n s scriptio structio technical description co in r...

A W O R L D O F C O M F O R T

ENV E h i c l E h E at E r s | T e C h n i C A L D O C u M e n TAT i O n

tEc

hN

ica

l D

Esc

rip

tio

N

rEp

air

iN

str

uc

tio

Ns

par

ts l

ist

iNs

tall

atio

N r

Eco

MM

END

atio

N

TeChniCAL DesCRipT iOn

hyDROniC i i COMFORT

heaters for petrol

B 5 sc – 12 V 20 1928 05 00 00

heaters for diesel

D 5 sc – 12 V 25 2598 05 00 00

thE tEchNical DEscriptioN, iNstallatioN, opEratiNg aND

MaiNtENaNcE iNstructioN is ValiD for thE followiNg

ENgiNE-iNDEpENDENt watEr-hEatErs:

2 | VehiCLe heATeRs – TeChniCAL DOCuMenTATiOn

COnTenTs

ChApTeR TiTLe COnTenT pAge

1 introduction Concept of this manual 5

special test structure, presentation and picture symbols 6

– special text formats and presentations 6

– picture symbols 6

important information before starting work 6

– Range of application of the heater 6

– intended purpose of the heater (via the vehicle's own heat exchanger) 6

statutory regulations 7

– general regulations 7

– Regulations concerning installation in the vehicle 7

hazard information and safety instructions for the installation and operation 8

Accident prevention 9

2 product information Order no. and scope of supply 10

– petrol heater 10

– Diesel heater 10

scope of supply – heater and installation kit 11

Main dimensions of petrol heater 14

Main dimensions of diesel heater 14

installation location 15

– installation example: petrol heater in a car 15

– installation example: Diesel heater in a transporter 15

permissible installation positions 16

– installation position – heater upright / vertical 16

– installation position – heater upright / on its side 16

3 installation installation and fixing – heater 17

nameplate 17

Fix fuse holder and relay socket 18

Connection to the coolant liquid circuit 18

installation of blanking element 19

Connection to the coolant fluid circuit, “inline” installation variant 19

Connection to the coolant fluid circuit, “Comfort” installation variant 19

exhaust system 21

– installing the exhaust system 22

– Fix bracket to the exhaust silencer 22

Combustion air system 23

VehiCLe heATeRs – TeChniCAL DOCuMenTATiOn | 3

Fuel supply 24

– install metering pump (only for petrol heater) and lay the fuel lines 24

Fuel supply – petrol heater 25

– installation position of the metering pump 26

– permissible suction and pressure head of the metering pump 26

Fuel supply – diesel heater with inlet pressure resistant metering pump up to 2.0 bar 27

Fuel supply – diesel heater 28

– permissible suction and pressure head, diesel fuel 28

– Fuel quality for petrol heater 29

– Fuel quality for diesel heater 29

– Operation with biodiesel 29

4 Operation and function Operating instructions 30

important instructions for operation 30

– initial commissioning of the heater 30

– safety checks before starting up the heater 30

– Before switching on 30

– parking ventilation 30

Description of functions 30

– switching on (parking heater mode) 30

– parking heater mode 30

– heating mode 30

– heating at high altitudes 30

Control and safety devices 31

emergency stop – eMeRgenCy OFF 31

5 electrics heater wiring 32

parts list for circuit diagram, heater and cable loom 32

Circuit diagram, cable harness, petrol heater 34

Circuit diagram, diesel heater 35

Circuit diagram, cable harness, diesel heater 36

Connection diagram, auxiliary heater function 37

Circuit diagram, control unit – easystart Timer 38

Circuit diagram, control unit – easystart Remote+ 39

Circuit diagram, control unit – easystart Remote 40

Circuit diagram, control unit – easystart select 41

Circuit diagram, control unit – easystart Call 42

COnTenTs


6 Troubleshooting / maintenance /

service if faults occur, please check the following items 43

Troubleshooting 43

Maintenance instructions 43

service 43

7 environment Certification 44

Disposal 44

– Disposal of materials 44

– Dismantling the heater 44

– packaging 44

eC Declaration of Conformity 44

8 Lists List of key words 45

List of abbreviations 46

COnTenTs


1 inTRODuCTiOn

coNcEpt of this MaNual

This manual aims to support the service company installing the heater

and to provide the user with all important information about the heater.

The manual has been divided into 8 chapters to make it easier to find

the corresponding information quickly.

1 inTRODuCTiOn

here you find important introductory information about installation

of the heater and about the structure of the manual.

2 pRODuCT inFORMATiOn

here you will find information about the scope of supply, the tech-

nical data and the dimensions of the heater.

3 insTALLATiOn

here you will find important information and instructions referring

to installation of the heater.

4 OpeRATiOn AnD FunCTiOn

here you will find information about the operation and function of

the heater.

5 eLeCTRiCs

here you will find information about the electronic system and

electronic components of the heater.

6 TROuBLeshOOTing / MAinTenAnCe / seRViCe

here you will find information about any necessary troubleshooting

procedures, maintenance and the service hotline.

7 enViROnMenT

here you will find information about certification and disposal of

the heater together with the eC Declaration of Conformity.

8 LisTs

here you will find the key word list and abbreviations list.


iMportaNt iNforMatioN BEforE startiNg work

RAnge OF AppLiCATiOn OF The heATeR

The water heater operating independently of an engine is intended for

installation in the following vehicles:

� All kinds of vehicles

� Construction machinery

� Agricultural machinery

� Boats, ships and yachts

plEasE NotE!The heater cannot be installed in vehicles used for the transport of

dangerous goods according to ADR.

inTenDeD puRpOse OF The heATeR (ViA The VehiCLe's OWn heAT

exChAngeR)

� pre-heating, de-misting windows

� heating and keeping the following warm:

– Driver and working cabs

– Freight compartments

– ship's cabins

– passenger and crew compartments

– Vehicle engines and units

On account of its functional purpose, the heater is not approved for the

following applications:

� Long-term continuous operation, e.g. for pre-heating and heating of:

– Residential rooms

– garages

– Work huts, weekend homes and hunting lodges

– houseboats, etc.

iMportaNt!use, operation and deployment of the heater outside the range indi-

cated by the manufacturer can cause considerable injuries to people

and/or damage to machinery and property.

Î Only use the heater for the stipulated purpose and in the permitted

range of application.

spEcial tEst structurE, prEsENtatioN aND picturE syMBols

special text formats and picture symbols are used in these instructions

to emphasise different situations and subjects. please refer to the fol-

lowing examples for their meanings and appropriate action.

speCiAL TexT FORMATs AnD pResenTATiOns

� This dot (�) indicates a list, which is introduced by a heading.

– if an indented dash (–) follows a “dot”, this list is a sub-section of

the black dot.

underlined blue text denotes a cross-reference, which can be clicked

in the pDF format. The part of the document named in the text is then

displayed.

piCTuRe syMBOLs

rEgulatioN!This information points out a statutory regulation.

Failure to comply with this regulation results in expiry of the type-

approval for the heater and preclusion of any guarantee and liability

claims on eberspächer Climate Control systems gmbh & Co. Kg.

DaNgEr!This information points out a potential serious or fatal danger. ignoring

this information can result in severe injuries.

Î This arrow indicates the appropriate precaution to take to avert the

danger.

iMportaNt!This information points out a dangerous situation for a person and / or

the product. Failure to comply with these instructions can result in inju-

ries to people and / or damage to machinery.

Î This arrow indicates the appropriate precaution to take to avert the

danger.

plEasE NotE!These remarks contain recommendations for use and useful tips for the

operation, installation and repair of the heater.

1 inTRODuCTiOn


1 inTRODuCTiOn

statutory rEgulatioNs

The Federal Motor Transport Authority has issued an approval for a

component according to eCe R122 and eCe-R10 for the heater for

installation in motor vehicles, with the following official type-approval

markings noted on the heater's nameplate.

heater type: EcE type approval mark:

hydronic ii 122 R – 000275

10 R – 045886

rEgulatioN!ExcErpt froM EcE rEgulatioN No. 122 of thE EuropEaN par-

liaMENt aND thE couNcil

geneRAL ReguLATiOns

� Operating state display

A clearly visible operating display in the user's field of vision must

indicate when the heater is switched on and off.

ReguLATiOns COnCeRning insTALLATiOn in The VehiCLe

� scope

– subject to differing stipulations in the following section, combus-

tion heaters must be installed according to the regulations 5.3 of

eCe-R122.

– it is assumed that Class O vehicles with heaters for liquid fuel con-

form to the regulations 5.3 of eCe-R122.

� Arrangement of the heater

– parts of the structure and other components near the heater must

be protected from excessive heat exposure and possible fuel or oil

contamination.

– The heater must not pose a fire hazard even if it overheats. This

requirement is deemed to be fulfilled if adequate clearance is

ensured for all parts during installation, sufficient ventilation is

provided and fireproof materials or heat shields are used.

– The heater must not be installed in the passenger compartment

of class M2 and M3 vehicles. however, a heater in a hermetically

sealed enclosure which also complies with the aforementioned

conditions may be used.

– The nameplate or duplicate of it must be affixed so that it can still

be easily read when the heater is installed in the vehicle.

