INSTALLATION RECOMMENDATION

Technical Description

Repair Instructions
V e h i c l e He at e r s | T e c h n i cal D oc u m e n tat i o n EN

Parts list
T ech ni cal de scr iption
H ydroni c II Comfort

The technical description, installation, operating and

maintenance instruction is valid for the following
engine-independent water-heaters:

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

A WORLD OF COMFORT
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

Contents

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
4 | Vehicle Heaters Technical Documentation

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
 Vehicle Heaters Technical Documentation | 5

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.
6 | Vehicle Heaters Technical Documentation

1 Introduction

Special test structure, presentation and picture symbols Important information before starting work

Special text formats and picture symbols are used in these instructions Range of application of the heater
to emphasise different situations and subjects. Please refer to the fol- The water heater operating independently of an engine is intended for
lowing examples for their meanings and appropriate action. installation in the following vehicles:
All kinds of vehicles
Special text formats and presentations
Construction machinery
This dot () indicates a list, which is introduced by a heading.
Agricultural machinery
If an indented dash () follows a dot, this list is a sub-section of
Boats, ships and yachts
the black dot.

Underlined blue text denotes a cross-reference, which can be clicked Please note!
in the PDF format. The part of the document named in the text is then The heater cannot be installed in vehicles used for the transport of
displayed. dangerous goods according to ADR.

Picture symbols
Intended purpose of the heater (via the vehicle's own heat
Regulation! exchanger)
This information points out a statutory regulation. Pre-heating, de-misting windows
Failure to comply with this regulation results in expiry of the type- Heating and keeping the following warm:
approval for the heater and preclusion of any guarantee and liability Driver and working cabs
claims on Eberspcher Climate Control Systems GmbH & Co. KG. Freight compartments
Ship's cabins
Danger! Passenger and crew compartments
This information points out a potential serious or fatal danger. Ignoring Vehicle engines and units
this information can result in severe injuries.
On account of its functional purpose, the heater is not approved for the
This arrow indicates the appropriate precaution to take to avert the
following applications:
danger.
Long-term continuous operation, e.g. for pre-heating and heating of:

Important! Residential rooms

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.
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.
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.
Only use the heater for the stipulated purpose and in the permitted
range of application.
 Vehicle Heaters Technical Documentation | 7

1 Introduction

Statutory regulations Fuel supply

The fuel filler neck must not be located in the passenger compart-
The Federal Motor Transport Authority has issued an approval for a
ment and must be sealed with a properly closing cover to prevent
component according to ECE R122 and ECE-R10 for the heater for
any fuel leaks.
installation in motor vehicles, with the following official type-approval
In heaters for liquid fuel where the heater fuel supply is separate
markings noted on the heater's nameplate.
from the vehicle fuel supply, the type of fuel and filler neck must
Heater type: ECE type approval mark: be clearly marked.
A warning sign is to be attached to the filler neck informing that
Hydronic II 122 R 000275
the heater must be switched off before refuelling.
10 R 045886
Exhaust system
Regulation! The exhaust outlet must be arranged so as to prevent any penetra-
Excerpt from ECE regulation No. 122 of the European Par- tion of exhaust fumes into the vehicle interior through the ventila-
liament and the Council tion system, warm air intakes or open windows.

Combustion air intake

General regulations The air for the heater's combustion chamber must not be sucked
Operating state display in from the vehicle's passenger compartment.
A clearly visible operating display in the user's field of vision must The air intake must be arranged or protected in such a way that it
indicate when the heater is switched on and off. cannot be blocked by other objects.

Automatic control of the heating system

Regulations concerning installation in the vehicle
If the engine fails, the heating system must be automatically
Scope
switched off and the fuel supply stopped within 5 seconds. The
Subject to differing stipulations in the following section, combus-
heater may remain in operation if a manual device has already
tion heaters must be installed according to the regulations 5.3 of
been activated.
ECE-R122.
It is assumed that Class O vehicles with heaters for liquid fuel con- Please note!
form to the regulations 5.3 of ECE-R122. The heater is not approved for installation in the driver's cab or pas-
Arrangement of the heater senger compartment of Class M1 vehicles (vehicles for passenger trans-
Parts of the structure and other components near the heater must port / cars) and N vehicles (vehicles for the transport of goods).
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.
8 | Vehicle Heaters Technical Documentation
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
Eberspcher 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!
Disconnect the vehicle battery before starting any kind of work.
Before working on the heater, switch the heater off and let all hot
parts cool down.
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!
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.
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.
The following measures are not allowed:
Changes to components relevant to the heater.
Use of third-party components not approved by Eberspcher
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.
Only original accessories and original spare parts must be used
during installation or repairs.
Only control units approved by Eberspcher may be used to operate
the heater.
Use of other control units can cause malfunctions.
Before the heater is installed again in another vehicle, rinse the
heater parts carrying water with clear water.
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.
 Vehicle Heaters Technical Documentation | 9

1 Introduction

Defective fuses must only be replaced by fuses with the prescribed

rating.
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.
The heater must be switched off when refuelling.
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.
If fuel leaks from the heater fuel system, arrange for the damage to
be repaired immediately by a JE service partner.
Use only anti-freeze products approved by the vehicle manufacturer
to top-up; please refer to the vehicles operating manual.
Any blending with unapproved anti-freeze can cause damage to the
engine and heater.
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.
10 | Vehicle Heaters Technical Documentation

2 Product In formation

Order No. and scope of supply Figure No. Designation

26 Non-return valve
Petrol heater
27 Blanking element
Figure No. Designation Order No.
1 B 5 SC 12 V 20 1928 05 00 00 Parts which, if required, must be ordered separately

