Eberspacher Hydronic 10 Workshop

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Water heater
10
Eberspächer ®
Troubleshooting and repair instructions
J. Eberspächer
GmbH & Co.
Eberspächerstr. 24
D -73730 Esslingen
Telefon (zentral)
(07 11) 9 39 - 00
Telefax
(07 11) 9 39 - 05 00
http://www.
eberspaecher.de
These troubleshooting and repair instructions are valid for the following heater versions
HYDRONIC 10
25 2081 05 00 00 - 12 V
25 2044 05 00 00 - 24 V
Page
Contents
First check the following if faults occur .....................................
2
Fuel quantity measurement .......................................................
2
Function and fault test ...............................................................
3–6
Functional sequence .................................................................
7
Wiring diagram HYDRONIC 10 – 25 2081 / 25 2044 .................
8, 9
Wiring diagram HYDRONIC 10-TRS 003 – 25 2081 / 25 2044 ..
10, 11
Repair instructions .....................................................................
12 – 14
25 2081 95 12 57
11.1998
Modifications reserved
Printed in Germany
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© Copyright J. Eberspächer GmbH & Co.
C41
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First check the following if faults occur
Performance and malfunction test
Fuel in tank?
Possible faults may be read-out by connecting a
diagnostic device (order No. 221512890000) to link
B2 (see wiring diagram page 9). Operation see
operating instructions for the diagnostic device. List
of faults below.
Heater lever (water valve) is „Hot” setting?
Fuses OK?
- When using the new module dial gauge, it is not
necessary to use a diagnostic device.
- When using the mini dial gauge displayed, the
adapter cable (order No. 221000300500) has to be
used together with the diagnostic device (order
No. 221512890000).
Electrical leads and connections OK?
Combustion air pipe or exhaust pipe clogged?
Alternatively, a LED can be used instead of the
operating device to display the flashing code (h in
wiring diagram). Fault signals can be found on the
next page.
Fuel quantity measurement
2. Measurement
Caution: Only measure the fuel when the battery is
sufficiently charged. At least 11/22 V and max. 13/26 V as
appropriate must be applied to the control unit during the
measurement.
Switch on the heater.
Fuel pumping starts about 63 seconds after switchon. After another 105 seconds of pumping it is
switched off automatically.
Wait for restart. If fuel pumping is switched off
automatically after another 75 seconds, switch off
the heater. Measure the fuel quantity in the
measuring glass.
1. Preparation
Detach the fuel line from the heater and place it in a
measuring glass (size: 50 cm3).
Switch on the heater. When fuel is fed smoothly (about
63 seconds after switch-on), the fuel line is filled and bled.
Switch off the heater and empty the measuring glass.
Nominal value: 19 ml +/– 10 %
If the quantity of fuel is outside the tolerance,
replace the metering pump.
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Remedy
–––––––––––––––––––––––––––––––––––––––––
Check to see if voltage between 13 and 14 of control unit
(external plug) is greater than 15 V or 30 V
Check to see if voltage between 13 and 14 of control unit
(external plug) is less than 10 V or 20 V
Switch heater off and on again
(TRS case due to D+ or HA/NA must be cancelled)
Check to see if voltage between 13 and 14 of control unit
(external plug) is greater than 15 V or 30 V
Check to see if voltage between 13 and 14 of control unit
(external plug) is less than 10 V or 20 V
Overtemperature sensor signals temperature of greater than
115 °C. Impedance at overtemperature sensor < 400 ohms.
Ventilate heater (water level too low). Open the heater slide
valve. Check water throughflow and sensor. Check the impedance at the control unit (internal plug). For this purpose,
dismantle the control unit, disconnect the internal plug from
the control unit and measure the impedance between 5 and 8.
Overtemperature sensor values:150 kohms at – 25 °C
10 kohms at + 25 °C
Flame sensor signals temperature of greater than 700 °C.
Impedance at flame sensor > 3400 ohms. Check the impedance at the control unit (internal plug). For this purpose,
dismantle the control unit, disconnect the internal plug from
the control unit and measure the impedance between 10
and 12. Flame sensor values: 900 ohms at – 25 °C
1100 ohms at + 25 °C
Temperature difference between measurements of overtemperature sensors is greater than 70 K. Ventilate heater
(water level too low). Open the heater slide valve and check
water throughflow. Check the overtemperature sensor.
Check the impedance between 5 and 8 at the control unit
(internal plug). Overtemperature sensor values:
150 kohms at – 25 °C / 10 kohms at + 25°C
The control unit is interlocked after three successive
overheats (error codes 012, 013 and 014). Eliminate the
case of the overheat. Unlocking by deleting the error
memory with diagnosis unit/PC or plus signal for 0.5 to 5
sec. on connection 7 (0.5 v) on the control unit (ext. plug)
with heater switched on.