– All appropriate precautions must be taken when arranging the

heater to minimise the risk of injuries to persons or damage to

other property.

� Fuel supply

– The fuel filler neck must not be located in the passenger compart-

ment and must be sealed with a properly closing cover to prevent

any fuel leaks.

– in heaters for liquid fuel where the heater fuel supply is separate

from the vehicle fuel supply, the type of fuel and filler neck must

be clearly marked.

– A warning sign is to be attached to the filler neck informing that

the heater must be switched off before refuelling.

� exhaust system

– The exhaust outlet must be arranged so as to prevent any penetra-

tion of exhaust fumes into the vehicle interior through the ventila-

tion system, warm air intakes or open windows.

� Combustion air intake

– The air for the heater's combustion chamber must not be sucked

in from the vehicle's passenger compartment.

– The air intake must be arranged or protected in such a way that it

cannot be blocked by other objects.

� Automatic control of the heating system

– if the engine fails, the heating system must be automatically

switched off and the fuel supply stopped within 5 seconds. The

heater may remain in operation if a manual device has already

been activated.

plEasE NotE!The heater is not approved for installation in the driver's cab or pas-

senger compartment of Class M1 vehicles (vehicles for passenger trans-

port / cars) and n vehicles (vehicles for the transport of goods).


1 inTRODuCTiOn

statutory rEgulatioNs

plEasE NotE! � Compliance with the statutory regulations, the additional regulations

and the safety instructions is prerequisite for guarantee and liability

claims.

Failure to comply with the statutory regulations and safety instruc-

tions and incorrect repairs, even if original spare parts are used,

make the guarantee null and void and preclude any liability for

ebers pächer Climate Control systems gmbh & Co. Kg.

� subsequent installation of this heater must comply with these instal-

lation instructions.

� The statutory regulations are binding and must also be observed in

countries which do not have any special regulations.

� When installing the heater in vehicles not subject to the german

Road Traffic Licensing Regulations (stVZO), for example ships, the

respective specially valid regulations and installation instructions

must be observed.

� installation of the heater in special vehicles must comply with the

regulations applying to such vehicles.

� Other installation requirements are given in the relevant sections of

this manual.

hazarD iNforMatioN aND safEty iNstructioNs for thE

iNstallatioN aND opEratioN

DaNgEr!RisK OF injuRy, FiRe AnD pOisOning!

Î Disconnect the vehicle battery before starting any kind of work.

Î Before working on the heater, switch the heater off and let all hot

parts cool down.

Î The heater must not be operated in closed rooms, e.g. in the ga-

rage or in a multi-storey car park.

iMportaNt!safety instructions for installation and operation!

Î The heater must only be installed by a je partner authorised by the

manufacturer according to the instructions in this manual and pos-

sibly according to special installation recommendations; the same

applies to any repairs to be carried out in the case of repairs or

guarantee claims.

Î Repairs by non-authorised third-parties or with non-original spare

parts are dangerous and therefore not allowed. They result in expiry

of the type-approval of the heater; consequently, when installed

in motor vehicles they can cause expiry of the vehicle operating

licence.

Î The following measures are not allowed:

– Changes to components relevant to the heater.

– use of third-party components not approved by eberspächer

Climate Control systems gmbh & Co. Kg.

– nonconformities in installation or operation from the statutory

regulations, safety instructions or specifications relevant to safe

operation as stated in the installation instructions and operating

instructions. This applies in particular to the electrical wiring,

fuel supply, combustion air system and exhaust system.

Î Only original accessories and original spare parts must be used

during installation or repairs.

Î Only control units approved by eberspächer may be used to operate

the heater.

use of other control units can cause malfunctions.

Î Before the heater is installed again in another vehicle, rinse the

heater parts carrying water with clear water.

Î When carrying out electric welding on the vehicle, the positive ca-

ble at the battery should be disconnected and placed at ground to

protect the control box.


Î Defective fuses must only be replaced by fuses with the prescribed

rating.

Î it is not permitted to operate the heater where there are readily

flammable materials (e.g. dry grass, leaves, paper, etc.) in the area

of the exhaust system or where ignitable fumes and dust can form,

e.g. near a

– fuel depot

– coal depot

– wood depot

– grain depots, etc.

Î The heater must be switched off when refuelling.

Î if the heater is fitted in a safety casing, etc., the heater's installa-

tion box must not be used as storage space 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 or transported on or next to the heater.

Î if fuel leaks from the heater fuel system, arrange for the damage to

be repaired immediately by a je service partner.

Î use only anti-freeze products approved by the vehicle manufacturer

to top-up; please refer to the vehicle‘s operating manual.

Î Any blending with unapproved anti-freeze can cause damage to the

engine and heater.

Î The after-running of the heater must not be prematurely inter-

rupted, e.g. by pressing the battery disconnector, except for an

emergency stop.

plEasE NotE!Following installation, attach the “switch off heater before refuelling!”

sticker near the tank filler neck.

acciDENt prEVENtioN

general accident prevention regulations and the corresponding work-

shop and operating safety instructions are to be observed.

1 inTRODuCTiOn


figure No. Designation26 non-return valve

27 Blanking element

parts which, if rEquirED, Must BE orDErED sEparatEly

quantity Designation order No.1 Fuel filter 25 1226 89 00 37

2 Adapters for the fuel filter 25 1888 80 01 02

1 pressure reducer 22 1000 20 08 00

1 Fuel lines kit for e85 22 1000 20 31 00

To be purchased from the trade:

– solenoid valve, 2/2 way

coNNEctioN caBlEs / caBlE looMs – sEE fig. pagE 11

A Connection, control units

B plus supply connection, fan relay

C Activation, vehicle fan

D Minus supply connection

e Connection to terminal 85 (1-pin, Bn)

F Connection to terminal 86 (1-pin, RDBK)

g Diagnosis query plug connection

h plus supply connection

plEasE NotE! � items 3 – 6 shown in the scope of supply sketch are only intended

for the petrol heater and item 8 is only for the diesel heater. item 7 is

required for the petrol heater to connect the “Metering pump” cable

loom to the “heater” cable harness. For the diesel heater, item 7

must be installed on the “heater” cable harness as a seal protection.

� An inlet pressure resistant metering pump up to 2.0 bar is installed

in the D 5 sC heater, see page 27.

� if the B 5 sC heater is to be run with e85 ethanol fuel (en 15 293),

the “fuel lines for e85” kit is required.

� parts without a figure no. are small parts and are packed in a bag.

� The self-tapping screws included in the “installation kit” scope of

supply can be used for a sheet metal thickness of 2 – 6 mm (tighten-

ing torque 9+1 nm).

� please refer to the “product information” document if any other parts

are required for the installation.

orDEr No. aND scopE of supply

peTROL heATeR

figure No. Designation order No.1 B 5 sC – 12 V 20 1928 05 00 00

heATeR sCOpe OF suppLy – see Fig. pAge 11

figure No. Designation3 Metering pump

4 Lead harness, metering pump

5 pipe, 4 x 1, 2 m long, blue

6 pipe, 4 x 1.25, 4 m long, transparent

7 housing, 2 pin

DieseL heATeR

figure No. Designation order No.2 D 5 sC – 12 V 25 2598 05 00 00

heATeR sCOpe OF suppLy – see Fig. pAge 11

figure No. Designation7 housing, 2-pin, with filler plug

8 pipe, 4 x 1, 5 m long, blue

To be ordered separately:

quantity Designation order No.1 installation kit 25 2598 80 00 00

1 Control unit * – – –

* For control unit see price list or “product information” document.

iNstallatioN scopE of supply – sEE fig. pagE 11

figure No. Designation9 exhaust silencer

10 Cable harness, heater

11 Bracket, heater

12 Water hose

13 Flexible exhaust pipe, 900 mm long

14 Flexible exhaust pipe end, 300 mm long

15 Z-bracket, exhaust silencer

16 L-bracket, exhaust silencer

17 Bracket, metering pump

18 Combustion air hose, 760 mm long

19 elbow, 105°

20 Adapter, Ø 7.5 / 3.5

21 Combined bracket

22 Lead harness, fan

23 Relay for fan

24 Tank connection

25 screw, M6 x 15



scopE of supply – hEatEr aND iNstallatioN kit

1

2

6

19

9

15

16

14

13

3

5

17

7

4

10

18

26

12

11

25

27

22

2123

24

20

8



tEchNical Data for thE pEtrol hEatEr

heater type hydronic ii

heater version B 5 sC

heating medium Mixture of water and anti-freeze

(proportion of antifreeze at least 10 % up to 50 % maximum)

Fuel petrol – standard commercially available (Din 51600 and en 228)

e85 ethanol fuel (en 51625)

Rated voltage 12 volt

Control of the heat flow power high Low

heat flow (watt) 5200 5000 2300

Fuel consumption (l/h) 0.72 0.69 0.32

Average electrical power consumption (watt)

during operation 50 47 22

while starting 130

Operating range

Lower voltage limit:

An undervoltage protection installed in the control box switches off

the heater if the lower voltage limit is reached.

10.5 V

upper voltage limit:

An overvoltage protection installed in the control box switches off the

heater if the upper voltage limit is reached.

