Eberspacher Airtronic D4 Operating

Eberspacher Airtronic D4 Operating
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Eberspächer uk | technical manual
Airtr on i c D2 / D 4 / D4+
O perati ng In str uc ti o ns an d Servi ce Boo k
20339 Issue F · PE/December/2011
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Uncontrolled Copy
This publication was correct at the time of going to print.
However, Eberspächer (UK) Ltd. have a policy of continuous improvement and reserve the right to
amend any specifications without prior notice.
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Contents
Technical Data.................................................................................................................... 4
Operating Instructions for 801 Series Digital Modulator..................................................... 5
Operating Instructions for Rheostat Control Switch............................................................ 6
Operating Instructions for Modulator Control (301 Series)................................................. 7
Adjusting Temperature Using Rheostat or Modulator Control ........................................... 8
Operating Instructions for 7 Day Timer with Temperature Controller...........................9 - 10
Operating Instructions for 701 Series Timer / Modulator........................................... 11 - 12
Airtronic Modulator Instructions 301 00 200..................................................................... 13
Mini Controller Operating / Mounting Instructions............................................................. 14
Operating Instructions for 801 Series Digital Modulator............................................15 - 16
Method of Operation Airtronic D2 / D4.......................................................................17 - 18
Sectional Drawing Airtronic D2 / D4.................................................................................. 19
Controls and Safety Devices............................................................................................ 20
Circuit Diagram Airtronic D2 / D4 - Short Optional Loom.................................................. 21
Wiring Diagram for Control Switches............................................................................... 22
Circuit Diagram Airtronic D2 / D4 - Long Optional Loom.................................................. 23
Wiring Diagram for Control Switches................................................................................ 24
Fuel at Low Temperatures................................................................................................ 25
Operation with Bio-diesel.................................................................................................. 26
Fault Diagnosis Using 7 day Timer............................................................................27 - 28
Recommended Service Schedule Airtronic D2 / D4......................................................... 29
Safety Instructions............................................................................................................ 30
Important Information........................................................................................................ 31
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Technical Data
Airtronic
Heater type
Heater
Airtronic D2 / Airtronic D4 / Airtronic D4 Plus
Version
D2 / D4 / D4 Plus
Heating
Product
2 medium
Air
information
Control of the heat flow
Stage
Technichal data
Heatertyp
Power
Large
Medium
Small
Off
Airtronic M
Heat flow (watt)
D2
2200
1800
1200
850
–
Version
D4
4000
3000
B4
2000
900
–
D4 Plus
4000
3000
Air
2000
900
–
105
90
Stage
60
40
13
Power
185
Large 150
Heater
Heating medium
Control
of therate
heat flow
Heater
air flow
D2 with hood Ø 60 mm
without counter-
D4 with hood Ø 90 mm
Heat flow (watt)
pressure (kg/h)
D4 Plus with hood Ø 75 mm
Heater air flow rate
with hood Ø 90 mm
Airtronic B4
3800
3200
185
160
175
Fuel without
consumption
(l/h) (kg/h)
counterpressure
D2
Fuel consumption (l/h)
D4
0.51
0.54
0.46 0.38
Elektr. power consumption (watt)
D4 Plus
0.51
0.38
operation (12 volt)
Elektr.inpower
consumption (watt)
D2
at start (12 volt)
in operation (12 and 24 volt)
Rated voltage
Operating range
D4
D4 Plus
0.28
140
40
34
40
55
29
Medium 110 Small
2100
1300
100
120
0.23
0.29
22
24
30
0.15
85
60 Off
–
55
0.10
24
0.25 0.18
0.11 –
0.25
0.11
22
–
–
–
15
12
100
13
7
5
16
7
5
12 volt
Lower
limit:
at start
(12voltage
and 24
volt)
9
24
5
8
5
100
approx. 10.5 volt
or 24
volt
Undervoltage protection 12
trigger
time:
20 seconds
An undervoltage protection in the controller
Ratedswitches
voltage off the heater when the voltage
limit is reached.
Operating range
Upper
voltage
limit:
Lower
voltage
limit:
An uppervoltage
protection in
in the
the controller
An undervoltage
protection
controller
switches off the heater when the voltage
switches off the heater when the voltage
limit is reached.
limit is reached.
approx.10.5
16 volt
approx.
volt resp. 21 volt
Undervoltage protection trigger time: 20 seconds
Undervoltage protection trigger time: 20 seconds
Fuel
Upper
voltage
“Fuel
quality“limit:
and “Fuel at low temperatures“
An uppervoltage
see page 28. protection in the controller
switches
off
the
when the voltage
Tolarable ambietheater
temperature
limit is reached.
Heater
Fuel
Dosing pump
“Fuel quality“ and “Fuel at low temperatures“
air intake temperature
seeMaximum
page 25.
Tolarable ambient temperature
Ventilation mode
approx. 16 volt resp. 32 volt
Overvoltage protection trigger
time: 20 seconds
Operation
Not running
–40 °C to +50 °C
–40 °C to +85 °C
–40 °C to +20 °C
–40 °C to +125 °C
Commercially available diesel fuel (DIN EN 590)
+40 °C
Interference suppression class 5 to DIN EN 55 025
Interference suppression
Weight
Commercially available petrol fuel (DIN EN 228)
Operation
Not running
approx. 4.5 kg
Heater
–40 °C to +70 °C
Dosing pump
–40 °C to +50 °C
possible
Maximum air intake temperature
–40 °C to +85 °C
–40 °C to +125 °C
+40 °C
Interference suppression
Interference suppression class 5 to DIN EN 55 025
Weight
D2 approx. 2.7 kg – D4 / D4 Plus approx. 4.5 kg
Ventilation mode
possible
Please note!