Fault code
Fault description
000 No fault
001 Advance warning – overvoltage
002 Advance warning – undervoltage
009 TRS 003 cutout
010 Overvoltage cutout
011 Undervoltage cutout
012 Overheat
013 Excess temperature at flame sensor
014 Difference between overheat and
water temperatue too large
015 Too many overheats
Function and fault test
0
2
4
Fault signal / flashing code
6
3
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▼
8 Sec.
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Check glow plug (nominal value: approx. 2 ohms), replace it
if necessary. Check terminal 4 (1.5 white) on the control unit
(internal plug) leading to glow plug to terminal 3 (1.5 brown)
for continuity/short-circuit. If O.K. → replace control unit.
020
4
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Check water pump (driven externally
Test connection 6 (0.5 swrt) on the control unit (int. plug) for
short circuit. Test water pumps and cables
Check terminal 2 (1 green) of control unit (external plug) for
short-circuit. Check connected components (max. current
6 A), replace them if necessary.
Check terminal 1 (1 blue) of control unit (external plug) and
leads up to metering pump for short-circuit/interruption.
Check the metering pump. Nominal value: approx. 20 ohms.
Replace if necessary.
The control unit is interlocked after it has been switched on
10 times in succession (= 20 failed starts) without flame
detection (fault code 052). Check the fuel supply, glow plug,
exhaust piping, combustion air piping and flame sensor.
Unlocking by deleting the error memory with diagnosis unit/
PC or plus signal for 0.5 to 5 sec. on connection 7 (0.5 v) on
the control unit (ext. plug) with heater switched on.
Flame sensor signals a temperature of greater than 80 °C
despite 4 minutes of cooling with cold air. Impedance at
flame sensor >1300 ohm. If no combustion takes place →
check the flame sensor, replace it if necessary.
Flame sensor values: 900 ohms at – 25 °C
1100 ohms at + 25 °C
037 Water pump is not working
042 Short-circuit at water pump output
043 Short-circuit at external components
047 Short-circuit of metering pump
050 Too many failed starts
051 Flame message is displayed
when heater is switched on
048 Metering pump interruption
Speed deviation for longer than 60 seconds.
Nominal values: 7300 rpm (POWER), 5700 rpm (HIGH),
Nominal values: 3600 rpm (MEDIUM), 2000 rpm (LOW).
• Check burner motor: apply supply voltage to motor.
Connect + to 1.5 black and – to 1.5 orange. Motor does
not turn → replace burner motor with integrated sensor.
• Check sensor supply. Switch on heater and measure
voltage between output 13 (0.25 red) and 14 (0.25 green)
at the control unit (internal plug). Nominal value: 8 V. If
deviation → replace control unit.
• Check sensor: Measure voltage between terminal 15 (0.25
violet) and 14 (0.25 green) with an analog voltmeter when
the blower is running. Nominal value: 4 V (+/– 0.3 V) average value (8 V square-wave signal). If deviation → replace
motor with integrated sensor. If sensor signal is O.K., then
the speed controller is defective. → Change control unit.
033 Burner motor or
speed controller defective,
speed deviation
021 Short-circuit at glow plug
Glow plug interruption
Remedy
Fault code
Fault description
Function and fault test
0
2
4
Fault signal / flashing code
6
▼
8 Sec.
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No flame was detected during the start-up phase. Flame
sensor value of less than 80 °C (1310 ohms). Check the fuel
supply, glow plug, exhaust piping, combustion air piping
and flame sensor.
Flame sensor values: 900 ohms at – 25 °C
Flame sensor values: 1100 ohms at + 25 °C
Heater has started (flame detected) and indicates flame
loss in a power setting. Check fuel flow rate, blower speed,
fuel supply, exhaust pipe and combustion air piping.
If combustion is O.K., check flame sensor, replace if
necessary.
Flame sensor values: 900 ohms at – 25 °C
Flame sensor values: 1100 ohms at + 25 °C
052 Safety time exceeded –
heater does not start
053 Flame loss in „Power” setting
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093 Control unit defective (RAM fault)
094 Control unit defective (EPROM fault)
097 Control unit defective (general fault)
090 Control unit defective (internal reset)
072 Short circuit in overheat sensor
071 Overheat sensor interruption
065 Short circuit in flame sensor
064 Flame sensor interruption
Internal control unit error in microprocessor/memory
detected.