16 V

permissible operating pressure up to 2.5 bar overpressure max.

Water volume in the heater approx. 0.25 l

Minimum water flow rate of the heater >250 l/h

Allowable ambient temperature During operation

–40 °C to +60 °C

Without operation

–40 °C to +105 °Cheater, continuous

heater, short time – – – +125 °C (5 x 2 h)

Temperature, coolant liquid

continuous –40 °C to +120 °C –40 °C to +120 °C

short time – – – +125 °C (1 h)

interference suppression class 5 (en 55025)

Weight – without coolant liquid and additional parts approx. 2.7 kg

iMportaNt!Operating the heater outside the specified technical data can cause

malfunctions.

Î The technical data must be complied with at all times.

plEasE NotE!if no limit values are given, the technical data listed is with the usual

heater tolerances of ± 10 % at nominal voltage and esslingen reference

altitude.



tEchNical Data for thE DiEsEl hEatEr

heater type hydronic ii

heater version D 5 sC

heating medium Mixture of water and anti-freeze

(proportion of antifreeze at least 10 % up to 50 % maximum)

Fuel Diesel – standard commercially available (en 590)

Blending with max. 20 % FAMe according to en 14214 is permitted

Rated voltage 12 volt

Control of the heat flow power high Low

heat flow (watt) 5200 5000 2100

Fuel consumption (l/h) 0.64 0.61 0.26

Average electrical power consumption (watt)

during operation 50 47 22

while starting 130

Operating range

Lower voltage limit:

An undervoltage protection installed in the control box switches off

the heater if the lower voltage limit is reached.

10.5 V

upper voltage limit:

An overvoltage protection installed in the control box switches off the

heater if the upper voltage limit is reached.

16 V

permissible operating pressure up to 2.5 bar overpressure max.

Water volume in the heater approx. 0.25 l

Minimum water flow rate of the heater >250 l/h

Allowable ambient temperature During operation

–40 °C to +80 °C

Without operation

–40 °C to +105 °Cheater, continuous

heater, short time – – – +125 °C (5 x 2 h)

Temperature, coolant liquid

continuous –40 °C to +120 °C –40 °C to +120 °C

short time – – – +125 °C (1 h)

interference suppression class 5 (en 55025)

Weight – without coolant liquid and additional parts approx. 2.9 kg

iMportaNt!Operating the heater outside the specified technical data can cause

malfunctions.

Î The technical data must be complied with at all times.

plEasE NotE!if no limit values are given, the technical data listed is with the usual

heater tolerances of ± 10 % at nominal voltage and esslingen reference

altitude.



MaiN DiMENsioNs of pEtrol hEatEr

A exhaust

B Fuel

V Combustion air

WA Water discharge

We Water inlet

MaiN DiMENsioNs of DiEsEl hEatEr

262

113

WA / WE WA

A V

WE

B

86

39 395

14990

184

16

Ø 20

Ø 20

Ø 20

21,5

Ø 20Ø 24

A exhaust

B Fuel

V Combustion air

WA Water discharge

We Water inlet


262

113 86

39 395

14990

184

16

Ø 20

Ø 20

Ø 20

21,5

Ø 20Ø 24

WA / WE WA

A V

WE B


iNstallatioN locatioN

The heater is installed in the engine compartment.

The heater must be installed below the min. cooling water level (header

tank, radiator, vehicle's heat exchanger) so that the heat exchanger of

the heater and water pump can independently vent.

plEasE NotE! � note and follow the relevant safety instructions from page 8.

� The installation suggestions made in the installation instructions are

examples.

Other installation locations are possible if they comply with the in-

stallation requirements stated in these installation instructions.

� note and observe the allowable installation positions together with

the operating and storage temperatures.

� ensure adequate distance from hot vehicle parts.

insTALLATiOn exAMpLe: peTROL heATeR in A CAR

86 7

1

2911

34

5

1012

1 heater

2 exhaust pipe

3 exhaust silencer

4 exhaust pipe end

5 Combustion air hose

6 Fan relay

7 Fuse bracket

8 Control unit

9 Metering pump

10 Tank connection

11 pressure line

12 intake line

insTALLATiOn exAMpLe: DieseL heATeR in A TRAnspORTeR

1

2

8

9

10

3

4

6

5

7

1 heater

2 exhaust pipe

3 exhaust silencer

4 exhaust pipe end


6 Fan relay

7 Fuse bracket

8 Control unit

9 Tank connection

10 intake line




heater for diesel fuel

3

1

2

3

max. 90°

1 horizontal installation position

2 Vertical installation position

3 Water connection

insTALLATiOn pOsiTiOn – heATeR upRighT / On iTs siDe

heater for petrol and diesel fuel

The upright installation position (normal position) with swivel range up

to the horizontal (heater on its side) installation position is permissible.

All installation positions between 0° and 90°are permitted.

heater for bioethanol fuel

The upright installation position (normal position) is permissible. The

horizontal installation position and the installation positions between

0° and 90° are not allowed.

plEasE NotE!if a heater is swivelled out of the normal position, the water connection

sockets (3) must always be at the top.

heater for petrol and ethanol fuel

32

3

1

max. 90°

1 upright installation position


3 Water connection socket

pErMissiBlE iNstallatioN positioNs

The heater should preferably be installed in the normal position.

Depending on the installation conditions the heater can be installed

within the allowable swivel ranges, except heater B 5 sC, if it is run

with bio-ethanol fuel e85. in this case on the normal upright and verti-

cal positions are allowed, see sketch.

plEasE NotE!in heating mode, the normal and maximum installation positions shown

can differ by up to +15° in all directions for a short time.

These differences, caused by tilted positions of the vehicle, do not have

any negative effects on the heater's function.

insTALLATiOn pOsiTiOn – heATeR upRighT / VeRTiCAL

heater for petrol and diesel fuel

The upright (normal position) installation position with swivel range up

to the vertical installation position is allowed.

All installation positions between 0° and 90°are permitted.

heater for bioethanol fuel

The upright installation position (normal position) and the vertical in-

stallation position are permissible.

All installation positions between 0° and 90°are not permitted.

plEasE NotE!in the vertical installation position two water connection sockets (3)

point downwards.

heater for petrol and ethanol fuel

3

1

2

3

max. 90°


2 Vertical installation position

3 Water connection socket


2. screw special screw M6 x 17 onto the heater.

Mount special screw M6 x 17 (with adhesive coating) on the heater, on

the right or left-hand side (torque: 6+2 nm).

3. insert the heater in the bracket and use 2 hexagon screws M6 x 12

(with adhesive coating) to fix it onto the bracket (torque: 6+2 nm).

NaMEplatE

The nameplate (1) is fastened to the end of the heater.

The 2nd nameplate (duplicate) is enclosed with the heater and if neces-

sary can be glued onto a readily visible place on the heater or in the

area of the heater.

1

1 nameplate

plEasE NotE!note and observe the relevant regulations on page 7.

heater for diesel fuel, horizontal installation position

32

3

1

max. 90°



3 Water connection

iNstallatioN aND fixiNg – hEatEr

use the bracket included in the installation kit to fix the heater in a suit-

able position on the vehicle. The installation steps are shown using the

example of a diesel heater. The petrol heater is installed in the same

way.

insTALLATiOn sTeps

1. use hexagon screws size M6 x 12 and hexagon nuts size M6 or

self-tapping screws to fix the bracket.

Fixing with 3 screws Fixing with 4 screws

3 insTALLATiOn


plEasE NotE! � When installing the heater, please note the direction of flow of the

coolant liquid circuit.

� Fill the heater and water hoses with coolant before connecting to the

coolant liquid circuit.

� Route the water hoses without any kinks, and in a rising position if

possible.

� When routing the water pipes, maintain sufficient clearance from hot

vehicle parts.

� protect all water hoses / water pipes from chafing and from extreme

temperatures.

� secure all hose connections with hose clips (tightening torque:

3+0.5 nm).

� Re-tighten the hose clips after the vehicle has been running for

2 hours or has travelled 100 km.

� The minimum water flow rate is only guaranteed if the temperature

difference of the heating medium does not exceed 10 K between

water inlet and water outlet during heating.

� Only overpressure valves with an opening pressure of min. 0.4 –

max. 2 bar may be used in the coolant liquid circuit.

� The coolant liquid circuit must contain at least 10 % antifreeze all

year round as corrosion protection.

� During cold periods the coolant liquid circuit must contain sufficient

antifreeze.

� Before commissioning the heater for the first time or after chang-

ing the cooling water, the whole coolant liquid circuit including the

heater must be vented until they are free of bubbles, according to the

vehicle manufacturer's instructions.

� Only use the anti-freeze approved by the vehicle manufacturer in the

permissible mix ratio (anti-freeze/ water).

� Water hoses / water pipes must be securely fixed to prevent dam-

age and / or odour emissions due to vibrations. Recommended guide

value: Fix outgoing water hoses / water pipes from the heater at a

distance of approx. 20 cm with hose clips, pipe clips or cable ties.

3 insTALLATiOn

fix fusE holDEr aND rElay sockEt

use a hexagon screw size M6 x 12 and hexagon nut size M6 to fix the

bracket in a suitable position within the vehicle's engine compartment.

