B 5 W S and D 5 W S

Technical Description Eberspächer ®

Mounting Instructions

J. Eberspächer
GmbH & Co.

tion
Eberspächerstr. 24

nta n*
D - 73730 Esslingen
e
um tio
Doc stalla
Telefon (zentral)
(0711) 939 - 00
in
for
Telefax
(0711) 939 - 0500

www.eberspaecher.com

Engine-independent water heater

HYDRONIC B 5 W S for petrol HYDRONIC D 5 W S for diesel

Order No. Order No.

HYDRONIC B 5 W S – 12 V 20 1819 05 00 00 HYDRONIC D 5 W S – 12 V 25 2217 05 00 00

Universal mounting kit 20 1819 80 00 00 Universal mounting kit 20 1819 80 00 00

HYDRONIC B 5 W S – 12 V 20 1822 05 00 00 HYDRONIC D 5 W S – 12 V 25 2228 05 00 00

As a complete package As a complete package

HYDRONIC D 5 W S – 24 V 25 2218 05 00 00
Universal mounting kit 25 2218 80 00 00

Contents Page Page

Items supplied .......................................................... 2, 3 Type plate .................................................................. 10
Control elements, optional ........................................ 2 Connection to the cooling water circuit ..................... 11 – 14 D
Government regulations and Conducting the combustion air / exhaust gas ........ 15
safety instructions concerning installation .............. 4 Fuel supply ................................................................ 16 – 19
Technical data ........................................................... 5 Circuit diagrams ........................................................ 20 – 25 S
Sectional drawing ..................................................... 6 Function ..................................................................... 26
Principal dimensions / Installation ........................... 7 Controls and safety devices ..................................... 27
Mounting instructions / mounting example ................ 8, 9 GGVS / TRS 003 / ADR / ADR 99 – GB
Permissible mounting positions ............................... 10 mode of operation ..................................................... 27

* Please hand this technical description / mounting instruction

to the customer after installation of the HYDRONIC.
F
Subject to change 1

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 Items supplied Control elements, optional

Quantity / Designation Order No. Quantity / Designation Order No.

1 HYDRONIC B 5 W S – 12 volt 20 1819 05 00 00 1 Change-over switch 22 1000 31 89 00

‘heating / ventilating’ 12 / 24 volt
To be additionally ordered: Can only be used in combination
1 Universal mounting kit 20 1819 80 00 00 with a control element.

or
1 Mini-clock – 12 / 24 volt 22 1000 31 31 00
1 HYDRONIC B 5 W S – 12 volt 20 1822 05 00 00
As a complete package* The mini-clock can be combined with
the TP 41i radio remote control.
1 HYDRONIC D 5 W S – 12 volt 25 2217 05 00 00
1 Module clock – 12 / 24 volt 22 1000 30 34 00
To be additionally ordered:
with temperature preselection
1 Universal mounting kit 20 1819 80 00 00

or The module clock can be

combined with the TP 4i
radio remote control.
1 HYDRONIC D 5 W S – 12 volt 25 2228 05 00 00
As a complete package*
1 Mounting parts for the 25 1482 70 01 00
module clock – only required
1 HYDRONIC D 5 W S – 24 volt 25 2218 05 00 00
when installed with a shade
To be additionally ordered:
1 Universal mounting kit 25 2218 80 00 00
1 TP 41i radio remote control 22 1000 31 39 00
12 / 24 volt
* The complete package consists of:
1 HYDRONIC B 5 W S or D 5 W S
1 Universal mounting kit The TP 41i radio remote control
can be used on its own or in combination
Optional extras with the mini-clock – Order No. 22 1000 31 31 00.
1 Check valve, Ø 18 mm 254 00 070

1 Check valve, Ø 20 mm 254 00 074

1 TP 4i radio remote control 22 1000 30 99 00
12 / 24 volt
1 Comfort mounting kit for engines from 2.5 l
cubic capacity 24 0132 00 00 00

