AIRTRONIC / AIRTRONIC M. Manual - part 2

 

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AIRTRONIC / AIRTRONIC M. Manual - part 2

 

 

5

Introduction

1

Statutory Regulations!

Directive 2001 / 56 / EU of the European
Parliament and the Council

• Arrangement of the heater

– Parts of the structure and other components near

the heater must be protected from excess heat
exposure and possible contamination from fuel or
oil.

– The heater must not pose a fire hazard even when

it overheats.
This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and
fire-proof materials or heat plates are used.

– The heater must not be mounted in the passenger

compartment of vehicles in class M

2

 and M

3

.

But a heater in a hermetically sealed enclosure
which otherwise complies with the conditions
stated above may be used.

– The factory nameplate or duplicate 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.

• Operating status display

– A clearly visible operating display in the user’s

field of vision must indicate when the heater is
switched on and off.

• Fuel supply

– The fuel intake connection must not be located in

the passenger compartment and must be sealed
with a properly closing lid to prevent any fuel leaks.

– In heaters for liquid fuel where the heater fuel is

separate from the vehicle fuel, the type of fuel and
intake connection must be clearly identified.

– A warning sign is to be fixed to the intake

connection indicating that the heater must be
switched off before refuelling.

• Exhaust system

– The exhaust outlet must be arranged so as to

prevent any penetration of exhaust fumes into the
vehicle interior through the ventilation system,
warm air intakes or open windows.

• Combustion air intake

– The air for the heater combustion chamber must

not be sucked in from the passenger compartment
of the vehicle.

– The air intake must be arranged or protected in

such a way that it cannot be blocked by other
objects.

• Heater air intake

– The heater air supply must consist of fresh air or

circulated air and be sucked in from a clean area
not contaminated by exhaust fumes of the drive
machine, the combustion heater or any other
source in the vehicle.

– The intake pipe must be protected by a grid or

other suitable means.

• Hot air outlet

– The hot air pipes within the vehicle must be

arranged or protected in such a way that there is
no risk of injury or damage if they are touched.

– The air outlet must be arranged or protected in

such a way that it cannot be blocked by any
objects.

Statutory regulations

The Federal Road Transport Directorate has issued
an "EC type approval" and an "EMC type approval"
for the heater for installation in motor vehicles and
with the following official type approval marks, noted
on the heater name plate.

Airtronic

EC- e1 00 0025

EMC- e1 031516

Airtronic M

EC- e1 00 0026

EMC- e1 031653

Statutory Regulations!

Mounting the heater in a vehicle for the transport of
dangerous goods as per ADR
• When the heater is to be installed in vehicles for the

transport of dangerous goods, the regulations of
ADR must also be observed (see page 6).

6

Introduction

1

Statutory Regulations!

Additional regulations for certain vehicles named in
Directive 94 / 55 / EC (ADR Framework Directive)

Scope
This appendix applies to vehicles for which the special
provisions of Directive 94 / 55 / EC apply to
combustion heaters and their installation.

Definition of terms used
For the purposes of this appendix, the vehicle
designations "EX / II", "EX / III", "AT", "FL" and "OX"
according to Chapter 9.1 of Annex B of Directive 94 /
55 / EC are used.

Technical regulations

General provisions (EX / II, EX / III, AT, FL and OX
vehicles)

Avoid heating and ignition
The combustion heaters and their exhaust gas routing
shall be designed, located, protected or covered so
as to prevent any unacceptable risk of heating or
ignition of the load. This requirement shall be
considered as fulfilled if the fuel tank and the exhaust
system of the appliance conform to provisions in
3.1.1.1 and 3.1.1.2. Compliance with these
regulations shall be checked in the complete vehicle.

Fuel tanks
Fuel tanks for supplying the heater shall conform to
the following regulations:
• In the event of any leakage, the fuel shall drain to

the ground without coming into contact with hot
parts of the vehicle or the load;

• fuel tanks containing petrol shall be equipped with

an effective flame trap at the filler opening or with a
closure enabling the opening to be kept
hermetically sealed.

