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Eberspacher Airtronic D4 Manual

Oct 25, 2015

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David Butler

Technical manual for the Eberspacher Airtronic D4 heater designed to support anyone installing the heater or users looking for important technical information about this product.
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Page 2: Eberspacher Airtronic D4 Manual

AIRTRONIC / AIRTRONIC MTechnical description, installation,

operation and maintenance instructions.

Air heater for diesel and petroloperating independently of the engine.

Airtronic Order no.

Airtronic D2, 12 V 25 2069 05 00 00Airtronic D2, 24 V 25 2070 05 00 00

Complete packageAirtronic D2, 12 V 25 2115 05 00 00Airtronic D2, 24 V 25 2116 05 00 00

Airtronic M Order no.

Airtronic D3, 12 V 25 2317 05 00 00

Airtronic B4, 12 V 20 1812 05 00 00

Airtronic D4, 12 V 25 2113 05 00 00Airtronic D4, 24 V 25 2114 05 00 00

Airtronic D4 Plus, 12 V 25 2484 05 00 00Airtronic D4 Plus, 24 V 25 2498 05 00 00

25 2069 90 99 5201.2011

Page 3: Eberspacher Airtronic D4 Manual

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8

7

Introduction1

Contents

Chapter Title Contents Page

Introduction • Contents ................................................................................................ 2• Concept of this manual .......................................................................... 3• Special text structure, presentation and picture symbols ....................... 4• Important information before starting work ............................................. 4• Statutory regulations .......................................................................... 5, 6• Safety instructions for installation and operation ................................... 7• Accident prevention ............................................................................... 7

Product information • Scope of supply: heater, universal installation kitand complete packages ..................................................................... 8, 9

• Scope of supply: heater and “Plus” installation kit .......................... 10, 11• Technical data Airtronic D2 .................................................................. 12• Technical data Airtronic D3, D4, D4 Plus ............................................. 13• Technical data Airtronic B4 .................................................................. 14• Main dimensions ................................................................................... 15

Installation • Installation and location ....................................................................... 16• Installing the 24 V heater in a vehicle for the transport

of dangerous goods .............................................................................. 17• Installation location ........................................................................ 16, 17• Possible installation positions ............................................................... 18• Cable harness connection, right or left ................................................. 18• Mounting and fastening ........................................................................ 19• Nameplate ............................................................................................ 20• Heater air system ................................................................................. 21• Exhaust system ..................................................................................... 22• Combustion air system .......................................................................... 23• Fuel supply ................................................................................... 24 – 28

Operation and • Operating instructions / important information for operation ................. 29function • Initial commissioning ............................................................................. 29

• Description of functions ........................................................................ 30• Control and safety devices / EMERGENCY OFF .................................... 31

Electrical system • Heater wiring ....................................................................................... 32• Parts list for the circuit diagrams / Circuit diagrams ..................... 33 – 45

Troubleshooting • In case of faults, please check the following points .............................. 46Maintenance • Troubleshooting .................................................................................... 46Service • Maintenance instructions ..................................................................... 46

• Service ................................................................................................. 46

Environment • Certification .......................................................................................... 47• Disposal ................................................................................................ 47• EU Declaration of Conformity ................................................................ 47

Lists • List of key words ............................................................................ 48, 49• List of abbreviations ............................................................................. 49

Page 4: Eberspacher Airtronic D4 Manual

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Introduction1

Concept of this manual

This manual aims to support the service companyinstalling the heater and to provide the user with allimportant information about the heater.The manual has been divided into 8 chapters to makeit easier to find the corresponding information quickly.

IntroductionHere you will find important introductoryinformation about installation of the heaterand about the structure of the manual.

Product informationHere you will find information about the scopeof supply, the technical data and thedimensions of the heater.

InstallationHere you will find important information andinstructions referring to installation of theheater.

Operation and functionHere you will find information about theoperation and function of the heater.

Electric systemHere you will find information about theelectronic system and electronic componentsof the heater.

Troubleshooting / maintenance / serviceThis section contains information on possiblefaults and malfunctions, troubleshooting,maintenance and the service hotline.

EnvironmentHere you will find information about certificationand disposal of the heater together with the EUDeclaration of Conformity.

ListsHere you will find the key word list andabbreviations list.

2

3

4 8

7

6

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Page 5: Eberspacher Airtronic D4 Manual

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Introduction1

Special text structure, presentationand picture symbols

This manual uses special text structures and picturesymbols to emphasise different contents.Please refer to the examples below for thecorresponding meanings and associated actions.

Special structure and presentations

A dot (•) indicates a list which is started by aheading. If an indented dash (–) follows a dot, this listis subordinate to the dot.

Picture symbols

Regulation!This picture symbol with the remark “Regulation”refers to a statutory regulation. Failure to comply withthis regulation results in expiry of the type permit forthe heater and preclusion of any guarantee andliability claims on J. Eberspächer GmbH & Co. KG andits associated companies.

Danger!This picture symbol with the remark “Danger!” refersto the risk of a fatal danger to life and limb. Undercertain circumstances, failure to comply with theseinstructions can result in severe or life-threateninginjuries.

Caution!This picture symbol with the remark “Caution!” refersto a dangerous situation for a person and / or theproduct.Failure to comply with these instructions can result ininjuries to people and / or damage to machinery.

These remarks contain application recommendationsand useful tips for installation of the heater.

Important information beforestarting work

Range of application of the heaterThe air heater operating independently of an engine isintended for installation in the following vehicles,depending on its heating output:• Vehicles of all kinds (max 9 seats)• Construction machinery• Agricultural machinery• Boats, ships and yachts (only diesel heaters)• Camper vans

• The heaters (only diesel heaters, 24 volt) can be in-stalled in vehicles used for the transport of dange-rous goods as per ADR.

• The current controller is to be replaced by a speci-al controller when the heater is to be used to heatthe freight compartment / cargo (order no. see hea-ter price list or spare parts list).

• The "Plus" installation kits are intended for installa-tion in a camper van.

Purpose of the heater• Pre-heating, de-misting windows• Heating and keeping the following warm:

– Driver and working cabs, Ship’s cabins– Freight compartments– Passenger and crew compartments– Camper vans

On account of its functional purpose, the heater is notpermitted for the following applications:• Long-term continuous operation, e.g. for preheating

and heating of:– Residential rooms– Garages– Work huts, weekend homes and hunting huts– Houseboats, etc.

• Heating or drying:– Living creatures (people or animals) by blowing hot

air directly at the subject– Objects– Blowing hot air into containers

Caution!Safety instructions for application andproper purpose• The heater must only be used and operated for the

range of application stated by the manufacturer incompliance with the “Operating instructions”included with every heater.

Please note!

Please note!

Page 6: Eberspacher Airtronic D4 Manual

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Introduction1

Statutory Regulations!Directive 2001 / 56 / EU of the EuropeanParliament and the Council

• Arrangement of the heater– Parts of the structure and other components near

the heater must be protected from excess heatexposure and possible contamination from fuel oroil.

– The heater must not pose a fire hazard even whenit overheats.This requirement is deemed to be fulfilled whenadequate clearance to all parts is observed duringinstallation, sufficient ventilation is provided andfire-proof materials or heat plates are used.

– The heater must not be mounted in the passengercompartment of vehicles in class M2 and M3.But a heater in a hermetically sealed enclosurewhich otherwise complies with the conditionsstated above may be used.

– The factory nameplate or duplicate must be affixedso that it can still be easily read when the heateris installed in the vehicle.

– All appropriate precautions must be taken whenarranging the heater to minimise the risk of injuriesto persons or damage to other property.

• Operating status display– A clearly visible operating display in the user’s

field of vision must indicate when the heater isswitched on and off.

• Fuel supply– The fuel intake connection must not be located in

the passenger compartment and must be sealedwith a properly closing lid to prevent any fuel leaks.

– In heaters for liquid fuel where the heater fuel isseparate from the vehicle fuel, the type of fuel andintake connection must be clearly identified.

– A warning sign is to be fixed to the intakeconnection indicating that the heater must beswitched off before refuelling.

• Exhaust system– The exhaust outlet must be arranged so as to

prevent any penetration of exhaust fumes into thevehicle interior through the ventilation system,warm air intakes or open windows.

• Combustion air intake– The air for the heater combustion chamber must

not be sucked in from the passenger compartmentof the vehicle.

– The air intake must be arranged or protected insuch a way that it cannot be blocked by otherobjects.

• Heater air intake– The heater air supply must consist of fresh air or

circulated air and be sucked in from a clean areanot contaminated by exhaust fumes of the drivemachine, the combustion heater or any othersource in the vehicle.

– The intake pipe must be protected by a grid orother suitable means.

• Hot air outlet– The hot air pipes within the vehicle must be

arranged or protected in such a way that there isno risk of injury or damage if they are touched.

– The air outlet must be arranged or protected insuch a way that it cannot be blocked by anyobjects.