The comfort mounting kit includes the following: The TP 4i radio remote control can only be used
1 thermostat, Ø 18 mm in combination with the module clock.
1 T-piece, Ø 18 mm
1 check valve, Ø 18 mm
1 water hose, Ø 18 mm
10 hose clamps
Please note!
D Please refer to the Extra Parts Catalogue for other
Control elements must be selected in accordance
with the intended use of the HYDRONIC and on the
additional parts.
basis of the distinction: air or water heater, simple
switching on and off, programme preselection and /
S Attention!
or radio remote control. The control elements are
Before switching on or preprogramming the heating, put
supplied with operating instructions. These are
the vehicle’s heating lever (provided the vehicle is
intended to be handed over to the customer together
equipped with one) to “HOT” (maximum position) and
GB the fan to “slowest speed” (low current consumption).
with the mounting and operating instructions for the
HYDRONIC.
For vehicles with automatic heating, put the heating
lever to “MAX.” and the desired damper position to
F “OPEN” before switching off the ignition.

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 Scope of the delivery

햲 HYDRONIC B 5 W S / D 5 W S * Part only contained in universal mounting kit of S

햳 Dosing pump HYDRONIC 24 V.
햴 Water pump ** Part only contained in universal mounting kit of
HYDRONIC 12 V.
Parts without drawing number are included GB
in the universal mounting kit. A Cable harness “control elements”
B Cable harness “fan control”
C Positive cable
D Negative cable
F
3

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 § Statutory regulations concerning
the installation of the HYDRONIC ! Safety instructions concerning the
installation and repair of the HYDRONIC
• For installation in motor vehicles subject to the
Regulations authorizing the Use of Vehicles for Road Danger of burns and injury!
Traffic (StVZO), the air heater has been approved by Before commencing any work on the HYDRONIC,
the German Federal Office for Motor Traffic in keeping disconnect the vehicle battery.
with the ‘General Design Certification’ (AGB) and the Always switch off the HYDRONIC prior to any repair work
official test symbol is marked on the type plate of the and allow hot components to cool down.
heater.

HYDRONIC B 5 W S S 288
HYDRONIC D 5 W S S 274 Important instructions for
ATTENTION !
the installation and repair
• The mounting requirements associated with the Gene- of the HYDRONIC
ral Design Certification (AGB) and further statutory
regulations have been printed in the corresponding When mounting or repairing the heater, only original
sections of these mounting instructions. accessories and original spare parts may be used.
• When the air heater is installed in special vehicles, the Changes to the HYDRONIC or to components relevant to
regulations governing such vehicles must be taken into the heating, the use of outside parts not approved by
account (e.g. GGVS / TRS 003 / ADR / ADR 99 for Eberspächer as well as an installation or operation
vehicles used to transport dangerous substances). differing from the statutory, safety and /or function rel-
• The year in which the air heater was operated for the evant specifications contained in the mounting instruc-
first time must be permanently recorded on the type tions and in the operating instructions are not permissible:
plate. To this end, 3 different years have been printed this applies in particular to the electric wiring (circuit
on the corresponding field of the type plate. The valid diagrams), the fuel supply, the combustion air and ex-
year is to be identified by removing (detaching) those haust gas duct.
two years which are not applicable. Fuel pipes and exhaust pipes must be safely fastened,
• Heaters have to be installed in accordance with the to avoid damage from vibrations (recommendation: at
mounting instructions. The installation must be intervals of approx. 50 cm).
checked by an officially approved specialist or Ensure that the insulation of electrical lines cannot be dam-
inspector for road traffic, a motor vehicle specialist or aged due to abrasion, kinking, squeezing or by exposure
an employee in accordance with paragraph 7.4 a of the to heat.
Annex to the StVZO, and must be certified on the
confirmation of acceptance included in the copy of the Only the control elements provided and / or approved by
general model approval (ABG) according to us, either on their own or in a given combination, may be
a) § 20 StVZO in case of a type approval of vehicles; used to operate the HYDRONIC. The use of other control
b) § 32 StVZO in case of an individual approval; elements may lead to malfunctions of the heater / heating
c) § 19 StVZO in case of an appraisal. operation.
For case c), the vehicle manufacturer, vehicle model
and vehicle identification number must also be Non-compliance with the statutory, safety and / or
specified. function relevant specifications leads to the lapse of the
The validity of the model approval depends on this. General Design Certification (ABG) of the HYDRONIC
The confirmation of acceptance must be carried in and to the exclusion of guarantee and liability on the part
the vehicle. of the company J. Eberspächer GmbH & Co.
• For vehicles not subject to the StVZO, it is necessary
to observe the specific regulations and mounting
instructions applicable to the given vehicle. Please note!
• The heater may only be installed or repaired – in case
of the heater being handed in for repair or guarantee • Further ‘Safety instructions concerning the installation
reasons – by a specialist workshop approved by the and repair of the HYDRONIC’ as well as ‘Important
manufacturer (service partner) in keeping with these instructions concerning the installation’ have been
D mounting instructions and possible special installation printed directly in the corresponding sections of these
recom-mendations. mounting instructions.
• The information sticker ‘Switch off heater before • The confirmation of acceptance has been enclosed
refuelling’ suppplied with the heater must be attached with the documents for the HYDRONIC.
S in a suitable position on the vehicle (close to the fuel
filler neck).