Caution!
Safety instructions for technical data!
Failure to comply with the technical data
can result in malfunctions.
Provided no limit values are given, the technical data
listed is subject to the tolerances usually applicable
to heaters of ±10% for nominal voltage, ambient
temperature 20 °C and reference altitude Esslingen.
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Operating Instructions for 801 Control Switch
Blue LED Indication Light
Ventilation / Diagnostics
Green LED Indication Light
Heater ON
Ventilation
Key
Instant
ON / OFF Key
Down Key
Up Key
Ambient Sensor /
External Temperature Sensor
Ambient Temperature Display
Temperature / Diagnostic
To Start Heating
Press “Instant On / Off” key to activate heater, the “Green LED Indication Light” will illuminate
and the blower motor will start and hot air will be delivered in approximately 120 seconds from
switch on. To select the temperature press the “Up” or “Down” key and hold until the desire
temperature is displayed.
Please Note: The ambient temperature is displayed by default, the set point temperature is
briefly displayed when either the “Up” or “Down” key is pressed.
To Stop Heating
Press the “Instant On / Off” key.
The “Green LED Indication Light” will go out. The blower motor will continue to run for
approximately 240 seconds and automatically switch off.
Please refer to page 15 for the complete 801 instructions guide.
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Operating Instructions for Rheostat Control Switch
High Heat
4
42
3
0
0
OFF
3
3
1
14
2
2
1
Low Heat
To Start Heating
Turn rotary knob clockwise to RED field. The dial is numbered from 0-4. Number 1 is low heat
and number 4 is high heat setting. The green pilot light in the centre of the switch will illuminate,
blower motor will start and hot air will be delivered in approximately 120 seconds from switch on.
To Stop Heating
Turn rotary knob anti-clockwise to ‘0’ position.
The green pilot light in the centre of the switch will go out. Blower motor will continue to run for
approximately 240 seconds and automatically switch off.
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Operating Instructions for Modulator Control (301 Series)
On / Off
Rocker Switch
Green Pilot Light
Red Pilot Light
Temperature Selector Dial
Long Segments – High Heat
Short Segments – Low Heat
To Start Heating
Press rocker switch to the left position for “ON”.
The red pilot light (power on) and green pilot light will illuminate. Turn rotary knob clockwise to
align with long segments on dial (high heat setting). Blower motor will start and hot air will be
delivered in approximately 120 seconds from switch on.
To Stop Heating
Press rocker switch to the right position for “OFF”.
The red and green pilot lights will go out.
Blower motor will continue to run for approximately 240 seconds and automatically switch off.
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Adjusting Temperature Using Rheostat or Modulator
Control
Select desired comfort heat level by turning the rheostat (see page 6) between number 1 & 4 or
modulator knob (see page 7) to align between long segments for high heat and short segments
for low heat level. To adjust temperature control for Timer Modulator Alarm see operating
instructions shown for appropriate controller. You may have to experiment to achieve the desired
heat comfort level as each vehicle will have different rates of heat loss through the roof, windows
etc.
A temperature sensor is fitted inside the heater, which, in conjunction with the operating
temperature control unit, controls the heat output between Power, High, Medium, Low or off
depending on the air temperature and/or control settings.
If the temperature of the air in the cab is less than approximately + 10°C the heater will
automatically maintain maximum heat output. Above 10°C the heater will automatically regulate
across all heat levels.
The heater will maintain a temperature of within approximately 4°C of the desired heat comfort
level by regulating between Power, High, Medium or Low heat output.
Should the temperature rise above the desired heat comfort level by 2°C or more, it will then
switch itself off. However, the blower fan will still continue to run at an extremely low fan speed
(constant ventilation mode) until the air temperature drops down by approximately 4°C. The
heater will then restart to maintain once again the desired heat comfort level.
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Operating Instructions for 7 Day Timer with
Temperature Controller and Fault Diagnostic Display
(Part Number: 22 1000 30 40 00)
8
9
10
11
1
2
3
4
5
6
7
7
MO
ϒC
6
1
2
3
4
5
8
9
10
11
Clock Time
Preselection
Heating
Back
Forward
Memory display
Symbol for radio remote control
(optional)
Time and weekday display
Temperature display (optional)
Operating display
Temperature controller
After connection of the power supply the display will show all the signals flashing
– the timer must now be set.
The heater cannot be switched on in this condition.
Setting up timer
Press
key briefly: 12:00 flashes on the display. Set the clock time with
stored after a short delay or the key is pressed. Then the weekday flashes.
Set the current day with
again.
or
. The day is stored after a short delay or the
or
. The time is
key is pressed
To adjust the current time or change day, follow the same procedure.
Heating Operation
To switch on heater press
To switch off heater press
. The heater remains in continuous operation.
, automatic delay in shut off for cooling down.
Pre-Selected Heating Start up Time
Press P several times until the required memory number (1, 2 or 3) appears flashing on the
display.
or
key briefly and release, then set pre-selected time using
or
keys.
Press
As soon as the flashing stops then the weekday starts flashing. Set the weekday using the
or
keys. The pre-selected time and weekday are stored as soon as the time display reverts back
to the current time. The memory number indicates what memory is activated. Only one memory
can be activated at a time.
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Changing Pre-Selected Heating Duration
The heater operates for 120 minutes from pre-selected start up time: This is factory set. Should
you wish to change the duration, press the
key and hold it down for approx. 3 seconds until
display changes to heating duration.
Adjust using the
or
keys until desired duration is selected.
After a short delay the display returns to current time and the duration is set.
