Air heaters B3LC / D3LC / B3LP / D3LP = Troubleshooting and Repair Instructions Eberspacher® 4. Eberspacher GmoH & Co spachorsr 24 730 Essingen D- Telefon (zontal) (0711) 938-00 Telelax (0711) 939-0500, rp ee The Troubleshooting and Repair Manual is valid for the following heater versions BIL C BaLP 20 1717 05 00 00- 12 Volt” 20 1734 05 00 00 - 12 Volt” DaL DSL P 25 1822 05 00 00 - 12 Volt" 25 1854 05 00 00 - 12 Volt” 25 1843 05 00 00 - 12 Volt” 25 1867 05 00 00 - 12 Volt” 25 1850 05 00 00 - 24 Volt” 25 1823 05 00 00 - 24 Volt”! 25 1844 05 00 00 - 24 Volt” "Without combustion off control 2 With combustion-off control and postventilation 3. With combustion-off control, without post-ventilation Contents Page First check the following if faults occur 2 Diagnosis test 35 Wiring diagrams 67 Repair instructions 813 ‘Test equipment and adapters 14,15 Fuel quantity measurement 16 25 1822.95 07 78 09.1905 Subjecttolerations Printedin Germany © Copyright J. Eberspaicher csaas7‘See spare parts list for availablé spare parts, ‘See the technical description/installation instructions/operating instructions included with every heater for description of operation. First check the following If fautts occur: Fuel in the tank? Fuses OK? Electrical leads and connections OK? ‘Combustion air and exhaust piping tree? When combustion generates soot ‘Combustion air pipe or exhaust pipa clogged? .. Metering pump convaying too much? ‘Deposits in heat exchanger, in exhaust pips’ » Clear obstruction .. Measure fuel quantity, replace metering pump .. Clean heat exchanger, exhaust pipe. Replace it if necessary. Check values ‘Speed of blower motor - 1% +3 % B3LC/D3LC B3LP/D3LP “High” setting: 3800 rpm /4200 rpm + 1% 3200 pms 1% "Medium" setting: 2000 rpm + 1% 2000 rpm & 1% "Low" setting: 1800 tom = 1% 1600 rpm = 1% + Continued running: 3800 rpm # 1% 1600 rpm = 1% «Continued ventilation (recirculatectair operation only): 1000 rpm = 1% 1000 pm = 1%AW Diagnosis test The diagnos's test can be performed as foltows: Call diagnostic signals using operating device 1, Switch on heater using the operating device. 2 Connect a cable jumper betwean chamber 812 (1 G2) and chamber 8/3 {1 swiws) for 0.5 to 5 seconds at the 6-pin control elements plug of the "Heater" cable hamess. Using the diagnostic signel, determine the fault code in the following table, then ascertain the romedial action which comesponds to this fault code in the table on pages 4 ana 8 Der el —= oe een — on | ween ———= lee | oevpenewae 029-083 | Bumer motor/speed control defective 036 052 Non-start Salety ime exceeded 23; 024 | PCE current controller Inierruption/short-circuit 012; 013 | Qverheatimeterina pump interruption Overtemperatute of flame sensor —— oo” Sorereuunreemmo one 060 - 063 | Temperate cont sensor inlerupaonisert circuit Setooirc aolentiomiterntenvotonishore-crcut 064,085 | Flame sensor nterruption/short-circuit 055; 056 | Flame loss in "Medium" setting Flame loss in “Low” setting 3 Perform diagnosis test using diagnostic unit Insert the dizgnostic unit and the necessary adapter cable between the cable harness anc “Operating” cable, The fault is then displayed on the diagnostic unit as a S-cigit number See pages 4 and § for a description of the fault code, fault description and remedial action Order No. for diagnostic unit Order No. for adapter cable 22 1912 8900 00 22 1000 30 20 00 Important! When connecting the diagnostic unit, fallow the operating instructions, (001: 902 [Advance warning Overvoltage/undervoltage 083; 054 | Flame loss in "Power" setting Flame loss in "High’ selling Contro} unit detective Fault caused by external interference voltage (reset)Fautt code Fault description Remarke/Remedial action 000 No fault 001 Advance warning: overvotage Voltage between AB and Aé greater than 14 V or 28 V at control unit. 002 Advance warning: undervoltage Voltage between A3 and Aé less than 11 V or 22 V at control unit (no advance warnings given with MB versions). 