GB

F
4

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 Technical data

Heater B5WS D5WS

Heating medium Water, glycol compounds

Heat flow settings Large Small Large Small

Heat flow (watt) 5000 1500 5000 2400

Fuel consumption (l/h) 0.69 0.20 0.62 0.27

Electrical input (watt) During operation 37 10 37 10

When starting 110

During after running 8

Rated voltage 12 V 12 V 24 V

Operating range
Lower voltage limit 10.2 V 10.2 V 20.4 V
An under-voltage protecting device in the controller
turns off the heater at approx. 10 V (after 20 seconds)

Upper voltage limit 16 V 16 V 32 V

An over-voltage protecting device in the controller
turns off the heater at approx. 16 V (after 20 seconds)

Permissible working pressure up to 2.5 bar excess pressure

Water throughput of water pump against 0.1 bar 800 l/h 800 l/h 950 l/h

Electric power consumption water pump 16 W 16 W 12 W

Min. water flow rate of heater 250 l/h

Fuel Commercial petrol Commercial diesel fuel

For “Fuel quality” and “Fuel at low temperatures” (to DIN 51600 (to DIN EN 590)
see Operating Instructions and DIN EN 228) PME (acc. to DIN V 51606)
only at D 5 W S, 24 V

Permissible ambient temperature

Operation – HYDRONIC –40 °C to +80 °C –40 °C to +80 °C

Operation – Dosing pump –40 °C to +20 °C –40 °C to +80 °C

Storage – HYDRONIC / Dosing pump –40 °C to +105 °C D

Degree of radio interference suppression 5 for VHF / SW / MW
2 for LW S
Weight
without water and add on pieces approx. 2.3 kg
including water pump and dosing pump approx. 2.9 kg
GB
All technical data ± 10 %
F
5

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 Sectional drawing (shown here is the HYDRONIC B 5 W S)

from vehicle engine

to heat exchanger

1 Electric motor 10 Combustion chamber A = Exhaust gas

D 2 Controller 11 Overheating sensor B = Fuel
3 Intersection / 12 Heat exchanger V = Combustion air
S 8-channel connector 13 Cup strainer, built into dosing pump WA = Water outlet
4 Relay, vehicle fan 14 Dosing pump WE = Water inlet
5 Main fuse / fuse holder 15 Exhaust piping with exhaust muffler
GB 6 Module clock 16 Glow plug
7 Combustion air blower 17 Flame sensor
8 Water pump 18 Combustion air tube
F 9 Temperature probe