Statutory regulations

The Federal Road Transport Directorate has issuedan "EC type approval" and an "EMC type approval"for the heater for installation in motor vehicles andwith the following official type approval marks, notedon the heater name plate.

Airtronic EC- e1 00 0025

EMC- e1 031516

Airtronic M EC- e1 00 0026

EMC- e1 031653

Statutory Regulations!Mounting the heater in a vehicle for the transport ofdangerous goods as per ADR• When the heater is to be installed in vehicles for the

transport of dangerous goods, the regulations ofADR must also be observed (see page 6).

Page 7: Eberspacher Airtronic D4 Manual

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Introduction1

Statutory Regulations!Additional regulations for certain vehicles named inDirective 94 / 55 / EC (ADR Framework Directive)

ScopeThis appendix applies to vehicles for which the specialprovisions of Directive 94 / 55 / EC apply tocombustion heaters and their installation.

Definition of terms usedFor the purposes of this appendix, the vehicledesignations "EX / II", "EX / III", "AT", "FL" and "OX"according to Chapter 9.1 of Annex B of Directive 94 /55 / EC are used.

Technical regulations

General provisions (EX / II, EX / III, AT, FL and OXvehicles)

Avoid heating and ignitionThe combustion heaters and their exhaust gas routingshall be designed, located, protected or covered soas to prevent any unacceptable risk of heating orignition of the load. This requirement shall beconsidered as fulfilled if the fuel tank and the exhaustsystem of the appliance conform to provisions in3.1.1.1 and 3.1.1.2. Compliance with theseregulations shall be checked in the complete vehicle.

Fuel tanksFuel tanks for supplying the heater shall conform tothe following regulations:• In the event of any leakage, the fuel shall drain to

the ground without coming into contact with hotparts of the vehicle or the load;

• fuel tanks containing petrol shall be equipped withan effective flame trap at the filler opening or with aclosure enabling the opening to be kepthermetically sealed.

Exhaust system and exhaust pipe layoutThe exhaust system as well as the exhaust pipes shalllaid out or protected to avoid any danger to the loadthrough heating or ignition. Parts of the exhaustsystem situated directly below the fuel tank (diesel)shall have a clearance of at least 100 mm or beprotected by a thermal shield.

Switching on the combustion heaterThe combustion heater may only be switched onmanually. Automatic switching on via a programmableswitch is not permitted.

EX / II and EX / III vehiclesCombustion heaters for gaseous fuels are notpermitted.

FL vehiclesCombustion heaters must be able to be taken out ofservice/disabled at least by the methods described inthe following:a) Switching off manually in the driver's cabinb) Switching off the vehicle's engine; in this case the

heater may be manually switched back on by thevehicle driver;

c) Starting up of a feed pump installed in the vehiclefor the dangerous goods carried.

Combustion heater after-runAfter-running of the switched off combustion heater ispermitted. In the cases named in the "FL vehicles"paragraph under letters b) and c) the supply ofcombustion air must be interrupted by suitable meansafter a maximum after-run period of 40 seconds. Onlycombustion heaters whose heat exchangers areverifiably not damaged by the reduced after-run periodof 40 seconds beyond their usual use period may beused.

Please note!

• Compliance with the statutory regulations, theadditional regulations and safety instructions isprerequisite for guarantee and liability claims.Failure to comply with the statutory regulations andsafety instructions and incorrect repairs even whenusing original spare parts make the guarantee nulland void and preclude any liability forJ. Eberspächer GmbH & Co. KG.

• Subsequent installation of this heater must complywith these installation instructions.

• The statutory regulations are binding and must alsobe observed in countries which do not have anyspecial regulations.

• When the heater is to be installed in vehicles notsubject to the German Ordinance for the Regis-tration of Motor Vehicles (StVZO), for exampleships, the specially valid regulations andinstallation instructions for these specialapplications must be observed.

• Installation of the heater in special vehicles mustcomply with the regulations applying to suchvehicles.

• Other installation requirements are contained in thecorresponding sections of this manual.

Page 8: Eberspacher Airtronic D4 Manual

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Safety instructions for installationand operation

Danger!Risk of injury, fire and poisoning!• The heater must only be started up when the

maintenance flap is closed and the outlet hood ismounted in position.

• The maintenance flap must not be opened duringoperation.

• Disconnect the vehicle battery before commencingany kind of work.

• Before working on the heater, switch the heater offand let all hot parts cool down.

• The heater must not be operated in closed rooms,e.g. in the garage or in a multi-storey car park.

• Adjustable hot air outlets must always be adjustedso that they cannot blow hot air directly at livingcreatures (people, animals) or objects sensitive totemperature (loose and / or fastened).

Caution!Safety instructions for installation and operation!• The year of initial commissioning must be marked on

the nameplate.• The heat exchanger of air heaters is a component

subject to high thermal loads which must bereplaced 10 years after initial commissioning of theheater. In addition, the installation date must beentered on the plate “original spare part” enclosedwith the heat exchanger must. Then affix the platenext to the nameplate on the heater.

• The heater must only be installed by a JE partnerauthorised by the manufacturer according to theinstructions in this manual and possibly according tospecial installation recommendations; the sameapplies to any repairs to be carried out in the caseor repairs or guarantee claims.

• Only the control elements approved byJ. Eberspächer GmbH & Co. KG must be used tooperate the heater. The use of other controlelements can cause malfunctions.

• Repairs by unauthorised third-parties or with notoriginal spare parts are dangerous and therefore notallowed. They result in expiry of the type permit ofthe heater; consequently, when installed in motorvehicles they can cause expiry of the vehicleoperating licence.

Introduction1

• The following measures are not allowed:– Changes to components relevant to the heater.– Use of third-party components not approved by

Eberspächer.– Nonconformities in installation or operation from

the statutory regulations, safety instructions orspecifications relevant to safe operation as statedin the installation instructions and operatinginstructions. This applies in particular to theelectrical wiring, fuel supply, combustion airsystem and exhaust system.

• Only original accessories and original spare partsmust be used during installation or repairs.

• When carrying out electric welding on the vehicle,the plus pole cable at the battery should bedisconnected and placed at ground to protect thecontroller.

• The heater must not be operated where there is arisk of an accumulation of flammable vapours ordust, for example close to– fuel depot– coal depot– wood depot– grain depots etc.

• The heater must be switched off when refuelling.• When the heater is mounted in a safety housing

etc., the installation compartment of the heater isnot a stowage compartment and must be kept clear.In particular fuel canisters, oil cans, spray cans,gas cartridges, fire extinguishers, cleaning rags,items of clothing, paper etc. must not be stored ortransported on or next to the heater.

• Defect fuses must only be replaced by fuses withthe prescribed rating.

• If fuel leaks from the heater fuel system, arrangefor the damage to be repaired immediately by a JEservice partner.

• After-running of the heater must not be interruptedprematurely e.g. by pressing the batterydisconnecting switch, apart from in the case of anemergency stop.

Accident prevention

General accident prevention regulations and thecorresponding workshop and operation safetyinstructions are to be observed.

Page 9: Eberspacher Airtronic D4 Manual

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Using the universal installation kits

Order No.Universal installation kit 25 2069 80 00 00• with outlet hood Ø 60 mm,

heater guide number 6, usable with:

– Airtronic D2, 12 V 25 2069 05 00 00– Airtronic D2, 24 V 25 2070 05 00 00

Universal installation kit 25 2113 80 00 00• with outlet hood Ø 90 mm,

heater guide number 10, usable with:

– Airtronic D3, 12 V 25 2317 05 00 00

– Airtronic B4, 12 V 20 1812 05 00 00

– Airtronic D4, 12 V 25 2113 05 00 00– Airtronic D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 90 mm,heater guide number 15, usable with:

– Airtronic D4 Plus, 12 V 25 2484 05 00 00– Airtronic D4 Plus, 24 V 25 2498 05 00 00

Universal installation kit 25 2144 80 00 00• with outlet hood Ø 75 mm,

heater guide number 3, usable with:

– Airtronic D3, 12 V 25 2317 05 00 00

– Airtronic B4, 12 V 20 1812 05 00 00

– Airtronic D4, 12 V 25 2113 05 00 00– Airtronic D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 75 mm,heater guide number 8, for recirculation modeheater guide number 10, for fresh air modeusable with:

– Airtronic D4 Plus, 12 V 25 2484 05 00 00– Airtronic D4 Plus, 24 V 25 2498 05 00 00

• For controls, please refer to the price list oraccessories catalogue.

• Parts without a figure no. are small parts and packedin a bag.

• Please consult the additional parts catalogue if anyother parts are required for installation.

• For notes on the units' guide numbers, please refer toadditional parts catalogue.

Product information2

Heater scope of supply, completepackages and universal installation kit

Heater Order No.

