!Safety instructions for technical
data!Failuretocomplywiththetechnicaldatacanresultinmalfunc-tions.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
12
Check values
Test speed for the blower
Airtronic D2 / D2 Camper(12volt/24volt)• 12volt 5000rpm±25%
atU=10,0volt• 24volt 5000rpm±25% atU=18,0volt
AirtronicB4 (12volt)AirtronicD3 / D3
Camper(12volt)AirtronicD4(12volt/24volt)AirtronicD4 Camper(12volt)•
12volt 4400rpm±25% atU=10,0volt• 24volt 4400rpm±25%
atU=18,5volt
AirtronicD4S/Airtronic D4 Plus (12volt/24volt)AirtronicD4 Camper
Plus (12volt)• 12volt 4400rpm±25% atU=10,5volt• 24volt 4400rpm±25%
atU=19,0volt
Resistance values at 20 °C
12 volt 24 volt
Glowplug 0.42 –0.70 1.2 –2.0Dosingpump 9.5±0.50 36.0±1.8
Control unit resistance values
Switch position, left limit stop
Switch position, right limit stop
Controldevice12volt/24volt
min.1720max.1760
min.2096max.2216
Modulartimerandmini-controller12volt/24volt
min.1730max.1780
min.2120max.2240
Switching value Overheatingsensor 140°C–170°C
measuredinthe“High”controlstage andatadistanceof300mmdownstream
fromthehotairoutletExhaust emission specificationCO2 in
exhaustincontrolstage“high”
7,5–12,5Vol.%SmokespotnumberaccordingtoBacharach <4
Temperature (°C)
Res
ista
nce
(ohm
)
2200
2000
1800
1600
1400
1200
1000±40 ±20 0 20 40±10±30 10 30
2400
50
Technicaldata3
Check “external” temperature
sensor(OrderNo.:251774890300)The“external”temperaturesensortestmustbecarriedoutusingadigitalmultimeter.Iftheresistancevalueisnotthesameasthecurveinthediagramorthetableofvalues,re-placethetemperaturesensor.
Table of values – “external” temperature sensor
Temperature°C Resistance
min. max.0 1600 16605 1670 173010 1745 180015 1820 187020 1895
195025 1970 203030 2050 211035 2130 219040 2210 228045 2295
2370
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
13
Troubleshooting4What to check first in case of faults
• Check– Fuelinthetank?– Fuelpipesleaking?(visualcheck)–
Summerdieselinthefuelpipe?–
Combustionairsystemorexhaustsystemdamagedorblocked?
– Hotairsystemblocked?–
Airpressuresensorinstalled?Ifyes,referto„Whattodoif…?“chapterofthe„AltitudeKit“installationinstructions.
– Newgenerationcontrolboxinstalled? Features:
>Cableloomofcontrolboxwoundwithcabletie
>Temperaturesensormountedonthesideofthecontrol
box(visiblewhencoverremoved)
• Electrical components– Cables,connectionsdamaged?–
Contactscorroded?– Fusesdefective?–
Incorrectwiring?(shortcircuits,interrupted/broken)
• Measure battery voltage–
Batteryvoltage<10.5volt,theundervoltageprotectionofthe12voltheaterhastriggered.
– Batteryvoltage<21volt,theun
• Measure voltage supply (Cl 30)
Disconnectthe16-pinconnectorS1/B1andmeasurethevoltageappliedatconnectorB1betweenchamber1(cable2.52rt)andchamber10(cable2.52br).
Ifitdiffersfromthebatteryvoltage,checkthefuses,thesupplycables,thenegativeconnectionandthepositivesupportpointonthebatteryforvoltagedrop(corrosion/interruption).
• Check switch-on signal
Disconnectthe16-pinconnectorS1/B1andthenswitchontheheateratthecontrolunit.
CheckwhethervoltageisappliedintheconnectorB1betweenchamber4(cable0.52ge)andchamber10(cable2.52br).
Ifnovoltageismeasured,thencheckthesupplycable(ca-ble0.52ge),the5Afuse(item2.7.1inthecircuitdiagram)andthecontrolunit.
• Check control unit
Control device, mini-timer, mini-controller and modular
timer
Disconnecttheconnectoratthecontrolunit;installajumperbetweenthered0.5²rtcableandtheyellow0.5²gecable.
IfavoltageismeasuredinconnectorB1betweencham-ber4(cable0.5²ge)andchamber10(cable2.5²br),thenreplacethecontrolunit.
EasyStart R+ / EasyStart R / EasyStart T
Disconnecttheconnectoratthecontrolunit;installajumperbetweentheblack/white0.5²bl/wscableandthered0.5²rtcable.
IfavoltageismeasuredinconnectorB1betweenchamber8(cable0.5²bl/ws)andchamber10(cable2.5²br),thenreplacethecontrolunit.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
14
Troubleshooting4Overview of the test equipment and control units
suitable for diagnosis
Theelectroniccontrolboxcanstoreupto5faults,whichcanbereadoutanddisplayed.Thefollowingtestequipmentand/orcontrolunitscanbeusedtoquerythefaultmemoryinthecontrolboxandifnecessarytodeletethelockingofthecontrolbox:
Test equipment Order No.:
• Testingdevice forthecontroldevice 221509890000
• Diagnosticunit 221529890000 additionallyrequired: Adaptercable
221000318600
• EDiTHdiagnostictool – Basicadapterwithsoftware 221542890000
additionallyrequired: Airtronicextension 221537890000
– ISO-adapter 221541890000 additionallyrequired: Adaptercable
221000318600
– „Airpressuresensor“adaptercable221000333100
Onlyforheaterswithconnectedairpressuresensorfor
readingoutthe„airpressuresensor“faultmemory.
Ifadiagnosticscableisconnected,thefollowingcontrolunitscanalsobeused:
Control units Order No.:
•Moduletimer 221000303400
• TP5radioremotecontrol 221000320100
• EasyStartT 221000328800
• EasyStartR+ 221000328000
Please note!
Ifthefaultmemorycannotbereadout,checkthediagnosticscableforcorrectlayingandpossibledamage.
Important notes on diagnosis of heaters with mini-controller
control unit
Caution!WhencheckingtheheaterwiththediagnosticsunitortheEDiTHdiagnosticstooltheordergiveninthefollowingnotesmustalwaysbefollowedasotherwisetheheaterdetectsError62(controlunit–interruption)andswitchestoemergencyoperation.
Mini-controller in stand-alone operation
•
Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Selectoperatingmode(Heat/Ventilate)atthemini-control-ler
•
PerformdiagnosisusingthediagnosticsunitortheEDiTHdiagnosticstool.
• Switchoffthemini-controllerafterfinishingthediagnosis•
Removetheadaptercable
Mini-controller in combination with mini-timer
•
Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Pressthembuttonofthemini-timer•
Selectoperatingmode(seemini-timeroperatinginstruc-tions)
•
PerformdiagnosisusingthediagnosticsunitortheEDiTHdiagnosticstool.
• Switchoffthemini-timerafterfinishingthediagnosis•
Removetheadaptercable
Mini-controller in combination with TP5
•
Connectadaptercable221000318600asdescribedintheoperatinginstruction.