Fix the fuse holder to the bracket using 2 blind rivets 4 x 8; to do this,

press in the bolts of the two blind rivets until the fuse holder sits se-

curely on the bracket.

use a blind rivet 5.5 x 12 to fix the relay socket to the bracket; to do

this, press in the bolt of the blind rivet until the relay socket sits se-

curely on the bracket.

coNNEctioN to thE coolaNt liquiD circuit

DaNgEr!RisK OF injuRies AnD BuRns

The high temperatures of the coolant liquid and the coolant liquid cir-

cuit components can cause injuries and burns.

Î parts conveying water must be routed and fastened in such a way

that they pose no temperature risk to man, animals or material

sensitive to temperature from radiation / direct contact.

Î Before working on the coolant liquid circuit, switch the heater off

and wait until all the components have cooled down completely, if

necessary wear protective gloves.

The heater is integrated in the coolant liquid circuit in the water flow

hose from the vehicle engine to the heat exchanger. To this end, the

inLine and COMFORT installation variants exist.

The installation options are described from page 19.


iNstallatioN of BlaNkiNg ElEMENt

For the “inline integration”, the top water inlet connection sockets of

the heater must be closed off using a blanking element. To do this, push

the blanking element onto the water connection socket. For correct fit,

the inner groove (a) of the blanking element must be guided over the

lug (b) on the water connection socket.

With slight pressure on the front of the blanking element, the sealing

elements are pressed onto the connection socket and the retaining

clip can be pushed down into the notch in the connection socket (see

sketch).

1.

2.

3.a b

plEasE NotE! � After installing the blanking element and initial commissioning of the

heater, the precise fit and leaktightness of the blanking element must

be checked.

� The blanking element is included in the installation kit scope of

supply.

coNNEctioN to thE coolaNt fluiD circuit, “iNliNE” iNstalla-

tioN VariaNt

inTegRATe The heATeR in The WATeR FLOW hOse FROM The VehiCLe

engine TO The heAT exChAngeR

Cut the water flow hose from the vehicle engine to the vehicle's heat

exchanger.

use connectors and water hoses to connect the heater to the water

flow hose.

heATing ChARACTeRisTiCs

if the heater is switched on, the heat is fed to the vehicle's own heat

exchanger.

After the water has reached a temperature of approx. 30 °C the vehicle

fan switches on and the heat is then also fed to the passenger com-

partment.

1

2

4

3

1 heater

2 heat exchanger

3 Vehicle engine

4 Blanking element

coNNEctioN to thE coolaNt fluiD circuit, “coMfort” iNstal-

latioN VariaNt

ARRAngeMenT OF The WATeR COnneCTiOn sOCKeTs AT The heATeR

When connecting the water hoses for the “Comfort” installation variant,

always ensure that the water hoses are connected to the correct water

connection sockets of the heater.

C

B

A

A Connection socket,

water outlet

B Connection socket, water inlet

C Connection socket,

water inlet / outlet

plEasE NotE! � The arrows on the water connection socket indicate the basic flow

direction. Depending on the setup of the coolant liquid circuit, an op-

posite flow direction is also possible at connection socket 3.

3 insTALLATiOn


heATing ChARACTeRisTiC in AuxiLiARy heATeR MODe –

heATeR On / VehiCLe engine on

if the vehicle engine is running, the coolant liquid is uniformly distrib-

uted to the heat exchanger and vehicle engine in a large coolant liquid

circuit. This causes accelerated heating up of the vehicle interior and

shortens the warming up phase of the engine.

1

2

4

3

AC

B

1 heater

2 heat exchanger

3 non-return valve

4 Vehicle engine

inTegRATe The heATeR, T-pieCe OR nOn-ReTuRn VALVe AnD sOLe-

nOiD VALVe in The COOLAnT LiquiD CiRCuiT –

TheRMOsTATiCALLy COnTROLLeD COOLAnT LiquiD CiRCuiT WiTh

pRiORiTy heATing OF The VehiCLe engine


exchanger and insert a T-piece or the non-return valve. use a water

hose to connect the heater to the T-piece.

Optionally, a solenoid valve can be inserted between the T-piece and

the heater.

Cut the water return hose from the vehicle's heat exchanger to the ve-

hicle engine and insert the heater.

heATing ChARACTeRisTiC in pARKing heATeR MODe –

heATeR On / VehiCLe engine off

initially, up to a temperature of 67 °C, the coolant liquid is only fed to

the vehicle engine – quick heating up of the vehicle engine.

1

2 5

4

3

AC

B

see page 21 for key

3 insTALLATiOn

coNNEctioN to thE coolaNt fluiD circuit, “coMfort”

iNstallatioN VariaNt

inTegRATe The heATeR AnD nOn-ReTuRn VALVe in The COOLAnT

LiquiD CiRCuiT


exchanger. use connectors and water hoses to connect the heater to

the water flow hose.

Cut the water return hose from the heat exchanger to the vehicle en-

gine. insert the non-return valve in the water return hose and use a

water hose to connect it to the heater.

heATing ChARACTeRisTiC in pARKing heATeR MODe –

heATeR On / VehiCLe engine off

initially, up to a temperature of 67 °C, the coolant liquid is only fed to

the vehicle's heat exchanger – quick heating up of the vehicle interior.

1

AC

B

2

4

3

1 heater

2 heat exchanger

3 non-return valve

4 Vehicle engine

From a coolant liquid temperature of approx 67 °C, part of the coolant

liquid is also fed to the vehicle engine. This causes slow heating of the

engine circuit, without rapid cooling of the “small coolant liquid circuit”

for interior heating.

1

2

4

AC

B

3

1 heater

2 heat exchanger

3 non-return valve

4 Vehicle engine


Exhaust systEM

DaNgEr!RisK OF injuRies AnD BuRns!

every type of combustion produces high temperatures and toxic ex-

haust fumes. This is why the exhaust system must be routed according

to these installation instructions.

Î Do not perform any work on the exhaust system while the heater is

working.

Î Before working on the exhaust system, switch off the heater first

and wait until all the parts have completely cooled down, wear

safety gloves if necessary.

Î Do not inhale exhaust fumes.

iMportaNt!The whole exhaust system gets very hot while the heater is running and

immediately afterwards. This is why the exhaust system must be routed

according to these installation instructions.

Î The exhaust pipe must end in the open air.

Î The exhaust pipe may not protrude beyond the lateral limits of the

vehicle.

Î Lay the exhaust pipe sloping slightly downwards. if necessary,

make a drain hole with approx. Ø 5 mm at the lowest point as a

condensation outlet.

Î important functional parts of the vehicle may not be impaired

(maintain sufficient clearance).

Î Mount the exhaust pipe with sufficient clearance to heat-sensitive

parts. pay particular attention to fuel lines (made of plastic or

metal), electrical cables and brake hoses, etc.!

Î exhaust pipes must be safely fixed (recommended clearance of

approx. 50 cm) to avoid damage from vibrations.

Î Lay the exhaust system so that the outflowing exhaust gases are

not sucked in as combustion air.

Î The mouth of the exhaust pipe must not become clogged with dirt

and snow.

Î The mouth of the exhaust pipe must not point in the direction of

travel.

Î Always fix the exhaust silencer to the vehicle.

Î Lay the exhaust system so that the exhaust fumes do not flow

directly onto heat-sensitive components.

1 heater

2 Vehicle engine

3 solenoid valve, 2/2 way,

normally open

4 T-piece or non-return valve

5 heat exchanger

From a coolant liquid temperature of approx 67 °C, part of the cool-

ant liquid is also fed to the vehicle's heat exchanger. This causes slow

heating of the vehicle interior, without rapid cooling of the “small cool-

ant liquid circuit” for the engine heating.

2 5

4

3

1

AC

B

1 heater

2 Vehicle engine


normally open


5 heat exchanger

heATing ChARACTeRisTiC in AuxiLiARy heATeR MODe –

heATeR On / VehiCLe engine oN

When the vehicle engine is running the solenoid valve is controlled

via D+ and closes the “small coolant liquid circuit”. The coolant liquid

is uniformly distributed to the heat exchanger and vehicle engine in

a large coolant liquid circuit. This causes accelerated heating up of

the vehicle interior and shortens the warming up phase of the vehicle

engine.

2 5

4

3

1

AC

B

1 heater

2 Vehicle engine


normally open


5 heat exchanger

3 insTALLATiOn


plEasE NotE! � note and follow the regulations and safety instructions for this chap-

ter from page 8.

� The exhaust pipe end should be much shorter than the flexible ex-

haust pipe from the heater to the exhaust silencer.

� To avoid contact corrosion, the clips for fixing the exhaust pipe must

be made of stainless steel. For the Order no. of the fixing clips,

please refer to the “product information” document.

The exhaust system consists of a flexible exhaust pipe, inner Ø 24 mm,

900 mm long, a flexible exhaust pipe end with end sleeve, inner

Ø 24 mm, 300 mm long and an exhaust silencer.

All parts for the exhaust system including the fixings are included in the

installation kit (for allowable line lengths, see sketch on page 23).

insTALLing The exhAusT sysTeM

Fix the exhaust silencer with a bracket (L bracket or Z bracket) and if

necessary a 180 mm long strut, in a suitable place on the vehicle (see

sketch on page 23).

