1. DL manuals
  2. Eberspächer
  3. Heating System
  4. hydronic 16
  5. Troubleshooting And Repair Manual

Eberspächer hydronic 16 Troubleshooting And Repair Manual

Summary of hydronic 16

  • Page 1

    J. Eberspächer gmbh & co. Eberspächerstr. 24 d - 73730 esslingen telephone (switchboard) +49 (0)711 939 - 00 fax +49 (0)711 939 - 0500 www.Eberspaecher.Com 25 1818 95 14 86 04.2001 the information contained in this document is subject to change without notice. (s.E.E.O.) printed in germany © j. Eber...

  • Page 2

    2 table of contents this table of contents provides detailed information on the contents of this technical description, troubleshooting and repair manual. 1 / introduction to find a term, use the index at the end of this document. Chapter title content page no. 1 introduction • table of contents ---...

  • Page 3

    3 1 / introduction chapter title content page no. 4 troubleshooting • in the event of faults, start by checking ----------------------------------------- 24 • control unit locking ---------------------------------------------------------------- 24 • release of control unit when locked --------------...

  • Page 4

    4 1 / introduction liability claims / warranty adherence to the official regulations and the safety instructions is essential if any liability claims are to be accepted. Failure to observe the official regulations and the safety instructions will result in exemption of the heater manufacturer from l...

  • Page 5

    5 1 / introduction important information prior to commencing work applications in which the hydronic may be used the engine-independent “hydronic 16 / 24 / 30 / 35” water heaters are intended for installation in the following vehicles (in each case, the heater output should be appropriate to the app...

  • Page 6

    6 statutory requirements to install the heater in a vehicle subject to the german regulations governing the registration of motor vehicles (stvzo), a “general type approval” has to be issued by the federal motor vehicle office (kraftfahrtbundesamt) and the appropriate official test symbol must be in...

  • Page 7

    7 1 / introduction emergency cutout - emergency circuit breaker if an emergency cutout - emergency circuit breaker - should be necessary during operation, the following procedure should be followed: • switch off hydronic on the control element or • take out the fuse or • open the battery isolating s...

  • Page 8

    8 cat. No. Hydronic and additional equipment fig. No. / designation cat. No. 1 hydronic 16 - 24 v 25 2165 02 00 00 1 hydronic 24 - 24 v 25 1817 02 00 00 2 hydronic 24 - 24 v 25 1817 05 00 00 compact model 1 hydronic 30 - 24 v 25 1818 02 00 00 2 hydronic 30 - 24 v 25 1818 05 00 00 compact model 1 hyd...

  • Page 9

    9 2 / product information drawing 1 1 4 5 7 5 6 9 14 24 23 22 21 20 16 26 27 28 18 18 19 17 5 2 3 11 8 10 12 13 15 25 18 29 30 31 5 control elements 32 35 34 33 18 25 5 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 10

    10 options • when the “lower temperature” option is selected, the adjustable “on / off” temperatures drop by approx. 8k. For information regarding the “on / off” switch for reducing the temperature, see the wiring diagrams on pages 48 to 50. • the water pump can also be operated independently of the...

  • Page 11

    11 sectional view 1 hood (co 2 setting) 2 coupling 3 control unit 4 ignition spark generator 5 flame monitor 6 solenoid valve 7 temperature sensor 8 ignition electrodes 9 combustion chamber 10 safety thermal cutout sensor 11 relay (vehicle blower control) a exhaust gases b fuel v combustion air wa w...

  • Page 12

    12 control diagram functional diagram 2 / product information drawing 3 nozzle holder heater (on at temp. Water pump solenoid valve ignition spark generator electric motor from control unit 25 1818 53 00 00, switching on and off the nozzle holder heater is temperature-controlled operation hydronic o...

  • Page 13

    13 technical data hydronic 16 hydronic 24 hydronic 30 hydronic 35 test symbol s 329 s 297 s 295 s 296 heating medium mixture of water and refrigerant (max 50% proportion of refrigerant heating capacity (at ambient temperature of 20ºc) 16,000 w 24,000 w 30,000 w 35,000 w temperature control values - ...