Heater scope of supply see Fig. Page 11 Quantity Designation Order No.
1 Fuel filter 25 1226 89 00 37
Figure No. Designation
2 Adapters for the fuel filter 25 1888 80 01 02
3 Metering pump
1 Pressure reducer 22 1000 20 08 00
4 Lead harness, metering pump
1 Fuel lines kit for E85 22 1000 20 31 00
5 Pipe, 4 x 1, 2 m long, blue
To be purchased from the trade:
6 Pipe, 4 x 1.25, 4 m long, transparent
Solenoid valve, 2/2 way
7 Housing, 2 pin

Connection cables / Cable looms see Fig. Page 11

Diesel heater A Connection, control units
Figure No. Designation Order No. B Plus supply connection, fan relay
2 D 5 SC 12 V 25 2598 05 00 00 C Activation, vehicle fan
D Minus supply connection
Heater scope of supply see Fig. Page 11
E Connection to terminal 85 (1-pin, BN)
Figure No. Designation F Connection to terminal 86 (1-pin, RDBK)
7 Housing, 2-pin, with filler plug G Diagnosis query plug connection
8 Pipe, 4 x 1, 5 m long, blue H Plus supply connection

To be ordered separately: Please note!

Quantity Designation Order No. Items 3 6 shown in the scope of supply sketch are only intended
1 Installation kit 25 2598 80 00 00 for the petrol heater and Item 8 is only for the diesel heater. Item 7 is
1 Control unit * required for the petrol heater to connect the Metering pump cable
loom to the Heater cable harness. For the diesel heater, Item 7
* For control unit see price list or Product Information document.
must be installed on the Heater cable harness as a seal protection.
Installation scope of supply see Fig. Page 11 An inlet pressure resistant metering pump up to 2.0 bar is installed
in the D 5 SC heater, see page 27.
Figure No. Designation
If the B 5 SC heater is to be run with E85 ethanol fuel (EN 15 293),
9 Exhaust silencer
the fuel lines for E85 kit is required.
10 Cable harness, heater
Parts without a figure no. are small parts and are packed in a bag.
11 Bracket, heater
12 Water hose The self-tapping screws included in the Installation kit scope of
13 Flexible exhaust pipe, 900 mm long supply can be used for a sheet metal thickness of 26mm (tighten-
14 Flexible exhaust pipe end, 300 mm long ing torque 9+1 Nm).
15 Z-bracket, exhaust silencer Please refer to the Product Information document if any other parts
16 L-bracket, exhaust silencer are required for the installation.
17 Bracket, metering pump
18 Combustion air hose, 760 mm long
19 Elbow, 105
20 Adapter, 7.5 / 3.5
21 Combined bracket
22 Lead harness, fan
23 Relay for fan
24 Tank connection
25 Screw, M6 x 15
 Vehicle Heaters Technical Documentation | 11

2 Product In formation

Scope of supply heater and installation kit

19
26
11
2
25

12 1

27

14

18
13
9

3
16 8 4
17

7
15
10
5

20 23
21

22
24
12 | Vehicle Heaters Technical Documentation

2 Product In formation

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:
10.5 V
An undervoltage protection installed in the control box switches off
the heater if the lower voltage limit is reached.
Upper voltage limit:
An overvoltage protection installed in the control box switches off the 16 V
heater if the upper voltage limit is reached.
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 Without operation
Heater, continuous 40 C to +60 C 40 C to +105 C
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! Please note!

Operating the heater outside the specified technical data can cause If no limit values are given, the technical data listed is with the usual
malfunctions. heater tolerances of 10 % at nominal voltage and Esslingen reference
The technical data must be complied with at all times. altitude.
 Vehicle Heaters Technical Documentation | 13

2 Product In formation

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:
10.5 V
An undervoltage protection installed in the control box switches off
the heater if the lower voltage limit is reached.
Upper voltage limit:
An overvoltage protection installed in the control box switches off the 16 V
heater if the upper voltage limit is reached.
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 Without operation
Heater, continuous 40 C to +80 C 40 C to +105 C
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! Please note!

Operating the heater outside the specified technical data can cause If no limit values are given, the technical data listed is with the usual
malfunctions. heater tolerances of 10 % at nominal voltage and Esslingen reference
The technical data must be complied with at all times. altitude.
14 | Vehicle Heaters Technical Documentation

2 Product In formation

Main dimensions of petrol heater

113 86

WA / WE WA
WE B
184

5
39 39
16

21,5
20 A V
24
90 149
20

20
A Exhaust
B Fuel
V Combustion air
20

WA Water discharge
WE Water inlet 262

Main dimensions of diesel heater

113 86

WA / WE WA

WE

B
184

5
39 39
16

21,5

20 A V
24
90
149
20

20

A Exhaust
B Fuel
V Combustion air
20

WA Water discharge
WE Water inlet 262
 Vehicle Heaters Technical Documentation | 15

2 Product In formation

Installation location
Please note!
The heater is installed in the engine compartment.
Note and follow the relevant safety instructions from page 8.
The heater must be installed below the min. cooling water level (header
The installation suggestions made in the installation instructions are
tank, radiator, vehicle's heat exchanger) so that the heat exchanger of
examples.
the heater and water pump can independently vent.
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

1 Heater
2 Exhaust pipe
3 Exhaust silencer
4 Exhaust pipe end
5 Combustion air hose
8 6 Fan relay
6 7
7 Fuse bracket
10
1 8 Control unit
12
5 11 9 Metering pump
9
2 4 10 Tank connection
3
11 Pressure line
12 Intake line