Airtronic D2, 12 V 25 2069 05 00 00Airtronic D2, 24 V 25 2070 05 00 00Airtronic D3, 12 V 25 2317 05 00 00Airtronic B4, 12 V 20 1812 05 00 00Airtronic D4, 12 V 25 2113 05 00 00Airtronic D4, 24 V 25 2114 05 00 00Airtronic D4 Plus, 12 V 25 2484 05 00 00Airtronic D4 Plus, 24 V 25 2498 05 00 00

The scope of supply includes:No. infigure Name

1 Heater2 Metering pump

Complete package Order No.

Airtronic D2, 12 VComplete package 25 2115 05 00 00Airtronic D2, 24 VComplete package 25 2116 05 00 00

Included in the scope of supply:No. infigure Name

1 Heater2 Metering pump– Installation kit with outlet hood Ø 60 mm3 Minicontroller4 Tank connection (only in complete package

25 2116 05 00 00)

Universal installation kit (all versions)

Included in the scope of supply:No. infigure Name

5 Lead harness, plus / minus6 Lead harness, operation7 Flexible exhaust pipe8 Combustion air hose9 Cable tie

10 Bracket, dosing pump11 Pipe, 6 x 212 Pipe, 4 x 1.2513 Hose clip (2x)14 Air outlet, rotatable15 Grid16 Hood17 Flexible pipe18 Exhaust silencer19 Cable harness, heater

Please note!

Page 10: Eberspacher Airtronic D4 Manual

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Scope of supply: Heater, universal installation kit and complete packages

* Only in complete package Airtronic D2** Only for Airtronic D3, B4, D4, D4 Plus

*** Only for Airtronic D2**** Only in complete package Airtronic D2, 24 volt

Product information2

Page 11: Eberspacher Airtronic D4 Manual

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Using the “Plus” installation kits

Order No.“Plus” installation kit 25 2069 81 00 00• with outlet hood Ø 75 mm,

heater guide number 12, usable with:

– Airtronic D2, 12 V 25 2069 05 00 00– Airtronic D2, 24 V 25 2070 05 00 00

“Plus” installation kit 25 2113 81 00 00• with outlet hood Ø 90 mm,

heater guide number 10, usable with:

– Airtronic D3, 12 V 25 2317 05 00 00

– Airtronic B4, 12 V 20 1812 05 00 00

– Airtronic D4, 12 V 25 2113 05 00 00– Airtronic D4, 24 V 25 2114 05 00 00

• with outlet hood Ø 90 mm,heater guide number 15, usable with:

– Airtronic D4 Plus, 12 V 25 2484 05 00 00– Airtronic D4 Plus, 24 V 25 2498 05 00 00

“Plus” installation kit 25 2484 81 00 00• with outlet hood Ø 75 mm,

heater guide number 8, for recirculation modeheater guide number 10, for fresh air modeusable with:

– Airtronic D4 Plus, 12 V 25 2484 05 00 00– Airtronic D4 Plus, 24 V 25 2498 05 00 00

• For controls, please refer to the price list oraccessories catalogue.

• Parts without a figure no. are small parts and packedin a bag.

• Please consult the additional parts catalogue if anyother parts are required for installation.

• For notes on the units' guide numbers, please refer toadditional parts catalogue.

• The “Plus” installation kits are particularly suitable forinstallations in camper vans and boats.

Scope of supplyHeater and “Plus” installation kit

Heater Order No.

Airtronic D2, 12 V 25 2069 05 00 00Airtronic D2, 24 V 25 2070 05 00 00Airtronic D3, 12 V 25 2317 05 00 00Airtronic B4, 12 V 20 1812 05 00 00Airtronic D4, 12 V 25 2113 05 00 00Airtronic D4, 24 V 25 2114 05 00 00Airtronic D4 Plus, 12 V 25 2484 05 00 00Airtronic D4 Plus, 24 V 25 2498 05 00 00

The scope of supply includes:No. infigure Name

1 Heater2 Metering pump

“Plus” installation kit (all versions)

The scope of supply includes:No. infigure Name

3 Combustion air intake silencer4 Exhaust silencer5 Hose connecting sockets6 Grid7 Y branch8 Tank connection kit9 Temperature control sensor

10 Cable loom for temperature control sensor11 EasyStart T timer12 Lead harness, plus / minus13 Lead harness, operation14 Hose clip (2x)15 Hose clip (6x)16 Pipe 4 x 1.25 (included in Item 8)17 Cable harness, heater18 Flexible exhaust pipe19 Grid20 Bracket metering pump21 Cable tie (2 sets)22 Hood23 Outlet (2x)24 Adapter Ø 6 / 425 Pipe 4 x 1 (included in Item 8)26 Pipe clip, Ø 50 mm27 Flexible pipe for hot air system

Product information2

Please note!

Page 12: Eberspacher Airtronic D4 Manual

11

Product information2

Scope of supply: Heater and “Plus” installation kit

Page 13: Eberspacher Airtronic D4 Manual

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Airtronic

Airtronic D2

D2

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

12 or 24 volt

approx. 10.5 volt resp. 21 voltUndervoltage protection trigger time: 20 seconds

approx. 16 volt resp. 32 voltOvervoltage protection trigger time: 20 seconds

Commercially available diesel fuel (DIN EN 590)

Operation Not running

–40 °C to +70 °C –40 °C to +85 °C

–40 °C to +50 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 2.7 kg

possible

Product information2

Caution!Safety instructions for technical data!Failure to comply with the technical datacan result in malfunctions.

Technichal data

Heater type

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt)

Heater air flow rate with hood Ø 60 mmwithout counterpressure (kg/h)

Fuel consumption (l/h)

Elektr. power consumption (watt)

in operation (12 and 24 volt)

at start (12 and 24 volt)

Rated voltage

Operating rangeLower voltage limit:An undervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Upper voltage limit:An uppervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Fuel“Fuel quality“ and “Fuel at low temperatures“see page 28.

Tolarable ambient temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

Please note!

Provided no limit values are given, the technical datalisted is subject to the tolerances usually applicableto heaters of ±10% for nominal voltage, ambienttemperature 20 °C and reference altitude Esslingen.

Page 14: Eberspacher Airtronic D4 Manual

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Product information2

Technichal data

Heatertyp

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt) D3

D4

D4 Plus

Heater air flow rate D3 with hood Ø 90 mm

without counter- D4 with hood Ø 90 mm

pressure (kg/h) D4 Plus with hood Ø 75 mm

Fuel consumption (l/h) D3

D4

D4 Plus

Elektr. power consumption (watt) D3

in operation (12 and 24 volt) D4

D4 Plus

at start (12 and 24 volt)

Rated voltage

Operating rangeLower voltage limit:An undervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Upper voltage limit:An uppervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Fuel“Fuel quality“ and “Fuel at low temperatures“see page 28.

Tolarable ambient temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

Airtronic M

Airtronic D3 / Airtronic D4 / Airtronic D4 Plus

D3 / D4 / D4 Plus

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

12 or 24 volt

approx. 10.5 volt resp. 21 voltUndervoltage protection trigger time: 20 seconds

approx. 16 volt resp. 32 voltOvervoltage protection trigger time: 20 seconds

Commercially available diesel fuel (DIN EN 590)

Operation Not running

–40 °C to +70 °C –40 °C to +85 °C

–40 °C to +50 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 4.5 kg

possible

Please note!Safety instructions for technical data and see page 12.

Page 15: Eberspacher Airtronic D4 Manual

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Product information2

Caution!Safety instructions for technical data!Failure to comply with the technical datacan result in malfunctions.

Technichal data

Heatertyp

Heater

Version

Heating medium

Control of the heat flow

Heat flow (watt)

Heater air flow rate with hood Ø 90 mmwithout counterpressure (kg/h)

Fuel consumption (l/h)

Elektr. power consumption (watt)

in operation (12 volt)

at start (12 volt)

Rated voltage

Operating rangeLower voltage limit:An undervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Upper voltage limit:An uppervoltage protection in the controllerswitches off the heater when the voltagelimit is reached.

Fuel“Fuel quality“ and “Fuel at low temperatures“see page 28.

Tolarable ambiet temperature

Heater

Dosing pump

Maximum air intake temperature

Interference suppression

Weight

Ventilation mode

Airtronic M

Airtronic B4

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

12 volt

approx. 10.5 voltUndervoltage protection trigger time: 20 seconds

approx. 16 voltUndervoltage protection trigger time: 20 seconds

Commercially available petrol fuel (DIN EN 228)

Operation Not running

–40 °C to +50 °C –40 °C to +85 °C

–40 °C to +20 °C –40 °C to +125 °C

+40 °C

Interference suppression class 5 to DIN EN 55 025

approx. 4.5 kg

possible

Please note!

Provided no limit values are given, the technical datalisted is subject to the tolerances usually applicableto heaters of ±10% for nominal voltage, ambienttemperature 20 °C and reference altitude Esslingen.