Clearing Preselect Memory
Press P several times until no memory numbers are displayed.
Displaying Preselect Memory
Press P . The activated pre-selected time and pre-selected day are displayed for approximately
5 seconds.
Operation - Temperature Controller
The desired room temperature can be set using the temperature controller (integrated into the
controller clock). The heating device adjusts itself automatically within the preset temperature
range.
Temperature Range
Left limit stop:
Lowest temperature approx. 10°C.
Right limit stop: Highest temperature approx. 30°C.
Please Note
Voltage drops and brief disconnection from the battery do not effect the timer, but if the display is
flashing then a reset is necessary.
Radio remote control operation is possible with the appropriate accessory.
If a fault occurs when the heater is switched on then the operating display flashes
fault code number is displayed. (Workshop Repair).
and the
In the Event of Malfunction, We Recommend
Switch off and back on again (not more than twice);
Check the main fuse;
Check air ducts for blockage;
Call in at an authorised service centre.
The heater must not be operated in a garage.
Always switch off the heater when filling the fuel tank.
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701 Series Timer / Modulator with Diagnostic Readout Instructions
Low Heat
8
9
10
11
12
13
High Heat
7
1.
Instant Heat ON/OFF key
7.
Day selected indicator boxes.
2.
Adjustment Up key
8.
Clock symbol.
5
3.
Disengaged pre-set symbol
9.
Heater operation symbol.
4
4.
Ventilation symbol
10. Preset Programme symbols.
5.
Temperature ramp.
11. Adjustment Down key.
6.
Current Time, Preset Time, 12. Programme key.
Heating Time, Run Time 13. Set/Programme key.
and Diagnostics.
6
3
2
1
Introduction
Your Timer/Modulator offers manual and
programmable control along with temperature
adjustment of your heater. When the heater
is switched on by the Timer/Modulator in a
programmed mode it will run for 1 hour or
for the duration time that you have selected
e.g Heater on at 0700, duration time of 1
hour, which means heater will be switched off
automatically at 0800.
continuous running operation (shown as C-: -on display) by repeatedly pressing the
key
while the heater is in operation. Current time
will be displayed every 5 seconds.
Clock Settings
Adjusting the Temperature
Press and hold
key until the
symbol
begins to flash. Use the
and
keys to set
correct time. Press and release the
key
and the day box will begin to flash. Use the
and
keys to set the correct day. Press and
release the
key again to reset the clock to
the start of the minute displayed. This may be
used to coincide with a known time signal.
Switching off the Heater (Manually)
The heater may be switched off at any time by
pressing the
key. The cooling down cycle
will then be initiated.
Pressing the
and
keys will alter the 20
segment temperature ramp shown on the
display. This level may be adjusted at any
time and will remain in the timer memory when
the heater is not in operation.
Diagnostic Readout
Please Note: These adjustments are not
possible when the heater is in operation. To
set the heater’s programmable switch on timer,
see “Setting Program Times”.
With the heater switched on, press and hold
key until the display shows “dAtA”. Release
key and display then shows “AF--” and
alternatively displays the current fault code.
Each press of the
key will scroll through the
last 5 previously stored fault codes.
Switching on the Heater (Manually)
Typical Fault Codes
Press the
key and the
symbol will appear
on the display. The heater will commence its
startup cycle. The display will change to show
a default of one hour heating countdown
time. This can be extended in increments
of 10 minutes, 30 minutes, 1 hour, 1 hour
30 minutes, 2 hours up to eight hours or to
10 = Over voltage - Check battery charging system.
11 = Under voltage - Check battery voltage.
12 = Overheating - Check air ducts for obstruction.
52 = Safety time exceeded - Check fuel supply.
For other codes consult your local dealer.
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Press
and
keys together to erase stored
faults and display shows “EEEE”.
To exit diagnostic mode, press and release
the
key. If stored faults cannot be erased
consult your local dealer.
Heater Run Time
Press and hold the
key until the display
shows the heater run time in hours.
Setting Programme Times
Press the
key and the P1 symbol will begin
to flash. Pressing the
key will alternate the
display between a preset time display and
“OFF”. With P1 flashing in the time display
mode the desired programme time can be set
using the
and
keys.
Once the desired time has been selected and
if no keys are depressed for 8 seconds the
display will revert to the clock mode. During
this 8 second period pressing the
key will
select P2 which can be used to select another
programme time or be set to “OFF” if not
required.
A further pressing of the
key will select the
P3 symbol which can be set or turned off in
the same manner as above.
Setting Programme Days
Having set programme times P1, P2 or P3 or
all three, press the
key, all the ‘P’ symbols
that have been selected will start flashing and
a box will appear around one of the days.
Setting Programme Duration
To set the desired heater duration, press and
hold the
key and whilst holding repeatedly
press the
key to select the desired time in
increments of 10 minutes, 30 minutes, 1 hour,
1 hour 30 minutes, 2 hours up until 8 hours.
Note: Continuous operation is not selectable
in this programme mode.
Once stored the preset duration time cannot
be adjusted during heater “ON” operation.
Switching on the Heater
(Programmed)
To activate your selected program settings,
press the
key to show the P1,P2,P3 (to
determine when the heater will switch on) or
symbol P to turn off all settings.
Note: If all presets and days have been
selected to “OFF” pressing the
key will have
no effect.
When the heater has been switched on
manually, it is possible to view which of the
programmed times have been set and whether
or not they have been activated. Press the
key to view and if any programmed time has
been activated, its corresponding P will flash.
If no programmed times have been activated
then P flashes. Press the
key to activate or
de-activate the programmed times as required.
Wait 8 seconds and the display will revert to
manual operation countdown.