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 Principal dimensions

HYDRONIC

A = Exhaust gas
B = Fuel
V = Combustion air
WA = Water outlet
WE = Water inlet

D
Water pump

GB

F
7

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 Mounting instructions

The heater, in conjunction with the vehicle’s heating (It is not permissible) to install the heater inside
system, is used to preheat the engine, to heat the vehicles used for the transport of hazardous sub-
passenger compartment and to defrost the window stances, inside the passenger compartment, driver’s
panes. cab, working cabin, seating compartment (troop
The heater is connected to the vehicle’s cooling- carrier, mini busses, motorbusses*) and generally in
water circulation, electrical system and fuel system. rooms used by people is not permissible. When
If it is wired accordingly, the heater will operate as installing the heater in special-purpose vehicles
additional heater, thereby increasing the heat flow of valid regulations have to be complied with.
the vehicle’s own heating – in particular in the case
of motors with optimised fuel consumption – to a * Vehicles with more than 9 seats.
comfortable level.

Mounting the heater and water pump Please note!

Point of installation is the engine compartment. Mount The proposed points of installation given in these
the heater as deeply as possible so that heat ex- mounting instructions are examples.
changer and water pump can deaerate automatically. Other points of installation are also permissible
Observe permissible mounting positions as well as if they comply with the installation requirements
operating and storage temperatures. specified in these mounting instructions.
Further information concerning the installation
(e.g. for boats and ships) may be obtained from
the manufacturer on request.

Mounting example

11

8
5 8
11
9
5 4
4
6 6 3 1
10 7
1 10 2
2
D
3

S
햲 Heater 햸 Thermostat
GB 햳 Exhaust piping with exhaust muffler 햹 Vehicle’s heat exchanger
햴 Combustion air tube with fan
햵 Water pump 햺 Tank connection / T-piece (fuel)
햶 Check valve 햻 Dosing pump
F 햷 T-piece (water circulation system) 햽 Module clock

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 Mounting the heater onto the holder

• Insert heater in retaining lugs on holder.

• Screw heater onto holder with fastening screw
(6+0.5 Nm).

Note:
Depending on the installation space, it is possible
to move the heater inside the holder and to secure it
with screws in one of the two fastening threads.

햲 HYDRONIC
햳 Retaining lugs
햴 Holder
햵 Fastening screw
햶 Fastening threads

Installation of the angular connection piece

HYDRONIC B 5 W S and D 5 W S are supplied with Should the angular connection piece cover the
straight connection pieces. Depending on the previous screw opening, the adjacent screw hole
installation conditions, it may be necessary to install has to be used.
angular connection pieces.
• Unscrew fastening screws on lid and remove lid. This must be done as follows:
• Push straight connection piece downwards. • A thread has to be tapped beforehand in the hole
• Undo serrated ring and remove O-ring. of the HYDRONIC’s aluminium casing by
• Pull connection piece out of lid. screwing one of the tapping screws into the hole
• Push angular connection piece into lid, insert new and unscrewing it again.
O-ring into the groove provided for that purpose • Put on lid and screw in all four screws – torque
and grease sparingly. 4.5 Nm.
• Mount serrated ring on angular connection piece,
twist connection piece depending on the installation Note:
position and insert into the lid’s toothed ring. The threads have to be tapped prior to mounting
• Screw lid back onto the casing with four screws – the lid.
torque 4 Nm.

GB
햲 Fastening screws 햵 O-ring 햸 Hole
햳 Straight connection 햶 Lid 햹 HYDRONIC
햴 Serrated ring 햷 Angular connection
F
9

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 Permissible mounting positions

The heater and the water pump are to be installed The maximum permissible deviations from the nor-
in the standard position. Depending on prevailing mal position are indicated in the drawing.
installation conditions, the heater and the water Please consult the manufacturer if wider deviations
pump can be tilted as shown in the drawing. are necessary.

HYDRONIC
Normal position horizontal (exhaust pipe to the
bottom) with permissible swivel range.

or

Water pump
Normal position horizontal with permissible swivel
range.

Please note!