  • Page 14

    14 2 / product information principal dimensions hydronic - compact model hydronic - standard model drawing 5 drawing 6 ø 38 (+) (-) 2 224 115 190 ø70 320 302 233 24 ø 3 8 180 130 min. 50 600 153 please note! • if there is enough space, the burner can be swung out for routine checks - see drawing. • ...

  • Page 15

    15 regulation! • installation in the driver‘s cab or passenger compartment of buses containing more than eight seats in addition to the driver‘s seat is not permitted. Please note! • mount the hydronic below the minimum cooling water level (expansion tank, radiator, vehicle heat exchanger). • furthe...

  • Page 16

    16 rating plate regulation! • the year in which the heater was first commissioned must be shown permanently on the rating plate. For this purpose 3 year numbers are printed on the appropriate area of the rating plate. The applicable year must be indicated by removing the years which are not applicab...

  • Page 17

    17 3 / installation permissible installation positions and attachment of the hydronc the hydronic should if possible be installed in the normal position. To do this, transfer the 4 fastening holes and the through-hole for the exhaust outlet - as shown in the diagram - to the mounting surface and dri...

  • Page 18

    18 template for holes 3 / installation water pump - standard model principal measurements and permissible installation positions installation of the water pump the water pump must be installed at the lowest point in the water circulation system, taking into account the installation position - see di...

  • Page 19

    19 3 / installation exhaust gas piping regulation! • the outlet must be implemented in such a way that insertion of a 16 mm dia. Ball is not possible. • exhaust pipes must be laid in such a way that there is no likelihood of any exhaust gases entering the vehicle interior. • the functioning of parts...

  • Page 20

    20 3 / installation examples of exhaust gas piping combustion air piping regulation! • the necessary combustion air must be drawn from the outside. • the combustion air inlet must be implemented in such a way that insertion of a 16 mm dia. Ball is not possible. Please note! • when laying the combust...

  • Page 21

    21 installation example the hydronic is installed into the coolant circuit of the vehicle. Another installation variant is to install a separate coolant circuit for the hydronic with an expansion tank. 3 / installation coolant circuit warning: contact with hot parts could cause burning. • the coolan...

  • Page 22

    22 fuel supply regulation! • when laying fuel lines and installing an additional fuel tank, §§45 and 46 stvzo (regulations governing the registration of motor vehicles) must be adhered to. Excerpt from §§45 and 46 stvzo: - fuel tanks may not be contained in passenger compartments or driver‘s cabs of...

  • Page 23

    23 temperature winter diesel summer diesel or el additive fuel oil petroleum regular-grade petrol 0 °c to -10 °c 100% or 70% + 30% or 30% -10 °c to -15 °c 100% or 50% + 50% ---- -15 °c to -20 °c 70% ---- ---- + 30% or 30% -20 °c to -25 °c 50% ---- ---- + 50% ---- fuel quality all commercial grade di...

  • Page 24

    24 4 / troubleshooting in the event of faults, start by checking… • defective wiring (short-circuits, open circuit). • visual inspection for - corroded contacts - defective fuses - damaged electric lines, joints and connections - damaged exhaust gas and combustion air piping • battery voltage on sta...

  • Page 25

    25 diagnosis the hydronic electronic control unit can store up to five faults. The faults can be read from the control unit and displayed by one of the following means: • flashing code after connection of an led and a series resistor (approx. 1 k Ω / 11 w) the function / fault is displayed as a flas...

  • Page 26

    26 fault diagnosis - flashing code (led with series resistor) the electronic control unit can store up to five faults. The function or type of fault is output by the control unit as a flashing code and displayed by an led (with series resistor). The led with series resistor is connected to the cable...

  • Page 27

    27 the electronic control unit can store up to 5 faults, which can be read out and displayed with the timer. The current error is shown as “af” and is always written to memory location f1. Previous faults are transferred to memory locations f2 - f5; if necessary, the content of memory location f5 is...

  • Page 28

    28 fault diagnosis with the iso adapter and the kd 2000 software iso adapter and kd-2000 software cat. No. 22 1524 89 00 00 to connect the iso adapter, an adapter cable is required. Adapter cable cat. No. 22 1000 31 66 00 installing kd 2000 software on the pc • place cd-rom in the cd drive. • double...