010 Overvottage cutout Voltage between A3 and A4 greater than 14.7 V or 29.4 V at control unit O11 Undervottage cutout Voltage between A3 and Ad less than 10.5 V or 21 V at control unit (vollages must be present for longer than 20 seconds). Check battery, controller and power leads, 012 Overheat or metering pump Check connection of control unit! B12 up to metering pump for continuity. interruption (B12) Check safety thermal cutout switch (switching value 160°C - 180°C). CChack hot air tines for blockage. Clear blockage if necessary. 013 Gvertemperature of flame Control unit interlock: flame sensor displays temperature of > 330°C at sensor (B10) heat exchanger, ohmic value between B2 and B10 > 2220 2, Flame sensor values: 900 Q at -25°C 1100 1 at +25°C Check hot air lines for blockage. Clear blockage if necessary. Check functioning of safety thermal cutaut switch, 020 Glow plug interruption (A1) Check glow plug. Replace if necessary. heck connection of control unit A1 and glow plug up to connection of PCB (12/3) for continuity. ‘Check connection of control unit A4 up to connection of PCB (12/6) for continuity, OK, replace PCB, 023. Current controller PCB Check connection of control unit 85 to connection of PCB (12/5) for continuity interruption (P5) ITOK, replace PCB. 024 Short-circuit in PCB current Check connection of control unit BS to connection of PCB (12/6) for controller (B5) short-circuit 10 supply +. 1 OK, replace PCB. 025 Short-circuit at diagnostic unit Check connection of contral unit B4 to connection of diagnostic unit for ‘output (B4) short-circuit 10 +. 025 Bummer motor oF ‘Speed deviation longer than 30 seconds: 030 Speed controller defective * Speed < 40% of nominal value (motor does not turn) 631 Speed deviation « Spead > 270% of nominal value (motor turns to limit) 32 Measure vollage at 5-pin motor plug between 4/2 (gr) and 4/1 (vi) using 033 analog voltmeter when blower is running. (Allention: this check cannot be carried out on 4-pole motor!) Sensor setpoint: 4 V (+/- 0.3 V}, average value. f deviation is found, replaca motor with integrated sensor. Xf sensor is OK, then speed controller is defactive. Replace PCB. 036 Short-circuit: speed setpoint ‘Check connection of contro! unit B6 to connection of signal (B6) PCB (12/2) for short-circuit to supply +. 1FOK, replace PCB. 047 Short-circult in metering pump (B12) ‘Check connection of control unit B12 to metering pump for short-circuit Check or replace metering pump if necessary.Fault code Fautt description Remarka/Remedial action 050 Too many startup attempts ‘Control unit interlocks when switched on § times in succession (10 startup attempts) without flame detection (tault code 062). 052 Non-start - safety time exceeded No fiame detected during start-up phase. Flame sensor value < 100°C (1380 9), Check fuel supply and glow plug. Check exhaust gas and combustion air ines. Check flame sensor Flame sensor values ‘ 900 Qat -25°C 1100 A at +25°O — 053. Flame loss in “Power" setting Heater has ignited (flame detected) and registers flame loss in a 054 Flame loss in “High” setting “Power” setting, 055 Flame loss in “Medium” setting Check fuel quantity, blower speed and fuel supply. 056 Flame loss in "Low" setting Check exhaust-gas line and combustion air line, If combustion is OK, cheok flame sensor and replace it if necessary. Flame sensor values: 900 Q at -25°C 1100 @ at +25°C 060. Flame sensor interrupted (B3)) Flame sensor registers temperature value outside control range. 