Page 16: Eberspacher Airtronic D4 Manual

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Main dimensions Airtronic

A = ExhaustB = FuelV = Combustion air

1 Minimum installation clearance (space) for opening the lid and fordismantling the glow plug and the controller.

2 Minimum installation clearance (space) for intake of heater air.

Main dimensions Airtronic M

* Outlet hood for Airtronic D2:- Ø 60 mm, included in the universal installation kit- Ø 75 mm, included in the “Plus” installation kit

** Outlet hood for Airtronic D3, B4, D4:- Ø 75 mm, included in the universal installation kit- Ø 90 mm, included in the universal installation kit or inthe “Plus” installation kitOutlet hood for Airtronic D4 Plus:- Ø 75 mm, included in the universal installation kit or in the “Plus” installation kit- Ø 90 mm, included in the universal installation kit or in the “Plus” installation kit

Product information2

**

*

Please note!

Installation of spherical reduction hood is notpermitted in the Airtronic D4 Plus.

Page 17: Eberspacher Airtronic D4 Manual

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Installation and location

The heater is suitable and certified for installation inparts of vehicles used by persons.Installation in the cab or passenger compartments ofcoaches or buses with more than 9 seats is notallowed.

When installing in compartments used by persons, theexhaust, combustion air and fuel pipes in these areasmust not have any detachable connections and mustbe routed splash-waterproof in the breakthroughs. Forthis reason, the heater can be mounted with its footusing the flange seal in the foot to the vehicle floor orto an outer wall of the vehicle.

The electronic control is integrated in the heater whichmakes wiring during installation much easier.

Installing the diesel heater 24 V in a vehiclefor the transport of dangerous goods as perADR

The 24 Volt diesel heater can be installed in vehiclesused for the transport of dangerous goods as per ADR.

The heater fulfils the regulations of ADR with thecorresponding electrical wiring, see circuit diagrams atthe end of this manual.

For information about the ADR regulations, please referto page 6, 31 and to the information leaflet no.25 2161 95 15 80.

For installation of the heater in vehicles for thetransport of dangerous goods, the regulations ofADR must be observed.• When installing the heater, always make sure there

is sufficient clearance left for intake of the heater airand for dismantling the glow plug and controller (seepage 15 “main dimensions“).

• The regulations and safety instructions to beobserved for this chapter are on page 4 – 7.

Installation3

Please note!

Please note!

1 Heater in front of the passenger seat2 Heater between the driver’s seat and the

passenger seat3 Heater under the vehicle floor4 Heater under the back seat5 Heater in the boot

Installation position

Installation position in a camper van

In a camper van, the heater is preferably installed inthe inner compartment or luggage compartment.If it is not possible to install the heater in thepassenger compartment or boot, the heater can alsobe mounted, protected against splashing water,under the vehicle floor.

The "Plus" installation kits are intended forinstallation in a camper van.

Please note!

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Installation

Installation in a car or people carrier

In a car or people carrier, the heater is preferablyinstalled in the passenger compartment or boot.If it is not possible to install the heater in thepassenger compartment or boot, the heater can alsobe mounted, protected against splashing water,under the vehicle floor.

1 Heater in front of the passenger seat2 Heater between the driver’s seat and the

passenger seat3 Heater under the vehicle floor4 Heater under the back seat5 Heater in the boot

Installation in a truck (only diesel heaters)

In a truck, the heater is preferably installed inside thedriver’s cab. If it is not possible to install the heaterinside the driver’s cab, it can also be mounted in thetool box or in a storage box.

Installation in an excavator cab (only diesel heaters)

In an excavator, the heater is preferably installed inthe cab. If it is not possible to install the heater in thecab, the heater can also be installed in a storage boxoutside the cab.

1 Heater in the passenger’s foot room2 Heater on the cab rear wall3 Heater under the bed4 Heater in the tool box

1 Heater in the seat box2 Heater on the cab rear wall3 Heater in a protective case

• The installation suggestions made in theinstallation instructions are just examples. Otherinstallation locations are possible, as long as theycorrespond to the installation requirements statedin these instructions.

• Other installation information (e.g. for boats andships) is available from the manufacturer onrequest.

• Observe the tolerable installation position togetherwith the operating and storage temperatures.

Installation

Please note!

3

3

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Possible installation positions

The heater is preferably installed in the normalposition as shown in the drawing.Depending on the installation conditions, the heatercan be tilted by max. 30° (flow direction to the bottom)or turned by max. 90° around its own longitudinal axis(exhaust connection horizontal, glow plug pointsupwards!).

Normal position horizontal (exhaust connectiondownwards) with tolerable swivel range

Cable harness connection, right or left

If necessary, the cable harness connection can bechanged over to the other side of the heater. To doso, the controller has to be removed and the lowersemi-circular cable harness cover unclipped.The cable harness can then be rerouted in thecontroller.Then mount the controller again, position the jacketshell and insert the cable harness bush and the bungsin the corresponding recesses in the lower jacketshell.

1 Heater air intake opening (fan wheel)2 Position of the glow plug3 Direction of flow

In the heating mode, the heater can deviate from theshown normal or maximum installation positions by upto +15° in all directions because of a slanting positionof the vehicle or boat, without any impaired functions.

Installation3

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1 There must be sufficient clearance between theheater and the vehicle floor – also check thatthe fan wheel runs freely.

2 The mounting surface must be flat and smooth.3 The flange seal must be mounted.

4 The vehicle wall must be flat and smooth.5 Reinforcement plate (if required, see above)6 Spring washer7 Hexagon nut M6 (torque 5+1 Nm)

Mounting and fastening

Make the necessary breakthroughs for exhaust,combustion air and fuel as shown in the holediagram. The support surface for the heater footmust be flat. An appropriate tool can be purchasedfrom the manufacturer for drilling the breakthroughsand also smoothing the support surface.The hole Ø 10.5 mm for the cable harness “dosingpump” is not included in the picture drawing and mustbe drilled after installation.

Picture hole Special tool

If the sheet metal of the support surface is thinnerthan 1.5 mm, an additional reinforcement plate willhave to be fitted.

Order no: reinforcement plate 20 1577 89 00 03Order no: special tool 99 1201 46 53 29

Fastening the unit on the vehicle floor

Installation3

Fastening the heater horizontallyto the vehicle wall

1 Contour of the bearing surface

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Nameplate

The nameplate is fastened to the front of the heater.The second nameplate (duplicate) is included in thescope of supply of the heater.If required, the duplicate nameplate can be adheredin a clearly visible position on the heater or near tothe heater.

The regulations and safety instructions to beobserved for this chapter are stated on page 5. 1 Original nameplate

2 2nd nameplate (duplicate)

Installation3

Please note!

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Heater air system (example)

Heater air system

The parts for the hot air system are included in thescope of supply of the "Universal" and "Plus"installation kits.The "Plus" installation kit does not include the flexiblepipe Ø 75 mm or Ø 90 mm, these must be orderedseparately. The order no. is given in the additionalparts catalogue.

Danger!Risk of burning and injuries!• The hoses of the heater air system and the hot air

outlet are to be routed and fastened in such a waythat they pose no temperature risk to people,animals or materials sensitive to temperature fromradiation / contact or blowing directly. If necessary,a cover is to be fitted to the heater air system orhot air outlet.

• The outflow hood must be fitted on the hot airoutflow side.

• A safety grid must be fitted to the heater air intakeside and outflow side if no air hoses are mounted,to prevent any injuries from the heater air fan orburns from the heat exchanger.

• High temperatures occur in the heater air systemduring and after the heater has been working.This is why it is important to avoid working in thevicinity of the heater air system while the heater isworking. In such cases, switch the heater offbeforehand and wait until all parts have cooleddown completely.If necessary, wear safety gloves.

Caution!• The heater air intake openings must be arranged in

such a way that under normal circumstances, it isnot possible for exhaust from the vehicle engine andheater to be sucked into the system, or for theheating air to be contaminated with dust, salt spray,etc.

• For circulating air, position the circulating air intakein such a way that the outflowing hot air cannot bedirectly sucked in again.

• In the event of possible overheating, it is possiblefor local lot air temperatures of up to max. 150 °Cor surface temperatures of up to max. 90 °C tooccur immediately before the defect shutdown.Therefore only temperature-resistant hot air hosesapproved by us must be used for the heater airsystem!

• When checking the functions, the mean outflowtemperature measured after the heater has beenrunning about 10 minutes at approx. 30 cm from theoutlet should not exceed 110 °C (at an intaketemperature of approx. 20 °C).

• If there is a risk of the driver and passengerstouching the heater when the vehicle is being drivennormally, a contact protection device must be fitted.

Installation3

1 Safety grid2 Outflow hood3 Hose clip4 Flexible hose

5 Rotating outflow6 Connection fitting7 Safety grid

Please note!

• Installation of spherical reduction hood is notpermitted in the Airtronic D4 Plus.

• The regulations and safety instructions to be observedfor this chapter are on page 4 – 7.

• If air duct parts are connected the heater codenumber in “Using Universal Installation Kits”, page 8and “Using Plus Installation Kits”, page 10 must beobserved.

