Air heater D 8 L C

and Repair Instructions

These troubleshooting and repair in,tRlctions are valid
for the following heater versions:
DalC
251890 00 00 00 -12 V
25 1891 00 00 00 - 24 V
Contents Page
Sectional view.... ............ ................ ... ......... .... ...... 2
Description of operation ................................ ....... 3
Arst check the following if faults occur ................. 4
Function and fault test ...... ... .... ................. ............ 4, 5
Wiring diagrams. ............ ........ .............................. 6 - 9
Repair Instructions . ........ ...... .......... ...................... 10- 14
Fuel quantity measurement ............... .. .. ............... 15
Use attest adapter ... .................................. ... ...... 16
25 1766 95 0922 08.1995 Subject to alterations. Printed In Germany.
Eberspacher
Copyright J . Eberspticher
J . Eberspache!
GmbH & Co.
Eberspi!lcherstr. 24
073730 Esslingen
Telelon (zen Ira I)
(071 1)939 - 00
Telelax
(0711) 939 - 0500
C33
Sectional view of Dale
UST OF PARTS
1 Hot air Impeller
2 Combustion air Impeller
3 Glow plug
4 Safety thermal cutout switch
5 Combustion chamber
6 Flame sensor
7 Heat exchanger
12
8 Outer casing
9 Exhaust pipe seal
10 Fuel line
11 Blower motor
3 16
13
12 Combustion air solenoid valve
13 Exhaust pipe
14 Fuel metering pump
17 18
97 8 20 21
15 Fuel screen
16 Control relay
17 Glow plug relay
18 Control unit
19 Temperature limiter
20 Operating device
21 Heater timer
6)
I
@I[j)(!)@[B
F = Fresh air
V = Combustion air
B = Fuel
W = Hot air
A = Exhaust gas
22 Extemal room temperature sensor
2
. ....,
J
22

Description of operation
Control elements
1. Operating device
2. Heater timer
A heater timer can be installed in addition to the operating
device. The heater timer can be used to switch on the
heater immediately or preset a switch-on time from 24
hours to 7 days depending on the version.
Mode of operation
Sequence after switch-on
Switch-on: Green pilot light on operating device
comes "ON"
Glow coil of glow plug comes "ON".
(A timing relay ensures that the voltage
of the glow plug does not exceed the
permissible range.) Blower comes "ON"
at max. speed.
After about 25 sec: Fuel metering pump comes 'ON"
(with fuel feed rate for "High" heat flow.)
Once a stable flame forms, the glow plug is switched off after
a delay of approx. 10 sec. The heater is then forced to
operate for at least another 30 sec in the "High" setting. Only
then can heat controller begin to operate.
Heat flow/room temperature control
Heat flow and room temperature are regulated by interaction
of the external temperature sensor installed in the room to be
heated, by the operating device, the control unit and a
temperature limiter fitted in the air outlet.
The heater operates in either the "High" setting or between
the "High" and "Low" settings until the room temperature set
at the operating device (approx. 10C to 30 0c) is reached.
Fuel feed and, after a 2-second delay, combustion air feed are
reduced in the "Low" setting.
If the room temperature continues to increase despite the fact
that the heater is in the "Low" setting, the heater switches to
the "Off" setting and the blower continues to run for 3
minutes. The heater then switches to standby mode (green
pilot light comes on).
After the room temperature has dropped below the set value,
the heater is restarted and runs for 80 seconds in the "High"
setting.
The outlet temperature is limited by the temperature limiter to
125C to 150 C regardless of the room temperature.
Switch-off
When the heater is finally switched off, the green pilot light
goes out. The blower then continues to operate at high
blower speed to cool the heater down. This is stopped
automatically after 3 minutes.
3
Control and safety functions
The flame is monitored by the flame sensor, and the max.
permissible temperature by the safety thermal cutout switch
(4). Both the flame sensor and the safety thermal cutout
switch influence the control unit (18), which switches off the
heater in the event of a fault.
1. If the heater fails to ignite within 90 seconds after fuel feed
has started, start-up is repeated as described above.
If the heater repeatedly fails to ignite within 90 seconds
after fuel feed has started, a fault cutout is triggered.
2. If the flame goes out by itself during operation, a restart is
first performed.
If the heater repeatedly fails to ignite within 90 seconds
after fuel feed has started or if it ignites but goes out again
within 10 minutes, a fault cutout is triggered.
A fault cutout can be cancelled by briefly switching the
heater on and off again.
3. In the event of an overheat, the safety thermal cutout
switch is triggered (4), fuel feed is interrupted and a fault
cutout is then triggered.
If an overheat is the cause of a fault putout, the switch-on
pilot light (green) on the operating device flashes at a
steady rate.
Other fault display signals can be called using auxiliary
equipment.
4. If the voltage drops below approx. 1 0.5V or 21V or if it
rises above approx. 15V or 30V, a fault cutout is triggered
after 20 sec. Voltage undershoots or overshoots of shorter
duration do not have any effect.