Exhaust system and exhaust pipe layout
The exhaust system as well as the exhaust pipes shall
laid out or protected to avoid any danger to the load
through heating or ignition. Parts of the exhaust
system situated directly below the fuel tank (diesel)
shall have a clearance of at least 100 mm or be
protected by a thermal shield.

Switching on the combustion heater
The combustion heater may only be switched on
manually. Automatic switching on via a programmable
switch is not permitted.

EX / II and EX / III vehicles
Combustion heaters for gaseous fuels are not
permitted.

FL vehicles
Combustion heaters must be able to be taken out of
service/disabled at least by the methods described in
the following:
a) Switching off manually in the driver's cabin
b) Switching off the vehicle's engine; in this case the

heater may be manually switched back on by the
vehicle driver;

c) Starting up of a feed pump installed in the vehicle

for the dangerous goods carried.

Combustion heater after-run
After-running of the switched off combustion heater is
permitted. In the cases named in the "FL vehicles"
paragraph under letters b) and c) the supply of
combustion air must be interrupted by suitable means
after a maximum after-run period of 40 seconds. Only
combustion heaters whose heat exchangers are
verifiably not damaged by the reduced after-run period
of 40 seconds beyond their usual use period may be
used.

Please note!

• Compliance with the statutory regulations, the

additional regulations and safety instructions is
prerequisite for guarantee and liability claims.
Failure to comply with the statutory regulations and
safety instructions and incorrect repairs even when
using original spare parts make the guarantee null
and void and preclude any liability for
J. Eberspächer GmbH & Co. KG.

• Subsequent installation of this heater must comply

with these installation instructions.

• The statutory regulations are binding and must also

be observed in countries which do not have any
special regulations.

• When the heater is to be installed in vehicles not

subject to the German Ordinance for the Regis-
tration of Motor Vehicles (StVZO), for example
ships, the specially valid regulations and
installation instructions for these special
applications must be observed.

• Installation of the heater in special vehicles must

comply with the regulations applying to such
vehicles.

• Other installation requirements are contained in the

corresponding sections of this manual.

7

Safety instructions for installation
and operation

Danger!

Risk of injury, fire and poisoning!
• The heater must only be started up when the

maintenance flap is closed and the outlet hood is
mounted in position.

• The maintenance flap must not be opened during

operation.

• Disconnect the vehicle battery before commencing

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 garage or in a multi-storey car park.

• Adjustable hot air outlets must always be adjusted

so that they cannot blow hot air directly at living
creatures (people, animals) or objects sensitive to
temperature (loose and / or fastened).

Caution!

Safety instructions for installation and operation!
• The year of initial commissioning must be marked on

the nameplate.

• The heat exchanger of air heaters is a component

subject to high thermal loads which must be
replaced 10 years after initial commissioning of the
heater. In addition, the installation date must be
entered on the plate “original spare part” enclosed
with the heat exchanger must. Then affix the plate
next to the nameplate on the heater.

• The heater must only be installed by a JE partner

authorised by the manufacturer according to the
instructions in this manual and possibly according to
special installation recommendations; the same
applies to any repairs to be carried out in the case
or repairs or guarantee claims.

• Only the control elements approved by

J. Eberspächer GmbH & Co. KG must be used to
operate the heater. The use of other control
elements can cause malfunctions.

• Repairs by unauthorised third-parties or with not

original spare parts are dangerous and therefore not
allowed. They result in expiry of the type permit of
the heater; consequently, when installed in motor
vehicles they can cause expiry of the vehicle
operating licence.

Introduction

1

• The following measures are not allowed:

– Changes to components relevant to the heater.
– Use of third-party components not approved by

Eberspächer.

– 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.

• When carrying out electric welding on the vehicle,

the plus pole cable at the battery should be
disconnected and placed at ground to protect the
controller.

• The heater must not be operated where there is a

risk of an accumulation of flammable vapours or
dust, for example close to
– fuel depot
– coal depot
– wood depot
– grain depots etc.