Press the
key to select “ON” if you require
the selected day to be programmed, or “OFF”
if you do not wish it to be selected.
Ventilation
To move onto the following day press the
key once again and select “ON” or “OFF” as
before. Repeat this procedure for all seven
days. To store these settings in the Timer /
Modulator memory, wait for 8 seconds and the
display will revert to the clock mode.
shows and display changes to 1 hour
countdown. To stop ventilation, press
key to
return to normal display time.
To activate Ventilation Mode, repeatedly
press
key until only one segment shows
in the ramp. Press and hold the
key until
Please Note: The ventilation countdown time
of 1 hour is not adjustable.
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Airtronic Modulator Instructions 301 00 200
Heating “ON” RED L.E.D
Ventilation “ON” BLUE L.E.D
Rotary temperature turn dial
The switched modulator with heat, vent
and built in external temperature sensor
is suitable for the Airtronic range of
heaters only. This unit is dual voltage.
Connect to 12v or 24v D.C
Ventilation Operation
When the fan (symbol) is selected on the rocker switch (right push) the Airtronic heater will
turn on the heater fan blower. No heated air will be produced from the heater unit. A blue L.E.D
illuminates.
Heating Operation
When the heat (symbol) is selected on the rocker switch (left push) the Airtronic heater will
turn on as detailed in the technical description manual. A red L.E.D illuminates. Select the
temperature required by adjusting the rotary turn dial. Temperature range is adjustable between
10°C and 30°C.
Long segments – Highest temperature
Short segments – Lowest temperature
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Mini Controller Operating / Mounting Instructions
Temperature preselection control knob
• Left-hand end stop approx. 8°C
- small amount of heat
• Right-hand end stop approx. 34°C
- large amount of heat
Heater
Red LED - Operation check for heater
Switch off (not in combination with mini clock)
Ventilator
Blue LED - operation check for ventilator
Order No. 22 1000 32 07 00
The mini controller enables you to set the heater installed in the vehicle to the temperature you
require.
You can either use the mini controller alone or in combination with the mini-clock.
Stand-Alone Mini-Controller
Start Heater - Heating Mode
Use the
button to start the heater in heating mode (continuous operation). You can adjust
the required temperature with the control knob
. If the heater is in heating mode, the red LED
lights up as a check.
Start Heater - Ventilation Mode
Use the
button to start the heater in ventilation mode (continuous operation). The control
knob
has no function in ventilation mode. If the heater is in ventilation mode, the blue LED
lights up as a check.
Switch off Heater
Use the
button to switch off the heater. Heater or ventilation mode is terminated and the
corresponding LED goes out.
Heating mode is terminated with after run.
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Operating Instructions for 801 Series Digital Modulator
Blue LED Indication Light
Ventilation / Diagnostics
Green LED Indication Light
Heater ON
Ventilation
Key
Instant
ON / OFF Key
Down Key
Up Key
Ambient Sensor /
External Temperature Sensor
Ambient Temperature Display
Temperature / Diagnostic
Introduction
The 801 Modulator offers manual control and digital temperature adjustment of your Airtronic
heater.
Switching on the Heater (Manually)
Press the
up cycle.
key and ‘ON’ will briefly appear on the display. The heater will commence its start
Also, the green LED ‘Heater ON’ indication light will illuminate and the display will now revert to
show ambient temperature (°C).
Note: The 801 10 001 version will only run for a maximum period of 1 hour.
The ambient display temperature range is from -9°C to +59°C.
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Switching off the Heater (Manually)
The heater may be switched off at any time by pressing the
key.
The heater cooling down cycle of 3 minutes will then be initiated. Wait for blower fan to stop
before isolating batteries (if isolator is fitted).
Adjusting the Temperature
Pressing the
or
keys will alter the desired temperature shown on the display. This level
may be adjusted at any time and will remain in the modulator memory when the heater is not in
operation.
When the
or
keys are released the display will revert back to show ambient temperature.
The Modulator temperature adjustment range is from 5°C to 32°C.
Diagnostic Readout
With the heater switched on, press and hold
key until the display shows ‘dA’. The blue LED
will briefly illuminate. Release the key. After a short time the LED flickers momentarily during
diagnostic data transfer then goes off. The display shows FO followed by its fault code then
automatically scrolls through any previously stored fault codes, up to a maximum of 5.
Typical Fault Codes
10 11 12 52 =
=
=
=
Over voltage - Check battery charging system.
Under voltage - Check battery voltage.
Overheating - Check air ducts for obstruction.
Safety time exceeded - Check fuel supply.
For other fault codes consult your local Eberspächer dealer.
Press
and
keys together to erase stored fault codes and display shows ‘EE’. To exit
diagnostic mode, press and release the
key.
If stored fault codes cannot be erased consult your local Eberspächer dealer.
Ventilation
To activate Ventilation Mode, press and hold the
display shows active rotating two digits.
key until the blue LED illuminates and
Note: The 801 10 001 version will only run for a maximum period of 1 hour.
To stop ventilation, press
temperature.
key briefly. Blue LED switches off and display shows ambient
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Method of Operation Airtronic D2 / D4 / D4+
Temperature Selection with the
Operating Controls
Function
Switching On
The pilot lamp in the operating control lights up
when the heater is switched on.
The glow pin is switched on and the fan will
start running at a low speed.
Please Note:
If there is any residual heat within the heat
exchanger from a previous heating operation,
the fan only (cold blowing) will run until the
residual heat has been dissipated.
Start
Airtronic D2
Fuel starts to be delivered after approx.
60 seconds.