• Pressthe buttonoftheTP5radioremotecontrol•
Selectoperatingmode(seeTP5radioremotecontroloper-atinginstruction)
• Performdiagnosis.•
SwitchoffTP5radioremotecontrolafterfinishingthediag-nosis
• Removetheadaptercable
Please note!
IftheoperatingmodeistobechangedduringthetesttheheatermustbeswitchedofffirstusingthediagnosticsunitortheEDiTHdiagnosticstool,otherwisetheheaterdetectsError62(controlunit–interruption)andswitchestoemergencyoperation.
Test mini controller
Themini-controllermustbeconnectedtotheheaterfortest-ing.ThesetpointvaluecanbedisplayedusingtheEDiTHdiagnosticstool.Iftherotaryknobisattheleftlimitstopthesetpointvalueis8°C,attherightlimitstopitis34°C.
Please note!
Theresistanceofthesetpointvaluepotentiometercannotbemeasureddirectly.Themeasuredvaluesarenotmeaningful.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
15
Troubleshooting4Testing device for the control
device(OrderNo.:221509890000)
Prepare for
testConnectthecorrectoperatingvoltage(12or24volt)tothete-stingdevice,withplusattheredconnectorsocketandminusattheblueconnectorsocket.
• Disconnectsocketfromthecontrolunit.•
Connectcableloomfromtestingdevicewiththecontrolunit.
•
Settherotaryknobofthecontrolunitto“Heat”,thecorre-spondingredLEDinthetestingdevicemustlightup.
•
Setcontrolunitto“0”,thenpressthe“LED–red”button,theredcontrollampinthecontrolunitmustlightup.
•
Setcontrolunitto“Heat”,thenpressthe“LED–green”button,correspondingredcontrollampinthetestingdeviceandthegreencontrollampinthecontrolunitmustlightup.
Caution!Safety instructions for checking the control
unit!Ensureyouusethecorrectoperatingvoltage,otherwisetheconnectedcomponentscanbeseverelydamaged.
Check the setpoint potentiometer of the control
unitSetthe“Temperaturesensor/Potentiometer”switchinthetestingdevicetothe“Potentiometer”settingandslowlyturntherotaryknobofthecontrolunit.ThegreenLED–temperaturesensor/potentiometermustlightupcontinuously.Incaseofafault,replacethecontrolunit.
1 Testingdevice2 Controldevice
Diagnostic unit(OrderNo.:221529890000)
Anadditionaladaptercableisrequiredtoconnectthediag-nosticunit(OrderNo.:221000318600).
Thecurrentfaultisdisplayedas“AF”anda2-digitnumberandisalwayswritteninthememorypositionF1.PrecedingfaultsaremovedtothememorylocationsF2–F5,ifnecessarythecontentsofmemorypositionF5isoverwrit-ten.
•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
Inheaterswithconnectedairpressuresensorthediagnos-ticsunitcanbeusedtoreadoutthefaultmemoryoftheheateronly.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
l–Deletefaultmemoryl–Deletefaultmemoryd–Switchheateron/off,requestdiagnosise–Reverse,F5–F1f–Forward,F1–F5,currentfault(AF)
Connectdiagnosticsunit,seepage16.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
16
Connect diagnostic unit•
Disconnectthe8-pinconnectoroftheheater’scablehar-nessandconnecttheadaptercable.
• Connectthediagnosticunittotheadaptercable.
Displayisasfollows:
Query fault memory• UsetheDkeytoswitchontheheater.
Displayisasfollows:
• After8secthefollowingisdisplayed: Displayisasfollows:
Heaterhasnomalfunction or
e.g.currenterror/faultcode64
or
Faultdiagnosisnotpossible
Possiblecauses: – Adaptercableisnotproperlyconnected. –
Controlboxisdefectiveorisnotcapableofdiagnosing
(notauniversalcontrolbox).
Display of the fault memory F1 – F5 or F5 – F1•
Presstheeorfbutton,orpressseveraltimes,todisplaythefaultmemory.
Displayisasfollows:
e.g.faultmemory2/faultcode10
Onlythefaultmemorypositionswithanerrorassignedtothemaredisplayed.
Delete fault memory•
PressbothLbuttonssimultaneouslyuntilthefollowingap-pearsinthedisplay:
Displayisasfollows:
•
Ifthefaultmemoryhasbeendeletedthemostrecentcur-rentfaultisdisplayed.Thecurrentfaultisnotresetto00untiltheheaterisrestarted–providedthereisnonew,morerecentfault.
Displayisasfollows:
Heaterhasnomalfunction
Cancel the control box lock•
Deletethefaultmemoryasdescribedandswitchofftheheaterusingthedkey.
• Thecontrolboxlockiscancelledandthediagnosisclosed.
Displayisasfollows:
Troubleshooting4
1 Heater2 Adaptercable3 Diagnosticunit
1
2
3
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
17
Troubleshooting4EDiTH diagnostic tool with ISO
adapter(OrderNo.:221541890000)
AnadditionaladaptercableisrequiredtoconnecttheISOadapter(OrderNo.:221000318600).
• Itisveryimportanttoalwaysinstallinthegivenorder.•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
•
TheEDiTHdiagnosticstoolscopeofsupplydoesnotincludethesoftware;thismustbedownloadedfromtheServicePortal.
Connect ISO adapter
• Disconnecttheheater’scableharness.•
Connecttheadaptercabletothecableharness–asshowninthesketch.
• ConnecttheadaptercabletotheISOadapter.•
ConnecttheSUB-DconnectioncablewiththePCandthe ISOadapter.
Installing the software on your PC•
Doubleclickthe“setup.exe”filetostarttheinstallationandfollowingtheSETUPprograminstructions.
Query / delete fault memory F1 – F5 or cancel the control box
lock• StartthesoftwareonyourPC: –
onthedesktop—>doubleclickthe“EDiTH”icon – Selectheatertype –
Pressthe“GO”button.
• Deletefaultmemoryorcancelthecontrolboxlock: –
pressthe“Deletefaultmemory”button
—>thestoredfaultsF1–F5aredeletedandthecontrol
boxisunlocked.
Quit diagnosis•
Pressthe“STOP”button—>faultmemoryqueryisended.
1 Heater2 Adaptercable3 ISOadapter
4 SUB-Dconnectioncable5 USBtoSerialRS-232adapter
e
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
18
Troubleshooting4Air pressure sensor diagnosis using EDiTH
diagnostics tool and ISO adapter(OrderNo.221524890000)
AnadditionaladaptercableisrequiredtoconnecttheISOadapter(OrderNo.:221000333100).
Theairpressuresensorconnectedtotheheatercanbediag-nosed.Iffaultsoccurduringthealtitudeadjustmenttheyarestoredintheairpressuresensor.Ifnecessary,faultscanbereadoutusingtheISOadapterinconjunctionwiththeEDiTHdiagnosticstool–fromVersionS3V7-F–andtheadditionallynecessaryadaptercable.
Please note!
• Itisveryimportanttoalwaysinstallinthegivenorder.•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonpages27.
•
TheEDiTHdiagnosticstoolscopeofsupplydoesnotincludethesoftware;thismustbedownloadedfromtheServicePortal.
Perform diagnosis of the air pressure sensor
Disconnecttheconnectorbetweentheairpressuresensor/heater,controlunit,connecttheISOadapterwiththeadaptercable(seesketch).Startthediagnosisoftheairpressuresensor.