  • Page 29

    29 the electronic control unit can store up to 5 faults, which can be read out and displayed with the timer. The current error is shown as “af” and is always written to memory location f1. Previous faults are transferred to memory locations f2 - f5; if necessary, the content of memory location f5 is...

  • Page 30

    30 fault code cause fault description • remedial measures 000 no fault ----------------- 010 overvoltage --> disconnection overvoltage (>30 v) exists for a minimum of 20 seconds without interruption at the control unit - hydronic not working. • unplug 18-pin connector on the control unit and start u...

  • Page 31

    31 fault code cause fault description • remedial measures 020 ignition spark generator - open circuit control line from ignition spark generator to the control unit has open circuit or short circuit. • check cable section from the ignition spark generator to the control unit and, if necessary, elimi...

  • Page 32

    32 fault code cause fault description • remedial measures 039 vehicle blower control - short circuit black 1 mm² cable from the 18-pin control unit connector, compartment 6 to the 8-pin cable harness connector, compartment 7, and from there to the blower relay has short-circuit. • check lead and con...

  • Page 33

    33 fault code cause fault description • remedial measures 054 flame loss during operation hydronic has ignited, detected the flame and reports flame loss twice within an operating period of 60 minutes. • check fuel supply (supply and return). • measure the amount of co 2 . • replace fuel atomizer no...

  • Page 34

    34 1 hood with hose connection 2 flexible hose 3 protective grille 4 hose clip 5 hood 6 fan wheel 7 control unit 8 electric motor 9 cable section 10* baffle plate 11 burner casing with integrated fuel pump 12 ignition spark generator 13 cartridge heater 14* temperature switch 15 nozzle holder 16 baf...

  • Page 35

    35 5 / repair instructions * only with heater models hydronic 16 - 25 2165 01 00 00 hydronic 24 - 25 1817 01 00 00 11 12 18 15 16 17 19 20 21 23 22 10* 20* 13 14* visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 36

    36 5 / repair instructions repair instructions the “repair instructions” chapter describes the approved repair work for the hydronic 16 / 24 / 30 / 35. Where extensive repair work is to be carried out, it is sensible to dismantle the hydronic. Mounting of the hydronic involves the reverse sequence o...

  • Page 37

    37 removing the hood (see drawing 24) • undo the two fixing screws on the hood. • take off the hood. Beware danger of injury! • the fan wheel has sharp edges. - avoid contact with the fan wheel and, if necessary, wear protective gloves. ~ fixing screw figure 1 figure 2 5 / repair instructions removi...

  • Page 38

    38 5 / repair instructions drawing 25 ~ fan wheel with marking removing the burner motor (see figures 3 and 4) • take off the hood. • unscrew the fan wheel in an anti-clockwise direction, counter-restraining the motor shaft with screwdriver. • if necessary, check the burner motor with the test unit ...

  • Page 39

    39 removing the fuel atomizer nozzle (see figure 6) • take off the hood. • remove burner. • remove ignition electrodes. • unscrew fuel atomizer nozzle from the nozzle holder. Please note! • when installing the fuel atomizer nozzle, do not touch the nozzle opening. • following installation of the fue...

  • Page 40: High Voltage

    40 5 / repair instructions checking the ignition spark generator with the test unit for burner head danger! • a spark gap with a voltage of approx. 20,000 v is formed between the electrodes. - only check ignition spark generator with the test unit for burner head. - do not check ignition spark gener...

  • Page 41

    41 5 / repair instructions figure 10 ~ solenoid valve Ä =connection of the “solenoid valve” cable section to the control unit, slot “d” removing the solenoid valve (see figure 10 and drawing 26) • take off the hood. • remove burner. • if necessary, check the solenoid valve with the test unit for bur...

  • Page 42

    42 figure 11 ~ heating cartridge - installed in the nozzle holder Ä securing pin for heating cartridge Å =connection of the “heating cartridge” cable section to the control unit, slot “f” removing the heating cartridge for the nozzle holder heater (see figures 11 and 12) • take off the hood. • remov...

  • Page 43

    43 ~ flame pipe Ä catch on the flame pipe Å heat exchanger drawing 27 figure 13 ~ flame pipe Ä catch on the flame pipe Å heat exchanger removing the flame pipe (see figure 13 and drawing 27) • take off the hood. • remove burner. • take flame pipe out of the heat exchanger. Please note! During instal...