Lay the flexible exhaust pipe from the heater to the exhaust silencer

and fasten with pipe clips (tightening torque: 6+0.5 nm), if necessary,

adjust the length.

if necessary, shorten the exhaust pipe end with end sleeve, push

onto the exhaust silencer and fix with a pipe clip (tightening torque:

6+0.5 nm).

if necessary, use pipe clips to fasten the flexible exhaust pipe and the

exhaust pipe end in suitable positions in the vehicle (recommended

clearance of approx. 50 cm).

if necessary, attach spacer rings to the flexible exhaust pipe and to the

exhaust pipe end.

Fix BRACKeT TO The exhAusT siLenCeR

Various options for fixing the L bracket to the exhaust silencer (tighten-

ing torque: 6+0.5 nm)

Various options for fixing the Z bracket to the exhaust silencer (tight-

ening torque: 6+0.5 nm)

3 insTALLATiOn


insTALLing The COMBusTiOn AiR sysTeM

The combustion air must be drawn out of an area which does not be-

come hotter than 25 °C and in which neither spray water or dust / dirt

are to be expected.

A flexible combustion air hose (double-walled, sound insulating),

di = 20 mm, 760 mm long, is included in the installation kit.

At one end the combustion air hose and the inner tube are tacked

together with a clip. push this end of the hose onto the combustion air

socket and fasten with a hose clip (tightening torque 5+0.5 nm).

Lay the connection air hose so that the combustion air is removed from

an area, which fulfils the conditions named above.

if necessary, the flexible combustion air hose can be shortened accord-

ing to the installation conditions.

When shortening the combustion air hose, ensure the cutting edge is

clean, small cut-off pieces could block the combustion air fan.

plEasE NotE! � note and follow the regulations and safety instructions for this chap-

ter from page 7.

exhAusT AnD COMBusTiOn AiR sysTeM

min. 200 mm / max. 760 mm max. 2 m

min. 200 mm

min. 150 mm

1 heater


3 Flexible exhaust pipe

4 exhaust silencer

5 exhaust pipe end with end sleeve

6 spacer ring

coMBustioN air systEM

iMportaNt!safety instructions for the combustion air system

Î The combustion air opening must remain free at all times.

Î Lay the combustion air intake to ensure that exhaust fumes cannot

be sucked in as combustion air.

Î Do not direct the combustion air intake against the vehicle's air-

stream.

Î The combustion air intake must not become clogged with dirt and

snow.

Î install the combustion air intake system sloping slightly down-

wards. if necessary, make a drain hole approx. Ø 5 mm at the low-

est point to drain off condensation.

Î if necessary, use fastening clips or cable ties to fix the flexible

combustion air hose to the vehicle in suitable places.

3 insTALLATiOn


fuEl supply

DaNgEr!RisK OF FiRe, expLOsiOn, pOisOning AnD injuRies!

Caution when handling fuel.

Î switch off the vehicle engine and the heater before refuelling and

before working on the fuel supply.

Î Avoid naked flames when handling fuel.

Î Do not smoke.

Î Do not inhale petrol fumes.

Î Avoid any contact with the skin.

iMportaNt!safety instructions for laying the fuel lines!

Î use a sharp knife only to trim the fuel hoses and pipes. interfaces

must not be crushed and must be free of burrs.

Î Wherever possible, lay the fuel lines from the metering pump to the

heater with a continuous rise.

Î Fuel lines must be securely fixed to avoid damage and / or noise

due to vibrations (recommended guideline value: clearance of

around 50 cm).

especially in electric vehicles, ensure that the fuel lines are fixed so

that sound transfer to the vehicle is prevented.

Î Fuel lines must be protected against mechanical damage.

Î Lay the fuel lines so that any twisting of the vehicle, engine move-

ments, etc. do not have a disadvantageous effect on their durability.

Î use hose clips to secure all hose connections in the fuel supply.

Î parts carrying fuel must be protected from interfering heat.

Î never route or fasten the fuel lines directly along the heater or ve-

hicle exhaust system.

Î When systems cross, always ensure there is a sufficient heat clear-

ance. if necessary, attach heat deflection plates.

Î Dripping or evaporating fuel must never be allowed to collect on

hot parts or ignite on electric equipment.

Î When connecting fuel lines with a fuel hose, always install the fuel

lines with a butt joint to prevent any bubbles from forming.

1 correctly laid lines

2 incorrectly laid lines – bubbles form

3 insTALLATiOn

insTALL MeTeRing puMp (OnLy FOR peTROL heATeR) AnD LAy The

FueL Lines

Always note and follow the safety instructions when installing the me-

tering pump (only for petrol heater) and when laying the fuel lines.

Deviations from the instructions stated here are not allowed. Failure to

comply can result in malfunctions.

iMportaNt!safety instructions for fuel lines and fuel tanks in buses and coaches!

Î in buses and coaches, fuel lines and fuel tanks must not be routed

through the passenger compartment or driver's cab.

Î Fuel tanks in buses and coaches must be positioned in such a way

that the exits are not in immediate danger if a fire occurs.

plEasE NotE! � The installation kit contains all parts required for the fuel supply.

� note and follow the regulations and safety instructions for this chap-

ter from page 7.


fuEl supply – pEtrol hEatEr

FueL exTRACTiOn WiTh TAnK COnneCTiOn OR WiTh ADApTeR

iMportaNt!safety instructions for the fuel supply!

The fuel must not be conveyed by means of gravity or overpressure in

the fuel tank.

Î The fuel may only be pumped by the metering pump included in the

scope of supply and approved by the manufacturer.

13 77

7

7

7

78

4

5

5

5

6

6

a

b

2

1 Tank connection, di = Ø 2 mm, da = Ø 4 mm – installed in the

vehicle's own tank fitting

2 Adapter, Ø 7.5 / 3.5 mm – connected to the vehicle's own tank

fitting, at a connection socket Ø 8 mm, used to pass through the

intake line (fuel pipe 4 x 1) up to just before the bottom of the tank.

3 Metering pump

4 Fuel filter – only required for contaminated fuel

5 Fuel pipe, 4 x 1 (di = Ø 2 mm, blue)

6 Fuel pipe, 4 x 1.25 (di = Ø 1.5 mm, transparent)

7 Fuel hose, 3.5 x 3 (di = Ø 3.5 mm), approx. 50 mm long

8 elbow, 105°

permissible line lengths

intake side

a = max. 2 m

pressure side

b = max. 6 m

plEasE NotE! � item (4) is not included in the “installation kit” scope of supply. Order

no. see page 10.

� installation of the fuel filter item (4) requires two adapters Ø 5 /

3.5 mm, Order no. see page 10.

� use two hose clips Ø 11 to secure the adapter Ø 7.5 / 3.5 mm, item

(2).

� if the B 5 sC heater is operated with e85 ethanol fuel, the fuel lines

must be suitable for operation with e85, Order no. “fuel lines for

e85” kit see page 10.

� When installing tank connection item (1), maintain a minimum dis-

tance of 5±2 mm from the end of the riser to the bottom of the tank.

3 insTALLATiOn


fuEl supply – pEtrol hEatEr

iMportaNt!safety instructions for installing the metering pump!

Î Always install the metering pump with the delivery side rising up-

wards – minimum angle 15°.

Î protect the metering pump and filter from impermissible heating

(max. 20 °C), do not install near to silencers and exhaust pipes.

insTALLATiOn pOsiTiOn OF The MeTeRing puMp

Always install the metering pump with the delivery side rising upwards.

Any mounting position over 15° is allowed, although a mounting posi-

tion between 15° and 35° is preferable.

1 installation position between 0° – 15° is not allowed

2 preferred installation position within range 15° – 35°

3 installation position within the range 35° to 90° is allowed

peRMissiBLe suCTiOn AnD pRessuRe heAD OF The MeTeRing puMp

pressure head from vehicle tank to metering pump:

a = max. 3000 mm

suction head in pressure-less vehicle tank:

b = max. 500 mm

suction head in a vehicle tank in which negative pressure occurs during

extraction (valve with 0.03 bar in the tank cap):

b = max. 150 mm for petrol

pressure head from the metering pump to the heater:

c = max. 2000 mm

plEasE NotE!Check tank ventilation.

3 insTALLATiOn

1

3

a

c

b

2

1 Connection at the heater

2 Max. fuel level

3 Min. fuel level


3 insTALLATiOn

fuEl supply – DiEsEl hEatEr with iNlEt prEssurE rEsistaNt

MEtEriNg puMp up to 2.0 Bar

FueL exTRACTiOn using T pieCe FROM The FueL ReTuRn Line LAiD

BeTWeen The VehiCLe engine TO The TAnK FiTTing

iMportaNt!safety instructions for the fuel supply!

Î To install the fuel hose at the heater, it must be moistened and care-

fully pushed onto the fuel connection socket.

Î it is not permitted to extract fuel downstream of the vehicle's own

fuel pump.

Î if using a T-piece in a plastic pipe, always insert support sleeves in

the plastic pipe.