• Double-clickthe>>EDiTH
-
19
Caution! Magnetic
field!Duringthetestoperationamagneticfielddevelopsattheadapter.Therefore,donotplaceanyobjectssuchasdatamedia,creditcards,etc.ontheadapterorinitsimmediatevicinity.
Troubleshooting4
(A) Basicadapter(B) SUB-Dconnectioncable(C) Mainsconnection(D)
Mainsswitch(E) USBtoSerialRS-232adapter(F) Adapter(G)
Controlbox
Cable colourssw = blackgn = greenbl = blue
EDiTH diagnostic tool with basic
adapterEDiTHbasicadapter(OrderNo.:221542890000)
Anadditionalextensionisrequiredtocheckthecontrolbox(OrderNo.:221537890000).
•
Itisimportanttoalwaysfollowthepreciseconnectionorderasgivenbelow!
•
TheHallsensorintegratedinthecontrolboxcanonlybeproperlytestedinthecontrolboxiscorrectlyplacedontheextension.
• Onlypushorpullontheconnectors,notonthecables!•
OnlyusethenetworkcableandRS232cablewithsnapferritesincludedinthescopeofsupply.Useoriginalacces-sorieswithsnapferritesonlytoconnectthetestequipment.
•
Notonlythedefectivecomponent,butalsoadefectivecurrentcircuitresultsinafaultbeingdisplayed.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Connect basic adapter•
Startcomputerandwaituntilthesystemhassuccessfullybooted.
• StartPCsoftware.•
Inserttheunitconnectorofthemainscableinthebasicadapter(A)andconnectthemainsconnection(C)tothemains.
•
ConnecttheSUB-Dconnectioncable(B)withthePCandbasicadapter(A).
Connect extension and test control box•
Connecttheextensiontothebasicadapter(A).•
Connectthecontrolbox(E)totheextensionandtheadap-ter(F).
• Switchonthebasicadapter(A)atthemainsswitch(D).•
Selectthecontrolboxversionandoperatingvoltage(12V/24V)inthePCsoftware.
•
StartthecontrolboxtestwiththePCsoftware.Amorede-taileddescriptionofhowtooperatethebasicadapters(A)isgivenintheEDiTHonlinehelp.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
20
Troubleshooting4Module timer(OrderNo.:221000303400)
Thecurrentfaultisdisplayedas“AF”andisalwayswritteninmemorypositionF1.PrecedingfaultsaremovedtothememorylocationsF2–F5,ifnecessarythecontentsofmemorypositionF5isoverwrit-ten.
•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
Inheaterswithconnectedairpressuresensorthemodulartimercannotbeusedtoperformdiagnoses.Thediagnos-ticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Query fault memory F1 – F5 Condition:Theheaterisswitchedoff.
• Pressckey–>theheaterisswitchedon.
• Pressakeyandkeeppressed, thenpresspkeywithin2seconds.
Displayisasfollows: AF=currentfault 3digitnumber=faultcode
cflashes.
•
Pressfkeyonceorseveraltimes,faultmemorypositionsF1–F5aredisplayed.
Cancel the control box lock and simultaneously delete the fault
memoryCondition:Anelectricalconnectionexistsfromterminal15(ignition)tothemoduletimer,12-pinconnector,chamber10.
• Pressckey Displayisasfollows: thecurrentfaultF15orF50.
•
Pressbuttona,keepitdepressedandthenpressbuttonpwithin2seconds.
Themoduletimerisnowinthe“Queryfaultmemory”pro-gram.
• Switchoffignition(terminal15).
•
Simultaneouslypressbuttonaandbuttonp,inaddition,switchontheignition(terminal15)andwaituntilthefollow-ingappearsinthedisplay.
Afterignition“ON”thefollowingappearsinthedisplay:
Displayflashes, Heatersymboldoesnotflash
•
Switchtheheateroffandon–>thecontrolboxisunlocked,theheaterrestarts.
Afterswitchingtheheateroffandonandrenewedqueryofthefaultmemory,thefollowingappearsinthedisplay:
Displayflashes, Heatersymboldoesnotflash
a–Timep–Presetc–Heate–Reversef–Forward
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
21
Troubleshooting4TP5 radio remote
control(OrderNo:221000320100)
Iffaultsoccurwhiletheheaterisrunning,theyaredisplayedwith“Err”afterthemobileunitisactivated.
Afterthediagnosticscable(bl/ws)hasbeenconnectedandthefirstlogshavearrivedatthestationaryunit,thediagnosecanbecarriedoutusingthemobileunitoftheTP5radioremotecontrol.Thecurrentfault“F0”isdisplayed.Thestoredfaults“F1”to“F5”canbequeried.
•
Inordertocarryoutthediagnosis,thediagnosticscable(bl/ws)mustbeconnectedtothestationaryunitandtheheatercableharness.Tothisend,pleaserefertoandfollowthecircuitdiagramfortheTP5radioremotecontrolandtheheater.
•
Ifthediagnosticscable(bl/ws)isnotconnected,the“Diag-nosis”menuisblocked.
•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
InheaterswithconnectedairpressuresensortheTP5radioremotecontrolcannotbeusedtoperformdiagnoses.ThediagnosticsunitortheEDiTHdiagnosticstoolmustbeusedtoperformthediagnosis.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Buttontoactivate/deactivatethemobileunit
Buttonforforwardtimesetting
Buttonforbackwardtimesetting
Buttonforactivatingthepossiblesettings
Buttonforswitchingheat/ventilateON/OFF;
Activate/deactivatepreselectedtime
Enquire / delete fault memoryUsethe
keytoactivatethemobileunit.Switchontheheaterwiththe key.Pressthe
keytwicetoopentheTimesettingmenu–thetimeflashesinthedisplay.
Pressthe
keyforapprox2sec–untilthefollowingap-pearsinthedisplay:
Press key.Press key.Press keytwice.Press key.
Malfunctioninheater: Heaterhasnomalfunction:
Usethe and buttonstocallupthefaultmemoryposi-tions1to5.
Delete fault memory / Cancel the control box lockUsethe
keytodeletethefaultmemory.
Toconfirm,pressthe keyforapprox2secuntil
lightsupinthedisplay–faultmemoryisdeleted.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
22
The following actions are possible• Callupfaultmemory.
CallupthefaultmemorypositionsF1–F5with or .
• Callupfaultmemoryagain. Brieflypress and simultaneously.
• Deletefaultmemory (displaydEL) Press .
Press again.
The diagnosis is completed.
Switch off heater.
Enquire / delete fault
memoryActivatemobilepart/timer(seeEasyStartR+/EasyStartToperatinginstructions)
Confirmsymbol with .
Heater is switched on.
Confirmoperatingtimewith .
Brieflypress and simultaneously.
Troubleshooting4EasyStart R+ radio remote
control(Order-No.:221000328000)
EasyStart T timer(Order-No.:221000328800)
Iffaultsoccurwhiletheheaterisrunning,theyaredisplayedwith“Err”afterthemobileunitortimerisactivated.
Thecurrentfaultisdisplayed.Thestoredfaults“F1”to“F5”canbequeried.