The fuel-air mixture in the combustion
chamber ignites. Once the combi-sensor
(flame sensor) has detected the flame, the
glow pin is switched off after 60 seconds.
After another 120 seconds the Airtronic has
reached the control stage POWER (maximum
fuel quantity and maximum fan speed).
Airtronic D4 / D4+
Fuel starts to be delivered after approx.
60 seconds.
The fuel-air mixture in the combustion
chamber ignites. Once the combi-sensor
(flame sensor) has detected the flame, the
glow pin is switched off after 80 seconds.
The desired temperature is pre-selected with
the operating controls. Depending on the
temperature selected, on the size of the room
to be heated, and on the prevailing outdoor
temperature. This value may range between
+10 °C and +30 °C. The control switch setting
to be selected is an experimental value.
Control in Heating Mode
In heating mode the room temperature and the
temperature of the heating air is continuously
measured.
Control commences if the temperature
exceeds the temperature pre-selected on the
control element.
4 control levels have been provided so
that the heat flow supplied by the heater
can be accurately adapted to the heating
requirements. Each control setting has its own
fan speed and fuel quantity. If the adjusted
temperature is ever exceeded at the lowest
control level then the Airtronic is adjusted to
the ‘OFF’ control level and the fan will continue
to run for approx. 240 seconds to allow the
heater to cool down.
Afterwards the fan will continue to run at the
slowest speed (re-circulation mode) or will be
switched off (fresh air mode) until a renewed
start of the heater.
The Airtronic is in the control mode.
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Fan Only Mode Ventilation
(Optional)
To start the Airtronic in fan mode, the changeover switch ‘heating/ventilating’ needs to be
actuated first before the heater is switched on.
Switching Off
As soon as the Airtronic is switched off the
pilot lamps go out and fuel pump is switched
off. The fan will continue to run for approx. 240
seconds to cool down the heater.
For cleaning, the glow pin is switched ON for
40 seconds while the fan is still running.
Heating Operation at High
Altitudes
Up to 1500 m
Unrestricted heating operation is possible.
Above 1500 m
Heating operation is in principle possible for
short periods when crossing a mountain pass
or during a brief stop at high altitude.
In case of extended stays (e.g. winter
camping) the fuel supply has to be adapted to
the high altitude conditions. Please consult the
responsible regional sales agency.
Page 18
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Sectional Drawing Airtronic D2 / D4 / D4+
1
Intake-air impeller.
2
Control unit.
3
Combustion air impeller.
4
Glow pin.
5Cover.
6
Heal exchanger.
7
Combi flame sensor /
overheating sensor.
8
Module clock.
9
Change-over switch heating /
ventilation optional.
10
Fuse carrier with main fuse and
switch fuse.
11
Electric motor.
12
Fuel connection.
13
Flange seal.
14
15
16
17
18
19
20
Combustion chamber.
Outlet hood
D2 = Ø 60/75 mm
D4 = Ø 75/90 mm.
Combustion air hose.
Fuel metering pump.
Filter built into the fuel pump.
Hot air outlet.
Flexible exhaust tube.
F
=
fresh air.
W
=
hot air.
A
=
exhaust gas.
B=fuel.
V
=
combustion air.
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Controls and Safety Devices
If the Airtronic does not ignite within
90 seconds after the fuel pump has started,
then the start is repeated in the manner
described. A malfunction cut-off is effected
if after a further 90 seconds of fuel pumping
the Airtronic once again fails to ignite, i.e.
fuel pump switches off and the blower motor
continues to run for approx. 240 seconds.
If the flame extinguishes by itself during
operation, a renewed start is carried out first.
If the Airtronic fails to ignite within 90 seconds
after fuel pumping has started again or if it
does ignite but then extinguishes itself within
the next 15 minutes, a malfunction cut-off is
effected, i.e. fuel pump switches off and the
blower motor continues to run for approx.
240 seconds.
It is possible to override a malfunction cutoff by briefly switching the heater off and on
again. Do not repeat this more than twice in
succession.
In the case of over-heating, the combi-sensor
will respond, the fuel supply will be interrupted
and a malfunction cut-off will be effected.
Once the cause of overheating has been
eliminated, the Airtronic can be restarted by
briefly switching it off and on again.
If the upper or lower voltage limit is reached,
a malfunction cut-off is effected after
20 seconds.
The speed of the fan motor is continuously
monitored. If the fan motor does not start
or if the speed deviates by more than
10%, a malfunction cut-off is effected after
30 seconds.
When switching off the Airtronic, the glow pin
is switched on for 40 seconds while the fan
motor is running to clean it of any combustion
residues.
In the Event of Malfunction, Check the
Following Points
If the Airtronic does not start when it is
switched on:
Switch off the Airtronic and then switch it
back on again, but no more than twice in
succession.
If the Airtronic still does not start, then check:
Is there fuel in the tank?
Have any fuses blown?
Airtronic 12 V - main fuse 20 A;
Airtronic 24 V - main fuse 10 A;
Airtronic 12/24 V - control fuse 5 A.
Are all electric wires and connections ok?
Are the heating-air duct, combustion air hose
or the exhaust-gas tube blocked?
The Airtronic will not start if the glow pin or
blower motor is defective or if the electrical line
to the fuel pump is interrupted.
If the Airtronic unintentionally remains in
‘ventilating’ mode after it is switched on, the
control element has to be checked for a short
circuit.
In the case of defective temperature-sensor
or interruption in the electric wire, the Airtronic
does not start and the malfunction shutdown
then takes place.
If these points are OK, then proceed with a
diagnosis test using the JE diagnosis unit
or either the 701 or 801 controller, which
incorporates fault code display.
