Hydronic L-II 16-35 TD 05-2009 EN

Heater OrderNo. OrderNo.–compactversion

HydronicL16 252486020000 –––

HydronicL24 252487020000 252487050000

HydronicL30 252488020000 252488050000

HydronicL35 252489020000 252489050000

HYDRONIC L-II Technical Description, Installation, Operating and Maintenance Instructions.

Engine-independent water heater for diesel.

25248890996905.2009

2

1 •Contents...................................................................................................... 2•Conceptofthismanual................................................................................ 3•Specialtextstructure,presentationandpicturesymbols.............................. 4•Importantinformationbeforestartingwork................................................... 4•Statutoryregulations................................................................................ 5,6•Safetyinstructionsforinstallationandoperation........................................... 7•Accidentprevention.................................................................................... 7

•Scopeofsupply/additionalparts............................................................ 8,9•Technicaldata,heaters.............................................................................. 10•Technicaldata,waterpump Flowtronic5000/5000S/6000SC............................................. 11,12,13•Pumpingandpressurelosscharacteristiccurves Flowtronic5000/5000S/6000SC............................................. 11,12,13•Maindimensions....................................................................................... 14•Maindimensions,compactversion............................................................ 14

•Permissiblemountingpositionandfasteningoftheheater......................... 15•Maindimensions,Flowtronic5000/5000S/6000SC................. 16,17,18•Permissiblemountingpositionandfasteningofthewaterpump Flowtronic5000/5000S/6000SC............................................. 16,17,18•Installationlocation.................................................................................... 19•Installingtheheaterinabox...................................................................... 20•Nameplate/NameplatewithEBANo........................................................ 21•Exhaustsystem(pipes)........................................................................ 22,23•Combustionairsystem.............................................................................. 24•Connectiontothecoolingwatercircuit...................................................... 25•Watercircuit.............................................................................................. 25•Fuelsupply....................................................................................... 26–28

•Structureoftheheater............................................................................... 29•Operationinstructions/importantinformationforoperation....................... 29•Initialcommissioningoftheheater............................................................. 29•Functionaldescription/Functionaldiagram............................................... 30•Controlandsafetydevices/EMERGENCYOFF........................................ 31

•Heaterwiring............................................................................................. 32•Partslist/circuitdiagram,heater–Part1.................................................. 33•Partslist/circuitdiagram,heater–Part2.................................................. 34•Partslist/circuitdiagram,controlunits...................................................... 35•Partslist,EasyStartR+/EasyStartR/EasyStartTcontrolunits................ 36•Circuitdiagrams,EasyStartcontrolunits............................................ 37–39

•Ifanyfaultsoccur,pleasecheckthefollowingitems................................... 40•Troubleshooting......................................................................................... 40•Maintenanceinstructions........................................................................... 40•Changingcomponents.............................................................................. 40•Service...................................................................................................... 40

•Certifications.............................................................................................. 41•Disposal.................................................................................................... 41•ECDeclarationofConformity..................................................................... 41

•Index........................................................................................................ 42•Listofabbreviations.................................................................................. 43

Introduction1

Chapter Title Contents Page

Contents

Introduction

Product information

Installation

Operation and function

Electrical system

FaultsMaintenanceService

Environment

Lists

6

5

4

3

2

7

8

3

Concept of this manual

Thismanualaimstosupporttheservicecompanyinstallingtheheaterandtoprovidetheuserwithallimportantinformationabouttheheater.Themanualhasbeendividedinto8chapterstomakeiteasiertofindthecorrespondinginformationquickly.

IntroductionHereyoufindimportantintroductoryinformationaboutinstallationoftheheaterandaboutthestructureofthemanual.

Product informationHereyouwillfindinformationaboutthescopeofsupply,thetechnicaldataandthedimensionsoftheheater.

InstallationHereyouwillfindimportantinformationandinstructionsreferringtoinstallationoftheheater.

Operation and functionHereyouwillfindinformationabouttheoperationandfunctionoftheheater.

Electrical systemHereyouwillfindinformationabouttheheater'selectricsandelectroniccomponents.

Troubleshooting / maintenance / serviceHereyouwillfindinformationaboutpossiblefaults,troubleshooting,servicing/maintenanceandtheservicehotline.

EnvironmentHereyouwillfindinformationaboutcertificationanddisposaloftheheatertogetherwiththeECDeclarationofConformity.

ListsHereyouwillfindthekeywordlistandabbrevia-tionslist.

4

Introduction1

5

6

1

2

37

8

4

Introduction1

Special text structure, presentation and picture symbols

Thismanualusesspecialtextstructuresandpicturesymbolstoemphasizedifferentcontents.Pleaserefertothefollowingexamplesfortheirmean-ingsandappropriateaction.

Special text formats and presentations

Adot(•)indicatesalistwhichisstartedbyaheading.Ifanindenteddash(–)followsadot,thislistissubordi-natetothedot.

Picture symbols

Regulation!

Thispicturesymbolwiththeremark"Regulation!"referstoastatutoryregulation.Failuretocomplywiththisregulationresultsinexpiryofthetype-approvalfortheheaterandpreclusionofanyguaranteeandliabilityclaimsonJ.EberspächerGmbH&Co.KG.

Danger!

Thispicturesymbolwiththeremark"Danger!"referstotheriskofafataldangertolifeandlimb.Undercertaincircumstances,failuretocomplywiththeseinstructionscanresultinsevereorlife-threateninginjuries.

Important!

Thispicturesymbolwiththeremark"Caution!"referstoadangeroussituationforapersonand/ortheproduct.Ignoringthisinformationcanresultininjuriestopeopleand/ordamagetomachinery.

Theseremarkscontainrecommendationsforuseandusefultipsforinstallationoftheheater.

Important information before starting work

Range of application of the heater

Thewaterheateroperatingindependentlyofanengineisintendedforinstallationinthefollowingvehicles:

•Alltypesofmotorvehicles,especiallybusesandcoaches

•Constructionmachinery

•Agriculturalmachinery

•Boats,shipsandyachts

•Railvehicles

•Installationoftheheaterinvehiclesusedforthetrans-portofdangerousgoodsaccordingtoADRisnotpermitted.

•Theheaterisprimarilyintendedforinstallationinbusesandisdesignedfortheirspecialrequirements.

Intended purpose of the heater (via the vehicle's own heat exchanger)

•Pre-heating,de-mistingwindows

•Heatingandkeepingthefollowingwarm:–Driverandworkingcabs–Freightcompartments–Ship'scabins–Passengerandcrewcompartments–Vehicleenginesandunits

Onaccountofitsfunctionalpurpose,theheaterisnotapprovedforthefollowingapplications:

•Long-termcontinuousoperation,e.g.forpre-heatingandheatingof:–Residentialrooms–Garages–Workhuts,weekendhomesandhuntinglodges–Houseboats,etc.

Important!Safety instructions for the range of application and proper, intended use!

Theheatermustonlybeusedandoperatedfortherangeofapplicationstatedbythemanufacturerandincompliancewiththeoperationinstructionsincludedwitheveryheater.

Please note!

Please note!

5

Statutory regulations

TheFederalRoadTransportDirectoratehasissuedan“ECtypeapproval”andan“EMCtype-approval”fortheheaterforinstallationinmotorvehiclesandwiththefol-lowingofficialtype-approvalmarks,notedontheheaternameplate.

HydronicL-II EC-e1000233

EMC-e1035282

TheFederalRailwayOfficehasissueda“typeapprovaltoArt33EBO”forinstallationoftheheaterinrailvehi-cles;thevehiclehasthefollowingofficialtypeapproval:

HydronicL-II EBA32AZ3/0097/08

Statutory regulations!Directive 2001 / 56 / EC of the European Parliament and the Council

• Position of the heater–Partsofthestructureandothercomponentsneartheheatermustbeprotectedfromexcessiveheatexposureandpossiblefueloroilcontamination.

–Theheatermustnotposeafirehazardevenwhenitoverheats.Thisrequirementisdeemedtobefulfilledifadequateclearanceisensuredforallpartsduringinstallation,sufficientventilationisprovidedandfireproofmaterialsorheatshieldsareused.

–TheheatermustnotbemountedinthepassengercompartmentofvehiclesinclassM1,M2,M3andN.Butaheaterinahermeticallysealedenclosurewhichotherwisecomplieswiththeconditionsstatedabovemaybeused.