•
Inordertocarryoutthediagnosis,thediagnosticscable(bl/geatheaterconnector,bl/wsatcableharnessconnector)mustbeconnectedtothestationaryunitandtheheatercableharness.Tothisend,pleaserefertoandfollowthecircuitdiagramfortheradioremotecontrolandtheheater.
•
Ifthediagnosticscableisnotconnected,the“Diagnosis”menuisblocked.
•
Notonlythedefectivecomponent,butalsoadefectivecur-rentcircuitresultsinafaultbeingdisplayed.
•
Theheaterdiagnosiscanalsobeperformediftheairpres-suresensorisconnected.
Thefaultmemoryofthe„airpressuresensor“canbereadoutusingtheEDiTHdiagnosticstoolonly.
•
Faultcode,faultdescription,cause/remedialactionaredescribedonPages23–27.
Backcontrolkey
Nextcontrolkey
ON/OFFactivationkeymobileunit/timer
OKkey(symbolselection/confirminput)
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
23
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
000 Nofaults ——
004 Warning:Shortcircuitincontrolbox,freshairoutput
•
DisconnectconnectorS1/B1attheheaterandattheconnectorB1,PIN16checkthecableuptothefreshairfanrelayforshortcircuittonegative,ifok—>replacecontrolbox.
005 Warning:Shortcircuitincontrolbox,caralarmoutput
•
DisconnectconnectorS1/B1attheheaterandattheconnectorB1,PIN15checkthecableuptotherelayisolatingswitchorburglaralarmsysteminputforshortcircuittonegative,ifok—>replacecontrolbox.
006
Warning:Inexplicableatmosphericaltitudeinformation(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
Controlboxhasnotreceivedanyexplicablealtitudeinformation.•
ReadoutfaultmemoryintheairpressuresensorusingtheEDiTHdiagnos-ticstoolandcorrectfault.
009 Cut-offADR
ADRshutdownduetosignalchangefrom(+)to(–)atconnectorS1,PIN13(D+)orplussignalatconnectorS1,PIN14(HA+).
010 Overvoltage–cut-off
Overvoltageappliedtocontrolboxforatleast20secondswithoutinterruption–heaternotworking.•
DisconnectconnectorS1/B1attheheater,startthevehicle’sengine,measurethevoltageatconnectorB1betweenPIN1(cable2.52rt)andPIN10(cable2.52br).
Airtronic12volt–voltage>16volt—>checkgeneratorregulator
Airtronic24volt–voltage>32volt—>checkgeneratorregulator
011 Undervoltage–cut-off
Undervoltageappliedtocontrolboxforatleast20secondswithoutinterrup-tion–heaternotworking.•
DisconnectconnectorS1/B1attheheater,thevehicle’sengineisswitchedoff,measurethevoltageatconnectorB1betweenPIN1(cable2.52rt)andPIN10(cable2.52br).
Themeasuredvalueandthevoltageatthebatteryshouldbethesame.
Incaseofavoltagedrop,checkthefuses,thesupplycables,thenegativeconnectionsandthepositivesupportpointonthebatteryforcorrosionandcorrectcontact.
012 Overheatingattheoverheatingsensor
Temperatureoftheoverheatingsensortoohigh.•
Checkhotairpipesforblockage—>removeblockage.•
Sumofthecomponentratingsofair-conductingpartsistoolarge—>Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
•
Checkoverheatingsensor,fordiagramandtableofvaluespleaserefertoPage32,ifok—>measurefuelquantity,seePage36.
013 Overheatingattheflamesensor
Flamesensorsignalstemperatureatheatexchangeristoohigh.•
Checkhotairpipesforblockage—>removeblockage.•
Sumofthecomponentratingsofair-conductingpartsistoolarge—>Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
•
Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsensordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,fordiagramandtableofvaluesforflamesensorandoverheatingsensorpleaserefertoPage32.
014
Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge
Temperaturedifferencebetweenflamesensorandoverheatingsensortoolarge•
Checkhotairpipesforblockage—>removeblockage.•
Sumofthecomponentratingsofair-conductingpartsistoolarge—>Checkairsystem,ifnecessaryre-lay–forcomponentratings,pleaserefertoadditionalpartscatalogue.
•
Checkflamesensor,ifok—>checkoverheatingsensor,ifoverheatingsen-sordefective—>replacecombinationsensor,ifoverheatingsensorok—>measurefuelquantity,seePage36,iffuelquantityok—>replacecontrolbox.Fordiagramandtableofvaluesforflamesensorandoverheatingsen-sor,seePage32.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
24
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
015 Operatinglock-out
Thefaultcode015isdisplayed,iftheheaterwasswitchedbackonafterthefaultcodedisplay017.
Thehardwarethresholdvaluefortheoverheatingsensorhasbeenexceeded—>thecontrolboxislocked.
• Replacecontrolbox.
017 Overheating
Thehardwarethresholdvaluefortheoverheatingsensorhasbeenexceeded,becausethecontrolboxfailedtorecognisethefaultcode012or013–>thecontrolboxislocked.Iftheheaterisswitchedonagain,thefaultcode015isdisplayed.•
Replacecontrolbox.
018
Startingenergyoftheglowplugistoolow(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
• Checkglowplug(seefaultcode020and021),ifok•
Checkglowplugcableharnessforcorrectlayinganddamage,ifok—>checkcableharnessforcontinuity,ifok—>replacecontrolbox.
019 Ignitionenergytoolow
•Checkglowplug(seefaultcode020and021),ifok•
Checkglowplugcableharnessforcorrectlayinganddamage,ifok—>checkcableharnessforcontinuity,ifok—>replacecontrolbox.
020
021
Glowplug–interruption
Glowplug–shortcircuit,overloadorshortcircuitafternegative
• Checkglowplugforfunctionandcontinuityatambienttemperature20°C.
12voltheater–0.42upto±0.7 24voltheater–1.2upto±2.0
•
Ifthevaluesareok—>checkglowplugleadharnessfordamageandcon-tinuity,ifok—>replacecontrolbox.
022 * Glowplug,output(+)–shortcircuitafterUB(batteryvoltage)
•
Checkglowplugleadharnessforcorrectlayinganddamage,ifok—>checkleadharnessforcontinuity,ifok—>replacecontrolbox.
025 *
Diagnosticscablebl/ws–shortcircuit–afterUB(batteryvoltage)
Faultcodedisplayisnotpossible.Thisfaultcodecannotbereadoutfromthefaultmemoryuntilthefaulthasbeencorrected.•
Checkdiagnosticscableforcorrectlayingandpossibledamage.
031 Blower–interruption •
Checkthattheleadharnessoftheblowermotorhasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessatcontrolboxandcheckforcontinuity,ifok—>replacecontrolbox.
032 Blowermotor–shortcircuitafternegative
Please note!
Ensurecompliancewiththetestvolt-age(seepage12).Thecomponentisdestroyedifthevoltagevalueisexceeded.Ensure
the power pack has ad-equate short-circuit resistance – min 20
A.
•
Carryoutfunctionaltestontheblowermotor,todothisremovethecon-nectorfromthecontrolbox.Applyatestvoltage(seepage12)totheblow-ermotorandmeasurethecurrentintensityafter40sec.
Currentintensity<6.5A–blowermotorok–>replacecontrolbox.
Currentintensity>6.5A—>replaceblower.•
Checkwiringforshortcircuit.