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Installation3

Exhaust system

Mounting the exhaust system

The “Universal” and “Plus” installation kits include aflexible exhaust pipe, inner Ø 24 mm, 1000 mm longand an exhaust silencer. The flexible exhaust pipe canbe shortened to 20 cm or lengthened to max. 2 m,depending on the installation conditions.Fasten the exhaust silencer to a suitable position inthe vehicle.Route the flexible exhaust pipe from the heater to theexhaust silencer and fasten with pipe clips. Use apipe clip to fix a short exhaust pipe end (with endsleeve) to the exhaust silencer.

Caution!Safety instructions!The whole exhaust system gets very hot during andimmediately after the heater has been working. This isthe reason why the exhaust system must be installedaccording to these instructions.• The exhaust outlet must end in the open air.• The exhaust pipe must not protrude beyond the

lateral limits of the vehicle.• Install the exhaust pipe sloping slightly downwards.

If necessary, make a drain hole approx. Ø 5 mm atthe lowest point to drain off condensation.

• Important functional parts of the vehicle must not beimpaired (keep sufficient clearance).

• Mount the exhaust pipe with sufficient clearance toheat-sensitive parts. Pay particular attention to fuelpipes (plastic or metal), electrical cables and brakehoses etc.!

• Exhaust pipes must be fastened safely(recommended clearance of 50 cm) to avoid damagefrom vibrations.

• Route the exhaust system so that the emitted fumesare not sucked in with the combustion air.

• The mouth of the exhaust pipe must not get cloggedby dirt and snow.

• The mouth of the exhaust pipe must not point in thedirection of travel.

• Always fasten the exhaust silencer to the vehicle.

Danger!Risk of injuries and burns!Every type of combustion produces high temperaturesand toxic exhaust fumes. This is the reason why theexhaust system must be installed according to theseinstructions.• Do not perform any work on the exhaust system

while the heater is working.• Before working on the exhaust system, first switch

the heater off and wait until all parts have cooleddown completely, wear safety gloves if necessary.

• Do not inhale exhaust fumes.

• Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.

• If a silencer is fitted, the exhaust end pipe must bemuch shorter than the flexible exhaust pipebetween the heater and the exhaust silencer.

• Small arrows indicating the direction of flow havebeen cast into the fittings to differentiate betweenthe combustion air and the exhaust fittings at theheater (see diagram page 23).

Please note!

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Caution!Safety instructions for the combustionair system!• The combustion air opening must be free at all

times.• Position the combustion air intake to be sure that

exhaust fumes cannot be sucked in with thecombustion air.

• Do not arrange the combustion air intake to pointingagainst the wind blast.

• The combustion air intake must not get clogged withdirt and snow.

• Install the combustion air intake system slopingslightly downwards. If necessary, make a drain holeapprox. Ø 5 mm at the lowest point to drain offcondensation.

Combustion air system

Mounting the combustion air system

The universal installation kit includes a flexiblecombustion air hose, inner Ø 25 mm , 1000 mm long.If necessary the flexible combustion air hose can beshortened to 20 cm or lengthened to max. 2 mdepending on the installation conditions.Fasten the combustion air hose to the heater witha pipe clip and at suitable points with hose clips orcable ties.Fit an end sleeve after completing the installation.

The „Plus“ installation kit includes a combustion airintake silencer with a flexible connection hose (innerdiameter 25 mm).Fasten the flexible connection hose to the heater witha pipe clip and fasten the combustion air intakesilencer with hose clips or cable ties at suitable points.Fit an end sleeve after completing the installation.

1 Combustion air hose, di = 25 mm2 Combustion air silencer,

– Included in the “Plus” installation kit3 Exhaust pipe, di = 24 mm4 Exhaust silencer5 Intake / outlet opening – protect from wind,

snow, dirt and water.6 End sleeve, combustion air7 End sleeve, exhaust8 Combustion air connection9 Exhaust connection10 End sleeve, combustion air11 Hose clip12 Exhaust hose clip

Installation3

Please note!

• For Airtronic and Airtronic M heaters a combustionair intake silencer can be fitted instead of the com-bustion air hose to reduce the noise level. The ordernumber is stated in the Accessories Catalogue.

• Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.

max. 2 m

min. 0.2 mmin. 0.2 – max. 2 m

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Installation3

1 Correct connection2 Incorrect connection – bubble formation

Fuel supply

Mounting the dosing pump, routing the fuel pipesand mounting the fuel tank

The following safety instructions must be observedwhen mounting the dosing pump, routing the fuel pipesand mounting the fuel tank.Deviations from the instructions stated here are notallowed.Failure to comply can result in malfunctions.

Danger!Risk of fire, explosion, poisoning and injuries!

Caution when handling fuel.

• Switch off the vehicle engine and heater beforerefuelling and before working on the fuel supply.

• No naked lights when handling fuel.

• Do not smoke.

• Do not inhale fuel vapours.

• Avoid any contact with the skin.

Caution!Safety instructions for routing the fuel pipes!

• Only use a sharp knife to cut off fuel hoses andpipes.Interfaces must not be crushed and must be freeof burrs.

• The fuel pipe from the dosing pump to the heatershould be routed at a continuous rise.

• Fuel pipes must be fastened safely to avoid anydamage and / or noise production from vibrations(recommended clearance of approx. 50 cm).

• Fuel pipes must be protected from any mechanicaldamage.

• Route the fuel pipes so that any distortion of thevehicle, engine movements etc. cannot have anylasting effect on the service life.

• Parts carrying fuel must be protected frominterfering heat.

• Never route or fasten the fuel pipes to the heater orvehicle exhaust system. At crossings, always ensureadequate heat clearance, if necessary attach heatdeflection plates or protective hose (for Order No.protective hose please refer to additional partscatalogue).

• Dripping or evaporating fuel must never be allowedto collect on hot parts or ignite on electric systems.

• When connecting fuel pipes with a fuel hose, alwaysmount the fuel pipes in a butt joint to prevent anybubbles from forming.

Safety instructions for fuel pipes and fuel tanksin buses and coaches

• In buses and coaches, fuel pipes and fuel tanksmust not be routed through the passengercompartment or driver’s cab.

• Fuel tanks in buses and coaches must bepositioned in such a way that the exits are not indirect danger from a possible fire.

• Comply with the regulations and safety instructionsfor this chapter on page 4 – 7.

• For noise reasons, do not rigidly fit fuel pipes ontostructural sound transferring components.A sponge rubber hose can be pushed over the fueltubes for nose reduction.

Please note!

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Fuel supply

Fuel feed point with T-piece from the fuel supply linefrom the tank fitting to the vehicle engine

1 Fuel flow line, vehicle tank2 To the vehicle's engine, mechanical fuel or

injection pump3 T-piece, 8-6-8 or 10-6-104 Dosing pump5 Fuel pipe, 4 x 1 (di = Ø 2 mm)6 Fuel pipe, 6 x 2 (di = Ø 2 mm)7 Fuel hose, 5 x 3 (di = Ø 5 mm)8* Fuel pipe, 4 x 1.25 (di = Ø 1,5 mm)9 Adapter Ø 6 / 410 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm),

approx. 50 mm long11 Fuel hose, 5 x 3 (di = Ø 5 mm),

approx. 50 mm long12 Pipe connectors, da = Ø 4 mm13 Fuel filter - required for contaminated fuel only.

* If necessary, a fuel pipe 4 x 1 (di = Ø 2 mm) canbe used for diesel heaters instead of the fuel pipe4 x 1.25 (di = Ø 1.5 mm), Item (8).The details regarding the pipe lengths remainunchanged.The fuel pipe, 4 x 1 must be order separately,Order No. see spare parts list or additional partscatalogue.

Installation3

• Insert the T-piece (3) in the fuel flow line upstream ofthe feed pump.

• Items (5), (9) and (12) are included in the "Plus"installation kit only.

• Item (6) is included in the universal installation kitonly.

• Items (7) and (13) must be ordered separately. Theorder no. is given in the additional parts catalogue.

Please note!

Installation position of the T-piece

Use the installation positions shown in the diagramwhen inserting a T-piece.

1 Direction of flow from the fuel tank2 Direction of flow to the vehicle engine

Possible pipe lengths

Intake sideAirtronica = max. 5 m

Airtronic Ma = max. 2 m

Pressure sideDiesel heaters• For suction pipe di = Ø 2 mm,

b = max. 6 m• For suction pipe di = Ø 5 mm,

b = max. 10 m

Petrol heater• b = max. 4 m

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Fuel feed point with tank connection – ascending pipe,integrated in the vehicle tank or in the tank fitting

1 Tank connection for metal tank -di = Ø 2 mm, da = Ø 6 mm

2 Tank connection for tank fitting -di = Ø 2 mm, da = Ø 4 mm

3 Dosing pump4 Fuel pipe, 4 x 1 (di = Ø 2 mm)5 Fuel pipe, 6 x 2 (di = Ø 2 mm)6 Fuel hose, 5 x 3 (di = Ø 5 mm)7 Fuel filter - required for contaminated fuel only.8* Fuel pipe, 4 x 1.25 (di = Ø 1,5 mm)9 Pipe connectors, da = Ø 4 mm10 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm)

approx. 50 mm long11 Adapter Ø 6 / 412 Fuel hose, 5 x 3 (di = Ø 5 mm),

approx. 50 mm long

* If necessary, a fuel pipe 4 x 1 (di = Ø 2 mm) canbe used for diesel heaters instead of the fuel pipe4 x 1.25 (di = Ø 1.5 mm), Item (8).The details regarding the pipe lengths remainunchanged.The fuel pipe, 4 x 1 must be order separately,Order No. see spare parts list or additional partscatalogue.