–Thefactorynameplateorduplicateofitmustbeaffixedsothatitcanstillbeeasilyreadwhentheheaterisinstalledinthevehicle.

–Allappropriateprecautionsmustbetakenwhenarrangingtheheatertominimisetheriskofinjuriestopersonsordamagetootherproperty.

Introduction1

• Fuel supply–Thefuelintakeconnectionmustnotbelocatedinthepassengercompartmentandmustbesealedwithaproperlyclosinglidtopreventanyfuelleaks.

–Inheatersforliquidfuelwheretheheaterfuelisseparatefromthevehiclefuel,thetypeoffuelandintakeconnectionmustbeclearlyidentified.

–Awarningsignistobefixedtotheintakeconnec-tionindicatingthattheheatermustbeswitchedoffbeforerefuelling.

• Exhaust system–Theexhaustoutletmustbearrangedsoastopreventanypenetrationofexhaustfumesintothevehicleinteriorthroughtheventilationsystem,warmairintakesoropenwindows.

• Combustion air intake–Theairfortheheater'scombustionchambermustnotbesuckedinfromthevehicle'spassengercompartment.

–Theairintakemustbearrangedorprotectedinsuchawaythatitcannotbeblockedbyotherobjects.

• Operating status display–Aclearlyvisibleoperatingdisplayintheuser'sfieldofvisionmustindicatewhentheheaterisswitchedonanoff.

6

Statutory regulations

ThelayingoffuellinesandinstallationofadditionalfueltanksmustcomplywithArt45and46oftheStVZO(Germanroadvehiclelicensingregulations).ExtractfromArt45and46StVZO:

•Fueltanksinbusesandcoachesmustnotbelocatedinthepassengercompartmentordriver'scab.Theymustbepositionedinsuchawaythatifafireoccurstheexitsarenotatimmediaterisk.

•Fuellinesinbusesandcoachesmustnotbelocatedinthepassengercompartmentordriver'scab.

•TheheatermaynotbeinstalledinclassesM1andN1,astheend-of-lifevehiclesregulations(ECEnd-of-LifeVehiclesDirective2000/53/EC)isnotcompliedwith.

•Compliancewiththestatutoryregulationsandsafetyinstructionsisprerequisiteforguaranteeandliabilityclaims.FailuretocomplywiththestatutoryregulationsandsafetyinstructionsandincorrectrepairsevenwhenusingoriginalsparepartsmaketheguaranteenullandvoidandprecludeanyliabilityforJ.EberspächerGmbH&Co.KG.

•Subsequentinstallationofthisheatermustcomplywiththeseinstallationinstructions.

•Thestatutoryregulationsarebindingandmustalsobeobservedincountrieswhichdonothaveanyspecialregulations.

•WheninstallingtheheaterinvehiclesnotsubjecttotheGermanRoadTrafficLicensingRegulations(StVZO),forexampleships,therespectivespeciallyvalidregulationsandinstallationinstructionsmustbeobserved.

•Installationoftheheaterinspecialvehiclesmustcom-plywiththeregulationsapplyingtosuchvehicles.

•Otherinstallationrequirementsarecontainedinthecorrespondingsectionsofthismanual.

•Manufacturer’srecommendationsforrailvehiclesarespeciallymarkedinthefollowingchapters.

Introduction1

Please note!

7

Safety instructions for installation and operation

Danger!

Risk of injury, fire and poisoning!

•Disconnectthevehiclebatterybeforestartinganykindofwork.

•Beforeworkingontheheater,switchtheheateroffandletallhotpartscooldown.

•Theheatermustnotbeoperatedinclosedrooms,e.g.inthegarageorinamulti-storeycarpark.

Important!Safety instructions for installation and operation!

•TheheatermustonlybeinstalledbyaJEpartnerauthorisedbythemanufactureraccordingtotheinstructionsinthismanualandpossiblyaccordingtospecialinstallationrecommendations;thesameappliestoanyrepairstobecarriedoutinthecaseofrepairsorguaranteeclaims.

•Repairsbynon-authorisedthird-partiesorwithnotoriginalsparepartsaredangerousandthereforenotallowed.Theyresultinexpiryofthetype-approvaloftheheater;consequently,wheninstalledinmotorvehiclestheycancauseexpiryofthevehicleoperatinglicence.

•Thefollowingmeasuresarenotallowed:–Changestocomponentsrelevanttotheheater.–Useofthird-partycomponentsnotapprovedbyEberspächerGmbH&Co.KG.

–Nonconformitiesininstallationoroperationfromthestatutoryregulations,safetyinstructionsorspecifica-tionsrelevanttosafeoperationasstatedintheinstallationinstructionsandoperatinginstructions.Thisappliesinparticulartotheelectricalwiring,fuelsupply,combustionairsystemandexhaustsystem.

•Installationandrepairmaybecarriedoutwithoriginalaccessorypartsandoriginalsparepartsonly.

•OnlycontrolunitsapprovedbyEberspächermaybeusedtooperatetheheater.Useofothercontrolunitscancausemalfunctions.

Introduction1

•Beforetheheaterisinstalledagaininanothervehicle,rinsetheheaterpartscarryingwaterwithclearwater.

•Whencarryingoutelectricweldingonthevehicle,thepositivecableatthebatteryshouldbedisconnectedandplacedatgroundtoprotectthecontrolbox.

•Theheatermustnotbeoperatedwherethereisariskofanaccumulationofflammablevapoursordust,forexamplecloseto–fueldepot–coaldepot–wooddepot–graindepotsetc.

•Theheatermustbeswitchedoffwhenrefuelling.

•Iftheheaterisfittedinasafetycasing,etc.,theheater'sinstallationboxmustnotbeusedasstor-agespaceandmustbekeptclear.Inparticularfuelcanisters,oilcans,spraycans,gascartridges,fireextinguishers,cleaningrags,itemsofclothing,paperetc.mustnotbestoredortransportedonornexttotheheater.

•Defectfusesmustonlybereplacedbyfuseswiththeprescribedrating.

•Iffuelleaksfromtheheaterfuelsystem,arrangeforthedamagetoberepairedimmediatelybyaJEserv-icepartner.

•Whentoppingupthecoolant,onlyusethecoolantpermittedbythevehiclemanufacturer,seethevehicleoperatingmanual.Anyblendingwithunpermittedcoolantcancausedamagetotheengineandheater.

•Theafter-runningoftheheatermustnotbeprema-turelyinterruptede.g.bypressingthebatteryisolatingswitch,exceptforanemergencystop.

Accident prevention

Generalaccidentpreventionregulationsandthecor-respondingworkshopandoperatingsafetyinstructionsaretobeobserved.

8

Product information2

Scope of supply

Fig. No. Designation Order No.

1 HydronicL16–24volt 252486020000

1 HydronicL24–24volt 252487020000

2 HydronicL24–24volt 252487050000 Compactversion

1 HydronicL30–24volt 252488020000


1 HydronicL35–24volt 252489020000


Thefollowingadditionalpartsarerequiredtoruntheheater:

•Additionalpartsforconnectiontothewatercircuit

•Additionalpartsforthefuelsupply

•Additionalpartsfortheexhaustsystem

•Controlunit

Additional parts which have to be ordered separately

Fig. No. Designation Order No.

3 Flowtronic5000 251818290000 4 Flowtronic5000S 251818300000 5 Flowtronic6000SC 252488250000 6 Hoseclip,ø40-47mm 15200158 7 Hoseelbow,ø38mm 36000300 8 Connectionpipe,ø38mm 251214890021 9 T-piece,ø38-38-38 25137189040010 Reducer,ø38/28mm 25121489001911 Hoseclip,ø32-39mm 1526109712 Pipeelbow,ø38mm 25121489000313 Waterhose,ø38mm 3607509614 Exhaustpipesocket,ø70mm 22100040040015 Exhaustpipeelbow,ø70mm 22100040030016 Fuelfilter 3300005217 Banjobolt,M14x1.5 1041004018 Ringhosenipple,A14x18 3231600619 Fuelsuctionline 25169805030020 Screwfixing,M14x1.5 2664200421 Sphericalliner 2633508022 Unionnut,M14x1.5 1161004023* Fuelpipe,

outerdiameterø6x1(Cu),24 Fuelhose,

innerdiameterø5x3 3607535025 Hoseclip,ø11mm 10206301109826 Screwfixing,M14x1.5 25170605010027 Ballvalve,M14x1.5 3300001928 Fuelreturnline 25169805040029 Valve 3300021030 Reducingcoupling8/6 2660002631 Shroudwithhoseconnection 22100040060032 1mflexiblehose,ø60mm 10211431000033 Hoseclip 10206405007034 Airhosefixingkit 22100050020035 Plasticgrille 25168880060036 RubberbufferM6x10,

height15mm 201607650002

* Thefuelpipemustbeboughtfromthetrade.