033 Blowermotorwon’trotateorshortcircuitafternegative
Please note!
Ensurecompliancewiththetestvolt-age(seepage12).Thecomponentisdestroyedifthevoltagevalueisexceeded.Ensure
the power pack has ad-equate short-circuit resistance – min 20
A.
Speeddeviation>10%fromsetpointvalueforlongerthan30seconds.Useanon-contactr.p.m.countertomeasurethespeedofthecombustionairfan(seepage12fortestspeedandtestvoltage).
• Speedtoolow:
Blowerblocks–checkblowerforfreerunning,ifnecessaryremoveforeignbody,ifok—>checkblower(seefaultcode032).
• Speedtoohigh:
–Magnetmissingfromblowerimpeller—>replaceblower. –
Speedsensorincontrolboxisdefective—>replacecontrolbox.•
Checkwiringforshortcircuit.
*
Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
25
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
034 *
Blowermotor,outlet(+)shortcircuitafterUB(batteryvoltage)
•
Checkthattheleadharnessoftheblowermotorhasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessatcontrolboxandcheckforcontinuity,ifok—>replacecontrolbox.
047 Meteringpump–shortcircuitoroverload
•
Removeconnectorfromthemeteringpump,ifthefaultcode048(inter-ruption)isdisplayedthemeteringpumpisdefective—>replacemeteringpump.
•
Ifthefaultcode047continuestobedisplayed,disconnectconnectorS1/B1attheheater,andattheconnectorB1,PIN5checkthecable12gn/rtuptothemeteringpumpforshortcircuittonegative(PIN10),ifok–>replacecontrolbox.
048 Meteringpump–interruption •
Disconnectconnectorfrommeteringpumpandmeasuretheresistancevalueofthemeteringpump(seePage12forvalues),ifresistancevalueok,re-connectthecableloomtothemeteringpump.
•
DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalue(seePage12)betweenPIN5andPIN10,ifok—>replacecontrolbox.
049 *
Meteringpumpoutlet(+)Shortcircuit–afterUB(batteryvoltage)
•
Checkthattheleadharnessofthemeteringpumphasbeencorrectlylaidandcheckfordamage,ifok—>removeleadharnessandcheckforconti-nuity,ifok—>replacecontrolbox.
050 Toomanyfailedstartattempts(opera-tinglock-out)
Thecontrolboxlocksaftertoomanyfailedstartattempts(max.255startat-tempts).•
Unlockthecontrolboxbydeletingthefaultmemorywiththetimer,thediagnosticunit,EDiTHdiagnostictool,theTP5radioremotecontrol/EasyStartR+andtheEasyStartTtimer.
051 Flamedetectedwhenswitchingon
If,afterbeingswitchedon,theresistancevalueoftheflamesensoris1274(>70°C)theheater’sfanrunsforapprox15mintocooldown,iftheresist-ancedoesnotfallbelowtheaforementionedvaluewithin15mintheheaterisswitchedoff.
•
Checkflamesensor,seePage32fordiagramandtableofvalues,ifok—>replacecontrolbox.
052 Safetytimeexceeded Noflamedetectedwithinthestartphase.•
Checkexhaustandcombustionairsystem.•
Checkfuelsupply/measurefuelquantity,seePage36.•
Checksparkplug(seefaultcode020and021)•
Checkflamesensor,diagramandtableofvalues,seePage32,ifok—>replacecontrolbox.
053
054
055
056
Flamecutoutinthe
“POWER”controlstage
“HIGH”controlstage
“MEDIUM”controlstage
“LOW”controlstage
Theheaterhasignited(flamedetected)andsignalsflamecutoutduringapowerstage.
• Checkexhaustandcombustionairsystem.•
Checkfuelsupply/measurefuelquantity,seePage36.•
Checkflamesensor,diagramandtableofvalues,seePage32,ifok—>replacecontrolbox.
057
Flamecutoutfromstartphase(Displayonlyifheaterslabelled“H-Kit”onthenameplate.)
Aflamecutoutwasdetectedduringthestartphase..•
Checkexhaustandcombustionairsystem.•
Checkfuelsupply/measurefuelquantity,seePage36.•
Checkglowplug(seefaultcode020and021).•
Checkflamesensor,diagramandvaluestable,seepage32,ifok—>replacecontrolbox.
060 Externaltemperaturesensor–interruption
•
DisconnecttheconnectorS4/B4oftheexternaltemperaturesensorandmeasuretheresistancevalueatconnectorB2,fordiagramandtableofva-luesseePage12,iftemperaturesensorok,reassembleconnectorS4/B4.
•
DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalueinconnectorhousingB1betweenPIN6andPIN12.Ifinterruptedtheohmicvalueis>7175/3k*.Ifresistancevalueok—>replacecontrolbox.
*
Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
26
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
061 Externaltemperaturesensor–shortcircuit
•
DisconnectconnectorS4/B4oftheexternaltemperaturesensor,iffaultcode060isdisplayed—>checkexternaltemperaturesensor,diagramandtableofvalues,seePage32.Iftemperaturesensorok—>checkconnec-tioncables0.5grand0.5br/wsforshortcircuit,ifok,reassemblethecon-nectorS2/B2.
•
DisconnectconnectorS1/B1attheheaterandmeasuretheresistancevalueinconnectorhousingB1betweenPIN6andPIN12.Incaseofshortcircuittheohmicvalueis<486/<800*.
Iferror061continuestobedisplayed—>replacecontrolbox.
062 Controlunit–interruption
Please note!
Refertonotesondiagnosiswithmini-controlleronpage14.
Heaterrunsin„High“controlstageonly•
Removeconnectoratthecontrolunitandmeasuretheresistancevalueofthesetpointpotentiometer,forconnectorpinsseePage42onwards.Iftheresistancevalueisok,reconnectconnectoratthecontrolunit.
•
DisconnectconnectorS1/B1attheheater,measuretheresistancevaluebetweenPIN6andPIN7inconnectorhousingB1,ifresistancevalueok—>replacecontrolbox.Resistancevalueincaseofinterruption>7175
/>3k *.Normalvalues:seepage12.
063 Controlunit–shortcircuit
Faultrecognitiononlyworksinhea-tingmode.If,ontheotherhand,theshortcircuithasalreadyoccurredandthentheheaterisswitchedon,„Venti-lation“isactive(notafaultcode).
•
Ifthe“Ventilate”switchisinstalled,disconnectitandcheckitworks.Ifnotok—>replaceswitch.
•
Disconnectconnectoratcontrolunit,iferrorcode062isdisplayed,replacethecontrolunit.Ifcontrolunitok,checkconnectioncables0.5gr/rtand0.5br/wsforshortcircuit,ifok—>reconnectconnectoratcontrolunit.
•
DisconnectconnectorS1/B1attheheater,iftheerror063continuestobedisplayed—>replacecontrolbox.Resistancevalueincaseofshort-circuit<486
/ <800 *.Normalvalues:seepage12.
064 Flamesensor–interruption •
Dismantlecontrolboxanddisconnectgreenconnectorfromcontrolbox.Checkflamesensor,diagramandtableofvalues,seePage32,ifflamesen-sorok—>replacecontrolbox.Resistancevalueincaseofinterruption>7175
/>3k *.