061 Short-circuit in flame sensor (B3) ‘Check the connecting lines. ‘Ohmic value between B2 and B3 > 3000 8 (in the event of an interruption). Ohmic value between B2 and B3 < 260 © {in the event of a short-circuit). Flame sensor values: 1750 Qat +8°C 2000 @ at +25°C. 2200 Q at +37°C 082 Setpoint potentiometer Operating device potentiometer registers selpoint outside control range. interrupted (@8) Check the connecting tines. 063 Short-circuit in setpoint ‘Ohmic value between B2 and BS > 3000 0 (in the event of an interruption) potentiometer ‘Ohmic value between B2 and BB < 260 @ (in the event of a short-circuit). Normal values: 1750 © - 2200 2 064 Flame sensor interrupted (B10) Flame sensor registers temperature value outside measurement range. 065. Short-circuit in flame sensor (B10) Ohmic value between B2 and B10 > 3200 © (in the event of an interruption). Ohmic value between B2 and B10 < 200 @ (in the event of a short-circuit). Check the connecting lines. Flame sensor values. 900 2 at -25°C 1100 @ at +25°C 091 Fault caused by external Control unit fault caused by interference voltages from vehicle interference voltage {(resel) electrical system. Possible causes: Poor batteries, chargers, other sources of interference Eliminate interforance voltages. 090 Control unit defective {Internal fault in microprocessorimemory detected, {internal faullreset) Replace control unit 092 Control unit defective {ROM faut) 093 Control unit defective {RAM fault) 084 Control unit defective {EEPROM fault) 255. Control unit fault memory erased Fault memory has been overwritten by external interference voltages. Eliminate interference voltages.Wiring diagram Parts List 1.1 Burner motor 12 Glow plug 1.5 Safety thermai cutout switch 1 PCB with control temperature sensor, speed changeover and multiple connector Flame sensor Flame sensor (external) 25 18220008 07 OC 2.4 Control unit 2.2 Fuel metering pump 2.7 Main fuse (25 A) 3.1.12 Faull code enquiry 5.1 Battery €) When connecting flame sensor (extemal), detach existing socket housing and attach socket housing of flame sensor 9) Connection of contra! elements to heaterBee ee ea GF 2160 Serao, enteral temperate 38 3.1.11 Operating unit 363 3.1.12 Fault code enquiry (garage) 364 3.1.18 Operating unit 38.1 3.1.14 Operating unit es 3.25 Timer 3.26 Timer 327 Timer Cable harness for 3.1.11 Cable hamess for 3.1.13 Cable harness for 8.1.14 Cable hamess for 3.2.7 Timer relay 25 16220067016 Test (garage) digital timer to terminal 15 fighting terminal 58 break line hers to connector timer 9.25/9.2.6/3,2.7 tobe connected hero Connection control elements to heater Remove S 3 and fit S 2ysip Buyeinsu yz Bunds Buueiay 21 {e9s Bnd MOD Ez PIGED Yum JOSUaS SWELY 91 1295 ib sypid uoyoeoid EHS seurens Bing 42 ‘End #o/6 20} 1929 SL 3g O1 yeu Buiseo sed) Bnig 02 8d Ph yenno ay sey Buiseo samo] € Yous ynOIno feuNaLR AjepPs 49} GED GL leas eBUeLY EL deg 2 JeMO}G ste UONSNGUOD Z ‘yous ynojno fewueyi Kiales eb (ued exeds & jou) Bulsroy euen eping zt osip Guess 9 ‘us6ueyaxe WO | Spare parts (see spare parts list for Cat. No.) Repalr Instructions- 6. Remove/install safety thermal cutout switch 7, Remove/install flame sensor 8. Remove blower from heat exchanger, change seals on heat exchanger 9. Change seal on blower 1. Removelinstall glow plug Unecrew cap Detach glow plug connector Unscrew glow plug Important When fiting the glow plug, always use a new seal, 2, Remove/inatall plug screen Remove the plug Sorean from the plug connection using pliers. ‘Clean off the plug vert using compressed alr. ‘When putting the plug screen back in ensure correct Positioning of the lug and parting joint — sae sketch. Carefully slide in the plug screen as far as it will go. ‘The hole for the plug vent (2 mm dla.) rust then be free, ‘Installation position of plug screan in D3 LC. Plug vent here Tab on plug screen e? Installation position of plug