Forfurtheradditionalparts,seeadditionalpartscatalogue.

Please note!

9


Scope of supply

10


Important!Safety instructions for technical dataFailuretocomplywiththetechnicaldatacanresultinmalfunctions.

Technical data

Heatertype Hydronic L-II

Heater HydronicL16 HydronicL24 HydronicL30 HydronicL35

Version HL2-16 HL2-24 HL2-30 HL2-35

Heatingmedium Mixtureofwaterandcoolant(min10%,max50%coolantasantifreeze)

Heatflowinwatts(atambienttemperature–10°C)

16000 24000 30000 35000

Temperaturevalues–atwaterinlet ON73°C/OFF78°C

Temperaturevalues–atwateroutlet ON85°C/OFF118°C

Fuel Diesel–commerciallyavailable(DINEN590)HeatingoilEL(DIN51603)

Fuelconsumption(atambienttemperature–10°C)

2.0l/h 2.9l/h 3.65l/h 4.2l/h

Ratedvoltage 24volt

Operatingrange•Lowervoltagelimit: Anundervoltageprotectioninstalledinthecontrolboxswitchesofftheheaterifthevoltagelimitisreached.

20volt

•Uppervoltagelimit: Anovervoltageprotectioninstalledinthecontrolboxswitchesofftheheaterifthevoltagelimitisreached.

30volt

Electricalpowerconsumption(inoperation) 60watt 80watt 105watt 120watt

Watervolume(intheheater) approx2.4l

Minimumthroughput(minimumattheheater)

1400l/h 2000l/h 2600l/h 3000l/h

Permissibleambienttemperature

Heater

inoperation

–40°Cto+85°C

withoutoperation

–40°Cto+100°C

Permissibleoperatingtemperature

Heatingmedium

Combustionair

–40°Cto+90°C/brieflyupto+120°C

<60°C

Operatingpressure(intheheater) 2.5bar

CO2values(%vol) 9–11 9–11 9–11 9,5–11,5

COintheexhaust <0,04

Smokespotno.(Bacherach) <4

Weight approx18kg

Interferencesuppressionclass 4forVHF/SW/LW,5forMW

Protection IP54

Providednolimitvaluesaregiven,thetechnicaldataprovidediswiththeusualheatertolerancesof±10%atratedvoltage,20°CambienttemperatureandreferencealtitudeEsslingen.

Please note!

11



Technical data

Pumptype Flowtronic 5000


Deliveryrate 5200l/h±10%at0.2bardeliverypressure

Operatingpressure,watercircuit max2bar

Weight(withoutbracket,clipandcoolant) 2.14kg

Ratedvoltage 24volt

Operatingrange 20–28volt

Powerconsumptionat5200l/hand0.2bardeliverypressure

104watt±10%

Interferencesuppressionclass 3toDIN57879/Part1VDE0879

Protection IP54AtoDIN40050Sheet1

Electricalfusingforthirdpartycontrols 15A

Temperatureconditions

–40°Cto+90°C short-term(15min)+115°CHeatingmedium

–40°Cto+90°C short-term(15min)+115°CAmbient,operating

Dryrunning No

Blocking Theengineremainsundamagedwithinaperiodofmax6seconds.

Shaft–impellerconnection Mechanicalseal

Pumping and pressure loss characteristic curves

•Providednolimitvaluesaregiven,thetechnicaldataprovidediswiththeusualwaterpumptolerancesof±10%atratedvoltage,20°CambienttemperatureandreferencealtitudeEsslingen.

•TheFlowtronic5000waterpumpisinstalledincom-pactheaters.

•Thewaterpumpsmustbeassignedtotheheatersdependingontheminimumthroughputandcoolingwatervolume.

Please note!

Volumetricflow(withwaterat20°C)

Flowresistance(whenpumpatastandstill)

p [

bar

]

Q [l/h]

12



Technical data

Pumptype Flowtronic 5000 S





Ratedvoltage 24volt



104watt±10%

Interferencesuppressionclass 1forVHF,5forSW,2forMWandLWtoDIN57879/Part1VDE0879

Protection IP54AtoDIN40050Sheet1


Temperatureconditions –40°Cto+90°C short-term(15min)+115°CHeatingmedium


Dryrunning No

Blocking Theengineremainsundamagedwithinaperiodofmax6seconds.

Shaft–impellerconnection Magneticclutch


Please note!





p [

bar

]

Q [l/h]

13



Technical data

Pumptype Flowtronic 6000 SC





Ratedvoltage 24volt



210watt±10%

Interferencesuppressionclass 5forLW,MW,SW1,SW2,VHFaccordingtoDINEN55025

Protection IP25(encapsulatedelectronics)accordingtoDIN40050,Part9


Temperatureconditions –40°Cto+90°C short-term(15min)+115°CHeatingmedium


Storage –40°Cto+120°C

Dryrunning approx45min.–themotorswitchesitselfoffafterapprox45min.

Anti-blockingprotection Yes–thestartingattemptsarecontinuedwithoutlimit.


Please note!





p [

bar

]

Q [l/h]

14

2

224

233

¯ 38

180

153

Main dimensions

Main dimensions – compact version


min.375forremovingtheheaderpipe

Please note!

Thisfigureshowsthedimensionsdifferingfromthetopversiononly.

15

Permissible mounting positions and fasten-ing of the heater

Theheatershouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesandthethroughholefortheexhaustfittingontothemountingsurface–asshowninthesketch–anddrillaccordingly.Fixtheheaterwith4screwsM8and4bodywashers.

•Thecontactsurfaceforthetwofasteningconsolesmustbeflat.

•Dependingontheinstallationconditions,theheatercanbetiltedatanangleasshowninthediagrams.Inheatingmode,theheatercandeviatefromthenormalpositionbyupto+15°inalldirectionsasaresultoftheslantedpositionofthevehicle.

•Forverticalmountingpositiontheheatermustalwaysbesupportedatthebottomoftheheatexchangerbyastablebearingsurface.Thefixingscrewsaresolelyforfixingtheheater.

Permissible mounting positions and hole pattern for the heater

Mounting position, compact version•Horizontalmountingpositionwiththeallowabledeviations.•Verticalmountingpositionnotallowed.

•Horizontalmountingpositionwiththeallowabledeviations.

•Verticalmountingpositionwith-outdeviations.

Drilling hole pattern

Installation3

Ø4.5forhexagonscrewM4Ø2.9forself-tappingscrewB3.9

Please note!

2

5˚

5˚

15˚ 15˚

2

16

Installation3

Main dimensions, Flowtronic 5000

Permissible mounting positions and fasten-ing of the water pump

Thewaterpumpshouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesontothemountingsur-face–asshowninthesketchofthemaindimensions–anddrillaccordingly.Ifpossible,fixthewaterpumptothevehiclewith4rub-berbuffersM6x10.

•Themountingpositionofthewaterpumpmustbechosentopreventlargequantitiesofwaterorexhaustgasfromenteringtheelectricmotor.

•Thelayingoftheconnectionlinesmustnotcauseanylateralstrainforcestooccurintheinletandoutletcon-nectionsocketsofthewaterpump(theconnectionsocketsandconnectionlinesmustbeinalignment).

•Theinstallationclearancefromadjacentcomponentsmustbeatleast10mm.

Please note!

a Preferredinstallationposition

b Permissiblemountingpositionb

aa

b

17

Installation3

Main dimensions, Flowtronic 5000 S


Thewaterpumpshouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesontothemountingsur-face–asshowninthesketchofthemaindimensions–anddrillaccordingly.Ifpossible,fixthewaterpumptothevehiclewith4rub-berbuffersM6x10.