065 Flamesensor–shortcircuit
Dismantlecontrolbox,removegreenconnectorfromcontrolbox,iferror064isdisplayed—>replacecombinationsensor.
Iferror065continuestobedisplayed—>replacecontrolbox.
Resistancevalueincaseofshortcircuit<486
/<500*,seealsodia-gramonPage32.
071 Overheatingsensor–interruption •
Dismantlecontrolbox,disconnectblueandgreenconnectorsfromcontrolbox.MeasureresistancevalueatblueconnectorPIN1(cable0.52bl)andatgreenconnectorPIN2(cable0.52br/ws),ifok,—>replacecontrolbox.
Resistancevalueincaseofinterruption>223k />1600k
*,seealsodiagramonPage32.
072 Overheatingsensor–shortcircuit •
Dismantlecontrolbox,removeblueconnectorfromcontrolbox,iferror071isdisplayed—>replacecombinationsensor.
Iferror072continuestobedisplayed—>replacecontrolbox.
Resistancevalueincaseofshortcircuit<183
/<95*,seealsodia-gramonPage32.
074 * Controlboxdefective
•Overheatingthresholdvalueisnotdetectedbycontrolbox—>replacecon-trolbox.
090 Controlboxdefective(internalfault) • Replacecontrolbox.
091 Externalinterferencevoltage •
Controlboxfaultduetointerferencevoltagesfromthevehicle’selectricalsystem.Possiblecauses:
Poorbattery,charger—>removeinterferencevoltage.
092 Controlboxisdefective(ROMerror) • Replacecontrolbox.
093 * Controlboxdefective • Replacecontrolbox.
*
Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
27
Troubleshooting4Fault codeDisplay
Fault description Comments• Remedial action
094 Controlboxdefective(EEPROM-Fehler)
• Replacecontrolbox.
095 * Controlboxdefective • Replacecontrolbox.
096 Internaltemperaturesensordefective •
Replacecontrolboxoruseanexternalroomtemperaturesensor..
097 Controlboxdefective • SReplacecontrolbox.
098 * Controlboxdefective • Replacecontrolbox.
099 * Toomanyresetsinsequence
Transistorerrorincontrolbox
•
Voltageshort-term<5–6volt(for12volt)or<7–8volt(for24volt).
Incaseofavoltagedrop,checkthefuses,thesupplycables,thenegativeconnectionsandthepositivesupportpointonthebatteryforcorrosionandcorrectcontact.
Testcontrolboxwithtestingdevice,ifok—>checkleadharnessoftheex-ternalcomponentshasbeencorrectlylaidandcheckfordamage,ifok—>checkleadharnessforcontinuity,ifok—>replacecontrolbox.
Air pressure sensor fault code displayFault code display
Fault description Comments• Remedial action
0 Nofaults —
11 Communicationloss
Interruptionofthediagnosticscablebetweenthecontrolbox(heater)andtheairpressuresensor•
Checkwiringandplug-inconnections
12 Noaltitudeadjustment
Controlbox(heater)doesnotsupportaltitudeoperationwiththeairpressuresensor•
Useacontrolbox(heater)whichsupportsaltitudeadjustment
13 Airpressuresensorfault Theairpressuresensorisdefective•
Replacetheairpressuresensor
*
Thisfaultcodeorohmicvalueisvalidforanewgenerationcontrolboxonly.Thisdiffersfromthecontrolboxtodatebyitscableloomwrappedincabletapeandbyatemperaturesensormountedontheside,whichbecomesvisiblewhenthecoverisremoved.
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
28
Repair instructions
Thepermittedrepairworktotheheaterisdescribedinthe“RepairInstructions”chapter.Ifextensiverepairsarenecessary,itmakessensetodismantletheheater.
Theheaterisassembledinthereverseorder,ifapplicablenotadditionalinstructions.
Aftercompletingalltheworkontheheater,youmustcarryoutafunctionalcheck(seePage4).
Always observe the following safety instructions before working
on the heater:
Danger!Risk of injury, burns and poisoning!•
Alwaysswitchofftheheaterbeforehandandleaveittocool.•
Disconnectthebattery.•
Theheatermustnotbeoperatedinclosedroomssuchasgaragesorworkshops.
Exception:
Exhaustsuctionavailabledirectlyattheentrytotheexhaustpipe.
Caution!• Thesealsofdismantledcomponentsmustberenewed.•
Duringrepairwork,checkallcomponentsfordamageandifnecessaryreplace.
•
Checkconnectorcontacts,plug-inconnectionsandcablesforcorrosionanddamageandifnecessaryrepair.
•
OnlyeveruseEberspächersparepartsifreplacementsarenecessary.
•
Operationortheafterrunningoftheheatermayonlybestoppedinanemergency(see“EMERGENCYOFF”Page8)byinterruptingthebatterycurrent(riskofheateroverheat-ing).
Repairinstructions5Special tool
AMP release tool
TheAMPreleasetoolisusedtoreleaseplug-incontactsinaconnectorhousing.
ThisreleasetoolcanbeordereddirectlyfromAMP.
• ForMicroTimer: AMPOrderNo.0-0539960-1
• ForJunior-Power-Timer: AMP-Bestell-Nr.1-1579007-6
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
29
Assembly drawing Airtronic / Airtronic M
Partslist
1 Combustionairfan 2 Seal–combustionairfan/heatexchanger 3
Combustionchamber 4 Seal–combustionchamber/heatexchanger 5
Heatexchanger 6 Controlbox 7
Combinationsensor(overheating/flamesensor)with
assemblytool
8 Bracket 9 Glowplug,withspecialtool(SW12)10
Lining–glowplugsocket,withassemblytool11 Cover12
Outershell(bottomsection)13 Flangeseal14 Sleeve(forpetrolonly)
Repairinstructions5
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
30
Repair step 1Remove the heater’s cover (seeFigure1)
Unlockbothfasteningclips,liftthecoverandremovefromthefront.
Theheater’scovermustberemovedforallrepairsteps.Ifnecessary,waituntiltheunithascooleddown.
Cableharnessoutletfromthehousingoptionallyonleftorright-handside.
1. 2.
Figure1
Cover Fasteningclips
Repair step 2Dismantle control box (seeFigure2)
• Repairstep1.• Unscrewfixingscrew,•
Presstogethertheretainingclamps.• Removethecontrolboxfromabove.•
Unclipcablesfromholderoncontrolbox (Notethepositionofthecables).•
Pullgrommetoutoftheoutershell(bottomsection).•
Pullconnectoroutofcontrolbox,thecontrolboxcannowberemoved.
Whenassemblingthecontrolbox,ensurethecablesareclip-pedintotheholderonthecontrolboxandtheconnectorsarepluggedintothecontrolbox(unmistakeable).TighteningtorqueofthefixingscrewItem:2+0.2Nm
Figure2
Fixingscrew Retainingclamp Controlbox Grommet
Check control box
TheEDiTHdiagnostictoolisrequiredtocheckthecontrolboxwhenitisdismantled.Forconnection,useandOrderNo.,seePage19.
5 Repairinstructions
Please note!
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
31
Repair step 3Dismantle glow plug (seeFigure3)
• Repairstep2.•
Disconnectconnectorfrom“glowplug”cableloomoncon-trolbox.