5. When the heater is started up, the blower motor undergoes
a functional check. If it fails to start, the heater switches to
fault mode.
The blower motor is monitored cyclically (every 4 min.)
during operation. If the motor speed is below the
permissible limit, a fault cutout is triggered ..
Please note:
If electrical welding work is to be carried out on the vehicle,
disconnect the positive terminal from the battery and connect
it to ground in order to protect the control unit.
For a functional check of the heater, turn the rotary knob at
the operating device right round to the "High" setting.
First check the following if faults occur
Fuel in tank?
Fuses OK?
Electrical leads and connections OK?
Combustion air and exhaust piping free?
When combustion generates soot, check the following:
Combustion air pipe or exhaust pipe clogged? ........ Clear obstruction.
Fuel metering pump feeding too much? ........ Measure fuel quantity, replace fuel metering pump if necessary.
Deposits inside heat exchanger? ........ Clean heat exchanger, replace if necessary.
Function and fault test
Call diagnostic signals
Insert a strap between terminals 6 (yellow) and 4 (black &
white) on the back of the operating device for 0.5 to 5 sec.
or
Place a jumper to plug 8 between connection 89 (yellow) and
811 (black & white) on the control unit for 0.5 to 5 sec (see
wiring diagram).
To do this, unscrew the cover from the electronics box on the
heater and unclip the control unit from the holder. The green
pilot light on the operating device flashes and emits diagnostic
signals (listed on page 5).
Rectify the fault as described under "Remarks/Remedial
Action".
Check values
Speed of blower motor (at set voltage)
High: 3400 rpm 10 %
Low: 3200 rpm 10 %
After-ventilation: 3400 rpm 10 %
Flame sensor: 1 060 to 1 090 (when heater is cold)
Check safety thermal cutout switch for continuity.
Extemal room temperature sensor: 1800 to 2200 at 20C
Air outlet temperature limiter: 550 to 570 at 20 C
4
;.
.'
Diagnostic signals
0
1 T Y 1 Y ? T ~
sec.
Remark/Remedial Action
Operation
Overvoltage/undervoltage warning
1---
Check controller, charge battery
Check controller, if necessary check
Overvoltage cutout
--
battery charger. Heater must be
connected directly to the battery
Undervoltage cutout
-
Charge battery, check controller
Check glow plug
Glow plug interruption
----
Check leads and connections
Check glow plug relay
Burner motor not turning, Check motor speed, Replace blower if necessary
speed changeover relay defective Check speed changeover
Short -circuit in glow plug relay
.-
Replace glow plug relay
contacts
Safety time exceeded
---
Check fuel supply
Non-start Check glow plug, replace if necessary
Check heating air piping, inlet and outlet,
for clogging,. and if necessary clear any obstruction.
Overheat
1---------
Check electrical leads and contacts to fuel metering
pump. Check safety thermal cutout switch and if
necessary check air outlet temperature limiter
Fuel metering pump
---
Check metering pump and
short circuit supply lines, replace if necessary
Plug connection to external temperature sensor in
External room temperature
cable harness plugged in?
monitor defective
--
Check external temperature sensor directl
Check connection of operating device
(tester for operating device)
Flame sensor defective
1--
-
Check flame sensor or connections
Check PCB using test adapter
Check fuel line for leaks, Check fuel filter
Flame loss in "Low" setting
--
Check fuel quantity
Heater goes out by itself Check blower speed
Check function of solenoid valve
Check fuel line for leaks,Check fuel filter
Flame loss in "High" setting
~
Check fuel quantity
Heater goes out by itself Check blower speed
Check function of solenoid valve
Control unit defective Replace control unit
External interference voltages
-
--
Eliminate cause
Check solenoid valve for short-circuit
Air outlet temperature limiter No flashing code Effect of short-circuit:
is not monitored by Heater still operates in "High" setting.
diagnostic unit and has Effect of interruption:
to be checked manually. Heater now operates only in "Low setting.