  • Page 44

    44 figure 14 ~ control unit, slot “g” for temperature sensor Ä control unit, slot “c” for safety thermal cutout sensor removing the temperature sensor and safety thermal cutout sensor (see figure 14 and drawing 28) drawing 28 ~ temperature sensor Ä safety thermal cutout sensor resistance [ohms] 800 ...

  • Page 45

    45 resistance [kohm] 100 10 1 -40 0 40 80 120 temperature [c°] 1000 drawing 30 diagram - safety thermal cutout sensor (excerpt) figure 15 ~ hollow screw and ring connection piece from the fuel supply line Ä fuel strainer please note! Note regarding fuel quantity it is not possible to accurately chec...

  • Page 46

    46 figure 16 ~ adjustment cap 5 / repair instructions measuring the co 2 content in the exhaust gas danger of injury, fire and poisoning! • the hydronic must not be operated in enclosed spaces such as garages or workshops without exhaust-gas extraction. • do not switch on hydronic with the burner di...

  • Page 47

    47 taking the water pump apart (standard model) (see drawing 31) • unscrew screws from the pump housing and take out the pump housing. • unscrew locknut and take out the impeller wheel. • remove axial face seal and ring from the motor shaft. • unscrew screws from the pump flange and take out the pum...

  • Page 48

    48 wiring diagram for the basic heater models hydronic 16 - 24 v 25 2165 01 00 00 hydronic 24 - 24 v 25 1817 01 00 00 hydronic 30 - 24 v 25 1818 01 00 00 hydronic 35 - 24 v 25 1819 01 00 00 1.14 heating cartridge for nozzle holder heater 2.1 control unit 2.5.1 relay, heating cartridge 2.5.6 relay, w...

  • Page 49

    49 parts list 2.5.7 relay for control, e.G. Of vehicle blower 2.7 main fuse 15 a 2.7.1 5a fuse for control switch 2.7.2 15a fuse for water pump 2.12.1 bus 2000 water pump 2.12.2 water pump a) hydronic connection d) either 2.12.1 or 2.12.2 f) if 3.2.6 is used, optionally terminal 15 or terminal 30 - ...

  • Page 50

    50 25 1818 00 97 01 e wiring diagram, control elements 6 / wiring diagram parts list 2.15.9 sensor, external temperature 3.1.1 universal switch 3.1.2 switch, heat, continuous operation 3.1.12 fault code inquiry 3.2.6 mini-timer 3.2.9 modular timer 3.2.12 mini-timer (new) b) connect to terminal +15 c...

  • Page 51

    51 certification the eberspächer company accepts the challenge and takes active steps to avoid and eliminate ecological problems. The hydronic heater is designed for environmentally friendly operation. Iso 9000 / iso 14001 our production process is certified to iso 9000 (quality management) and iso ...

  • Page 52

    52 regional offices - germany postcode town company road telephone 17358 torgelow eberspächer heizgeräte gmbh wilhelmstraße 47 tel. +49 (0)3976 23 50 - 0 20539 hamburg j. A. Schlüter söhne ausschläger billdeich 62–64 tel. +49 (0)40 7 88 16 86 industrie-vertriebs-gmbh 44139 dortmund eugen boss gmbh &...

  • Page 53

    53 8 / service / index representative offices abroad country company town telephone poland eberspächer sp.Zo. Pl- 62081 przezmierowo tel. 061 - 81 6 18 50 russia company okma rus - 105023 moscow tel. 095 - 111 90 95 sweden svenska eberspächer ab s - 12830 skarpnäck tel. 0 8 - 683 11 00 switzerland t...

  • Page 54

    54 index a-m keyword page a accident prevention --------------------------------------- 2, 4 additional equipment ----------------------------- 2, 8, 10, 22 adr --------------------------------------------------------5, 54 adr99 -----------------------------------------------------5, 54 ambient temp...

  • Page 55

    55 keyword page t table of contents---------------------------------------------- 2 technical data ---------------------------------------------2, 13 technical description ------------------------ front cover, 2, 5 temperature control values ---------------------------------13 temperature controller...