•
Removerubbergrommetandunscrewtheglowplugusingthespecialtool(SW12).
(Thespecialtoolisincludedwiththeglowplug).
Tighteningtorqueforglowplug:6+0.5Nm
Specialglowplugtool
Withtheglowplugdismantled,visuallycheckthesocketliningoftheinstalledglowplugfordirt.Iftheliningishighlysoiledanditssurfaceclosed,renewthelining.
Figure3
Glowplug Connectorfromglowplugcableloom Rubbergrommet
Removing the lining (see Figure 4)
Uselongnoseplierstopulltheliningoutofthesocketfromabove.Blowoutthesocketwithcompressedairandifnecessarycleanthesideventhole.
Usethespecialtooltoinstallthenewlining.Thespecialtoolisincludedwiththelining.Pushtheliningonthetool.Pushinthetooltogetherwiththelininguptothelimitstop.
Figure4
Specialtool Lining
5
Repairinstructions
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
32
Repair step 5 Dismantle combination sensor (overheating / flame
sen-sor) (seeFigure5)
• Repairstep2.•
Removebothconnectorsfromthe“combinationsensor”cableloomatthecontrolbox.
• Unlockbracketfromcombinationsensor.•
Removethecombinationsensor.
Figure5
“Combinationsensor”cableloom Bracket,unlocked
Check combination sensor
Theexternaltemperaturesensormustbecheckedwithadig-italmultimeter.Replacetheoverheatingorflamesensoriftheresistancevalueisnotthesameasthecurveinthediagramorthetableofvalues.
Table of overheating sensor values
Temperature °C Resistance k min. max. – 40 1597.00 1913.00 – 20
458.80 533.40 0 154.70 175.50 20 59.30 65.84 40 25.02 28.04 60
11.56 13.16 80 5.782 6.678 100 3.095 3.623 120 1.757 2.081 140
1.050 1.256 160 0.6554 0.792 180 0.4253 0.5187 200 0.2857
0.3513
Table of flame sensor values
Temperature °C Resistance min. max.– 40 842.7 825.9 859.6– 20
921.6 803.2 940.0 0 1000.0 980.0 1020.0 20 1077.9 1056.4 1099.5 40
1155.4 1132.3 1178.5 60 1232.4 1207.8 1257.1 80 1308.9 1282.8
1335.1 100 1385.1 1357.4 1412.8 120 1460.7 1431.5 1489.9 140 1535.8
1505.1 1566.6 160 1610.5 1578.3 1642.8
Resistance(kOhm)
Temperature(°C)
5
Notethemax.temperatureof320°Cforthetest.
Temperature(°C)
Resistance(Ohm)
Overheating sensor Flame sensor
Repairinstructions
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
33
Sketch2
Specialtool–onlyrequiredforAirtronic Combinationsensor
Figure6
Specialtool–onlyrequiredforAirtronic Combinationsensor
Repair step 6 Install combination sensor (overheating / flame
sensor)(seeFigure6,7andSketch2–4)
•Repairstep2.• ForAirtronic(assemblywithspecialtool,seeSketch2)
Pushthespecialtoolaontothecombinationsensorb.Usethespecialtooltopositionthecombinationsensorontheheatexchanger,thespecialtoolslidesontheheatexchang-eruntilthecombinationsensorhitsthecollar(installationpositionofthecombinationsensor).
Lockthecombinationsensor’sbracketandremovethespecialtool.Thenalwayscheckthatthecombinationsen-sorsitsflatontheheatexchanger.Ifnecessary,useaidssuchasamirrorandlamp.
Laythe“combinationsensor”cableloomalongthebracket,throughthebracketeyeletuptothecontrolboxandcon-nect.
• ForAirtronicM(assemblywithoutspecialtool)
Placethecombinationsensorontheheatexchanger;itisimportanttoensurethecombinationsensorsitsflatontheheatexchanger.
Lockthecombinationsensor’sbracketandcheckagainthatthecombinationsensorissittingflatontheheatex-changer.
Laythe“combinationsensor”cableloomalongthebracket,throughthebracketeyeletuptothecontrolboxandcon-nect.
Sketch4
Bracket Combinationsensor
Figure7
Bracket,locked “Combinationsensor”cableloom
Specialtool–onlyrequiredforAirtronic
Circuit diagram for combination sensor (overheating sensor /
flame sensor)
Sketch3
NTC50KΩ=overheatingsensorPT1000=flamesensor
Connectorblue
Connectorgreen
5 Repairinstructions
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
34
Repair step 7 Dismantle heat exchanger
(seeFigure8andSketch5)Dismantle combustion air fan
(seeFigure8andSketch5)
• Repairstep2.•
Removeflangeseal.Removeheaterfromtheoutershell(bottomsection).
Unscrewthe4fixingscrewsfromthecombustionairfan.
Removethecombustionairfanandthesealfromtheheatexchanger.
Caution!Wheninstallingthecombustionairfanthesealmustalwaysberenewed.
Tightenthe4fixingscrewsofthecombustionairfan–intheordershowninSketche–withatighteningtorqueof4+0.5Nm.
Figure8
Combustionairfan Heatexchanger Fixingscrew
Sketch5
1–4 Tightenthefixingscrewsinthisorderwithatightening
torqueof4+0.5Nm
5
5
Alwaysrenewthesealbetweenthecombustionairfanandtheheatexchanger.
5
2
4
3
1
Repairinstructionshttp://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
35
Repair step 8Dismantle combustion chamber
(seeFigure9andSketch6)
• Repairstep3.• Repairstep7.• Unscrewthefixingscrews.
IntheAirtronic=3fixingscrews, intheAirtronicM=4fixingscrews.•
Pulloutthecombustionchamberfromthefrontandremovetheheatexchanger’sseal.
Caution!Whenassemblingthecombustionchamber,alwaysrenewtheseal,whichisincludedwiththesparepart.
Tightenthefixingscrewsofthecombustionchamberwithatighteningtorqueof5+0.5Nm
Iftheheatexchangerisreplacedthecombinationsensor(overheatingsensor/flamesensor)mustbedismantledandfittedonthenewheatexchanger(seeRepairstep6,Page33).
Sketch6
1Combustionchamber2Alwaysrenewthesealbetweenthecombustionchamberandtheheatexchanger.
3Heatexchanger
4Fixingscrew Airtronic=3fixingscrews
AirtronicM=4fixingscrews
Figure9
Combustionchamber Heatexchanger Fixingscrew
Airtronic=3fixingscrews AirtronicM=4fixingscrews
5
4
1
2
3
Repairinstructions
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
36
Measuring the fuel quantity
1. Preparation
Removethefuelpipeattheheaterandinsertameasuringcylinder(size10ml).Switchontheheater,ifthefuelisuniformlypumped(beginsapprox.60secafterbeingswitchedon),thefuelpipeisfullandvented.Switchoffheaterandemptymeasuringcylinder.
Forprecisefuelmeasurementatleast11volt/22voltormaximum13volt/26voltshouldbeappliedtothecontrolboxduringthemeasurement.
2. Measurement
Thefuelbeginstobepumpedapprox.60secafterswitchingontheheater.Holdthemeasuringcylinderatglowpluglevelduringthemeasurement.
Airtronic
Afterapprox.90secofthefuelbeingpumpeditisautomati-callyswitchedoff.