•Theinstallationclearancefromadjacentcomponentsmustbeatleast10mm.

Please note!


b Permissiblemountingposition

b

a

a

b

18

Installation3

Main dimensions, Flowtronic 6000 SC


Thewaterpumpshouldpreferablybeinstalledinahorizontalposition.Transferthefourfasteningholesontothemountingsur-face–asshowninthesketchofthemaindimensions–anddrillaccordingly.FixthewaterpumptothevehicleusingtheM6rubberbuffersincludedinthescopeofsupply.



•Thedistancefromadjacentpartsmustbeatleast10mmtoensureventilation.

Please note!


b Permissiblemountingposition

a

b

19

Installation location

Theheaterandthewaterpumpareintegratedinthecoolingwatercircuitofthevehicleorinaseparatewatercircuit.Theheatershouldbeinstalledaslowaspossibleinthevehicle,e.g.intheenginecompartmentorinastowagecompartment.Thisguaranteesautomaticventilationoftheheaterandthewaterpump.Otherinstallationlocationsarepossibleiftheycomplywiththeinstallationrequirementsstatedintheseinstalla-tioninstructions.

Whenchoosingthemountingposition,spacemustbelefttodismantletheshroud(130mm)andtheheaderpipe(375mm).Breakthroughstotheoutsidemustbesplashproof.

Additional notes on the location in rail vehicles

Inrailvehiclestheheatermustbefixedintheenginecompartment(e.g.locomotive)orunderfloorintheinstallationboxonthevehiclebody(e.g.railcar).OtherlocationsrequireanacceptanceinspectionbyJ.EberspächerGmbH&Co.KG.

Installation3

Installation example in a bus and in a rail vehicle

1 Heater2 Waterpump3 Tankconnection

4 Vehicleengine5 Frontheater6 Roofairducts

7 Roofheater8 Floorheater9 Additionalwaterpump

•Complywiththestatutoryregulationsandsafetyinstructionsregardingthecontentsofthischapteronpage4–7.

•Mounttheheaterundertheminimumcoolingwaterlevel(headertank,radiator,vehicleheatexchanger).

•Ifinstallingtheheaterinaseparatelyinstalledwatercircuittheinstallationmustalwaysbesubjectedtoanacceptanceinspectionbytheheatermanufacturer.

Please note!

Ifthisinstallationacceptancedoesnottakeplaceanywarrantyorliabilityclaimswhatsoeverexpire.

•Itisnotpermissibletofixtheheaterinrailvehicleswithmetal-rubberbuffers.

•Installationrequirements(e.g.forboatsandships)areavailablefromthemanufactureronrequest.

20

Installing the heater in a box

Iftheheatercannotbeinstalledintheenginecompart-mentorinastowagecompartmentofthevehicle,itcanalsobeinstalledinabox.Theboxwiththeinstalledheateristhenfixedtothevehicleatasuitablepointe.g.longitudinalframe.

•Complywiththestatutoryregulationsandsafetyinstructionsregardingthischapteronpage4–7.

•Theboxmustbeadequatelyventilatedfromtheout-sidesothatthepermissibleambienttemperatureisnotexceeded.

•Ventilationopeningsmustbepositionedintheboxinsuchawaythattheycannotbecloggedupbydirtandsnow.

•Anywaterwhichpenetratestheboxmustbeallowedtodrainoff.

Installation3

1 Box2 Heater3 Shroudwithhoseconnection4 Flexiblehosewithsafetygrille5 Waterpump6 Fuellines7 Waterhose8 Waterinlet9 Wateroutlet

Theinstallationofahoodwithhoseconnectionisrecommendedforintakeofcombustionair.Thecombustionairisthensuckedinfromoutsidetheboxthroughaflexiblehose.Asafetygrilleistobefittedtotheflexiblehose.

Installation example – heater in a box

Please note!

21

Nameplate

Thenameplatestuckontotheheatermustbeprotectedagainstdamageandmustbeeasytoreadwhentheheaterisinstalled.Ifthisisnotthecasetheinstallercanstickaduplicatenameplateontotheheaterorintheareaoftheheaterinapositioninwhichitiseasytoseeandread.Theduplicatenameplateisgluedontotheshroudoftheheater,andcanbepulledoffifnecessary.


•HeatersapprovedforinstallationinrailvehiclesareidentifiedbyanEBANo.onthenameplate.

1 Originalnameplate2 Duplicatenameplate

Please note!

Installation3

22

Exhaust system (pipes)

Danger!Risk of injuries and burns!

Everytypeofcombustionproduceshightemperaturesandtoxicexhaustfumes.Thisiswhytheexhaustsys-temmustalwaysbelaidaccordingtotheseinstallationinstructions.

•Donotperformanyworkontheexhaustsystemwhiletheheaterisworking.

•Beforeworkingontheexhaustsystem,switchofftheheaterfirstandwaituntilallthepartshavecompletelycooleddown,wearsafetyglovesifnecessary.

•Donotinhaleexhaustfumes.

Important!Safety instructions for the exhaust system!

•Theexhaustpipemustendintheopenair.

•Theexhaustpipemustnotprotrudebeyondthelaterallimitsofthevehicle.

•Installtheexhaustpipeslopingslightlydownwards,ifnecessarydrilladrainholeapproxØ5mmatthelow-estpointasacondensationoutlet.

•Importantfunctionalpartsofthevehiclemustnotbeimpaired(keepsufficientclearance).

•Installtheexhaustpipewithsufficientclearancefromheat-sensitivecomponents.Payparticularattentiontofuellines(madeofplasticormetal),electricalcablesandbrakehoses,etc.!

•Exhaustpipesmustbesafelyfixed(recommendedclearanceof50cm)toavoiddamagefromvibrations.

•Laytheexhaustsystemsothattheoutflowingexhaustgasesarenotsuckedinascombustionair.

•Themouthoftheexhaustpipemustnotbecomecloggedwithdirtandsnow.

•Themouthoftheexhaustpipemustnotpointinthedirectionoftravel.

•Inrailvehiclesitisimportanttoensurethattheexhaustopeningdoesnotpointinoneofthepossibledirectionsoftravel(90°tothedirectionoftravel).

Installation3

Installing the exhaust system

Pushanexhaustpipeelboworanexhaustpipesocketontotheheater'sexhaustconnectionandfixtothefloorofthevehicle.OrderNo.oftheexhaustsystemparts,seepage8.

Arigidorflexibleexhaustpipe,innerØ70mm,canbefixedtotheexhaustbendasanextension.Theexhaustpipecanbeuptoamaximumof4mlong,dependingontheinstallationconditions.

Arigidexhaustpipemadefromunalloyedoralloyedsteeloraflexibleexhaustpipemadefromalloyedsteel,innerø=70mm,iscurrentlynotavailable.Ifneededtheexhaustpipeandthecorrespondingpipeclipsmustbepurchasedfromaspecialiststore;thewallthicknessoftherigidexhaustpipemustbeatleast1mm.

Aftertheexhaustsystemhasbeeninstalled,makeanendsleeve(seepage17)andpushitontotheendoftheexhaustpipe.

•Theexhaustsystemcanbelaidwithmax.3x90°angles,thetotallengthreducesby0.5mwitheach90°-bend.

•Usepipeclipstofixtheexhaustpipetothevehicleflooratsuitableplaces.


Please note!

23

Installation3

Example for the exhaust system

Metal end sleeve with separators for exhaust pipe

Ifnecessaryyoumustmakeametalendsleevewithseparatorsfortheexhaustpipeyourself.

Sketch1

1 Heater2 Exhaustconnection3 Exhaustpipeelbow90°4 Exhaustpipe5 Flexibleexhaustpipe6 Pipeclip7 Endsleeve

Items4–6mustbepurchasedfromaspecialiststore.YoumustmakeItem7yourself.

Exhaust system (pipes)

di=70

7,5

5035

7,57,530

Please note!

24

Combustion air system

Important!Safety instructions for the combustion air system!

•Thecombustionairmaynotbedrawninfromroomsinwhichtherearepeople.

•Thecombustionairopeningmustbefreeatalltimes.•Positionthecombustionairintaketobesurethatexhaustfumescannotbesuckedinwiththecombus-tionair.

•Donotdirectthecombustionairintakeagainstthevehicle'sairstream.