• The heater must be switched off when refuelling.
• When the heater is mounted in a safety housing

etc., the installation compartment of the heater is
not a stowage compartment 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.

• Defect fuses must only be replaced by fuses with

the prescribed rating.

• If fuel leaks from the heater fuel system, arrange

for the damage to be repaired immediately by a JE
service partner.

• After-running of the heater must not be interrupted

prematurely e.g. by pressing the battery
disconnecting switch, apart from in the case of an
emergency stop.

Accident prevention

General accident prevention regulations and the
corresponding workshop and operation safety
instructions are to be observed.

8

Using the universal installation kits

Order No.

Universal installation kit

25 2069 80 00 00

• with outlet hood Ø 60 mm,

heater guide number 6, usable with:

– Airtronic D2, 12 V

25 2069 05 00 00

– Airtronic D2, 24 V

25 2070 05 00 00

Universal installation kit

25 2113 80 00 00

• with outlet hood Ø 90 mm,

heater guide number 10, usable with:

– Airtronic D3, 12 V

25 2317 05 00 00

– Airtronic B4, 12 V

20 1812 05 00 00

– Airtronic D4, 12 V

25 2113 05 00 00

– Airtronic D4, 24 V

25 2114 05 00 00

• with outlet hood Ø 90 mm,

heater guide number 15, usable with:

– Airtronic D4 Plus, 12 V

25 2484 05 00 00

– Airtronic D4 Plus, 24 V

25 2498 05 00 00

Universal installation kit

25 2144 80 00 00

• with outlet hood Ø 75 mm,

heater guide number 3, usable with:

– Airtronic D3, 12 V

25 2317 05 00 00

– Airtronic B4, 12 V

20 1812 05 00 00

– Airtronic D4, 12 V

25 2113 05 00 00

– Airtronic D4, 24 V

25 2114 05 00 00

• with outlet hood Ø 75 mm,

heater guide number 8, for recirculation mode
heater guide number 10, for fresh air mode
usable with:

– Airtronic D4 Plus, 12 V

25 2484 05 00 00

– Airtronic D4 Plus, 24 V

25 2498 05 00 00

• For controls, please refer to the price list or

accessories catalogue.

• Parts without a figure no. are small parts and packed

in a bag.

• Please consult the additional parts catalogue if any

other parts are required for installation.

• For notes on the units' guide numbers, please refer to

additional parts catalogue.

Product information

2

Heater scope of supply, complete
packages and universal installation kit

Heater

Order No.

Airtronic D2, 12 V

25 2069 05 00 00

Airtronic D2, 24 V

25 2070 05 00 00

Airtronic D3, 12 V

25 2317 05 00 00

Airtronic B4, 12 V

20 1812 05 00 00

Airtronic D4, 12 V

25 2113 05 00 00

Airtronic D4, 24 V

25 2114 05 00 00

Airtronic D4 Plus, 12 V

25 2484 05 00 00

Airtronic D4 Plus, 24 V

25 2498 05 00 00

The scope of supply includes:
No. in
figure Name

1

Heater

2

Metering pump

Complete package

Order No.

Airtronic D2, 12 V
Complete package

25 2115 05 00 00

Airtronic D2, 24 V
Complete package

25 2116 05 00 00

Included in the scope of supply:
No. in
figure Name

1

Heater

2

Metering pump

Installation kit with outlet hood Ø 60 mm

3

Minicontroller

4

Tank connection (only in complete package
25 2116 05 00 00)

Universal installation kit (all versions)

Included in the scope of supply:
No. in
figure Name

5

Lead harness, plus / minus

6

Lead harness, operation

7

Flexible exhaust pipe

8

Combustion air hose

9

Cable tie

10

Bracket, dosing pump

11

Pipe, 6 x 2

12

Pipe, 4 x 1.25

13

Hose clip (2x)

14

Air outlet, rotatable

15

Grid

16

Hood

17

Flexible pipe

18

Exhaust silencer

19

Cable harness, heater

Please note!

 

 

 

 

 

 

 

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