Display if provided
.--------
5
Wiring diagram - 251890 -12 V Design up to model year mid-1995
251891-24 V
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Parts list
1.1 Burner motor 2.1 Control Length AS + length CD
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1.1 ,1 Resistor for burner motor (partial load)
1.2 Glow plug 2.2 Fuel metering pump
< 5 m, cross-section 4 mm
2
> 5 m < 8 m, cross-section 6 mm
2
l.5 Safety thermal cutout switch
1.7 PCB
1.B.5 Varistor
1.12 Flame sensor
1.13 Temperature sensor
2,3 Air solenoid valve (for combustion air)
2.5.1 Glow plug relay
2.5.5 Control relay
2.7 12V1S0A main fuse
24V125A
2,15.1 Room temperature sensor
2.15.9 Outside temperature sensor
6
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3.1 .12 Fault code enquiry
3.2.5 Timer, rectangular, 7 -day
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5.1 Battery
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83
Test (garage) digital timer
When connecting timer
cut wil9 here x
Vehicle light terminal 58
Terminal 15
Terminal 31 (battery-)
7
Plug housing and socket housing aI9 shown
from the conductor entry side
Wiring diagram -- 25 1890 - 12 V Design up to model year mid-1995
251891-24 V
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Parts list
1 .1 Burner motor
1 .1 .1 Resistor for burner motor (partial load)
1 .2 Glow plug
1.5 Safety themlal cutout switch
1.7 PCB
1.8.5 Varistor
1 .12 Flame sensor
1.13 Temperature sensor
2.1 Control unit
2.2 Fuel metering pump
2.3 Air solenoid valve (for combustion air)
2.5.1 Glow plug relay
2.5.5 Control relay
2.7 12V/30A main fuse
24V125A
2.15.1 Room temperature sensor
2.15.9 Outside temperature sensor
8
Length AB + length CD
< 5 m, cross-section 4 mm'
> 5 m < 8 m. cross-section 6 mm'
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3.1.11 Operating device
3.1.12 Fault code enquiry
3.2.5 Timer. rectangular, 7-day
3.2.7 Timer, rectangular, surface-mounted
5.1 Battery
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b)
c)
d)
e)
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Test (garage) digital timer
When connecting timer
cut wire here x
Vehicle light terminal 58
Terminal 15
Terminal 31 (battery-)
9
Plug housing and socket housing are shown
from the conductor entry side
Repair instructions
For designation and
Cat. No. of spare parts,
see spare parts list
10
Repair steps
Remove / Install
1. Cover
2. Glow plug
3. Solenoid valve
4. PCB
5. Control unit
6. Safety thermal cutout switch
7. Temperature limiter
8. Flame sensor
Overall view of heater
11
9. Preparations for removal
of outer casing
10. Brackets, reducing pieces
11 . Outer casing
12. Heat exchanger with blower, remove
from outer casing
13. Blower and heat exchanger
14. Blower impeller
15. Combustion chamber lining
Remove I install
1. Cover 4. PCB
2. Glow plug 6. Control unit
3. Solenoid valve 6. Safety thermal cutout switch
12
7. Temperature limiter
8. Flame sensor
9. Preparations for removal of outer casing
13
10. Brackets, reducing pieces
11. Outer casing
When inserting the screws along the longitudinal
seam, draw together the casing using tightening strips.
12. Heat exchanger with blower, remove from outer casing
-.,
13. Blower and heat exchanger
14. Blower impeller
15. Combustion chamber lining
14
30
ml 25
20
Fuel quantity measurement
CAUTIONI Only measure the fuel when the battery is
sufficiently charged. At least 11/22V and max. 13/26V as
appropriate must be applied to the control unit during
measurement.
1. Preparation
Detach the fuel line from the heater and place it In a
measuring glass.
Connect a voltmeter to terminals 3 (+) and 4 (-) on the control
unit.
Switch on the heater. When fuel is fed smoothly (about 25 to
55 seconds after switch-on), the fuel line is filled and bled.
Switch off the heater and empty the measuring glass.
2. Measurement
Switch on the heater.
Fuel pumping starts about 25 to 55 seconds after switch-on.
Keep the measuring glass at the level of the plug during
measurement.
Read off the voltage at the voltmeter.
About 90 seconds of pumping it is switched off automatically.
Switch off the heater.
Measure the fuel quantity in the measuring glass.
DalC (12V)
Fuel consumption in ml/90 sec.
Fuel consumption In (mV90 sec.)
~ o
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29.0
..--
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-
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11 11,5 12 12,5 13
Operating voltage in (V)
3. Evaluation
Plot the readings onto the diagram.
Fuel consumption is OK when the intersection of the two
values is inside the limit curve.
If they intersect outside the curve, the fuel metering pump
must be replaced.
DalC (24V)
Fuel consumption in mV90 sec.
Fuel consumption in (mV90 sec.)
30
~ o
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---
28.0
---
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ml 25
.---
--
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--
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20
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22 23 24 25 26
Operating voltage In (V)
15
Tester for operating device
Disconnect the plug from the operating device.
Connect the tester to the operating device.
Connect the operating voltage.
Set the switch on the operating device to the "Ventilation and
Heating" setting. The appropriate lights must come on.
The pilot light in the switch must also come on:
* This test is not necessary during operation with heater timer.
Tester for operating deviceg
Set the operating device to the "0" setting.
Call the light.
Press key 1 and also key 2.
Pilot light must change from red to green.
Connect the ohmmeter. Turn the rotary knob right round.
The set value of 1800 to 2200 must be sustained without
interruption.
In the event of a fault, replace the operating device.
--------
1800- 2200
4.>-+----(
5 > - ~ - - - - - - - - - - - - - - - - - - - - ~ - - ~ ~
Heating
6
'9
----- - - - - - - - - - - - . ~
16
+
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Key 2
Green LED
Key 1
Red LED
. ~