•Thecombustionairintakemustnotbecomecloggedwithdirtandsnow.

•Installthecombustionairsystemslopingslightlydownwards.Ifnecessary,makeadrainholeapprox.Ø5mmatthelowestpointasacondensationoutlet.

•Iftheheaterisinstallednearthevehicle'stankinajointinstallationspacethecombustionairmustbedrawninfromtheoutsideandtheexhaustmustbedischargedoutsideintotheopenair.Theopeningsmustbemadesplashproof.

•Inrailvehiclesitisimportanttoensurethatthecom-bustionairopeningdoesnotpointinoneofthepos-sibledirectionsoftravel(90°tothedirectionoftravel).

Complywiththestatutoryregulationsandsafetyin-structionsregardingthischapteronpage4–7.

Theventilationopeningforthecombustionairmustbepositionedontheboxsothatitcannotbecomeblockedbydirtandsnowandexhaustgasescannotbesuckedin.

Example for the combustion air system

Installation3

Combustion air intake

Thecombustionairisroutedtotheburnerintheheaterviathehood.Noinstallationworkisnecessary.Iftheheaterisinstalledinaboxortheinstallationconditionsareveryconfinedand/orthetemperatureisunaccept-ablyhigh,werecommendfittingahoodwithhoseconnectionfordrawinginthecombustionair.Thecom-bustionairisthensuckedinthroughaflexiblehose.Thisensuresthatthecombustionairissuckedinfromanareaintherighttemperaturerangewhichisprotectedfromdirt.Asafetygrilleistobefittedtotheflexiblehose.

Ifahoodwithhoseconnectionisnotusedwhentheheaterisinstalledinabox,thecombustionairmustbesuckedinthroughaventilationopeningwithaneffectiveminimumcrosssectionwhichcorrespondstoapipewithØ60mm.

Combustionairintakethroughagillplate.

Combustionairintakewithaflexiblehoseø60mm,max1mlong.

Please note!

Please note!

25

10 10 10

9 9 9

5 5 5 3

348

1 26

7

Connection to the cooling water circuit

Theheaterisintegratedinthevehicle'scoolingwatercircuit.Analternativeinstallationoptionistoinstalltheheaterwithitsowncoolingwatercircuitwithaheadertank.

Danger!Risk of injuries and burns!

Thecoolingwaterandcomponentsofthecoolingwatercircuitcangetveryhot.•Partsconveyingwatermustberoutedandfastenedinsuchawaythattheyposenotemperaturerisktoman,animalsormaterialsensitivetotemperaturefromradiation/directcontact.

•Beforeworkingonthecoolingwatercircuit,switchtheheateroffandwaituntilallthecomponentshavecooleddowncompletely,ifnecessarywearsafetygloves.

•Wheninstallingtheheater,pleasenotethedirectionofflowofthecoolingwatercircuit.

•ThewaterhosesincludedintheEberspächerscopeofsupplymustbeused.Ifnot,thehosesusedmustatleastconformtoDIN73411.

•Filltheheaterandwaterhoseswithcoolingwaterbeforeconnectingtothecoolingwatercircuit.

•Routethewaterhoseswithoutanykinks,andinaris-ingpositionifpossible.

•Whenroutingthewaterpipes,observeasufficientclearancetohotvehicleparts.

•Protectallwaterhoses/waterpipesfromchafingandfromextremetemperatures.

•Secureallhoseconnectionswithhoseclips.•Afterthevehiclehasbeenoperatingfor2hoursortravelled100km,tightenthehoseclipsagain.

•Theminimumwaterflowrateisonlyguaranteedifthetemperaturedifferenceoftheheatingmediumdoesnotexceed10Kbetweenwaterinletandwateroutletduringheating.

•Onlyoverpressurevalveswithanopeningpressureofmin.0.4–max.2barmaybeusedinthecoolingwatercircuit.

•Ascorrosionprotectionthecoolingwatermustcon-tainatleast10%antifreezethewholeyearround.

•Duringcoldperiodsthecoolantwatermustcontainsufficientcoolant(antifreeze).

•Beforecommissioningtheheaterforthefirsttimeorafterchangingthecoolingwater,thewholecoolingwatercircuitincludingtheheatermustbeventedwith-outbubblesaccordingtothevehiclemanufacturer'sinstructions.

•Correctventilationisidentifiablebyawaterpumpwhichoperatesvirtuallynoise-free.Poorventilationcanresultinoverheatingoftheresettablethermalcut-outinheatingmode.

•Onlytopupwithcoolantapprovedbythevehiclemanufacturer.

•Insertthewaterpumppreferablyinthewaterinletlinetotheheater.

Water circuitThediagramshowstheheaterinte-gratedinthecoolingwatercircuitofabusorcoach/railvehicle.

Installation3

1 Heater 2 Flowtronicwaterpump 3 Shutoffvalve 4 Electricalshutoffvalve 5 Non-returnvalve 6 Fromvehicleengineorheader

tank 7 Tothevehicleengineorheader

tank 8 Frontheater/driver’scab 9 Spaceheater10 Convectionheater

Please note!

26

•Neverlayorfixthefuelpipesimmediatelynexttotheheater'sexhaustsystempipesoralongthevehicle'sexhaustsystem.Ifthesystemscross,alwaysensurethereissufficientheatclearance.Ifnecessary,installheatdeflectionplates.

•Drippingorevaporatingfuelmustneverbeallowedtocollectonhotpartsorigniteonelectricequipment.

•Whenconnectingfuelpipeswithafuelhose,alwaysmountthefuelpipesinabuttjointtopreventanybub-blesfromforming.

Safety instructions for fuel pipes and fuel tanks in buses and coaches

•Inbusesandcoaches,fuelpipesandfueltanksmustnotberoutedthroughthepassengercompartmentordriver'scab.

•Fueltanksinbusesandcoachesmustbepositionedinsuchawaythattheexitsarenotinimmediatedan-gerifafireoccurs.

Complywiththestatutoryregulationsandsafetyinstruc-tionsregardingthischapteronpage4–7.

Important!Safety instructions for laying the fuel pipes!

•Useasharpknifeonlytotrimthefuelhosesandpipes.Interfacesmustnotbecrushedandmustbefreeofburrs.

•Theintakeandreturnlinemustbefilledwithfuelwhenputtingintoservice.Theheateronlyworkswithventedpipesandlines(filter).

•Fuelpipesmustbesecurelyfixedtoavoidanydam-ageand/ornoiseduetovibrations(recommendedguidelinevalue:atspacingsofapprox.50cm).

•Fuelpipesmustbeprotectedagainstmechanicaldamage.

•Laythefuelpipessothatanydistortionorshakingofthevehicle,enginemovements,etc.donothaveadisadvantageouseffectontheservicelife.

•Partscarryingfuelmustbeprotectedfromdisruptiveheat.

Fuel supply

Thefuelistakenfromthevehicle'sfueltankorasepa-ratefueltank.Thefollowingsafetyinstructionsmustalwaysbeobservedwhenlayingthefuellinesandinstallingafueltank.Deviationsfromtheinstructionsstatedherearenotallowed.Failuretocomplycanresultinmalfunctions.

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

Cautionwhenhandlingfuel.•Switchoffthevehicleengineandtheheaterbeforerefuellingandbeforeworkingonthefuelsupply.

•Avoidnakedflameswhenhandlingfuel.

•Donotsmoke

•Donotinhalepetrolfumes.

•Avoidanycontactwiththeskin.

Installation3

Please note!

27

Operation with biodiesel (FAME)

Theheatersarenotapprovedforoperationwithbiodie-selfuel(FAMEaccordingtoDINEN14214).

Installation3

Please note!

Fuel supply

Fuel quality

•Theheaterrunsproblem-freeonstandardcommercialgradedieselfuelaccordingtoDINEN590.

Duringthewintermonthsthedieselfuelisadaptedtothelowtemperaturesof0°Cto–20°C.Problemscanthereforeonlyariseatextremelylowoutdoortempera-tures–asisthecasewiththevehicleengine–pleaserefertothevehiclemanufacturer'sinstructions.

•Inspecialcasesandatoutdoortemperaturesabove0CtheheatercanalsoberunonELheatingoilaccordingtoDIN51603.