Î Always insert the T-piece in the fuel return line

Î Connect the T-piece and the plastic pipe with the relevant fuel hoses

and secure with hose clips.

Î if the pressure in the fuel pipe is more than 2.0 bar up to max. 4.0

bar, use a pressure reducer (order no. see page 10) or a separate

tank connection.

Î if the pressure in the fuel pipe is over 4.0 bar or if there is a non-

return valve in the return pipe (in the tank), a separate tank con-

nection must be used.

Î The vehicle must be delivered with an almost empty vehicle tank.

Î After cutting the fuel return line, with the vehicle engine switched

off, use suction to check whether fuel extraction from the vehicle

tank without air bubbles is ensured. This ensures that the fuel re-

turn line ends just above the bottom of the tank and no non-return

valve is installed.

if this is not so, the fuel must be extracted using a separate tank

connection.

1 37

4

56

a

4

2

1 Fuel return line from the vehicle's tank fitting

2 Fuel flow line from the vehicle's tank fitting

3 T-piece




7 to the vehicle engine / to the vehicle's own fuel pump

plEasE NotE!items (3) and (5) are not included in the “installation kit” scope of sup-

ply. Order no. see page 10.


intake side

a = max. 5 m

insTALLATiOn pOsiTiOn OF The T-pieCe

use the installation positions shown when inserting the T-piece.

1 Direction of flow to the fuel tank

2 Direction of flow from the vehicle engine


fuEl supply – DiEsEl hEatEr

FueL exTRACTiOn WiTh TAnK COnneCTiOn – insTALLeD in The TAnK

FiTTing

1 3

4a

22

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




plEasE NotE! � When installing tank connection item (1), maintain a minimum dis-

tance of 5±2 mm from the end of the riser to the bottom of the tank.

� item (4) is not included in the “installation kit” scope of supply. Order

no. see page 10.

� installation of the fuel filter item (4) requires two adapters Ø 5 /

3.5 mm, Order no. see page 10.


intake side

a = max. 5 m

peRMissiBLe suCTiOn AnD pRessuRe heAD, DieseL FueL

pressure head from vehicle tank to heater:

a = max. 3000 mm

suction head in pressure-less vehicle tank:

b = max. 10000 mm

suction head in a vehicle tank in which negative pressure occurs during

extraction (valve with 0.03 bar in the tank cap):

b = max. 400 mm

plEasE NotE!Check tank ventilation.

3 insTALLATiOn

1

3

a

b

2

1 Connection at the heater

2 Max. fuel level

3 Min. fuel level


3 insTALLATiOn

fuEl supply

FueL quALiTy FOR peTROL heATeR

The heater runs problem-free on standard commercial quality fuel in

accordance with en 51600 and en 228, which you use to run your ve-

hicle engine.

The B 5 sC can also be operated with ethanol e85.

plEasE NotE! � if operating with ethanol e85, fuel hoses specially suitable for this

fuel must be used, Order no. “fuel lines for e85” kit see page 10.

� if operating with ethanol e85 the heating output is reduced by around

30 %.

FueL quALiTy FOR DieseL heATeR

� The heater runs problem-free on standard commercial grade diesel

fuel according to Din en 590.

During the winter months the diesel fuel is adapted to the low tem-

peratures of 0 °C to –20 °C.

This means that problems can only arise if extreme drops in tem-

perature occur – as is the case for the vehicle engine too – please

refer to the vehicle manufacturer's instructions.

� in special cases and at outdoor temperatures above 0 C the heater

can also be run on eL heating oil according to Din 51603.

� if the heater is run from a separate tank, please comply with the fol-

lowing rules:

– at outdoor temperatures over 0 °C,

use diesel fuel according to en 590;

– at outdoor temperatures of 0 °C to –20 °C,

use winter diesel fuel according to en 590.

– at outdoor temperatures of –20 °C to –40 °C,

use Arctic diesel or polar diesel.

plEasE NotE! � it is not permitted to add used oil!

� After refuelling with winter or cold diesel, the fuel lines and the me-

tering pump must be filled with the new fuel by letting the heater run

for 15 minutes!

OpeRATiOn WiTh BiODieseL

(FAMe FOR DieseL engines ACCORDing TO en 14 214)

The D 5 sC heater is not approved for running on biodiesel according to

en 14214.


DEscriptioN of fuNctioNs

sWiTChing On (pARKing heATeR MODe)

pARKing heATeR MODe

When the heater is switched on, the symbol appears in the control

unit or the operating display lights up.

heATing MODe

The water pump starts up and, following a preset sequence, the com-

bustion air fan, glow plug and metering pump are started.

The glow plug is switched off once a stable flame has formed in the

combustion chamber.

Depending on the heat requirements, the heater runs at the follow-

ing levels: power – high – Low – Off (pause mode). The temperature

thresholds for these are permanently programmed in the electronic

control box.

if the coolant liquid is cold, the heater starts in control stage “high” and

if necessary switches to the “power” control stage. if the coolant liquid

is hot, the start takes place in “Low” control stage.

After the water temperature has reached approx. 75 °C – depending on

the selected fan setting – the heater switches to “high” control stage.

if the water temperature continues to rise up to 80 °C, the heater

switches to “Low” control stage.

� if the heat output achieved in “Low” control stage is insufficient,

the water temperature drops to 70 °C – the heater switches back to

“high” control stage.

� if the heating output in the “Low” control stage is sufficient the

heater remains in “Low” control stage. if the water temperature rises

to 85 °C, the heater switches to the “Off” control stage (pause mode)

and then starts the afterrun.

� if the water temperature cools to 75 °C during pause mode, a con-

trolled start follows in “Low” control stage.

During pause mode the water pump continues to run and the On

symbol continues to be displayed in the control unit.

heATing AT high ALTiTuDes

When 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:

– The heater can be run for short periods (e.g. driving through a

mountain pass or taking a break in your journey).

– During longer stays, e.g. winter camping, the fuel supply must be

adjusted to the altitude.

The altitude adjustment can be made by installing an air pressure

sensor. The air pressure sensor is included in the altitude kit –

order no. 22 1000 33 22 00.

opEratiNg iNstructioNs

The heater is operated by a control unit. Detailed operating instructions

are supplied with the control unit.

plEasE NotE!you will be issued the operating instructions by the installation work-

shop.

iMportaNt iNstructioNs for opEratioN

iniTiAL COMMissiOning OF The heATeR

The following points are to be checked by the company installing the

heater during initial commissioning.

� Following installation of the heater, the coolant liquid circuit and the

whole fuel supply system must be carefully vented. Comply with the

instructions issued by the vehicle manufacturer.

� Open the coolant circuit before the trial run (set the temperature

control to “WARM”).

� During the heater trial run, all water and fuel connections must be

checked for leaks and secure, tight fit.

� if faults occur while the heater is running, use a diagnostic unit to

determine and correct the cause of the fault.

sAFeTy CheCKs BeFORe sTARTing up The heATeR

After a lengthy stoppage (summer months), check all components for

secure fit (tighten screws where necessary).

Carry out a visual check of the fuel system for leaks.

BeFORe sWiTChing On

Before switching on or pre-programming heating mode, switch the ve-

hicle's heating control to “WARM” (maximum setting) and the blower to

“slow level” (low electricity consumption).

in vehicles with automatic heating, before switching off the ignition,

switch the heating control to “MAx” and the required damper position

to “Open”.

pARKing VenTiLATiOn

parking / cab ventilation means: possible activation of the vehicle fan

directly via the control unit or – even more useful – via the radio remote

control by bypassing heating mode, in order to ventilate the often over-

heated vehicle interior with fresh air just before driving away.



coNtrol aND safEty DEVicEs

� if the petrol heater does not ignite within 100 seconds of being

switched on or the diesel heater does not ignite within 70 seconds,

the start is repeated.

The heater is automatically shut down if, after three further start at-

tempts in the case of a petrol heater and two attempts with a diesel

heater, the petrol heater fails to start within the preset safety period

(240 seconds).

After an impermissible number of failed start attempts, the control

box is locked.*

� if the flame independently goes out during operation, the heater is

restarted and if necessary, a maximum of two further start attempts

are made within the preset safety time.

if the heater does not ignite or ignites but goes out again within 15

minutes, a safety lock-out occurs. The safety lock-out can be can-

celled by briefly switching off and on again (heater On / OFF).

� in the case of overheating (e.g. water shortage, poorly ventilated

coolant liquid circuit), the overheating sensor triggers, the fuel supply

is interrupted and the heater is automatically shut down. Once the

cause of the overheating has been eliminated, the heater can be re-

started by switching off and on again.

precondition: the heater has cooled down sufficiently, water tem-

perature < 70 °C.

After an impermissible number of shut-downs on overheating, the

control box is locked*.

� if the lower or upper voltage limit is reached, the heater is automati-

cally shut down.

� The heater does not start up if the glow plug is defective or if the

electric cable to the metering pump is interrupted.

� The speed of the fan motor is continuously monitored. if the blower

motor does not start up, if it is blocked or if the speed falls below 40

% of the desired speed, the heater is automatically shut down after

60 sec.

* Cancellation of the lock or reading out errors is possible:

� using the easystart T timer

� with the easystart R+ radio remote control

� using the eDiTh diagnostics tool.