Installation example: Diesel heater in a transporter

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
6 7 8 9 Tank connection
10 Intake line
9

1 10
5
2
4
3
16 | Vehicle Heaters Technical Documentation

2 Product In formation

Permissible installation positions Heater for diesel fuel

The heater should preferably be installed in the normal position. 3
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.
max. 90
Please note!
1
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 2

Heater for petrol and diesel fuel
The upright (normal position) installation position with swivel range up 3
to the vertical installation position is allowed.
1 Horizontal installation position 3 Water connection
All installation positions between 0 and 90are permitted.
2 Vertical installation position
Heater for bioethanol fuel
The upright installation position (normal position) and the vertical in- Installation position heater upright / on its side
stallation position are permissible. Heater for petrol and diesel fuel
All installation positions between 0 and 90are not permitted. The upright installation position (normal position) with swivel range up
to the horizontal (heater on its side) installation position is permissible.
Please note! All installation positions between 0 and 90are permitted.
In the vertical installation position two water connection sockets (3)
Heater for bioethanol fuel
point downwards.
The upright installation position (normal position) is permissible. The
horizontal installation position and the installation positions between
Heater for petrol and ethanol fuel
0 and 90 are not allowed.
3
Please note!
If a heater is swivelled out of the normal position, the water connection
sockets (3) must always be at the top.

max. 90
Heater for petrol and ethanol fuel
1 3

1
2
2
3
3 max. 90

1 Upright installation position 3 Water connection socket

2 Vertical installation position
1 Upright installation position 3 Water connection socket
2 Horizontal installation position
 Vehicle Heaters Technical Documentation | 17

3 Installation

Heater for diesel fuel, horizontal installation position 2. Screw special screw M6 x 17 onto the heater.
Mount special screw M6 x 17 (with adhesive coating) on the heater, on
3
the right or left-hand side (torque: 6+2 Nm).

2
max. 90 3

1 Upright installation position 3 Water connection

2 Horizontal installation position 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).

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

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 Nameplate

Please note!
Note and observe the relevant regulations on page 7.
18 | Vehicle Heaters Technical Documentation
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.
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.
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.
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
2hours 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.
 Vehicle Heaters Technical Documentation | 19

3 Installation

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 4
the blanking element onto the water connection socket. For correct fit, 1
3
the inner groove (a) of the blanking element must be guided over the
lug (b) on the water connection socket.
2
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 Heater 3 Vehicle engine
a b 2 Heat exchanger 4 Blanking element
3.

1.
Connection to the coolant fluid circuit, Comfort instal-
2. lation variant

Arrangement of the water connection sockets at the heater

When connecting the water hoses for the Comfort installation variant,
Please note! always ensure that the water hoses are connected to the correct water
After installing the blanking element and initial commissioning of the connection sockets of the heater.
heater, the precise fit and leaktightness of the blanking element must
be checked.
C A
The blanking element is included in the installation kit scope of
supply.

Connection to the coolant fluid circuit, Inline installa-

tion variant
B
Integrate the heater in the water flow hose from the vehicle
A Connection socket, C Connection socket,
engine to the heat exchanger
water outlet water inlet / outlet
Cut the water flow hose from the vehicle engine to the vehicle's heat B Connection socket, water inlet
exchanger.
Use connectors and water hoses to connect the heater to the water Please note!
flow hose. The arrows on the water connection socket indicate the basic flow
direction. Depending on the setup of the coolant liquid circuit, an op-
Heating characteristics
posite flow direction is also possible at connection socket 3.
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.
20 | Vehicle Heaters Technical Documentation

3 Installation

Connection to the coolant fluid circuit, Comfort Heating characteristic in auxiliary heater mode
installation variant heater on / vehicle engine on

Integrate the heater and non-return valve in the coolant If the vehicle engine is running, the coolant liquid is uniformly distrib-

liquid circuit
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.
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.

Cut the water return hose from the heat exchanger to the vehicle en- C A
gine. Insert the non-return valve in the water return hose and use a B 1
4
water hose to connect it to the heater.

Heating characteristic in parking heater mode 2

heater on / vehicle engine off 3

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 Heater 3 Non-return valve
2 Heat exchanger 4 Vehicle engine

C A
Integrate the heater, T-piece or non-return valve and sole-
B 1 noid valve in the coolant liquid circuit
4
Thermostatically controlled coolant liquid circuit with
2 priority heating of the vehicle engine
3 Cut the water flow hose from the vehicle engine to the vehicle's heat
exchanger and insert a T-piece or the non-return valve. Use a water
1 Heater 3 Non-return valve hose to connect the heater to the T-piece.
2 Heat exchanger 4 Vehicle engine 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-
From a coolant liquid temperature of approx 67 C, part of the coolant
hicle engine and insert the heater.
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 Heating characteristic in parking heater mode
for interior heating. heater on / vehicle engine off
Initially, up to a temperature of 67 C, the coolant liquid is only fed to
C A the vehicle engine quick heating up of the vehicle engine.