•Iftheheaterisrunfromaseparatetank,pleasecom-plywiththefollowingrules:

–atoutdoortemperaturesover0°C: UsedieselfuelaccordingtoDINEN590.

–atoutdoortemperaturesof0°Cto–20°C: usewinterdieselfuelaccordingtoDIN590.

–atoutdoortemperatures–20°Cto–40°C: UseArcticdieselorPolardiesel.

•Additionsofusedoilarenotallowed!

•Afterrefuellingwithwinterorcoldweatherdieselthefuellinesmustbefilledwiththenewfuelbylettingtheheaterrunfor15minutes!

28

Installation3

Fuel supply

Connection of the intake and return pipe to the heater

Iffuelhosesareused,fuelhosessuppliedbyJ.Eberspächermustbeused.Ifnot,thefuelhosesusedmustatleastconformtoDIN73379-1,Type3.Thematerialsusuallyusedinvehicleconstruction,e.g.steelandplasticlinesmadeofsoftset,lightandtem-perature-stabilisedPA11orPA12(e.g.MecanylRWTL)accordingtoDIN73378canbeusedasfuellines,incompliancewiththerespectiveconnectiontechniques.

Permissible dimensions of the fuel linesInnerdiameterofthesuctionandreturnline:•forconnectiontotheringhosenippleø6mm:minø5mm/maxø6mm,

•Special case–forconnectiontotheringhosenippleø8mm:minø7mm/maxø8mm.

Important!Installationforashut-offdeviceinthereturnlineisnotallowed!

•Fuelhosesandfuelpipesareavailableasadditionalparts,seeadditionalpartscatalogue.

•Fuellineswithinnerdiameterø7mm/ø8mmaswellasringhosenipplewithø8mmmustbepurchasedfromthetrade.

•Pleaseconsultthemanufacturerforoperationinsinglelinesystems.

•Pleasecontactthemanufacturerifanadditionalfuelpumpistobeinstalled.

1 Connectionofthesuctionlinetotheringhosenippleø6mm

2 Connectionofthereturnlinetotheringhosenippleø6mm

Functional performance of the heater depending on the underpressure in the fuel system

Inordertoensurethefuelpumpworksproperly,itisnecessarytoensurethattheunderpressureinthefuelsystemisnottoohigh(seetable).

Fuel pressure (P)Heater inlet

Fuel pressure (P)Filter inlet

Preferredrange* min–0.3bar min–0.2bar

Allowablerange** –0.45barto–0.3bar –0.35barto–0.2bar

Criticalrange*** –0.55barto–0.45bar –0.45barto–0.35bar

Heatingmodenotpossible <–0.55bar <–0.45bar

*Rangefordesignofthefuelsupply **Overtheoperatingperiodthecounterpressure

inthefuelsupplycanincreaseasaresultofdeposits(filterclogsup).***Heaterbecomessusceptibletofaults(gasbubbleformation/faultcode52,54)

Please note!

Permissible suction height and lengths of the suction line:•Suctionheightupto1.5m—>max.length=25m•Suctionheight1.5mto4.0m—>max.length=15m

Permissible length of the return line:•max.length=18m

2

29

Operation and function4

Structure of the heater

Theheaterconsistsofaheatexchangerandaremov-ableburner.Theheatexchangercontainsacombustionchamberconsistingofaheaderpipewithintegratedmixer.Theheaderpipecanbepulledoutoftheheatexchangerifnecessary.Thecontrolboxandelectricmotorarefixedtotheburnerflangeundertheshroudoftheburner.Thefuelpumpisintegratedintheburnerhousing.

Thefollowingadditionalpartsarerequiredtoruntheheater:•Waterpump –alreadyinstalledincompactversion

•Additionalpartsforconnectiontothewatercircuit

•Additionalpartsforthefuelsupply

•Additionalpartsfortheexhaustsystem

•Controlunit

FororderNo.oftheadditionalpartsseepage8,forfurtheradditionalpartsseeadditionalpartscatalogue.

Operating instructions

Theheaterisoperatedbyacontrolunit.Detailedoper-atinginstructionsaresuppliedwiththecontrolunit.

Youwillbeissuedtheoperatinginstructionsbytheinstallationworkshop.

Important notes on operation

Perform safety checks before the start

Afteralengthystoppage(summermonths),checkallcomponentsforsecurefit(tightenscrewswhereneces-sary).Carryoutavisualcheckofthefuelsystemforleaks.

Before switching on

Beforeswitchingonorpre-programmingheatingmode,switchthevehicle'sheatingleverto"WARM"(maximumsetting)andtheblowerto"slowlevel"(lowerelectricityconsumption).Invehicleswithautomaticheating,beforeswitchingofftheignition,switchtheheatingleverto"MAX"andtherequireddamperpositionto"OPEN".

Heating at high altitudes

Whenusingtheheaterathighaltitudes,pleasenote:•Heatingataltitudesupto1500m:–Unlimitedheatingpossible.

•Heatingataltitudesover1500m:–Youcanusetheheateratthisaltitudeforshortperi-ods(e.g.drivingthroughamountainpassortakingabreakinyourjourney).

–Forlongerstaysitisnecessarytoadjustthelevelofthefuelsupply,pleasecontactaJEpartnerforfurtherdetailsandadvice.

Initial commissioning of the heater

Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.

•Ensureyoureadtheoperatingandmaintenanceinstructionsbeforestartinguptheheater.

•Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

•Openthecoolantcircuitbeforethetrialrun(setthetemperaturecontrolto"WARM").

•Duringtheheatertrialrun,allwaterandfuelconnec-tionsmustbecheckedforleaksandsecure,tightfit.

•Iffaultsoccurwhiletheheaterisrunning,useadiag-nosticunittodetermineandcorrectthecauseofthefault.

Please note!

30


Functional description

Switch on the heater

Whentheheaterisswitchedonacomponenttestisperformed(3seconds),thewaterpumpisthenstartedup.

Note:

Thenozzlepre-heaterisswitchedonthefirsttimetheheaterisswitchedon.•IntheHydronicL16/L24,thenozzlepre-heaterremainsswitchedonuntiltheheaterswitches“OFF”orisswitchedoffbeforehand.

•IntheHydronicL30/L35,theoperatingtimeofthenozzlepre-heaterislimitedto15min.

Burner start

Theelectricmotorstartsanddrivesthecombustionairimpellerandthefuelpump.Afterapprox10secondstheignitionisswitchedonandthenthefuelsolenoidvalveopens.Withinthese10sec-ondsarotarycheckisperformedontheelectricmotor.Thefuelandcombustionairinthecombustionchamberformanignitablemixture.Themixtureisignitedbyahigh-voltageignitionspark.Theflamemonitorrecognisestheflame'sflickerfrequencyandswitchesofftheignitionsparkgenera-tor.Thehotcombustiongasesflowthroughtheheatexchangerandtransfertheheattotheheatdistributionmedium.

•Theheateroperatesdependingontheheatrequire-ments,thismeanstheburner'sswitchingonandswitchingofftimesvary.

•Thewaterpumpremainsinservicethewholetimetheheaterisrunning,evenduringpausemodeandduringafter-running.

Options•Iftemperatureloweringisactivatedthe"ON/OFF"controltemperaturesareloweredbyapprox8K.

ConnectionoftheON/OFF-switchfortemperaturelowering,seecircuitdiagramonpage34.

•Thewaterpumpcanberunindependentlyoftheheaterifappropriatecontrolsareinstalled.Forcon-nectionoftheadditional"ON/OFF"switchforsepa-ratewaterpumpcontrol,seecircuitdiagramonpage34.

•Withcontrolofthevehicle'sblower,thevehicleblowerisswitchedonoroffatthefollowingwatertempera-tures.–Watertemperature>55°C —>Vehicleblower"ON"–Watertemperature<50°C —>Vehicleblower"OFF"

Forcontrolofthevehicle'sblower,seecircuitdiagramonpage34.

Please note!

Nozzlepre-heater(Thenozzlepre-heateris

switchedonthefirsttimetheheaterisswitchedon.)

Waterpump

Operatingdisplay

Solenoidvalve

Flamesensor

Ignitionsparkgenerator

Controltemperaturesensor

Electricalmotor

HeaterON

Componentstest

Heatingmode Pausemode

After-run

StartphaseON

Heatingmode

HeaterOFF

After-run

3sec

3sec

10sec

10sec

180sec

10sec

10sec

180sec

Functional diagram

HydronicL16/L24

HydronicL30/L35

(Operatingtimelimitedtomax.15min.)