soreen in B 3 L C Plug vent hers Parting joint on-plug sorean3. Removefinetall PCB Detach plug trom PCB. . Press down the lug. Pull out the PCB. Caution: There is a risk of components being destroyed by electrostatic discharges ‘when the PCB is touched. Therolore only pick the PCB up ‘byits outer edges! PCB with blower speed controller, electronic power switch and temperature sensor (intemal). Aiter installation of the PCB, check whether the heater combustion process can be switched off in the “Low setting, If necessary, accelerate this operation by returning hot air to the intake side. Important: When connecting the 4-pin motor plug, plug it in to match its counterpart on the PCB. > @ Flare senso: for heating sit {interna) mounied on PCB pee Connect individual plug here. Important: The PCB must be kept inside its packaging bag nil itis actualy fitted. 4, Detach air outlet 105. Detach/attach upper casing half To remove t ck the pin through Use a new rivet for reassembly Remove the upper During as a Use a new clamping spring for reassembly.6. Removefinstall safety thermal cutout switch 8, Remove flame sensor 7. Install flame sensor Oya Removed partsAWA 9. Remove blower from heat exchanger ‘Change seals on heat exchanger. Unscrew cover (1 ) from heat exchange Fit new seals (2) and (3). 10. Change seals on blower Detach/scrape old seal from blower housing, Attach new seal (self-adhesive), Important! When fitting the combustion air blower/heat exchanger in the lower casing half, care must be taken thal the supports for the blower are seated in the recesses of the lower casing half, otherwise the blawer wheel might catch Remove blower. After fitting, measure the current input of the heater in the ‘Ventiiation” setting, and check that the heater combustion process can be switched off in the "Low" setting 42 V heater | = max. 3.0,A 24V heater | = max. 1.5 ATester and test adapter =| Cat. No. of tester 22 4509 89 00 00 Cat. No. of test adapter 22 1518. 89.00 00 Prior to test Connect the correct operating voltage (12 V or 24 V) to the two connecting sockets. Connect + to red socket and - to blue socket. Important Ensure that the operating voltage is correct, otherwise the connected components may become irreparably damaged, Connect test adapter to tester and PCB Disconnect cable from tester (PCB connection). Connect test adapter cable to tester (PCB connection). Remove cap from heater. Disconnect 12-pin plug from PCB. Connect test adapter cable to PCB. Disconnect cable from tester Check operating device Cat. No. of 12V operating device 25 1767 71 00 00 Cat. No. of 24 V operating device 25 1768 71 0000, * Disconnect plug of operating device from cable hamess and connect to tester. * Set rotary knob of operating device to “Ventilation” setting and then to "Heating" setting. ‘The appropriate red LEDs on the tester must come on. * Sef operating device to “0” position. Press "LED - red” pushbutton. The red pilot light on the control unit must come on. * Set operating device to “Heating” or “Ventilation” setting, Press the "LED - green” pushbutton. The appropriate red pilot light on the control unit and the green pilot light on the operating device must come on. Check setpoint potentiometer of operating device Set the "Temp. sensor/potentiometer” switch on the tester to the "Potentiometer” setting and slowly tura,the rotary knob of the operating device as far as itil: go. The green “Temp. sensoripotentiometer” LED must remain lit without interruption. In the event of a fault. Replace the operating device. Connect to PCB 14Cheek blower motor, speed control and PCB 3 blower speeds can be checked using the “Blower speed - off-control/medium’ switch and the "Blower speed - high" pushbutton. Nominal blower speed (+ 10%) *In“Ott-contro!” setting: Speed 1000 rpm ‘+ in “Medium” setting: Speed 2000 rem +I “High” setting: Speed 8800 rpmn/4200 rpm (tight-hand switch of tester must be in the “Medium” setting) If the nominal values specified above are achieved, the blower motor and speed control are OK. Ht nominal values are not achieved: ‘+ Motor runs at max. speed (5000 rpm) immediately ‘Speed LED in test adapter does not come on Voltage LED in test adapter comes on. Cause: Speed sensor defective Connecting fines broken Remedy: Replace blower motor with integrated speed sensor ‘© Motor does not turn Disconnect 4-pin plug from motor and connect supply voltage to chambers 3 + 4 (brown and black). - f motor turns Replace PCB - If motor does not turn Replace motor * “Voltage” LED in test adapter does not come on Cause: PCB defective Remedy: Replace PCB * “Watchdog” LED of glow plug line on test adapter does not come on Cause: PCB defective Remedy: Replace PCB AA Check glow plug contro! Pushbutton in "ON" setting * “Glow plug” LED on test adapter does not come on Cause: PCB defective Remedy: Replace PCB * sGlow plug" LED comes on and “Voltage” LED goes off PCB OK ‘Check safety thermal cutout switch, flame sensor, flame sensor and PCE Set ‘Flame sensor/potentiometer" switch on tester to “Flame sensor’ * Three green LEDs on tester come on, the connected sensors are OK. ‘* ‘Safety thermal cutout switch” LED on tester does not come on Cause:, Safety thermal cutout switch defective PCB defective Connecting lead broken Remedy: Check parts. Replace if necessary ‘+ "Flame sensor” LED on tester does not come on Cause: Ohmic value of flame sensor is outside range 700 - 4000 2. Flame sensor defective Connecting lead broken PCB detective Remedy: Check parts. Replace if necessary * “Flame sensor” LED on tester does not come on Cause: Ohmic value of temperature sensor is outside range 1600 - 2400 Q. ‘Temperature sensor defective Connecting lead broken PCB defective Remedy: Check parts. Replace if necessary 16Fuel quantity measurement | BaLC : ml CAUTION! Only measure the fus! when the battery is 90 sek. sufficiently charged. At least 11/22 V and max. 13/26 V as appropriate: must be applied to the control unit during " T measurement. Initially, the temperatures at the fuel system | during the measurement should be less than + 20° C. 7 —_t—_} + 1. Preparation Nennmenge —| Detach the fuel line from the heater and place it in a ta measuring glass (15 cc. capacity). So | | Connect a voltmeter to the 4-pin plug, terminal 3 (+) 8 and 4 (-) of the control unit. . Undo the nut on the plug connection, and switch on the heater. 2 ‘After the blower has started, detach the plug cable. After Date about 45 seconds, the metering pump starts to pump fuel. , an mi When the fuel is coming out smoothly and free of bubbles, 90 sek. the fuel line is filed and biew ‘Switch off the heater and empty the measuring glass. 10 8 z 2, Measurement Reattach the plug cable. ‘Switch on the heater. ‘After the blower has started, detach the plug cable. Fuel pumping starts about 45 seconds after switch-on. Keep the measuring glass at the level of the plug during measurement. Read off the voltage at the voltmeter. ‘After about 90 seconds, {uel pumping is switched off automatically BSLP Switch off the heater, otherwise the start is repeated, Measure the fuel quantity in the measuring glass. 3. Evaluation Plot the readings onto the diagram. 10 Fuel consumption is OK when the intersection of the two values is inside the limit curve. If they intersect outside this curve, the fuel metering pump oo must be replaced, Nennmenge Cort Z 10 12 14 Volt 20 4 28 D3LP mi 90 sek. Positive line Negative line 10 wai tL Bem ge : —- la ! {Late 3 8 Voltmeter connection to conto unit Nennmenge 7 Pe 10 12 14 Volt 20 24 28 Measuring glass 15ce. 16