1
4 B
4

2
3 2 3 5

C A
1 Heater 3 Non-return valve
B
2 Heat exchanger 4 Vehicle engine 1

See page 21 for key

 Vehicle Heaters Technical Documentation | 21

3 Installation

1 Heater 4 T-piece or non-return valve Exhaust system

2 Vehicle engine 5 Heat exchanger

Danger!
3 Solenoid valve, 2/2 way,
Risk of injuries and burns!
normally open
Every type of combustion produces high temperatures and toxic ex-
haust fumes. This is why the exhaust system must be routed according
From a coolant liquid temperature of approx 67 C, part of the cool-
to these installation instructions.
ant liquid is also fed to the vehicle's heat exchanger. This causes slow
Do not perform any work on the exhaust system while the heater is
heating of the vehicle interior, without rapid cooling of the small cool-
working.
ant liquid circuit for the engine heating.
Before working on the exhaust system, switch off the heater first
and wait until all the parts have completely cooled down, wear
4 safety gloves if necessary.
Do not inhale exhaust fumes.
2 3 5
Important!
C A
The whole exhaust system gets very hot while the heater is running and
B
immediately afterwards. This is why the exhaust system must be routed
1
according to these installation instructions.
The exhaust pipe must end in the open air.
1 Heater 4 T-piece or non-return valve The exhaust pipe may not protrude beyond the lateral limits of the
2 Vehicle engine 5 Heat exchanger vehicle.
3 Solenoid valve, 2/2 way, Lay the exhaust pipe sloping slightly downwards. If necessary,
normally open make a drain hole with approx. 5mm at the lowest point as a
condensation outlet.
Heating characteristic in auxiliary heater mode Important functional parts of the vehicle may not be impaired
heater on / vehicle engine on (maintain sufficient clearance).
Mount the exhaust pipe with sufficient clearance to heat-sensitive
When the vehicle engine is running the solenoid valve is controlled
parts. Pay particular attention to fuel lines (made of plastic or
via D+ and closes the small coolant liquid circuit. The coolant liquid
metal), electrical cables and brake hoses, etc.!
is uniformly distributed to the heat exchanger and vehicle engine in
Exhaust pipes must be safely fixed (recommended clearance of
a large coolant liquid circuit. This causes accelerated heating up of
approx. 50 cm) to avoid damage from vibrations.
the vehicle interior and shortens the warming up phase of the vehicle
Lay the exhaust system so that the outflowing exhaust gases are
engine.
not sucked in as combustion air.
The mouth of the exhaust pipe must not become clogged with dirt
4 and snow.
The mouth of the exhaust pipe must not point in the direction of
2 3 5 travel.
Always fix the exhaust silencer to the vehicle.
C A Lay the exhaust system so that the exhaust fumes do not flow
B directly onto heat-sensitive components.
1

1 Heater 4 T-piece or non-return valve

2 Vehicle engine 5 Heat exchanger
3 Solenoid valve, 2/2 way,
normally open
22 | Vehicle Heaters Technical Documentation

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 24 mm,

900 mm long, a flexible exhaust pipe end with end sleeve, inner
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+0.5Nm), 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+0.5Nm).
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- Various options for fixing the Z bracket to the exhaust silencer (tight-
ing torque: 6+0.5 Nm) ening torque: 6+0.5 Nm)
 Vehicle Heaters Technical Documentation | 23

3 Installation

Exhaust and combustion air system

min. 150 mm

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

1 Heater 4 Exhaust silencer

2 Combustion air hose 5 Exhaust pipe end with end sleeve
3 Flexible exhaust pipe 6 Spacer ring

Combustion air system Installing the combustion air system

Important!
Safety instructions for the combustion air system
The combustion air opening must remain free at all times.
Lay the combustion air intake to ensure that exhaust fumes cannot
be sucked in as combustion air.
Do not direct the combustion air intake against the vehicle's air-
stream.
The combustion air intake must not become clogged with dirt and
snow.
Install the combustion air intake system sloping slightly down-
wards. If necessary, make a drain hole approx. 5 mm at the low-
est point to drain off condensation.
If necessary, use fastening clips or cable ties to fix the flexible
combustion air hose to the vehicle in suitable places.
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.
24 | Vehicle Heaters Technical Documentation

3 Installation

Fuel supply Install metering pump (only for petrol heater) and lay the
fuel lines
Danger!
Risk of fire, explosion, poisoning and injuries! Always note and follow the safety instructions when installing the me-
Caution when handling fuel. tering pump (only for petrol heater) and when laying the fuel lines.
Switch off the vehicle engine and the heater before refuelling and Deviations from the instructions stated here are not allowed. Failure to
before working on the fuel supply. comply can result in malfunctions.
Avoid naked flames when handling fuel.
Important!
Do not smoke.
Safety instructions for fuel lines and fuel tanks in buses and coaches!
Do not inhale petrol fumes.
In buses and coaches, fuel lines and fuel tanks must not be routed
Avoid any contact with the skin.
through the passenger compartment or driver's cab.
Fuel tanks in buses and coaches must be positioned in such a way
Important! that the exits are not in immediate danger if a fire occurs.
Safety instructions for laying the fuel lines!
Use a sharp knife only to trim the fuel hoses and pipes. Interfaces Please note!
must not be crushed and must be free of burrs. The installation kit contains all parts required for the fuel supply.
Wherever possible, lay the fuel lines from the metering pump to the Note and follow the regulations and safety instructions for this chap-
heater with a continuous rise. ter from page 7.
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.
Fuel lines must be protected against mechanical damage.
Lay the fuel lines so that any twisting of the vehicle, engine move-
ments, etc. do not have a disadvantageous effect on their durability.
Use hose clips to secure all hose connections in the fuel supply.
Parts carrying fuel must be protected from interfering heat.
Never route or fasten the fuel lines directly along the heater or ve-
hicle exhaust system.
When systems cross, always ensure there is a sufficient heat clear-
ance. If necessary, attach heat deflection plates.
Dripping or evaporating fuel must never be allowed to collect on
hot parts or ignite on electric equipment.
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
 Vehicle Heaters Technical Documentation | 25

3 Installation

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.
The fuel may only be pumped by the metering pump included in the
scope of supply and approved by the manufacturer.