31


Control and safety devices

Theheaterisequippedwiththefollowingcontrolandsafetydevices.

•Iftheheaterdoesnotignitethecontrolbox*islockedafteranunpermissiblenumberofunsuccessfulstartattempts.

•Ifthewaterflowistoolowthewaterdischargetem-peratureislimitedbyprematurecompensation.

•Thetimetakenforthetemperatureriseintheheatdistributionmediumismonitored.Ifitrisestoofast(waterflowtoolow)theheaterautomaticallyswitches"OFF"andbeginswiththeafter-running,thecyclethenbeginsagain.

•Constantcomparisonofthetemperaturesensorandoverheatingsensormeasuredvaluesprovidesaddi-tionalheatersafety,becauseifthedifferencebetweenthemeasuredvaluesistoolarge(waterflowtoolow)theheaterisprematurelyswitchedoff(shut-downonfault).

Afteranimpermissiblenumberofshut-downsonfault,thecontrolboxislocked.*

•Iftheloweroruppervoltagelimitisreached,theheaterisautomaticallyswitchedoff.

•Iftheflamesensordetectsaflameduringtheheater'safter-runningtheheaterisautomaticallyswitchedoff.

Afteranimpermissiblenumberofshut-downsonfault,thecontrolboxislocked.*

* Thelockcanbecancelledandfaultsreadout:•withthemodulartimer/EasyStartTtimer•withtheradioremotecontrolTP5/EasyStartR+.

Forothercontrolunitsbyconnecting:•thediagnosticsunit•theEDiTHdiagnosticstool.

Foroperationandfaultlist,pleaserefertotheenclosedoperatinginstructionsorthetroubleshootingandrepairinstructionsfortheheater.

Emergency stop – EMERGENCY OFFIfanemergencystop–EMERGENCYOFF–isnec-essaryduringoperation,proceedasfollows:•Switchtheheateroffatthecontrolunitor•pullthefuseoutor•disconnecttheheaterfromthebattery.

Please note!

Switch off the heater

Iftheheaterisswitchedoffthefuelsolenoidvalveclosesandafter-runningsimultaneouslystartsforapprox3minutes.Aftertheafter-runninghasfinishedtheheaterisauto-maticallyswitchedoff.

Untilitisswitchedoff,includingduringtheafter-running,thefueliscirculated.

32

Heater wiring

Danger!Danger high voltageBeforeopeningtheheater,disconnecttheplug-incon-nectorwiththevehicle.

Important!Safety instructions!

Theheateristobeconnectedupelectricallyaccord-ingtotheEMCdirectives.ImpropertamperingwiththeheatercanaffecttheEMC.Forthisreason,complywiththefollowinginstructions:

•Ensurethattheinsulationofelectricalcablesisnotdamaged.

Avoid:Chafing,kinking,jammingorexposuretoheat.

•Sealanyconnectionchambersofwaterproofcon-nectorsnotinusewithfillerplugstoensuretheyaredirt-proofandwaterproof.

•Electricalconnectorsandearthconnectionsmustbefreeofcorrosionandsecurelyconnected.

•Lubricateconnectionsandgroundconnectionsout-sidetheheaterinteriorwithcontactgrease.

Electrical system5

Please note!

Complywiththefollowingwhenwiringtheheaterandthecontrolunit:

•Thenegativeandpositivepolesoftheheater'scon-trolsaretobedirectlyconnectedtothevehicle'sbat-tery.

•Contacttheheatermanufacturerregardingconnec-torsdifferingfromthestandardversion.

•Electricalleads,switchandcontrolgearmustbeposi-tionedinthevehiclesothattheycanfunctionperfectlyundernormaloperatingconditionswithoutimpairment(e.g.duetoheatexposure,moisture,etc.).

•Thefollowingcablecross-sectionsaretobeusedbetweenthebatteryandheater.Thisensuresthatthemax.permissiblevoltagedropinthecablesdoesnotexceed0.5Vfor12Vor1Vfor24Vratedvoltage.

Cablecross-sectionsforacablelength(pluscable+minuscable)of:–upto5m=cablecross-section4mm2

–from5mto8m(pluscable+minuscable)=cablecrosssection6mm2

•Ifthepositivecableistobeconnectedtothefusebox(e.g.terminal30),thevehicle'scablefromthebatterytothefuseboxmustalsobeincludedinthecalcula-tionforthetotalcablelengthandre-dimensionedifnecessary.

•Insulateunusedcableends.

33

251818009601D

Parts list

1 Heater1.1 Burnermotor1.2 Ignitionelectrodes1.3 Ignitionsparkgenerator1.5 Overheatingsensor

1.11 Fuelsolenoidvalve1.13 Sensor,controltemperature,interior1.14 Heatingelementforfuelnozzle

2.1 Controlbox

2.5.6 Relay,waterpump2.5.10 Relay,heatingcartridge

a) Connection,controlunit

X Graphicillustrationofthecontrolboxfromtheimpellerside

Connectorsandbushhousingsareshownfromthecableinletside.

Heater circuit diagram – Part 1

Electrical system5

34

Heater circuit diagram – Part 2

Electrical system5

Parts list

2.5.7 Relayforcontrol,vehicleblower2.7 Mainfuse15A2.7.1 Fuse,actuation5A2.7.3 Fuse,waterpump15A2.12.1Waterpump,Flowtronic6000SC2.12.2Waterpump,Flowtronic5000/5000S

3.1.4 Switch,temperaturelowering3.1.5 Switch,waterpump

3.4.1 Switchoncontrol3.4.3 Faultindicatorlamp3.4.6 Fuelindicatorlamp

5.1 Battery5.2 Batteryisolatingswitch

a) Heaterconnectiond) Optionally2.12.1or2.12.2f) Ifusing3.2.6optionallyterminal15orterminal30

–otherwiseswitchonpositive(cable1²yellow)

252488009701

35

252488009701

Circuit diagram for control units

Electrical system5

Parts list

2.15.9 Temperaturesensor(outsidetemperature)

3.1.1 Universalswitch3.1.2 Switch,heat,continuousoperation3.1.12 Faultcodequery

3.2.9 Moduletimer3.2.12 Timer,mini(12/24volt)3.2.14 Timer,minilighting(12/24volt)

3.9.2 Diagnosticunit

b) Connectto+15c) Lighting,terminal58e) External"ON/OFF"button(optional)i) Connection,radiomodulek) Notincludedinthescopeofsupplyof3.9.2z) Terminal58(lighting)

Insulateunusedcableends.


36

Electrical system5

Parts list, circuit diagrams, control units EasyStart R+ / EasyStart R and EasyStart T

2.15.1 Temperaturesensor(roomtemperature) (withEasyStartR+includedinscopeofsupply, withEasyStartTandEasyStartRoptional)2.15.9 Temperaturesensor(outsidetemperature)

(optional)

3.1.7 "OFF"button3.1.9 "Heat/ventilate"switch (withEasyStartTincludedinscopeofsupply, WithEasyStartRoptional)3.1.16 Radioremotecontrolbutton

3.2.15 Timer,EasyStartT

3.3.9 Radioremotecontrol,EasyStartR(stationaryunit)

3.3.10 Radioremotecontrol,EasyStartR+(stationaryunit)

3.6.1 Leadharness

3.8.3 Antenna

c) Terminal58(lighting)d) Parking/cabventilationwithvehicleblower

(optional)e) Connection,EasyStartTtimerg) External"ON/OFF"button(optional)

Cable colours circuit diagrams

sw = blackws = whitert = redge = yellowgn = greenvi = violetbr = browngr = greybl = blueli = purple


Forcircuitdiagrams,seepage37–39.

Please note!

37

Electrical system5

PartslistPage36

Circuit diagram, EasyStart R+ control units

251818009703C

38

Electrical system5

PartslistPage36

Circuit diagram, EasyStart R control units

251818009704B

39

Electrical system5

Circuit diagram, EasyStart T control units

251818009705APartslistPage36

40

If any faults occur, please check the follow-ing items

•Iftheheaterdoesnotstartafterbeingswitchedon:–Switchtheheateroffandonagain.