Caution!Switch off heater,asotherwiseitwillstartupagain.
Readoffthequantityoffuelinthemeasuringcylinder.
Airtronic
MAfterapprox.105secofthefuelbeingpumpeditisautomati-callyswitchedoff.
Caution!Switch off heater,asotherwiseitwillstartupagain.
Readoffthequantityoffuelinthemeasuringcylinder..
Ifthemeasuredfuelquantityliesoutsidethevaluesgivenbelow,themeteringpumpmustbereplaced.
1 Heater2 Meteringpump
Check fuel supply
Beforemeasuringthefuelquantity,checkthefollowingpointsinthefuelsupply.
• Checkthescreeninthemeteringpump.•
Checkthelayingofthefuelpipes.• Checkfuelpipesforleaks.•
Checkandtightenthehoseconnections.•
Isthefuelremovalinstalledaccordingtothedetailsinthetechnicaldescription?
5
3 Measuringcylinder(size10ml)4
Disconnectfuelpipeatheaterandinsertinameasuringcylinder.
1
2
3
4
Table of values – fuel quantity
Heater Fuel Fuel quantity
Minimal Maximal
Airtronic diesel 3,5ml/90sec 4,3ml/90sec
AirtronicM petrol 6,8ml/105sec 7,6ml/105sec
AirtronicM diesel 5,0ml/105sec 6,0ml/105sec
Bitte beachten!
Repairinstructionshttp://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
37
Circuitdiagram6Overview of the parts lists and circuit
diagrams
PartslistcircuitdiagramAirtronic/AirtronicM................................................................................................................................
38CircuitdiagramAirtronic/AirtronicM..............................................................................................................................................
39
Thiscircuitdiagramisforheaterswithonediagnosticscableandacontrolboxcableloomwhichisfirmlyencapsulated.CircuitdiagramAirtronic/AirtronicM..............................................................................................................................................
40
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
Partslistcontrolunits.....................................................................................................................................................................
41Circuitdiagramscontrolunits...................................................................................................................................................42–48
PartslistEasyStartR+/R/Tcontrolunits.....................................................................................................................................
49EasyStartR+circuitdiagram...................................................................................................................................................50–52EasyStartRcircuitdiagram......................................................................................................................................................53–55EasyStartTcircuitdiagram.......................................................................................................................................................
56,57
PartslistcircuitdiagramAirtronic/AirtronicM–ADR.....................................................................................................................
58CircuitdiagramAirtronic/AirtronicM–ADR...................................................................................................................................
59
Thiscircuitdiagramisforheaterswithonediagnosiscableandacontrolboxcableloomwhichisfirmlyencapsulated.CircuitdiagramAirtronic/AirtronicM–ADR...................................................................................................................................
60
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolboxcableloomiswoundwithcabletape.
Partslistcontrolunits–ADR..........................................................................................................................................................
61Circuitdiagramcontrolunits–ADR...............................................................................................................................................
62EasyStartT–ADRcircuitdiagram............................................................................................................................................
63,64
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
38
Parts list circuit diagrams Airtronic / Airtronic M
1.1 Burnerengine1.2 Glowplug1.5 Overheatingandflamesensor2.1
Controlbox2.2 Meteringpump2.7 Mainfuse 12volt=20A
24volt=10A2.7.1Fuse,actuation5A5.1 Battery
a)
Connectionofcontrolunitandexternalsensoraccord-ingto“controlunits”circuitdiagram
•rt Powersupply,plus–terminal30 •ge Switch-onsignal–S+ •gr
Temperature–actualvalue •wsrt Switchofftheanti-theftalarmsystem
(ADR–feedbacksignalfortimer) •br Powersupply,minus–terminal31 •blws
Diagnosis •grrt Temperature–setpoint •brws
Groundconnectionforexternaltempera-
turesensorandtemperaturesetpoint b) Option •Vehiclefancontrol
and/or •separatefreshairfan
Thecircuitdiagramsareassignedviatheinstalledcontrolbox:•
Controlboxwithonediagnosticscable:
Atthe16pinconnectorthediagnosticscablebl/wsiscon-nectedtochamber8.
• Controlboxwith2diagnosticscablesandJEdiagnosis:
Atthe16pinconnectorthediagnosticscablebl/wsisconnectedtochamber3,thediagnosticscablebl/geisconnectedtochamber8.
• Insulateunusedcableends.•
Connectorsandbushhousingsareshownfromthecableinletside.
Circuitdiagram6
Cable colours circuit diagramssw = blackws = whitert = redge =
yellowgn = greenvi = violetbr = browngr = greybl = blueli =
purple
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
39
Circuit diagram – Airtronic / Airtronic M
252069009801APartslistPage38
Circuitdiagram6
Thiscircuitdiagramisforheaterswithadiagnosticscableandwhosecontrolboxcableloomwhichisfirmlyencapsulated.
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
40
Circuit diagram – Airtronic / Airtronic M
Circuitdiagram6
Thiscircuitdiagramisforheaterswith2diagnosticscableandwhosecontrolunitcableloomiswoundwithcabletape.
252069009801BPartslistPage38
Bitte beachten!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic
-
41
Circuitdiagram6Parts list circuit diagrams, control units
2.15.1 Temperaturesensor,external(roomtemperature)2.15.9
Temperaturesensor(externaltemperature)3.1.9
Changeoverswitch“heat/ventilate”3.1.11 Controlunit,round3.1.16
Radioremotecontrolbutton3.1.17 MinicontrollerAirtronic3.1.18
ButtonCalltronic3.2.8 Moduletimer(ADR–potentiometer)3.2.12
Timer,mini–12/24volt3.2.14 Lighting,timer,mini–12voltonly3.3.6
RadioremotecontrolstationarypartTP41i3.3.7
RadioremotecontrolstationarypartTP53.3.8
RemotecontrolCalltronic3.8.3 Antenna3.9.1 Diagnosis,JEdiagnosis
a)ConnectioncontrolelementstotheAirtronic •rt
Powersupply,plus–terminal30 •ge Switch-onsignal–S+ •gr
Temperature–actualvalue •wsrt Switchoffburglaralarm
(ADR–feedbackfortimer) •br Powersupply,minus–terminal31 •blws
Diagnosis •grrt Temperature–setpoint •brws
Groundconnectionforexternaltempera-
turesensorandtemperaturesetpoint b)
Terminal15–necessaryforconnectionTP4i c) Lighting,terminal58d)
Connection,diagnosticunit e) Connection,externaltemperaturesensor
g) Connection,externalheatingbutton h)
Connection,radioremotecontrolTP4i j)
Connection,temperaturesensor(outsidetemperature) k)
Ifconnectingtimerorradioreceiver– Disconnectcablehere l)
Connection,change-overswitch“heat/ventilate” option)
Initialoperation:Activatechangeoverswitch
“heat/ventilate”,thenswitchontheheater. z) Lighting,terminal58
• Insulateunusedcableends.•
Connectorsandbushhousingsareshownfromthecableinletside.
Cable colours circuit diagramssw = blackws = whitert = redge =
yellowgn = greenvi = violetbr = browngr = greybl = blueli =
purple
Please note!
http://www.hagerbv.com/catalogus/87-eberspacher-d2-airtronic