Page 20
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br 2.5
1.5 rt
0.5 bl / ws
0.5 gr / rt
0.5 br / ws
1 gn / rt
0.5 ge
1.5 br
0.5 sw / gr
0.5 rs
0.5 bl / sw
0.5 bl
0.5 gr
Circuit Diagram - Airtronic D2 / D4
Heaters supplied with short optional loom
rt 0.5
ge 0.5
gr 0.5
sw/rt 0.5
br 0.5
bl/ws 0.5
gr/rt 0.5
br/ws 0.5
2.2
gn
br
gn/rt 1.0
br 1.0
1
2
3
4
5
6
7
8
gr 0.5
br 0.5
8 way
Housing
2
1
3.19
2.7
2.7.1
1.1
1.2
1.5
2.1
2.2
Blower Motor.
Glow Pin.
Combi flame sensor/overheating sensor.
Electronic Control Unit (ECU).
Fuel Metering Pump.
2.7
Main fuse 20A- 12v, 10A- 24v.
2.7.1 Switch Fuse 5A.
2.15.1 External Temperature Sensor (Optional).
30
+
Parts List
31
-
4br
Fuse Blade Type- main fuse
10A For 24v System
20A For 12v System
4rt
1rt
2.7
4rt
Option plug
for external
temperature
sensor
5.1
3.1.7 Mini controller (22 1000 32 07 00).
3.1.8 Modulator with vent (301 00 200).
3.1.11 Rheostat switch (Optional).
3.1.12 Modulator switch (Optional - 301 series).
3.2.8 DIN timer 7 day with temperature control
(Optional).
3.2.9 Timer / Modulator 7 day, (701 10 003 series).
3.2.10 Digital Modulator 801 Series.
5.1Battery.
Page 21
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Wiring Diagram for Control Switches
1 4 7 10
2 5 8 11
3 6 9 12
3.1.7
br/ws
8
8 way
Housing
TRS
rt
ge
a7
gr/rt
a8
br/ws
B2
DIAG
S2
rt
ge
rt
rt
ge
br
gr
gevi
3.1.
bl
B2
3.1.8
gr/rt
rt
ge
gr
2
3
AIRTRONIC
1
br/ws
gr/rt
S2
6 5 4 3 2 1
gr/rt
7
a1
a2
6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
rt
ge
br
bl/ws
1
2
5
6
3 2 1
3.2.8
rt
rt
ge
br
gr
gevi
bl
0
4
5
br/ws
3.1.8
3.2.9
rt
ge
1
2
5
6
7
gr/rt
2
bl/ws
4
gr/rt
8
br
3
bl/ws
rt
5
br/ws
ge
6
1 2 3
8 way
Housing
rt
ge
5
4
6
0
3
2
2
1
8 way
Housing
1
2
5
7
8
a8
br/ws
rt
ge
gr
0
AIRTRONIC
4
5
a6
a7
bl/ws
gr/rt
a8
1
2
Eberspächer
3
4
5
br/ws
6
D
8 way
Housing
1 2
3 4
5 6
6 way
Junior Power
Tab Housing
rt
ge
3.1.12
3.1.9
br/ws
gr/rt
1
br
3
a3
2
a8
4
6
T
Wiring Colour Codes
sw - black
3
3.2.10
a1
a2
a3
5
rt - red
br - brown
ws - white
2
1 2
8 way
Housing
1
10
0
9
br
gr/rt
br/ws
3
4
5
7
8
a7
gr/rt
1
4 5 6
3.1.11
1
2
rt
ge
gr
a1
a2
a3
1
gn - green
ge - yellow
gr - grey
bl - blue
2.15.1
8 way
Housing
a1
a2
a3
a4
a5
a6
a7
a8
Page 22
Supply to positive terminal 30.
Switch on signal S+.
External temperature sensor (Optional).
Fresh air blower integrated in vehicle
blower control (Optional).
Supply to negative terminal 31.
Fault diagnostic signal.
Nominal temperature rheostat signal.
Sensor reference signal.
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1.5 rt
br 2.5
1.5 br
0.5 bl / ws
0.5 gr / rt
0.5 br / ws
1 gn / rt
0.5 ge
0.5 sw / gr
0.5 rs
0.5 bl / sw
0.5 bl
0.5 gr
Circuit Diagram - Airtronic D2 / D4 / D4+
Heaters Supplied with Long Optional Loom
rt 0.5
ge 0.5
gr 0.5
2.2
gn
br
gn/rt 1.0
br 1.0
a1
a2
br 0.5
bl/ws 0.5
gr/rt 0.5
br/ws 0.5
a5
a7
a8
sw/ws
sw/rt
ws/rt
1rt
a1
2
3
4
5
6
2.7
30
5.1
Fuse Blade Type- main fuse
10A For 24v System
20A For 12v System
Blower Motor.
Glow Pin.
Combi flame sensor /
overheating sensor.
Electronic Control Unit (ECU).
Fuel Metering Pump.
Main fuse 20A- 12v, 10A- 24v.
Switch Fuse 5A.
External Temperature Sensor (Optional).
7 8
b1 a3 a5 a6 c1 b2
4rt
4rt
-
+
1.1
1.2
1.5
2.1
2.2
2.7
2.7.1
2.15.1
4br
31
Parts List
1
2.7
2.7.1
8 way Housing
Diagnostic Test
Plug and optional
correction
3.1.7
Mini controller (22 1000 32 07 00).
3.1.8
Modulator with vent (301 00 200).
3.1.11
Rheostat switch (Optional).
3.1.12 Modulator switch (Optional).
3.2.8
DIN timer 7 day with temperature control
(Optional).
3.2.9
Timer / Modulator 7 day, (701 10 003 series).