Replace control unit
Overheat sensor signals temperature value outside measurement range. Check the connecting leads (0.35 blue). Impedance between terminals 5 and 8 of the control unit
(internal plug): greater than 700 kohms (in the event of
interruption) less than 100 ohms (in the event of short-circuit)
Overheat sensor values: 150 kohms at – 25 °C
10 kohms at + 25 °C
Flame sensor signals temperature value outside
measurement range. Check the connecting leads (0.35
green). Impedance between terminals 10 and 12 of the
control unit (internal plug):
greater than 50 kohms (in the event of interruption)
less than 100 ohms (in the event of short-circuit)
Flame sensor values: 900 ohms at – 25 °C
1100 ohms at + 25 °C
Control sensor signals temperature value outside measurement range. Check the connecting leads (0.35 yellow). For
this purpose, dismantle the control unit, disconnect the internal
plug from the control unit and measure the impedance
between 9 and 11. Impedance between terminals 9 and 11 of the
control unit (internal plug): greater than 10 kohms (in the event of
interruption) less than 100 ohms (in the event of short-circuit)
Temperature sensor values: 650 ohms at – 25 °C
1000 ohms at + 25 °C
060 Temperature control sensor interruption
061 Short circuit in temperature control sensor
Check water circulation (012) and temperature control
sensor (060/061)
059 Water temperatur rises too quickly
056 Flame loss in „Low” setting
055 Flame loss in „Medium” setting
054 Flame loss in „High” setting
Remedy
Fault code
Fault description
Function and fault test
0
2
4
Fault signal / flashing code
6
▼
8 Sec.
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No hot air in interior
Combustion generates soot
Faults which are not displayed:
Faults
Switch on vehicle blower
Replace relay
Renew fuse
Vehicle blower relay defective
Vehicle blower fuse blown
Remove heat exchanger and clean
Deposits inside heat exchanger
Vehicle blower not switched on
Measure CO2 content. If ≥ 13% in
„High” setting, replace blower.
Combustion air blower speed too low
Open heater lever
Measure fuel quantity
Metering pump conveying too much
Heater lever closed
Clear obstruction
Remedy
Combustion air pipe/
exhaust pipe clogged
Cause
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• If heat demand is 7500 Watts or higher, the heater
operates in the „HIGH”setting. If the water temperature
drops to 60 °C in the process, the heater switches back
to the „POWER” setting.
Mode of operation
Switch-on
The pilot light in the switch or heating timer comes on when
the heater is switched on. The combustion air blower and
water pump start and the preheating phase of the glow
plug begins.
After the preheating phase, which takes approx. 60
seconds, the metering pump starts and fuel into the
combustion chamber. The fuel/air mixture ignites. Then the
speed of the combustion air fan increases together with the
pulse frequency for the dosing pump continuously to the
stage „MEDIUM”, then to „HIGH”, then if necessary to
„POWER with 9500 watt”, to bring the combustion chamber
up to temperature.
Glow plug cutout is time-controlled. If no flame is detected
by the flame sensor, the heater is restarted.
If no flame is detected when the heater is started for a
second time, the heater cuts out and a fault is displayed.
The blower continues to run cool down the heater.
• If heat demand is between 7500 Watts and 3200 Watts,
the heater switches between „HIGH and MEDIUM”.
• If heat demand is 1500 Watts or less, the heater operates
in the „LOW” setting.
If heat demand in the „LOW” setting is so low that the
cooling water temperature reaches 85 °C, the heater
switches from „LOW” to „OFF”. The blower continues to
run for 210 seconds.
The coolant pump continues to run until re-start of the
heating device and vehicle fan.
Once the temperature of the cooling water drops to 70 °C
(for example), the heater restarts in the „MEDIUM”
setting.
Speed of
blower motor
Control temperatures
Heating operation
When the heater is first started up after switch-on, it works
in the „Power” setting 9500 W until
• either the water temperature exceeds the changeover
limit „POWER”/„HIGH” (e.g. 72 °C),
• or the max. operating time in this setting (2 hours) is
exceeded.
The heater then switches to the „HIGH-MEDIUM-LOW-OFF”
settings depending on heat demand. If the cooling water
reaches 55 °C (for example), the temperature sensor
switches on the vehicle blower. The max. cooling water
temperature in the individual control steps is 85 °C.