•Iftheheaterstilldoesnotstart,checkwhether:–Fuelinthetank?–Thefusesareok?–Theelectricalcables,connections,terminals,areok?

–Anythingiscloggingthecombustionairsupplyorexhaustsystem?

–Fuelsupplyok?

Troubleshooting

If,aftercheckingtheseitems,theheaterisstillfaultyoranothermalfunctionoccursinyourheater,pleasecontact:

•Iffactory-installed,yourcontractworkshop/garage.

•Ifsubsequentlyinstalled,theworkshop/garagewhichinstalledtheheater.

Pleasenotethatguaranteeclaimscanexpireiftheheaterismodifiedbyathirdpartyorifnon-originalpartsareinstalled.

Maintenance instructions

•Switchtheheateroffonceamonthforabout10min-utes,evenoutsidetheheatingperiod.

•Beforetheheatingperiodstarts,atrialrunshouldbecarriedoutfortheheater.Ifthick,persistentsmokedevelops,unusualburningnoisesoraclearfuelsmelloccursorifelectric/electronicpartsoverheat,theheatermustbeswitchedoffandputoutofservicebyremovingthefuse.

Inthiscase,theheatershouldnotbestartedupagainuntilithasbeencheckedbyqualifiedstaffwhohavebeentrainedonEberspächerheaters.

•Checktheopeningsofthecombustionairsupplyandexhaustsystemafterlongerstandstillperiods,cleanifnecessary!

Initial commissioning

Thefollowingpointsaretobecheckedbythecompanyinstallingtheheaterduringinitialcommissioning.

•Afterinstallationoftheheater,thecoolantcircuitandthewholefuelsupplysystemmustbeventedcarefully.Complywiththeinstructionsissuedbythevehiclemanufacturer.

•Openthecoolingwatercircuitbeforethetrialrun(setthetemperaturecontrolto"WARM").

•Duringtheheatertrialrun,allwaterandfuelconnec-tionsmustbecheckedforleaksandsecure,tightfit.

•Iffaultsoccurwhiletheheaterisrunning,useadiag-nosticunittodetermineandcorrectthecauseofthefault.

Changing components

Thecomponentslistedbelowmustbeexchangedattheendofthegivenoperatingperiod:

•Heatexchangerafter5000operatinghours,

•Burnerafter3000operatinghours,

•Nozzleafter600operatinghoursoratleastonceperyear.

Service

Ifyouhaveanytechnicalqueriesorproblemswithyourpre-heater,dialthefollowingservicephonenumberfromwithinGermany:

HotlinePhone+49(0)800/1234300

FaxhotlinePhone+49(0)1805/262624

OutsideofGermany,pleasecontacttherespectiveEberspächernationalrepresentative.

Troubleshooting / maintenance / service6

Please note!

41

EC Declaration of Conformity

Withregardtothefollowingproducts

Heater type Hydronic L-II

weherewithconfirmthatitconformswiththeprimesafetyrequirementsstipulatedinthedirectivesoftheEUCouncilforharmonisationofthelegalregulationsofthememberstateswithregardtoelectromagneticcompat-ibility(89/336/EEC).Thisdeclarationappliestoallheatersproducedaccord-ingtotheproductiondrawingsHydronicL-II–whichareanintegralpartofthisdeclaration.Thefollowingstandards/directiveshavebeenusedtoassesstheproductwithregardtoelectromagneticcompatibility:

•EN50081–1Basicforminterferenceemission

•EN50082–1Basicformofinterferenceimmunity

•72/245/EEC–Modificationstatus2006/28/ECinterferencesuppressioninmotorvehicles.

Certifications

ThehighqualityofEberspächer'sproductsisthekeytooursuccess.Toguaranteethisquality,wehaveorganisedallworkprocessesinthecompanyalongthelinesofqualityman-agement(QM).Evenso,westillpursuealargenumberofactivitiesforcontinuousimprovementofproductqualityinordertokeeppacewiththesimilarlyconstantlygrowingrequirementsmadebyourcustomers.Allthestepsnecessaryforqualityassurancearestipulatedininternationalstandards.Thisqualityistobeconsideredinatotalsense.Itaffectsproducts,proceduresandcustomer/supplierrelationships.Officiallyapprovedexpertsassessthesystemandthecorrespondingcertificationcompanyawardsacertificate.

Eberspächerhasalreadyqualifiedforthefollowingstandards:

Quality management in accordance with DIN EN ISO 9001:2000 and ISO/TS 16949:1999

Environmental management system in accordance with DIN EN ISO 14001:1996

Disposal

Disposal of materials

Olddevices,defectivecomponentsandpackagingma-terialscanallbeseparatedandsortedintopure-gradefactions,ifnecessary,sothatallpartscanbedisposedofinanenvironment-friendlywayorthematerialsrecycled.Electricmotors,controlboxesandsensors(e.g.temperaturesensors)aredeemedtobe"electronicscrap".

Dismantling the heater

Theheaterisdismantledaccordingtotherepairstagesinthecurrenttroubleshooting/repairinstructions.

Packaging

Theheater'spackagingcanbekeptincaseithastobesentback.

Environment7

42

Lists6

AAccidentprevention..................................................... 7Altitude...................................................................... 29Ambienttemperature......................................... 10–13

CCablecolours............................................................ 36Cablelengths............................................................ 28Certification............................................................... 41Changingcomponents.............................................. 40Circuitdiagrams...................................33–35,37–39Combustionairsystem.............................................. 24Conceptofthismanual................................................ 3Connection,watercoolingcircuit............................... 25Contents..................................................................... 2Controldevices.......................................................... 31Coolingwatercircuit.................................................. 25

DDeclarationofconformity........................................... 41Disposal.................................................................... 41

EECDeclarationofConformity..................................... 41Electricalsystem................................................ 32–39Emergencyoff........................................................... 31Environment.............................................................. 41Exhaustsystem(pipes).............................................. 22Exhaustsystem........................................................... 5

FFixing......................................................................... 15Fuelquality............................................................... 29Fuelsupply........................................................ 26–28Fuelsupply.................................................................. 5Functionaldescription................................................ 30

HHeatflow................................................................... 10Heatingmode............................................................ 29Hotline....................................................................... 40

IInformation.................................................................. 4Initialcommissioning.................................................. 29Installationlocation.............................................. 19,20Intendeduse............................................................... 4Interferencesuppression.................................... 10–13Introduction................................................................. 2

LListofabbreviations................................................... 43

MMaindimensions.......................................... 14,16–18Maintenance.............................................................. 40Materials.................................................................... 41Mountingpositions............................................ 15–18

NNameplate................................................................. 21Notes...................................................................... 4,5

OOperatinginstructions................................................ 23Operation.......................................................... 29–31

PPicturesymbols........................................................... 4Positionoftheheater................................................... 5Powerconsumption.......................................... 10–13

RRatedvoltage.................................................... 10–13Regulations............................................................. 5,6Representations.......................................................... 4

SSafetydevices........................................................... 31Scopeofsupply...................................................... 8,9Specialtextformats..................................................... 4Startprocedure......................................................... 30Statutoryregulations................................................ 5,6Storagetemperature.......................................... 10–13Switchingon.............................................................. 30

TTechnicaldata................................................... 10–13Testmark.................................................................... 5Textstructure............................................................... 4Troubleshooting......................................................... 40

VVoltagelimit....................................................... 10–13Voltage.............................................................. 10–13

WWeight............................................................... 10–13Wiring........................................................................ 32

List of key words, A – Z index

Key word Page Key word Page

43

List of abbreviations

ADREuropeanagreementabouttheinternationaltransportofdangerousgoodsontheroad.

EC type-approvalPermitawardedbytheFederalVehicleOfficefortheproductionofaheaterforinstallationinmotorisedvehicles.

EMC DirectivesElectromagneticcompatibility.

JE-partnerJ.Eberspächerpartner.

Lists6

252488909969EN05.2009SubjecttochangewithoutnoticePrintedinGermany©J.EberspächerGmbH&Co.KG

J.EberspächerGmbH&Co.KGEberspächerstr.24D-73730EsslingenPhone0711939-00Fax0711939-0643info@eberspaecher.com

www.eberspaecher.com

Hydronic L-II 16-35 TD 05-2009 EN

Documents

heater orderno

maintenance instructions

technical description