3.2.10 Digital Modulator 801 Series.
5.1Battery.
Page 23
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Wiring Diagram for Control Switches
1 4 7 10
2 5 8 11
3 6 9 12
a8
br/ws
8 way
Housing
rt
ge
a7
gr/rt
a8
br/ws
DIAG
B2
S2
rt
ge
rt
rt
ge
br
gr
gevi
3.1
bl
B2
3.1.8
rt
ge
gr
gr/rt
br/ws
gr/rt
S2
2
6 5 4 3 2 1
gr/rt
TRS
a1
a2
6 5 4 3 2 1
a7
3 2 1
rt
ge
br
bl/ws
12 11 10 9 8 7 6 5 4 3 2 1
a1
a2
a5
a6
3.1.7
3.2.8
3
AIRTRONIC
1
rt
rt
ge
br
gr
gevi
bl
0
4
5
br/ws
3.1.8
3.2.9
a1
a2
a5
a6
a7
a8
rt
ge
2
3
bl/ws
4
gr/rt
5
br/ws
6
gr/rt
br
bl/ws
rt
a7
gr/rt
a8
br/ws
ge
1 2 3
8 way
Housing
1
2
3
0
AIRTRONIC
4
5
4 5 6
3.1.11
rt
ge
a1
a2
5
4
6
3
4
0
10
3
2
2
1
8 way
Housing
a1
a2
a5
a7
a8
rt
ge
gr
a6
a7
bl/ws
gr/rt
3.2.10
1
2
a8
Eberspächer
3
4
5
br/ws
8 way
Housing
6
D
1 2
3 4
5 6
6 way
Junior Power
Tab Housing
rt
ge
3.1.12
3.1.9
br/ws
gr/rt
1
br
3
a3
4
a8
2
5
6
T
Wiring Colour Codes
rt - red
br - brown
ws - white
sw - black
a1
a2
a3
gn - green
ge - yellow
gr - grey
bl - blue
1 2
8 way
Housing
1
br
gr/rt
br/ws
0
9
a5
a7
a8
rt
ge
gr
a1
a2
a3
1
2.15.1
8 way
Housing
a1 Supply to positive terminal 30.
a2 Switch on signal S+.
a3 External temperature sensor
(Optional).
a5 Supply to negative terminal 31.
a6 Fault diagnostic signal.
a7 Nominal temperature rheostat
signal.
Page 24
a8 Sensor reference signal.
b1 Ignition + positive for TRS
(ADR/Pet Reg) heaters only
(Optional).
b2 Timer disconnect for TRS ADR/Pet Reg heater only.
c1 Optional fresh air blower
integrated in vehicle blower
control.
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Fuel at Low Temperatures
Supply from Separate Fuel Tank Only
The heater works on commercially available diesel fuel (to DIN EN590 specification). Adoption
of the fuel to normal winter temperatures is automatically allowed for by the oil refineries (winter
diesel). Difficulty could only arise in the event of an extreme drop in temperature (as it would also
for the engine - see the vehicle instruction manual).
To avoid such a possibility, if the heater is supplied from a separate fuel tank, the
following rules should be followed. At temperature above freezing (0oC or 32oF), any type of
diesel fuel or light fuel oil may be used. At temperatures below freezing, fuel oils will require the
appropriate additives.
If no special cold weather diesel fuel is available for low temperatures, mix kerosene, paraffin
or gasoline according to the adjacent table. A separate tank is available from the Eberspächer
dealer.
For use with Separate Fuel Tank Only
Temperature WinterAdditive
Diesel Oil
From
0ºC to -15ºC**
100%–
From
-15ºC to -25ºC
50%
50% kerosene or petrol
From
-25ºC to -40ºC
–
100% kerosene*
* or special winter diesel oils.
** or in accordance with fuel manufacturer’s specifications.
The fuel line and the fuel pump must be filled with new fuel by operation for 15 minutes.
Fuel Supply
Danger of fire and explosion!
Poisonous fumes!
Caution when handling fuel before filling up, and when working on the fuel supply switch off the
vehicles engine and the Airtronic heater.
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Operation with Bio-Diesel (FAME)
Airtronic
The heater is not approved for operation with bio-diesel fuel (FAME). Up to 10% bio-diesel fuel
(FAME) may be added.
Airtronic M
The diesel heater is approved for operation with bio-diesel fuel (FAME) according to
DIN EN 14 214.
Please Note:
Bio-diesel fuel (FAME) according to DIN EN 14 214:
• During the winter months is adapted to low temperatures from 0 °C to -20 °C.
•
The Flowability reduces at temperatures below 0 °C.
When using 100% bio-diesel, the heater should be operated twice a year with diesel fuel (in the
middle and at the end of a heating period) in order to burn off any possible bio-diesel residues
deposited. To do so, let the vehicle tank run almost empty and then fill with diesel fuel. While
running on this tank filling, switch the heater on 2 to 3 times for 30 minutes at a time at the
highest temperature setting.
When operating with diesel / bio-diesel mixtures of up to 50% bio-diesel, intermediate operation
with pure diesel fuel is not necessary.
Page 26
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Fault Diagnosis Using the 7 Day Timer
with Temperature Control (Optional)
Timer Module Display
Part. No. 22 1000 30 40 00
6
MO
F64
1
1
3
5
2
Clock time
Heating
Forwards
ϒC
3
4
2
4
6
5
Preset
Backwards
Display with fault indication
If the control unit detects a fault when the heater is switched on or while the heater is in
operation, the timer module indicates this by means of an F and as a 2-figure number within 15
seconds.
Reading on display, e.g. F64 (Current fault) and flashing heating symbol.