VEHICLE BLOWER
ON
55 °C
POWER – 7300 rpm
POWER → HIGH
72 °C
HIGH
HIGH → MEDIUM
78 °C
MEDIUM– 3600 rpm
MEDIUM → LOW
79 °C
LOW
LOW → OFF
85 °C
OFF → MEDIUM
68 °C
MEDIUM → HIGH
68 °C
LOW → MEDIUM
73 °C
HIGH → POWER
60 °C
– 5700 rpm
– 2000 rpm
Startup sequence
Speed of blower motor
(rpm)
Glow plug
8
Blower motor rpm
7
Frequency of
metering pump (Hz)
6
5
4
3
2
1
0
0
50
100
150
200
250
Time (s)
7
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300
350
400
450
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Wiring diagram: Heater, standard version – 25 2081 / 25 2044
8
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Wiring harness and operating elements, standard version – 25 2081 / 25 2044
Parts list
1.1
Burner motor
1.2
Glow plug
1.5
Safety thermal cutout switch
1.12
Flame sensor
1.13
Temperature sensor
2.1
2.2
2.5.7
2.5.18
Control unit
Fuel metering pump
Vehicle blower relay
Switch-over relay for water
circulation system, to be fitted
by customer if required
2.7
Main fuse
12 volt = 20 A
24 volt = 15 A
2.7.1 Fuse for control switch 5 A
2.7.5 Fuse for vehicle blower 25 A
2.12
Water pump
2.15.9 Sensor, external temperature
3.1.2
3.1.16
3.2.9
3.2.12
3.3.6
Heating switch (continuous operation)
Key button, radio remote control
Timer
Timer "Mini 98" version
Radio remote control
5.1
Battery
a)
b)
c)
d)
e)
f)
g)
h)
Connection for operating device
External control for water pump
(with plus signal)
Water circulation changeover:
relay closes at a water temperature
of 68 °C and opens at 63 °C
Ignition (terminal +15)
Vehicle blower step switch
Light (terminal 58)
Connection for heater
Display, flashing code (optional)
(LED at choice, series resistor 1.5 kohms)
i)
Connection for external heating key
k)
Connection leads in plug B2, B4 or B5
a2)
a3)
a4)
a5)
a6)
Diagnosis
Switch-on signal, S+
Plus supply, +30
Minus supply, –31
Battery separating switch (+) on / off
(diode: order number 208 00 012)
*
Length A – B and C – D:
< 5 m: cross-section 4 mm2
> 5 m < 8 m: cross-section 6 mm2
Plug housing and socket housing are shown
from the conductor entry side
Cable colours
2044602B.
9
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sw
ws
rt
ge
gn
vi
br
gr
bl
li
= black
= white
= red
= yellow
= green
= violet
= brown
= grey
= blue
= lila
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Wiring diagram: Heater, TRS 003 version – 25 2081 / 25 2044
10
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Wiring harness and operating elements, TRS 003 version – 25 2081 / 25 2044
Parts list
1.1
Burner motor
1.2
Glow plug
1.5
Safety thermal cutout switch
1.12
Flame sensor
1.13
Temperature sensor
2.1
2.2
2.5.7
2.5.18
2.7
2.7.1
2.7.5
2.12
Control unit
Fuel metering pump
Vehicle blower relay
Switch-over relay for water
circulation system, to be fitted
by customer if required
Main fuse
12 volt = 20 A
24 volt = 15 A
Fuse for control switch 5 A
Fuse for vehicle blower 25 A
Water pump
(max. additional load: 4 A)
3.1.2
3.2.9
Heating switch (continuous operation)
Timer
5.1
Battery
a)
b)
Connection for operating device
External control for water pump
(with plus signal)
c) with TRS D+ (alternator)
d) with TRS HA– (auxiliary drive /
secondary drive) / minus switch
Connect lead to + pole if unavailable
e) Water circulation changeover:
relay closes at a water temperature
of 68 °C and opens at 63 °C
(with D+ 58 °C / 45 °C)
f) Ignition (terminal +15)
g) Vehicle blower step switch
h) Display, flashing code (optional)
(LED at choice, series resistor 1.5 kohms)
k) Connection leads in plug B2 or B6
l) Connection for heater
m) Light (terminal 58)
n)
Connection for external heating key
a1)
a2)
a3)
a4)
a5)
a6)
TRS feedback
Diagnosis
Switch-on signal, S+
Plus supply, +30
Minus supply, –31
Battery separating switch (+) on / off
(diode: order number 208 00 012)
*
Length A – B and C – D:
< 5 m: cross-section 4 mm2
> 5 m < 8 m: cross-section 6 mm2
Plug housing and socket housing are shown
from the conductor entry side
2044601B.
Cable colours
sw
ws
rt
ge
gn
vi
br
gr
bl
li
11
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= black
= white
= red
= yellow
= green
= violet
= brown
= grey
= blue
= lila
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Repair steps
Remove / install
7. Housing including heat exchanger, dismantled
8. Burner
9. Burner, dismantled
10. Heat exchanger
11. Heat exchanger, dismantled
1. Control unit
2. Glow plug cable
3. Glow plug
4. Safety thermal cutout switch/temperature sensor/water
pump
5. Cover/blower
6. Flame sensor/heat exchanger fastening screws
Overall view of heater
12
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Remove / install
1. Control unit (on installation of the control unit,
grease the gasket with sealing paste)
4. Safety thermal cutout switch/temperature sensor/water
2. Glow plug cable
5. Cover/blower (on installation of the cover,
clean the sealing surface and apply liquid seal)
3. Glow plug
6. Flame sensor/heat exchanger fastening screws
13
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7. Housing including heat exchanger, dismantled
10. Heat exchanger
8. Burner
11. Heat exchanger, dismantled
9. Burner, dismantled
14
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