Fuel supply

• Items (2), (4), (8), (9) and the connection parts areincluded in the “Tank Connection” kit, Order No. 221000 20 13 00 (The “Tank Connection” kit is includedin the "Plus" installation kit).

• Item (5) is included in the universal installation kitonly.

• Item (11) is included in the “Plus” installation kit only.• Items (6) and (7) must be ordered separately, for Order

No. please refer to additional parts catalogue.• When installing tank connection maintain a minimum

distance of 50 ± 2 mm from the end of the riser pipeand the bottom of the tank.

• Consult the vehicle manufacturer before installing thetank connection in a metal tank.

Installation3

Caution!Safety instructions for the fuel supply!

• The fuel must not be conveyed by gravity oroverpressure in the fuel tank.

• Withdrawal of fuel after the vehicle’s fuel pump isnot allowed.

• When the pressure in the fuel pipe is more than0.2 bar to max. 4,0 bar, use a pressure reducer(order no. 22 1000 20 08 00) or separate tankconnection.

• When the pressure in the fuel pipe is more than4,0 bar or there is a non-return valve in the returnpipe (in the tank), a separate tank connection mustbe used.

• When using a T-piece in a plastic pipe, always usesupport sleeves in the plastic. Connect the T-pieceand the plastic pipe with corresponding fuel hosesand secure with hose clips.

Please note!

Possible pipe lengthsIntake sideAirtronica = max. 5 m

Airtronic Ma = max. 2 m

Pressure sideDiesel heaters• For suction pipe di= Ø 2 mm,

b = max. 6 m• For suction pipe di= Ø 5 mm,

b = max. 10 m

Petrol heater• b = max. 4 m

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Possible suction and pressure heightof the dosing pump

Pressure height from vehicle tank to dosing pump:a = max. 3000 mm

Intake height in pressure-less vehicle tank:b = max. 1000 mm for dieselb = max. 1500 mm for petrol

Intake height in vehicle tanks with withdrawal bynegative pressure (valve with 0.03 bar in tank cap):b = max. 400 mm

Pressure height of the dosing pump to the heater:c = max. 2000 mm

Check tank venting.

1 Connection to heater2 Max. fuel level3 Min. fuel level

Installation3

Fuel supply

Installation position of the dosing pump

Always mount the dosing pump with the pressure siderising upwards. Every installation position over 15° isallowed, although an installation position between 15°and 35° is preferable.

1 Installation position between 0° and 15°is not allowed.

2 Preferred installation position in range 15° to 35°.3 Installation position in range 35° to 90° is allowed.

Caution!Safety instructions for installingthe dosing pump• Always mount the dosing pipe with the pressure

side rising upwards – minimum incline 15°.

• Protect the dosing pump and filter from intolerableheat, do not mount near to the silencers andexhaust pipes.

Please note!

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Installation3

Fuel supply

Caution!Fuel supply safety informationIt is not permitted to operate the heater withunapproved fuel / fuel mixtures or the addition of usedoil.Failure to comply with this can lead to personalinjuries as well as a malfunction or damage to theheater.Only the fuel approved by the manufacturer or by thevehicle manufacturer is to be used.

Fuel quality for petrol heatersThe heater runs without problems on normalcommercial petrol according to DIN EN 228.

Fuel quality for diesel heaters• The heater runs without problems on normal

commercial diesel fuel according to DIN EN 590.During the winter months the diesel fuel is adapted tolow temperatures from 0 °C to –20 °C. Problems cantherefore only arise if outdoor temperatures areextremely low - which also applies to the vehicle'sengine - please refer to the vehicle manufacturer'sregulations.

• In special cases and at outdoor temperatures above0 °C the heater can also be run on heating oil ELaccording to DIN 51603.

• If the heater is run from a separate tank, pleasecomply with the following rules:

– if outdoor temperatures over 0 °C,Use diesel fuel according to DIN EN 590.

– if outdoor temperatures from 0 °C to –20 °C,Use winter diesel fuel according to DIN 590.

- if outdoor temperatures –20 °C to –40 °C,Use Arctic Diesel or Polar Diesel.

After refuelling with winter or cold diesel, the fuelpipes and the metering pump must be filled with thenew fuel by letting the heater run for 15 min!

Please note!

Operation with biodiesel (FAME)

AirtronicThe heater is not approved for operation with biodiesel fuel (FAME). Up to 10 % bio diesel fuel (FAME)may be added.

Airtronic MThe diesel heater is approved for operation with biodiesel fuel (FAME) according to DIN EN 14 214.

• Bio diesel fuel (FAME) according to DIN EN 14 214– during the winter months is adapted to low

temperatures from 0 °C to –20 °C.– The Flowability reduces at temperatures below

0 °C.

• When using 100 % bio diesel, the heater should beoperated twice a year with diesel fuel (in the middleand at the end of a heating period) in order to burnoff any possible biodiesel residues deposited.To do so, let the vehicle tank run almost empty andthen fill with diesel fuel. While running on this tankfilling, switch the heater on 2 to 3 times for 30minutes at a time at the highest temperature setting.

• When operating with diesel / bio diesel mixtures of upto 50 % bio diesel, intermediate operation with purediesel fuel is not necessary.

Please note!

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Operation and function4

Operating instructions

The heater is operated by a control element.Detailed operating instructions are enclosed with thecontrol unit.

The workshop / garage installing the heater will issueyou with the operating instructions.

Important instructions for operation

Safety checks before the startAfter a lengthy period of non-use (summer months)check that all parts fit securely (tighten screws wherenecessary).Check the fuel system visually for any leaks.

Heating at high altitudesWhen using the heater at high altitudes, please note:

• Heating at altitudes up to 1500 m:– Unlimited heating possible.

• Heating at altitudes over 1500 m – 3000 m:– Heating is possible for short periods at this altitude

(e.g. driving over a mountain pass or taking abreak in a journey).

– During longer stays, e.g. winter camping, the fuelsupply must be adjusted to the altitude. This canbe done by installing an air pressure sensor. Theair pressure sensor is included in the Altitude kit -Order No. 22 1000 33 22 00.

Heaters suitable for high altitudes are labelled with“H-Kit” on the side nameplate.

Initial commissioning

The following points are to be checked by thecompany installing the heater during initialcommissioning.

• After installation of the heater, the coolant circuitand the whole fuel supply system must be ventedcarefully. Comply with the instructions issued by thevehicle manufacturer.

• During the trial run of the heater, check all water andfuel connections for leaks and firm fitting.

• If the heater shows a fault during operation, findand eliminate the cause of the fault using adiagnosis unit.

Please note!

Please note!

During the initial start-up of the heater, odours can beproduced for a short time. This is fully normal duringthe first few minutes of operation and does notindicate a malfunction in the heater.

Please note!

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Description of functions

Switching on

When the heater is switched on, the control lamp inthe control element lights up.The glow plug is switched on and the fan starts atlow speed.

If there is still too much residual heat in the heatexchanger from when the heater was last used, firstlyonly the fan starts up (cold blowing).Once the residual heat has been cleared, the heaterstarts.

Starting Airtronic

After approx. 65 seconds the fuel supply starts andthe fuel / air mixture in the combustion chamberignites.Once the combined sensor (flame sensor) hasdetected the flame, the glow plug is switched off after60 seconds. The heater is now in standard operation.

Starting Airtronic M

After approx. 60 seconds the fuel supply starts andthe fuel / air mixture in the combustion chamberignites.After the flame sensor has detected the flame, theglow plug is switched off after approx. 90 sec. Theheater is now in standard operation.After another 120 seconds, the heater has reachedthe “POWER” stage (maximum fuel quantity, maximumfan speed).

Temperature selection with the control element

The control can be used to preselect an interiortemperature.The resulting temperature can be within the range of+10 °C to +30 °C and depends on the selectedheater, on the size of the space to be heated and onthe prevailing outdoor temperature.The setting to be selected at the control is anempirical value.

Operation and function4

Please note!

Control in the heating mode

During the heating mode, the room temperature or thetemperature of the sucked in heating air is constantlymeasured.If the temperature is higher than the temperatureselected on the control element, the heater starts toregulate its output. There are 4 control stages so thatthe outflow of heat produced by the heater can beadjusted finely to the heating requirements. Fan speedand fuel quantity correspond to the particular controlstage.If the set temperature is still exceeded in the smallestcontrol stage, the heater goes to the “OFF” stage withthe fan running on for approx. 4 minutes to cool off.Then the fan continues at minimum speed (circulationmode) or is switched off (fresh air mode) until theheater is started again.