For operation and fault list, please refer to the enclosed operating in-

structions or the troubleshooting and repair instructions for the heater.

plEasE NotE!Do not repeat the switching off / on routine more than twice.


EMErgENcy stop – EMErgENcy off

if an emergency stop – eMeRgenCy OFF – is necessary during

operation, proceed as follows:

� switch the heater off at the control unit or

� remove the fuse or

� disconnect the heater from the battery.


hEatEr wiriNg

iMportaNt!safety instructions for wiring the heater!

The heater is to be connected up electrically according to the eMC

directives. eMC can be affected if the heater is not connected up cor-

rectly. For this reason, comply with the following instructions:

Î ensure that the insulation of electrical cables is not damages.

Avoid:

chafing, kinking, jamming or exposure to heat.

Î seal any connector chambers of watertight connectors not in use

with filler plugs to ensure they are dirt-proof and water-proof.

Î electrical connections and negative connections must be free of

corrosion and firmly connected.

Î Lubricate connections and ground connections outside the heater

interior with contact grease.

plEasE NotE!Comply with the following when wiring the heater and the control unit:

� electrical leads and components must be positioned in the vehicle so

that they can function perfectly under normal operating conditions

without impairment (e.g. due to heat exposure, moisture, etc.).

� The following cable cross-section is to be used between the battery

and heater.

This ensures that the max. permissible voltage drop in the cables

does not exceed 0.5 V for 12 V rated voltage.

Cable cross-section for a cable length (plus cable + minus cable) up

to 6 m = cable cross-section 4 mm².

� if the positive cable is to be connected to the fuse box (e.g. terminal

30), the vehicle's cable from the battery to the fuse box must also be

included in the calculation for the total cable length and re-dimen-

sioned if necessary.

� insulate unused cable ends.

5 eLeCTRiCs

parts list for circuit DiagraM, hEatEr aND caBlE looM

-A7 Control box

-B1 Control / overheating sensor

-B3 surface sensor

-B5 Flame sensor

-F1 Fuse, heater

-F2 Fuse, control unit

-F3 Fuse, vehicle fan

-Fx Fuse block, vehicle

-hg heater

-K1 Relay, vehicle fan

-M1 Burner motor

-M11 Water pump

-R1 glow plug

-s3 Vehicle fan

-s4 Vehicle fan

-xTR1 Disconnect cable

-y1 Fuel metering pump

a to the cable harness connector xB2

b to the heater connector xs2

c to the control unit

d Fan activation

e Auxiliary heating criterion

f switch-on signal

plEasE NotE!The 12 volt relay (-K1, from terminal 30 to terminal 87a) has a maxi-

mum current carrying capacity of 40 A; i.e. the value of the vehicle‘s

own fan fuse may not be more than 40 A. Circuit diagram see page

33,36.

assigNMENt of coNNEctor -xs2

cham-

ber

cross-

section

colour function

1 2.5 red Battery “plus” (positive) (terminal 30)

2 2.5 brownBattery “minus” (negative) (terminal

31)3 0.5 black/red Vehicle fan4 1.0 green Metering pump “plus”5 0.5 blue/white je diagnosis6 0.5 blue Auxiliary heating criterion7 0.5 yellow switch on “plus”8 0.5 violet Water pump “plus”9 1.0 brown Water pump “Minus”

10 1.0 brown/green Metering pump “Minus”

caBlE colours

RD red gR grey BK blackBu blue ye yellow gn greenWh white VT violet Bn brown


circuit DiagraM, pEtrol hEatEr

+

-

M

M- +

-M114

13

1

-A7

Θ

Θ

Θ

-XS21

2

3

4

5

6

7

8

2,5 RD

2,5 BN

0,5 BKRD

1,0 GN

0,5 BUWH

0,5 BU

0,5 YE

0,75 BN

0,75 BK

0,6 (0,5) BK

0,6 (0,5) BK

0,5 WH

0,5 WH

1,5 WH

1,5 BN

0,22 BN

0,22 BN

-HG

0,12 WH

0,12 WH

-B5

-R1

-B3

-B1

9

10

0,5 VT

1,0 BN

1,0 BNGN

a

12

11

10

9

8

7

6

5

4

3

2

-M11 BA

A B

1,0 BN

0,5 VT

COnneCTOR AnD Bush hOusing CiRCuiT DiAgRAM, heATeR AnD CABLe hARness

-XB2 -XS2 -XB10 -XS10 -XB3 -XS3

Connectors and bush housings are shown from the cable inlet side.

parts list see page 32 25 2598 00 96 01 / 1

5 eLeCTRiCs


circuit DiagraM, caBlE harNEss, pEtrol hEatEr

123

-S3-XTR1

M

1

2

3

4

5

6

7

8

9

10

2,5 RD

2,5 BN

0,5 BKRD

0,75 GN

0,5 BUWH

0,5 BU

0,5 YE

-XB2

0,75 BNGN

-Y112V 12

2 1-XB4

-XB32 1

2 1-XS3

-K112V

c

d

e

f

-Fx

X:30Bat (+)

X:31(-)

X:15Ign (+)

4,0

RD

1,5

RD

4,0

RD

6,0

RD

-F120A

-F25A

-F325A

-W1

-XB10

1

2

3

0,5 BN

0,5 RD

0,5 BUWH

4,0

BN

-XS10

3

2

1

0,5 BN

0,5 RD

0,5 RD

0,75

BN

GN

0,75

BN

4,0

RD

WH

4,0

BK

4,0

BK

VT

0,5

BK

RD

0,5

BN

+86-XB8 8587 87a 30

b

0,5 BKRD


5 eLeCTRiCs


circuit DiagraM, DiEsEl hEatEr

+

-

M

M- +

-Y112V 21

1 2

-M114

13

1

-A7

Θ

Θ

Θ

-XS21

2

3

4

5

6

7

8

2,5 RD

2,5 BN

0,5 BKRD

1,0 GN

0,5 BUWH

0,5 BU

0,5 YE

0,75 BN

0,75 BK

0,6 (0,5) BK

0,6 (0,5) BK

0,5 WH

0,5 WH

1,5 WH

1,5 BN

0,22 BN

0,22 BN

-HG

0,12 WH

0,12 WH

-B5

-R1

-B3

-B1

9

10

0,5 VT

1,0 BN

1,0 BNGN

a

12

11

10

9

8

7

6

5

4

3

2

-M11 BA

A B

1,0 BN

0,5 VT

0,5 GN

0,5 GN

COnneCTOR AnD Bush hOusing CiRCuiT DiAgRAM, heATeR AnD CABLe hARness

-XB2 -XS2 -XB10 -XS10 -XB3 -XS3



5 eLeCTRiCs


circuit DiagraM, caBlE harNEss, DiEsEl hEatEr

123

-S3-XTR1

M

1

2

3

4

5

6

7

8

9

10

2,5 RD

2,5 BN

0,5 BKRD

0,75 GN

0,5 BUWH

0,5 BU

0,5 YE

-XB2

0,75 BNGN

-XB32 3

2 3-XS3

-K112V

c

d

e

f

-Fx

-X1:30Bat (+)

-X1:31(-)

-X1:15Ign (+)

4,0

RD

1,5

RD

4,0

RD

6,0

RD

-F120A

-F25A

-F325A

-XB10

1

2

3

0,5 BN

0,5 RD

0,5 BUWH

4,0

BN

-XS10

3

2

1

0,5 BN

0,5 RD

0,5 RD

4,0

RD

WH

4,0

BK

4,0

BK

VT

0,5

BK

RD

0,5

BN

+86-XB8 187 89 88

b

0,5 BKRD


5 eLeCTRiCs


coNNEctioN DiagraM, auxiliary hEatEr fuNctioN

VARiAnT 1: FOR eAsysTART COnTROL uniTs

0,5 BUe D+

T1 T1

T3

T4

T7

T8T2

T2

f

0,5 YE

VARiAnT 2: ALL COnTROL uniTs exCepT eAsysTART

0,5 BU

0,5 YE

T8

T3

T6

T5

T5

D+ef

e Auxiliary heating criterion

f switch-on signal

T1 join cable ends

T2 Cut loops in the cable harness

T3 Auxiliary heating criterion

T4 Tie back and insulate

T5 Do not cut open loops in the cable harness

T6 switch-on signal

T7 Temperature sensor (< 5 °C)

T8 On / OFF switch (optional)

5 eLeCTRiCs


circuit DiagraM, coNtrol uNit – Easystart tiMEr

X:58Light (+)

X:15Ign (+)

-E3

0,5* RD

0,5* BUWH

0,5* BN

1

2

3

4

5

6

7

8

-XB10

9

10

1

2

3

4

5

6

7

8

-XS10

9

10

0,35 RD

0,22 GYBK

0,22 BN

0,22 BUWH

0,22 VT

0,35 YE

0,22 BNYE

0,22 WHRD

0,22 BNWH

0,22 GY

0,5 GYBKc

0,22 BNWH

0,22 GYΘ

-B8

-XB10 -XS10

22 1000 34 97 01

parts list

-B8 Room temperature sensor (optional)