2 6
5 7
1 8
7 5 4 3 6 7
7
7
7

5
a

1 Tank connection, di = 2 mm, da = 4 mm installed in the Permissible line lengths

vehicle's own tank fitting Intake side
2 Adapter, 7.5 / 3.5 mm connected to the vehicle's own tank a = max. 2 m
fitting, at a connection socket 8 mm, used to pass through the
Pressure side
intake line (fuel pipe 4 x 1) up to just before the bottom of the tank.
b = max. 6 m
3 Metering pump
4 Fuel filter only required for contaminated fuel
5 Fuel pipe, 4 x 1 (di = 2 mm, blue)
6 Fuel pipe, 4 x 1.25 (di = 1.5 mm, transparent)
7 Fuel hose, 3.5 x 3 (di = 3.5 mm), approx. 50 mm long
8 Elbow, 105

Please note!
Item (4) is not included in the installation kit scope of supply. Order If the B 5 SC heater is operated with E85 ethanol fuel, the fuel lines
No. see page 10. must be suitable for operation with E85, Order No. fuel lines for
Installation of the fuel filter Item (4) requires two adapters 5 / E85 kit see page 10.
3.5mm, Order No. see page 10. When installing tank connection Item (1), maintain a minimum dis-
Use two hose clips 11 to secure the adapter 7.5 / 3.5 mm, Item tance of 52mm from the end of the riser to the bottom of the tank.
(2).
26 | Vehicle Heaters Technical Documentation

3 Installation

Fuel supply petrol heater

Important! 2
Safety instructions for installing the metering pump!
Always install the metering pump with the delivery side rising up- 1
wards minimum angle 15.
Protect the metering pump and filter from impermissible heating
(max. 20 C), do not install near to silencers and exhaust pipes.
a
c
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 Connection at the heater

2 Max. fuel level
3 Min. fuel level

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.
 Vehicle Heaters Technical Documentation | 27

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!
To install the fuel hose at the heater, it must be moistened and care-
fully pushed onto the fuel connection socket.
It is not permitted to extract fuel downstream of the vehicle's own
fuel pump.
If using a T-piece in a plastic pipe, always insert support sleeves in
the plastic pipe.
Always insert the T-piece in the fuel return line
Connect the T-piece and the plastic pipe with the relevant fuel hoses
and secure with hose clips.
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.
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.
The vehicle must be delivered with an almost empty vehicle tank.
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.

2 1 3
7

4 4

5
6

1 Fuel return line from the vehicle's tank fitting Permissible line lengths
2 Fuel flow line from the vehicle's tank fitting Intake side
3 T-piece a = max. 5 m
4 Fuel hose, 3.5 x 3 (di = 3.5 mm), approx. 50 mm long
Installation position of the T-piece
5 Fuel filter only required for contaminated fuel
Use the installation positions shown when inserting the T-piece.
6 Fuel pipe, 4 x 1 (di = 2 mm, blue)
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.
1 Direction of flow to the fuel tank
2 Direction of flow from the vehicle engine
28 | Vehicle Heaters Technical Documentation

3 Installation

Fuel supply diesel heater

Fuel extraction with tank connection installed in the tank

fitting

1 2 3
2
4
a

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

2 Fuel hose, 3.5 x 3 (di = 3.5 mm), approx. 50 mm long Intake side
3 Fuel pipe, 4 x 1 (di = 2 mm, blue) a = max. 5 m
4 Fuel filter only required for contaminated fuel

Please note!
When installing tank connection Item (1), maintain a minimum dis-
tance of 52mm 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 5 /
3.5mm, Order No. see page 10.

Permissible suction and pressure head, diesel fuel

Pressure head from vehicle tank to heater:

2
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):
a
b = max. 400 mm

Please note!
Check tank ventilation.

1
b

1 Connection at the heater

2 Max. fuel level
3 Min. fuel level
 Vehicle Heaters Technical Documentation | 29

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 15minutes!

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.
30 | Vehicle Heaters Technical Documentation
4 Op eration an d fun ctio n
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.
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 70C 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 75C 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.
 Vehicle Heaters Technical Documentation | 31

4 Op eration an d fun ctio n

Control and safety devices

If the petrol heater does not ignite within 100 seconds of being Emergency stop EMERGENCY OFF

switched on or the diesel heater does not ignite within 70 seconds, If an emergency stop EMERGENCY OFF is necessary during

the start is repeated. operation, proceed as follows:

The heater is automatically shut down if, after three further start at- Switch the heater off at the control unit or

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

heater, the petrol heater fails to start within the preset safety period disconnect the heater from the battery.

(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.
32 | Vehicle Heaters Technical Documentation