Ventilating mode

In the ventilating mode, first the changeover switch“heating / venting” has to be activated and then theheater is switched on.

Switching off

When the heater is switched off, the control lampgoes off and the fuel supply is switched off.The fan runs on for approx. 4 minutes to cool down.While the fan is running on, the glow plug is switchedon for approx. 40 seconds to clean.Special case:If no fuel has been supplied or if the heater is in the“OFF” stage until it is switched off, the heater isstopped without any after running.

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Do not switch the heater off and on again morethan twice.

Forced shutdown in ADR / ADR99 mode(only for diesel heaters)

In vehicles for the transport of dangerous goods(e.g. tanker trucks), the heater must be switched offbefore the truck drives into a danger area (refinery,fuel service station, etc.).Failure to comply results in the heater switching offautomatically when:• The vehicle engine is switched off.• An additional unit is started up (e.g. auxiliary drive

for unloading pump etc.).• A vehicle door is opened (ADR99 regulation,

only in France).The fan then runs on for max. 40 seconds.

Control and safety devices

• If the heater does not ignite within 90 seconds afterstarting the fuel pump, the start is repeated. If theheater still does not ignite after another 90 secondsof pumping fuel, the heater is switched off, i.e. thefuel supply is off and the fan runs on for approx.4 minutes.

• If the flame goes off by itself during operation, theheater is restarted. If the heater does not ignitewithin 90 seconds after the fuel pump has started,or ignites and goes off again within 15 minutes, theheater is switched off, i.e. the fuel supply is off andthe fan runs on for approx. 4 minutes.This status can be remedied by briefly switching offand on again.Do not repeat the switching off/on routine morethan twice.

• In the case of overheating, the combined sensor(flame sensor / overheating sensor) triggers, thefuel supply is interrupted and the heater switchedoff. Once the cause of the overheating has beeneliminated, the heater can be re-started byswitching off and on again.

• If the lower or upper voltage limit is reached, theheater is switched off after 20 seconds.

• The heater does not start up when the glow plug isdefect or when the electric lead to the dosing pumpis interrupted.

• If the combined sensor (flame sensor / overheatingsensor) is defect or the electric lead interrupted, theheater starts up and is then switched off againduring the start phase.

• The speed of the fan motor is monitoredcontinuously. If the fan motor does not start up or ifthe speed deviates by more than 10%, the heater isswitched off after 30 sec.

• When the heater is switched off, the glow plug isswitched on for 40 seconds (after-glowing) while thefan runs on to clean off any combustion residues.

Operation and function4

Please note!

Emergency shutdown – EMERGENCY OFFIf an emergency shutdown – EMERGENCY OFF –is necessary during operation, proceed as follows:• Switch the heater off with the control or• pull the fuse out or• disconnect the heater from the battery.

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Electrical system5

Heater wiring

Caution!Safety instructions for wiring the heater!The heater is to be connected up electricallyaccording to the EMC directives.EMC can be affected if the heater is not connectedup correctly. For this reason, comply with the followinginstructions:

• Ensure that the insulation of electrical cables is notdamaged. Avoid: chafing, kinking, jamming orexposure to heat.

• In waterproof connectors, seal any connectorchambers not in use with filler plugs to ensure theyare dirt-proof and water-proof.

• Electrical connections and ground connections mustbe free of corrosion and firmly connected.

• Lubricate connections and ground connectionsoutside the heater interior with contact grease.

Comply with the following when wiring the heater and thecontrol element:• Electrical leads, switchgear and controllers must be

arranged in the vehicle so that they can functionperfectly under normal operating conditions(e.g.heat exposure, moisture etc.).

• The following cable cross sections are to be usedbetween the battery and heater. This ensures thatthe max. tolerable voltage loss in the cables doesnot exceed 0.5 V for 12 V or 1 V for 24 V ratedvoltage.Cable cross sections for a cable length of:– up to 5 m (plus cable + minus cable) = cable cross section 4 mm²– from 5 to 8 m (plus cable + minus cable) = cable cross section 6 mm²

• If the plus cable is to be connected to the fuse box(e.g. terminal 30), the vehicle cable from the batteryto the fuse box must be included in rating the overallcable length and possibly re-dimensioned ifnecessary.

• Insulate unused cable ends.

Please note!

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1.1 Burner engine1.2 Glow plug1.5 Overheating and flame sensor2.1 Controller2.2 Dosing pump2.7 Main fuse 12 volt = 20 A

24 volt = 10 A2.7.1 Fuse, actuation 5 A5.1 Battery5.2.1 Battery operation switch d)

(operation, e.g. controlled by the ignitionkey)

5.2.2 Battery separating switch d)(Emergency off function for ADR / ADR99)

5.3 Auxiliary drive HA+5.3.1 Switch, auxiliary drive5.5 Generator D+

a) Connection of the control unit and externalsensor according to the circuit diagram“control units”• rt Power supply, plus – terminal 30• ge Switch-on signal – S+• gr Actual temperature• wsrt Switch off burglar alarm system,

PIN 15, positive signal output forrelay, Imax = 200 mAfor ADR – feedback signal for timer

• br Power supply, minus – terminal 31• blws Diagnosis• grrt Nominal temperature• brws Reference signal sensor

b) OptionActivation of vehicle blower and / orseparate fresh air fanThe positive signal is only applied during the“Low” control stage (PIN 16, positive signalfor relay, Imax = 200 mA)

c) Wiring for operation to ADR / ADR99 (HGVvehicle transporting dangerous goods,e.g. tanker truck)

d) When only one switching element is used foritem 5.2.1 and 5.2.2 it must be ensured thaton activating the function “open the batteryseparating switch” (EMERGENCY OFFfunction for ADR / ADR99 etc.), the switchalways separates immediately (regardless ofthe heater status) and all the heater circuitsare disconnected from the battery.

Parts list for the circuit diagramsAirtronic / Airtronic M andAirtronic / Airtronic M – ADR mode

Electrical system5

Please note!

Circuit diagram for Airtronic / Airtronic Mon page 34.Circuit diagram for Airtronic / Airtronic M - ADR onpage 35.

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Airtronic / Airtronic M

25 2069 00 98 01 BParts list page 32

Electrical system5

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35

Electrical system5

Airtronic / Airtronic M – ADR mode

25 2069 00 96 01 CParts list page 32

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EasyStart R+

1 Terminal 31 (negative)2 – –3 Ventilate (switching signal –)4 DAT cable5 Pushbutton / LED (negative)6 Temperature sensor (negative)7 Terminal 30 (positive)8 S+ (switching on signal)9 LED (positive)

10 Diagnosis cable (K line)11 Pushbutton (negative)12 Temperature sensor (positive)

EasyStart R

1 Terminal 31 (negative)2 – –3 – –4 DAT cable5 Pushbutton / LED (negative)6 – –7 Terminal 30 (positive)8 S+ (switching on signal)9 LED (positive)

10 Diagnosis cable (K line)11 Pushbutton (negative)12 – –

Pin assignment at connector B1

EasyStart T

1 Terminal 30 (positive) rt2 S+ (switching on signal) ge3 Terminal 31 (negative) br4 DAT cable vi5 Diagnosis cable (K line) bl/ws6 Terminal 58 gr/sw7 Temperature sensor (positive) gr8 Temperature sensor (negative) br/ws9 – – – –

Electrical system5

Cable colourssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple

Parts list, circuit diagrams EasyStart R+ / R / T andEasyStart T - ADR mode

2.15.1 Sensor – room temperature, display(included in the EasyStart R+ scope ofsupply, optional for EasyStart R / T)

2.15.9 Sensor – outdoor temperature, display

3.1.7 ”ON / OFF“ button3.1.16 Radio remote control button3.1.17 ”Mini controller“ control unit

3.2.15 EasyStart T timer

3.3.9 EasyStart R radio remote control(stationary unit)

3.3.10 EasyStart R+ radio remote control(stationary unit)

3.6.1 Adapter cable

3.8.3 Antenna

a) Connection of control units at the heaterc) Terminal 58 (lighting)d) Parking ventilation with vehicle blower

(optional)e) EasyStart T timer connectiong) External ”ON / OFF“ button (optional)h) Parking ventilation with vehicle blower

(optional)x) ADR jumpery) Connect and insulate cables

• The timer / radio remote control must be connectedin accordance with the circuit diagrams(page 37 – 41).

• Insulate unused cable ends.• Connectors and bush housings are shown from the

cable inlet side.• You must definitely create the jumper marked in the

circuit diagram with y.

Please note!