-e3 easystart Timer

c to the heater


* Cable cross-section 0.75 mm² hydronic M ii

5 eLeCTRiCs


circuit DiagraM, coNtrol uNit – Easystart rEMotE+

X:58Light (+)

X:15Ign (+)

-E5

1

-XB12

2

12

3

4

5

6

7

8

9

10

11

-H2

0,5* RD

0,22 RDYE

0,5* BUWH

0,22 BNWH

0,22 GY

0,22 BNYE

-W2

0,5* BN

Θ

-B8

0,22 BN

c

-XB12

22 1000 34 97 22

parts list

-B8 Room temperature sensor

-e5 stationary unit easystart Remote+

-h2 Button

-W2 Antenna

c to the heater



5 eLeCTRiCs


circuit DiagraM, coNtrol uNit – Easystart rEMotE

X:58Light (+)

X:15Ign (+)

-E4

1

-XB12

2

12

3

4

5

6

7

8

9

10

11

-H2

0,5* RD

0,22 RDYE

0,5* BUWH

0,22 BNYE

-W2

0,5* BN

0,22 BN

c

-XB12

22 1000 34 97 33

parts list

-e4 stationary unit easystart Remote

-h2 Button

-W2 Antenna

c to the heater



5 eLeCTRiCs


5 eLeCTRiCs

circuit DiagraM, coNtrol uNit – Easystart sElEct

X:58Light (+)

X:15Ign (+)

-E2

0,5* RD

0,5* BUWH

0,5* BN

1

2

3

4

-XB41

2

3

4

-XS40,35 RD

0,35 GYBK

0,35 BN

0,35 BUWH

0,5 GYBKc

-XB4 -XS422 1000 34 97 34

parts list

-e2 easystart select

c to the heater




5 eLeCTRiCs

circuit DiagraM, coNtrol uNit – Easystart call

X:58Light (+)

X:15Ign (+)

-E1

1

-XB12

-XB12

2

12

3

4

5

6

7

8

9

10

11

-H1

0,5* RD

0,22 RDYE

0,5* BUWH

0,22 BNWH

0,22 GY

0,22 BNYE

-W1

0,5* BN

Θ

-B8

0,22 BN

c

22 1000 34 97 18parts list

-B8 Room temperature sensor

-e1 easystart Call

-h1 Button

-W1 Antenna

c to the heater




6 TROuBLeshOOTing / MAinTenAnCe / seRViCe

if faults occur, plEasE chEck thE followiNg itEMs

� 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:

– Fuel in the tank?

– The fuses are ok?

– The electrical cables, connections, terminals, are ok?

– Anything is clogging the combustion air supply or exhaust system?

plEasE NotE!Always ensure that there is sufficient fuel in the tank, as the heater

switches to fault and locks if operated without fuel.

trouBlEshootiNg

if, after checking these items, the heater is still faulty or another mal-

function occurs in your heater, please contact:

� if factory-installed, your contract workshop / garage.

� if subsequently installed, the workshop / garage which installed the

heater.

plEasE NotE!please note that guarantee claims can expire if the heater is modified

by a third party or if non-original parts are installed.

MaiNtENaNcE iNstructioNs

� switch the heater on once a month for about 10 minutes, even out-

side the heating period.

� Before the heating period starts, the heater should be put through a

trial run. if thick, persistent smoke develops, unusual burning noises

or a clear fuel smell occurs or if electric / electronic parts overheat,

the heater must be switched off and put out of service by removing

the fuse. in this case, the heater should not be started up again until

it has been checked by qualified staff who have been trained on

eberspächer heaters.

� Check the openings of the combustion air supply and exhaust system

after longer standstills, clean if necessary!

sErVicE

if you have any technical queries or problems with your pre-heater, dial

the following service phone number from within germany:

hotline

Tel. 0800 / 12 34 300

Fax hotline

Tel. 01805 / 26 26 24

Outside of germany, please contact the respective eberspächer national

representative.


7 enViROnMenT

cErtificatioN

The high quality of eberspächer's products is the key to our success.

To guarantee this quality, we have organised all work processes in the

company along the lines of quality management (qM).

even so, we still carry out a large number of activities for continual im-

provement of product quality in order to keep pace with the constantly

growing requirements of our customers.

All the steps necessary for quality assurance are stipulated in interna-

tional standards.

This quality is to be considered in a total sense.

it affects products, procedures and customer / supplier relationships.

Officially approved public experts assess the system and the corre-

sponding certification company awards a certificate.

eberspächer has already qualified for the following standards:

quality MaNagEMENt iN accorDaNcE with

DiN EN iso 9001:2008 aND iso/ts 16949:2009

ENViroNMENtal MaNagEMENt systEM iN accorDaNcE with

DiN EN iso 14001:2004

Disposal

DispOsAL OF MATeRiALs

Old devices, defect components and packaging material can all be

separated and sorted into pure-grade factions so that all parts can be

disposed of as required in an environment-friendly manner recycled

where applicable.

electric motors, control boxes and sensors (e.g. temperature sensors)

are deemed to be “electronic scrap”.

DisMAnTLing The heATeR

The heater is dismantled according to the repair stages in the current

troubleshooting / repair instructions.

pACKAging

The packaging of the heater can be kept in case it has to be sent back.

Ec DEclaratioN of coNforMity

The manufacturer:

Eberspächer climate control systems gmbh & co. kg

Address:

eberspächerstraße 24

D-73730 esslingen

herewith declares that the following product:

product name Vehicle heaterType hydronic iiVersion B 4 s / B 5 s

D 4 s / D 5 s

E 4 s

B 4 sc / B 5 sc

D 4 sc / D 5 sc

fulfils the requirements of the following eC Directives:

a) heating systems directive 2001/56/eC,

Revision status 2006/119/eC

b) Radio interference (eMC) of vehicles 72/245/eeC,

Revision status 2009/19/eC

c) heater control eCe-R 122,

Revision status 00

d) eMC of vehicles eCe-R 10,

Revision status 03

The following eC Directives and un regulations have been used to

assess the product:

2001/56/eC; 72/245/eeC; eCe-R 122; eCe-R 10


8 L isTs

list of kEy worDs

aAccident prevention 9Arrangement of the heater 7Automatic control 7

BBefore switching on 30Biodiesel 29

cCertification 43Circuit diagram, cable harness, diesel heater 36Circuit diagram, control unit – easystart Call 41Circuit diagram, control unit – easystart R 39Circuit diagram, control unit – easystart R+ 38Circuit diagram, control unit – easystart T 40Circuit diagram, diesel heater 35Circuit diagram, petrol heater 33Combustion air intake 7Combustion air system 23Concept of this manual 5Control and safety devices 31Cooling water circuit 18 – 21

DDismantling the heater 43Disposal 43Disposal of materials 43

EeC Declaration of Conformity 43emergency shutdown – eMeRgenCy OFF 31emergency stop 31en 14 214 29environmental management system 43exhaust silencer 22exhaust silencer, fasten 22exhaust system 7, 21

fFAMe 29Faults 42Fax hotline 42Fuel lines, lay 24Fuel quality 29Fuel quality for diesel heater 29Fuel quality for petrol heaters 29Fuel supply 7, 24 – 27Fuel withdrawal with tank connection 25Functional description 30Fuse bracket 18

hhazard information and safety instructions 8heater installation position 16heater scope of supply 10heater wiring 32heating at high altitudes 30heating mode 30hotline 42

iimportant information 6initial commissioning 30installation 8installation and fixing – heater 17installation example 15installation kit scope of supply 10installation location 15installation position of the metering pump 26installation steps 17installing the combustion air system 23installing the exhaust system 22instructions for operation 30introduction 5

MMain heater dimensions 14Maintenance instructions 42Main water pump dimensions 14Metering pump, install 24

Nnameplate 17

oOperating instructions 30Operation 8Operation with biodiesel 29

ppackaging 43parking heater mode 30parking ventilation 30parts list 32permissible installation positions 16permissible line lengths 25, 27, 28permissible suction and pressure head 26picture symbols 6purpose 6

qquality management 43

rRelay socket 18


8 L isTs

list of aBBrEViatioNs

aDr

european agreement about the international transport of dangerous

goods on the road.

EcE regulation

internationally agreed, uniform technical specifications for vehicles,

parts and equipment of motor vehicles.

EMc directive

electromagnetic compatibility.

E85 ethanol fuel

petrol containing 85 % ethanol.

faME

Biodiesel to en 14214.

JE-partner

j. eberspächer partner.

ssafety check 30scope of supply 10, 11service 42special text formats 6statutory regulations 7switching on 30

tTechnical data for the diesel heater 13Technical data for the petrol heater 12

wWater pump installation position 16

headquarters:

eberspächer Climate Control systems

gmbh & Co. Kg

eberspächerstraße 24

73730 esslingen

hotline: 0800 1234300

Fax hotline: 01805 262624

[email protected]

www.eberspaecher.com 25 2

598

90 0

0 01

en

03.2

013

su

bjec

t to

chan

ge w

ithou

t not

ice

©

ebe

rspä

cher

Clim

ate

Cont

rol s

yste

ms

gmbh

& C

o. K

g

n s scriptio structio technical description co in r...

Documents