How to Enquire for Fault Memory in the Heater Control Unit Using
the Timer Module
The electronic control unit can store up to 5 faults which can be read out and displayed on the
timer module. The current fault is written to memory location F1.
Preceding faults are written to memory locations F2 – F5.
Fault Memory Enquiry
Press the
key - the heater is switched on - then press the
key, hold it down and press the
key within 2 seconds. The current error is now displayed by AF, i.e. AF 64.
The stored errors (i.e. F 64) can be called up using the
and
keys.
Page 27
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Lock Out of the Heater Control Unit can be Caused by
Overheat
The hardware limit for the overheat has been exceeded. Code 17 is shown. If
switched on again code 15 is displayed. The control unit is locked out.
Cancelling the Control Unit Lock Out, and/or Erasing the Fault
Memory
Note: This can only be operated providing that the electrical connection from ignition to the timer
module (12-pin connector) terminal 10 is connected.
To Cancel Control Unit Lock Out
Turn on the ignition.
Press
key - the current fault is displayed (i.e. F15 / F50)
- then press the
key within 2 seconds.
key, hold it down and press the
The timer module is now in the “Enquire fault memory” program.
Now Proceed as Follows
Turn off the ignition.
and
simultaneously, switch on the ignition and wait until the following reading
Press keys
appears on the display.
Reading on display after switching ignition “ON”.
Display flashing, heating symbol not flashing.
The control unit lock out is cancelled after 3 seconds, then the heater will start up. Providing
there are no further faults with the heater.
Reading on display after heater has started.
Display: No current fault.
Heating now operational.
Note: For diagnostic wiring connections (i.e.: blue/white wire) see pages 21 and 23.
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Recommended Service Schedule Airtronic D2 / D4 / D4+
Every
Month
Every 6
Months
Every Year
(each September)
1. Remove glow pin and inspect for carbon build up. Clean
and/or replace.
2. Replace fuel screen in glow pin port with special tool
supplied with new screen.
3. Check for blocked or damaged ducting and rectify or
replace as required.
4. Inspect intake and outlet grilles for blockages; also
inspect intake fan blades for any restriction.
5. Check electrical connections, including main fuse
holders, for corrosion.
6. Check for blocked or damaged exhaust tube.
7. Check for blocked or damaged combustion air tube.
8. Test fire heater and check for correct operation
9. Check exhaust colour as a guide for carbon build up.
10. Check heater delayed shut down time, (approximately
240 seconds after switching off).
11. Check all fuel lines and connections for security and
abutments; also ensure there are no fuel leaks.
12. Remove fuel metering pump filter and replace.
13. Remove all dirt and corrosion from fuel metering pump.
14. Check fuel metering pump for correct delivery of fuel
as shown in the Airtronic D2/D4 Troubleshooting and
Repair Manual. (Service station only).
Important: Please note the heat exchanger must be
replaced after 10 years of service.
Note: It is advisable that the 6 month/annual service is
carried out by an approved Eberspächer Agent.
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Safety Instructions Concerning the
Installation and Repair of the Airtronic
Danger of Burns and Injury!
Before commencing any work on the Airtronic, disconnect the vehicle battery.
The Airtronic may only be started up if the top cover and the hood have been mounted in
accordance with the regulations and if the air duct on the suction and heating air side has also
been carried out in accordance with the regulations.
During operation the top cover must not be opened and hot parts must not be touched.
Important Instructions for the Installation and Repair of the
Airtronic
When installing, servicing, and mounting or repairing the heater, only original spare parts must
be used.
Changes to the Airtronic or to components relevant to the heating are not approved by
Eberspächer. This includes air and exhaust systems.
Only the control elements provided and / or approved by Eberspächer, either on their own or in a
given combination, may be used to operate the Airtronic. The use of other control elements may
lead to malfunctions of the heater / heating.
Operation
Non-compliance with the statutory, safety and / or function specifications may lead to the lapse
of the General Design Certification (ABG) of the Airtronic and also to the exclusion of guarantee
and liability on the part of the company J. Eberspächer GmbH & Co.
Page 30
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Important Information
Caution
•
Switch off heater before refuelling.
•
Do not cover heater in such a way as to block inlet or outlet air ducts.
•
Never operate the heater in confined spaces (i.e. garages).
•
Every combustion process generates exhaust gas, which has toxic constituents, because
of this and high temperatures generated, the exhaust pipe must comply with the
installation instruction.
•
Failure to comply with the instruction or operation of the heater in confined spaces
(i.e. garages) harbours the risk of poisoning.
•
The heater may only be used for the purpose specified by the manufacturer and in
compliance with the operating instructions supplied with every heater.
•
Operating the heater is not permitted when inflammable vapours or dust can build up,
e.g. near fuel, coal or sawdust stores, grain silos, granaries etc.
•
Switch off heater and wait for blower fan to stop before isolating batteries.
•
When the heater or the heating system is damaged, an authorised workshop must be
called in to repair the damage using genuine spare parts.
•
When carrying out electric welding work on the vehicle, disconnect the positive terminal
from the battery and earth it in order to protect the control unit.
•
Do not place aerosol cans, gas canisters, alcohol, inflammable liquids or inflammable
materials in front of the heater or hot air outlets.
•
Prior to entering flood or standing water, please switch off heater and wait 240 seconds
for heater to stop.
Page 31
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Eberspächer (UK) Ltd
Headlands Business Park
Salisbury Road, Ringwood
Hampshire BH24 3PB
Tel: +44 (0)1425 480151
Fax: +44 (0)1425 480152
enquiries@eberspaecher.com
www.eberspacher.com
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