Pin assignment at the stationary unit connector

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Electrical system5

25 2361 00 97 01 CParts list page 36

Circuit diagram - EasyStart R+ andEasyStart R+ in combination with EasyStart T

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Electrical system5

Parts list page 36

25 2361 00 97 05 B

Circuit diagram – EasyStart R in combination with mini controller

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Electrical system5

Parts list page 36

25 2361 00 97 02 B

Circuit diagram – EasyStart R+ in combination with EasyStart T

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Electrical system5

Parts list page 36 25 2361 00 97 03 A

Circuit diagram - EasyStart T andEasyStart T in combination with EasyStart T

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Electrical system5

Parts list page 36 25 2361 00 97 04 A

Circuit diagram - ADR modeEasyStart T and EasyStart T in combination with EasyStart T

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Electrical system5

Parts list for the circuit diagrams for thecontrol units and ADR mode controls

2.15.9 Sensor – outdoor temperature, display2.15.10 Sensor – control temperature, external

(interior)3.1.9 Changeover "heating / venting"3.1.17 Mini controller3.2.8 Module timer (ADR potentiometer)3.2.14 Timer, mini – 12 / 24 volt

a) Connection of control elements at the heater• rt Power supply, plus – terminal 30• ge Switch-on signal – S+• gr Actual temperature• wsrt Switch off burglar alarm

(ADR – feedback for timer)• br Power supply, minus – terminal 31• blws Diagnosis• grrt Nominal temperature• brws Ground connection forexternaltemperature sensor andnominaltemperature

c) Lighting, terminal 58e) Connection, Sensor – control temperature,

external (interior)g) Connection, external heating buttonh) Connection, radio remote control TP4ij) Connection, Sensor – outdoor temperature,

displayl) Connection, "heating / ventilation" selector

switch (option). To start: Actuate changeoverswitch "heat / ventilate", then switch on theheater

z) Lighting, terminal 58

Connectors and bush housings are shownfrom thecable inlet side.

Please note!

Circuit diagrams for the controls on page 43 and 44.Circuit diagrams for the ADR controls on page 45.

Cable colourssw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple

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Electrical system5

Parts list page 42

Circuit diagram for control units

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Electrical system5

Parts list page 42

Circuit diagram for control units

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Electrical system5

Parts list page 42

Circuit diagram, ADR mode controls

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Troubleshooting / Maintenance / Service6

In case of faults, please check the followingpoints

• If the heater does not start after being switched on:– Switch the heater off and on again.

• If the heater still does not start, check whether:– There is fuel in the tank?– The fuses are OK?– The electrical cables, connections etc. are OK?– Anything is clogging the combustion air supply or exhaust system?

Troubleshooting

If the heater remains faulty even after these pointshave been checked, or another malfunction occursin your heater, please contact:

• For installation ex works, your contract workshop.

• For subsequent installation, the workshop whoinstalled your heater.

Please note that warranty claims can be become voidif the heater is changed by a third party or by thisinstallation of third party parts.

Maintenance instructions

• Switch the heater on once a month for about10 minutes, even outside the heating period.

• Before the heating period starts, the heater shouldundergo a trial run.If persistent extreme smoke develops, unusualburning noises or a clear fuel smell can be perceivedor if electric / electronic parts heat up, the heatermust be switched off and put out of service byremoving the fuse.In this case, the heater should not be started upagain until it has been checked by qualified staffwho have been trained on Eberspächer heaters.

• Check the openings of the combustion air supplyand exhaust system after longer standstill periods,clean if necessary!

Service

If you have any technical queries or problemswith your pre-heater, dial the following servicephone number:

HotlinePhone. 0800 / 12 34 300

Fax hotlineFax 01805 / 26 26 24

Outside of Germany, please contact the respectivenational Eberspächer service agent.

Please note!

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Environment7

EU Declaration of Conformity

With regard to the following products

heater type Airtronic / Airtronic M

we herewith confirm that it conforms with the primesafety requirements stipulated in the directives of theEU Council for harmonisation of the legal regulationsof the member states with regard to electromagneticcompatibility (89 / 336 / EEC).This declaration applies to all heaters producedaccording to the production drawings Airtronic /Airtronic M, which are an integral part of thisdeclaration.

The following standards / directives have been usedto assess the product with regard to electromagneticcompatibility:• EN 50081 – 1 Basic form interference emission.• EN 50082 – 1 Basic form interference resistance.• 72 / 245 / EEC – Modification status 2006 / 28 / EU

interference suppression in motor vehicles.

Certification

The high quality of Eberspächer’s products is the keyto our success.To guarantee this quality, we have organised all workprocesses in the company along the lines of qualitymanagement (QM).Even so, we still pursue a large number of activitiesfor continuous improvement of product quality in orderto keep pace with the similarly constantly growingrequirements made by our customers.All the steps necessary for quality assurance arestipulated in international standards.This quality is to be considered in a total sense.It affects products, procedures and customer / supp-lier relationships.Officially approved public experts assess the systemand the corresponding certification company awardsa certificate.

Eberspächer has already qualified for the followingstandards:

Quality management as perDIN EN ISO 9001:2000 and ISO/TS 16949:1999

Environment management system as perDIN EN ISO 14001:1996

Disposal

Disposal of materialsOld devices, defect components and packagingmaterial can all be separated and sorted into pure-grade factions so that all parts can be disposed of asrequired in an environment-friendly manner or recycledwhere applicable.Electric motors, controllers and sensors (e.g.temperature sensors) are deemed to be “electronicscrap”.

Dismantling the heaterThe heater is dismantled according to the repairstages in the current troubleshooting / repairinstructions.

PackagingThe packaging of the heater can be kept in caseit has to be sent back.

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List of key words A – Z

Keyword Page

AAccident prevention ................................................... 7ADR .......................................................................... 16ADR99 ...................................................................... 31Altitude ..................................................................... 29Ambient temperature ........................................ 12 – 14

CCable harness connection ........................................ 18Certificates ............................................................... 47Circuit diagrams ..................... 34, 35, 37 – 41, 43 – 45Combustion air system ............................................. 23Control devices ........................................................ 31Control in heating mode ............................................ 30Contents ..................................................................... 2

DDangerous goods .............................................. 16, 31Declaration of conformity ......................................... 47Description of functions ........................................... 30Disposal .................................................................... 47Dosing pump ..................................................... 24 – 27

EElectronic components ................................ 33, 36, 42Emergency off .......................................................... 31Environment management ......................................... 47EU Declaration of Conformity .................................... 47Exhaust system ........................................................ 22

FFaults ....................................................................... 46Fastening .................................................................. 19Fan operation ........................................................... 30Forced shut-down ..................................................... 31Formation of air bubbles ........................................... 24Fuel supply .................................................. 5, 24 – 28Fuel consumption ............................................. 12 – 14Fuel quality ............................................................... 28

HHeat flow .......................................................... 12 – 14Hotline ...................................................................... 46

Keyword Page

IIntroduction ........................................................... 4, 5Installation ........................................................ 16 – 28Installation area ................................................. 16, 17Interference suppression class ........................ 12 – 14Initial commissioning ................................................ 29Installation location ........................................... 16, 17Installation position .................................................. 18Information ................................................................. 4Important instructions .............................................. 29

LList of abbreviations ................................................. 49

MMaintenance ............................................................. 46Main dimensions ....................................................... 15

NNameplate ................................................................ 20

OOperation .................................................................. 29Operating instructions .............................................. 29

PPicture symbols .......................................................... 4Power consumption ........................................... 12 – 14Pressure height ........................................................ 27Pressure side .................................................... 25, 26Presentation ............................................................... 4Purpose ...................................................................... 4

RRated voltage ................................................... 12 – 14Regulations ............................................................ 5, 6

SSafety devices .......................................................... 31Safety check (before starting) .................................. 29Scope of supply ................................................. 8 – 11Storage temperature ......................................... 12 – 14Statutory regulations ............................................. 5, 6Start procedure ......................................................... 30Suction height ........................................................... 27Switching on ............................................................. 30Switching off ............................................................. 30

Lists8

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Lists8

Keyword Page

TTechnical data .................................................. 12 – 14Temperature selection .............................................. 30Test symbol ................................................................ 5Text structure ............................................................. 4T-piece ...................................................................... 25Transport .................................................................. 16Troubleshooting ........................................................ 46

UUse ............................................................................. 4

VVoltage ............................................................. 12 – 14Voltage limit ...................................................... 12 – 14

WWeight .............................................................. 12 – 14Wiring ....................................................................... 32

List of abbreviations

ADREuropean agreement about the international transportof dangerous goods on the road.

EC Type approvalPermit awarded by the Federal Vehicle Office for theproduction of a heater for installation in motorisedvehicles.

EMC directiveElectromagnetic compatibility.

JE partnerJ. Eberspächer partner.

FAMEBiodiesel according to DIN V 14 214.

List of key words A – Z

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www.eberspaecher.com

J. EberspächerGmbH & Co. KGEberspächerstr. 24D - 73730 EsslingenTelefon 0711 939 - 00Telefax 0711 939 - [email protected]