5 Electrics

Heater wiring Parts list for circuit diagram, heater and cable loom

Important! -A7 Control box

Safety instructions for wiring the heater! -B1 Control / overheating sensor
The heater is to be connected up electrically according to the EMC -B3 Surface sensor
directives. EMC can be affected if the heater is not connected up cor- -B5 Flame sensor
rectly. For this reason, comply with the following instructions: -F1 Fuse, heater
Ensure that the insulation of electrical cables is not damages. -F2 Fuse, control unit
Avoid: -F3 Fuse, vehicle fan
chafing, kinking, jamming or exposure to heat. -Fx Fuse block, vehicle
Seal any connector chambers of watertight connectors not in use -HG Heater
with filler plugs to ensure they are dirt-proof and water-proof. -K1 Relay, vehicle fan
Electrical connections and negative connections must be free of -M1 Burner motor
corrosion and firmly connected. -M11 Water pump
Lubricate connections and ground connections outside the heater -R1 Glow plug
interior with contact grease. -S3 Vehicle fan
-S4 Vehicle fan
-XTR1 Disconnect cable
Please note!
Comply with the following when wiring the heater and the control unit: -Y1 Fuel metering pump
Electrical leads and components must be positioned in the vehicle so a to the cable harness connector XB2
that they can function perfectly under normal operating conditions b to the heater connector XS2
without impairment (e.g. due to heat exposure, moisture, etc.). c to the control unit
The following cable cross-section is to be used between the battery d Fan activation
and heater. e Auxiliary heating criterion
This ensures that the max. permissible voltage drop in the cables f Switch-on signal
does not exceed 0.5 V for 12 V rated voltage.
Please note!
Cable cross-section for a cable length (plus cable + minus cable) up
The 12 volt relay (-K1, from terminal 30 to terminal 87a) has a maxi-
to 6 m = cable cross-section 4 mm.
mum current carrying capacity of 40 A; i.e. the value of the vehicles
If the positive cable is to be connected to the fuse box (e.g. terminal
own fan fuse may not be more than 40 A. Circuit diagram see page
30), the vehicle's cable from the battery to the fuse box must also be
33,36.
included in the calculation for the total cable length and re-dimen-
sioned if necessary. Assignment of connector -XS2
Insulate unused cable ends. Cham- Cross- Colour Function
ber section
1 2.5 red Battery plus (positive) (terminal 30)
Battery minus (negative) (terminal
2 2.5 brown
31)
3 0.5 black/red Vehicle fan
4 1.0 green Metering pump Plus
5 0.5 blue/white JE diagnosis
6 0.5 blue Auxiliary heating criterion
7 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 black
BU blue YE yellow GN green
WH white VT violet BN brown
 Vehicle Heaters Technical Documentation | 33

5 Electrics

Circuit diagram, petrol heater

-HG
-A7

-M1 -
0,75 BN
M 14
0,75 BK
13
+ 0,5 VT
12
-XS2
0,6 (0,5) BK 2,5 RD 1
-B1 11
0,6 (0,5) BK 2,5 BN 2
10

1,0 BN 0,5 BKRD 3
9
1,0 GN 4
0,12 WH 0,5 WH
-B3 8 0,5 BUWH 5
0,12 WH 0,5 WH
7 0,5 BU 6 a

1,5 WH 0,5 YE 7
6
0,5 VT 8
5
1,0 BN 9
4
-R1 1,0 BNGN 10
1,5 BN
3
0,22 BN
-B5 2
0,22 BN
1

A B

-M11
A B
M
- +

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

34 | Vehicle Heaters Technical Documentation

5 Electrics

Circuit diagram, cable harness, petrol heater

Ign (+)
X:15
Bat (+)
X:30
-XTR1 -S3
-Fx 1
2
3

(-)
X:31
6,0 RD

4,0 BN

0,5 BN
0,5 RD
4,0 RD

1,5 RD

4,0 RD

c
0,5 BUWH
0,5 BN 1 3
2 2
-F1 -F2 -F3 3 1
0,5 RD
20A 5A 25A
-XB10 -XS10

0,5 RD
-XB2
1 2,5 RD
2 2,5 BN
3 0,5 BKRD 0,5 BKRD
d
4 0,75 GN
5 0,5 BUWH
b 6 0,5 BU
e
7 0,5 YE
f
8
9
10 0,75 BNGN

-XS3
2 1

-XB3
2 1
4,0 RDWH

0,5 BKRD
4,0 BKVT
0,75 BNGN

0,5 BN
4,0 BK
0,75 BN

-W1 -XB8 87 87a 30 +86 85

-XB4 2 1
-K1
-Y1 12V
2 1
12V

Parts list see page 32 25 2598 00 96 01 / 2

 Vehicle Heaters Technical Documentation | 35

5 Electrics

Circuit diagram, diesel heater

-HG
-A7

-M1 -
0,75 BN
M 14
0,75 BK
13
+ 0,5 VT
12
-XS2
0,6 (0,5) BK 2,5 RD 1
-B1 11
0,6 (0,5) BK 2,5 BN 2
10

1,0 BN 0,5 BKRD 3
9
1,0 GN 4
0,12 WH 0,5 WH
-B3 8 0,5 BUWH 5
0,12 WH 0,5 WH
7 0,5 BU 6 a

1,5 WH 0,5 YE 7
6
0,5 GN 0,5 VT 8
5
0,5 GN 1,0 BN 9
4
-R1 1,0 BNGN 10
1,5 BN
3
0,22 BN
-B5 2
0,22 BN
1

A B 1 2

-M11 -Y1
A B 12V 1 2

M
- +

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 / 3

36 | Vehicle Heaters Technical Documentation

5 Electrics

Circuit diagram, cable harness, diesel heater

Ign (+)
-X1:15
Bat (+)
-X1:30
-XTR1 -S3
-Fx 1
2
3

(-)
-X1:31
6,0 RD

4,0 BN

0,5 BN
0,5 RD
4,0 RD

1,5 RD

4,0 RD

c
0,5 BUWH
0,5 BN 1 3
2 2
-F1 -F2 -F3 3 1
0,5 RD
20A 5A 25A
-XB10 -XS10

0,5 RD
-XB2
1 2,5 RD
2 2,5 BN
3 0,5 BKRD 0,5 BKRD
d
4 0,75 GN
5 0,5 BUWH
b 6 0,5 BU
e
7 0,5 YE
f
8
9
10 0,75 BNGN

-XS3
2 3

-XB3
2 3
4,0 RDWH

0,5 BKRD
4,0 BKVT

0,5 BN
4,0 BK

-XB8 87 89 88 +86 1

-K1
12V

Parts list see page 32 25 2598 00 96 01 / 4

 Vehicle Heaters Technical Documentation | 37

5 Electrics

Connection diagram, auxiliary heater function

Variant 1: For EasyStart control units

T8
T1 T2 T1
0,5 BU
e D+
f T3

T7

0,5 YE
T4

T2

Variant 2: All control units except EasyStart

T5 T8

0,5 BU
e D+
f T3

0,5 YE
T6

T5

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)
38 | Vehicle Heaters Technical Documentation

5 Electrics

Circuit diagram, control unit EasyStart Timer

X:15
Ign (+)
X:58
Light (+)

-E3

-XB10 -XS10
0,5* RD 1 1 0,35 RD
0,5 GYBK 2 2 0,22 GYBK
c 0,5* BN 3 3 0,22 BN
0,5* BUWH 4 4 0,22 BUWH
5 5 0,22 VT
6 6 0,35 YE
7 7 0,22 BNYE
8 8 0,22 WHRD
0,22 BNWH 9 9 0,22 BNWH
-B8
0,22 GY 10 10 0,22 GY

-XB10 -XS10

22 1000 34 97 01

Parts list
-B8 Room temperature sensor (optional) Connectors and bush housings are shown from the cable inlet side.
-E3 EasyStart Timer
* Cable cross-section 0.75 mm Hydronic M II
c to the heater
Please note!
Further circuit diagrams for the EasyStart Timer are printed in the In-
stallation Instructions Plus, these are available to view and download
from the Service Portal.
 Vehicle Heaters Technical Documentation | 39

5 Electrics

Circuit diagram, control unit EasyStart Remote+

X:15
Ign (+)
X:58
Light (+)

-E5 -W2

-XB12
0,5* RD
1
2
c 0,5* BN
3
0,5* BUWH
4
5

-H2 0,22 RDYE

6
0,22 BNYE
7

0,22 BN
8
0,22 BNWH
-B8 9
0,22 GY
10

11
12

-XB12

22 1000 34 97 22

Parts list
-B8 Room temperature sensor Connectors and bush housings are shown from the cable inlet side.
-E5 Stationary unit EasyStart Remote+
* Cable cross-section 0.75 mm Hydronic M II
-H2 Button
-W2 Antenna Please note!
c to the heater Further circuit diagrams for the EasyStart Remote+ are printed in the
Installation Instructions Plus, these are available to view and download
from the Service Portal.
40 | Vehicle Heaters Technical Documentation

5 Electrics

Circuit diagram, control unit EasyStart Remote

X:15
Ign (+)
X:58
Light (+)

-E4 -W2

-XB12
0,5* RD
1
2
c 0,5* BN
3
0,5* BUWH
4
5

-H2 0,22 RDYE

6
0,22 BNYE
7

0,22 BN
8
9
10
11
12

-XB12

22 1000 34 97 33

Parts list
-E4 Stationary unit EasyStart Remote Connectors and bush housings are shown from the cable inlet side.
-H2 Button
* Cable cross-section 0.75 mm Hydronic M II
-W2 Antenna
c to the heater Please note!
Further circuit diagrams for the EasyStart Remote are printed in the
Installation Instructions Plus, these are available to view and download
from the Service Portal.
 Vehicle Heaters Technical Documentation | 41

5 Electrics

Circuit diagram, control unit EasyStart Select

X:15
Ign (+)
X:58
Light (+)

-E2

-XB4 -XS4
0,5* RD 1 1 0,35 RD
0,5 GYBK 2 2 0,35 GYBK
c 0,5* BN 3 3 0,35 BN
0,5* BUWH 4 4 0,35 BUWH

-XB4 -XS4
22 1000 34 97 34

Parts list
-E2 EasyStart Select Connectors and bush housings are shown from the cable inlet side.
c to the heater
* Cable cross-section 0.75 mm Hydronic M II

Please note!
Further circuit diagrams for the EasyStart Select are printed in the
Installation Instructions Plus, these are available to view and download
from the Service Portal.
42 | Vehicle Heaters Technical Documentation

5 Electrics

Circuit diagram, control unit EasyStart Call

X:15
Ign (+)
X:58
Light (+)

-E1 -W1

-XB12
0,5* RD
1
2
c 0,5* BN
3
0,5* BUWH
4
5

-H1 0,22 RDYE

6
0,22 BNYE
7

0,22 BN
8
0,22 BNWH
-B8 9
0,22 GY
10

11
12

-XB12
22 1000 34 97 18
Parts list
-B8 Room temperature sensor Connectors and bush housings are shown from the cable inlet side.
-E1 EasyStart Call
* Cable cross-section 0.75 mm Hydronic M II
-H1 Button
-W1 Antenna Please note!
c to the heater Further circuit diagrams for the EasyStart Call are printed in the Instal-
lation Instructions Plus, these are available to view and download from
the Service Portal.
 Vehicle Heaters Technical Documentation | 43

6 Tro uble shootin g / ma int ena nc e / s ervic e

If faults occur, please check the following items Service

If the heater does not start after being switched on: If you have any technical queries or problems with your pre-heater, dial
Switch the heater off and on again. the following service phone number from within Germany:

If the heater still does not start, check whether: Hotline

Fuel in the tank? Tel. 0800 / 12 34 300
The fuses are ok?
Fax hotline
The electrical cables, connections, terminals, are ok?
Tel. 01805 / 26 26 24
Anything is clogging the combustion air supply or exhaust system?
Outside of Germany, please contact the respective Eberspcher national
Please note! representative.
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
Eberspcher heaters.
Check the openings of the combustion air supply and exhaust system
after longer standstills, clean if necessary!
44 | Vehicle Heaters Technical Documentation

7 Envi ro nmen t

Certification EC Declaration of Conformity

The high quality of Eberspcher's products is the key to our success. The manufacturer:
To guarantee this quality, we have organised all work processes in the Eberspcher Climate Control Systems GmbH & Co. KG
company along the lines of quality management (QM).
Even so, we still carry out a large number of activities for continual im- Address:
provement of product quality in order to keep pace with the constantly Eberspcherstrae 24
growing requirements of our customers. D-73730 Esslingen
All the steps necessary for quality assurance are stipulated in interna-
tional standards. herewith declares that the following product:
This quality is to be considered in a total sense.
Product name Vehicle heater
It affects products, procedures and customer / supplier relationships.
Type Hydronic II
Officially approved public experts assess the system and the corre- Version B4S/B5S B 4 SC / B 5 SC
sponding certification company awards a certificate. D4S/D5S D 4 SC / D 5 SC
Eberspcher has already qualified for the following standards: E4S

Quality management in accordance with fulfils the requirements of the following EC Directives:
DIN EN ISO 9001:2008 and ISO/TS 16949:2009 a) Heating systems directive 2001/56/EC,
Revision status 2006/119/EC
Environmental management system in accordance with
b) Radio interference (EMC) of vehicles 72/245/EEC,
DIN EN ISO 14001:2004
Revision status 2009/19/EC
c) Heater control ECE-R 122,
Disposal Revision status 00
d) EMC of vehicles ECE-R 10,
Disposal of materials Revision status 03
Old devices, defect components and packaging material can all be
separated and sorted into pure-grade factions so that all parts can be The following EC Directives and UN regulations have been used to
disposed of as required in an environment-friendly manner recycled assess the product:
where applicable. 2001/56/EC; 72/245/EEC; ECE-R 122; ECE-R 10
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.
 Vehicle Heaters Technical Documentation | 45

8 L i sts

List of key words H

A Hazard information and safety instructions 8
Accident prevention 9 Heater installation position 16
Arrangement of the heater 7 Heater scope of supply 10
Automatic control 7 Heater wiring 32
Heating at high altitudes 30
B
Heating mode 30
Before switching on 30
Hotline 42
Biodiesel 29
I
C
Important information 6
Certification 43
Initial commissioning 30
Circuit diagram, cable harness, diesel heater 36
Installation 8
Circuit diagram, control unit EasyStart Call 41
Installation and fixing heater 17
Circuit diagram, control unit EasyStart R 39
Installation example 15
Circuit diagram, control unit EasyStart R+ 38
Installation kit scope of supply 10
Circuit diagram, control unit EasyStart T 40
Installation location 15
Circuit diagram, diesel heater 35
Installation position of the metering pump 26
Circuit diagram, petrol heater 33
Installation steps 17
Combustion air intake 7
Installing the combustion air system 23
Combustion air system 23
Installing the exhaust system 22
Concept of this manual 5
Instructions for operation 30
Control and safety devices 31
Introduction 5
Cooling water circuit 1821
M
D
Main heater dimensions 14
Dismantling the heater 43
Maintenance instructions 42
Disposal 43
Main water pump dimensions 14
Disposal of materials 43
Metering pump, install 24
E
N
EC Declaration of Conformity 43
Nameplate 17
Emergency shutdown EMERGENCY OFF 31
Emergency stop 31 O
EN 14 214 29 Operating instructions 30
Environmental management system 43 Operation 8
Exhaust silencer 22 Operation with biodiesel 29
Exhaust silencer, fasten 22 P
Exhaust system 7, 21 Packaging 43
F Parking heater mode 30
FAME 29 Parking ventilation 30
Faults 42 Parts list 32
Fax hotline 42 Permissible installation positions 16
Fuel lines, lay 24 Permissible line lengths 25, 27, 28
Fuel quality 29 Permissible suction and pressure head 26
Fuel quality for diesel heater 29 Picture symbols 6
Fuel quality for petrol heaters 29 Purpose 6
Fuel supply 7, 2427 Q
Fuel withdrawal with tank connection 25 Quality management 43
Functional description 30 R
Fuse bracket 18 Relay socket 18
46 | Vehicle Heaters Technical Documentation

8 L i sts

S List of abbreviations
Safety check 30
ADR
Scope of supply 10, 11
European agreement about the international transport of dangerous
Service 42
Special text formats 6 goods on the road.
Statutory regulations 7 ECE regulation
Switching on 30
Internationally agreed, uniform technical specifications for vehicles,
T parts and equipment of motor vehicles.
Technical data for the diesel heater 13
Technical data for the petrol heater 12 EMC directive
Electromagnetic compatibility.
W
Water pump installation position 16 E85 ethanol fuel
Petrol containing 85 % ethanol.

FAME
Biodiesel to EN 14214.

JE-partner
J. Eberspcher partner.
 25 2598 90 00 01 EN 02.2014Subject to change without notice Eberspcher Climate Control Systems GmbH & Co. KG

Headquarters:
Eberspcher Climate Control Systems
GmbH & Co. KG
Eberspcherstrae 24
73730 Esslingen
Hotline: 0800 1234300
Fax hotline: 01805 262624
info@eberspaecher.com
www.eberspaecher.com