The outlet nozzle must be pointing 5° upward,

as shown in the drawing.

Type plate

The type plate must be clearly visible after the

D heater has been installed. If necessary, a second
type plate (duplicate) with the same details as the
original one can be mounted at a clearly visible
S point on the air heater or a cover in front of the air
heater.
A second type plate is not necessary if the original
type plate is clearly visible under a cover that can
GB be removed without having to use tools. The type
plate is mounted on the basic unit.

F
10

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 Connection to the cooling water circuit

A careful deaeration of the water cycle (including Please note!

heater) after installation of the heater is necessary for
the perfect functioning of the device: If the heater is integrated in a vehicle engine’s cooling
system, it is part of this cooling system.
1. Fill heater and water hoses with coolant after instal-
lation, but before connection to the cooling water The following points thus need to be taken into account:
cycle. The vent screw must remain open during
filling. If water issues from the opening of the vent • The heater must always be mounted beneath the
screw, the heater is deaerated. Close the vent min. cooling water level (coolant recovery bottle,
screw again. radiator, vehicle heat exchanger) in such a manner
that it works in the direction of flow of the engine
2. Afterwards, the entire cooling system must be cooling cycle. After installation, the entire cooling
deaerated to remove any bubbles in accordance system including the heater must be deaerated to
with the engine manufacturer’s instructions. remove any bubbles in accordance with the engine
manufacturer’s instructions. This also applies after
The pressure in the water cycle must be limited every interference with the cooling water system
to max. 2.5 bar excess pressure inside a pressure (repair, exchange of cooling water). All water con-
control valve (e.g. radiator filler cap). nections (clamps) have to be perfectly tightened
and retightened after the vehicle has been driven
for 2 hours or approx. 100 km. Any water-carrying
pipes must be protected against chafing and ex-
Attention! cessive temperatures (radiant heat from exhaust
pipes). To prevent corrosion, the cooling water must
During operation with auxiliary heating, the vehicle’s contain at least 10% antifreeze all the year round.
heating valve must always be kept completely open The coolant must contain sufficient antifreeze for low
either electrically or mechanically. temperatures.

Recommendation: • Operating the heater with frozen coolant is danger-

Use switches with final position contact (“break ous and thus inadmissable.
contact”) for all heating cycles.
When refilling coolant, only use the one authorized by
the vehicle manufacturer. Compare the vehicle’s
operating instructions. Mixing it with unauthorized
coolant may lead to damage to the engine and heater.
Before remounting a heater into another vehicle, rinse
all water carrying parts of the heater with clear water.

GB

F
11

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 There are several possibilities:

1. Inserting heater into inflow line – Characteristic heating curve:

this arrangement is the simplest one With the stationary heating switched on, the heat is
Cut open the inflow line running from the vehicle first fed to the vehicle engine. After the cooling water
engine to the heat exchanger and insert the heater temperature has reached approx. 30 °C, the heat is
and the water pump. also fed to the passenger compartment, depending
on the fan position selected.

햲 Heater
햳 Water pump
2 햴 Vehicle’s heat exchanger
햵 Vehicle engine

4
1

2. Inserting the check valve into the inflow line

Cut open the inflow line running from the vehicle Characteristic heating curve as for water cycle “1”
engine to the heat exchanger and insert the check
valve. Advantage:
Insert the heater and the water pump into the water No loss of efficacy of engine heating with the station-
circulation system as shown in the drawing. ary heating switched off.

Check valve Ø 18 mm – Order No. 254 00 070

Check valve Ø 20 mm – Order No. 254 00 074

햲 Heater
3 햳 Water pump
햴 Check valve
햵 Vehicle’s heat exchanger
햶 Vehicle engine

D 2

S
5
1
GB
4

F
12

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 3. Integrating the deluxe installation kit
into the water circulation system

Deluxe installation kit, Order No. 24 0132 00 00 00 Characteristic heating curve:

First, up to a cooling water temperature of approx.
Cut open the inflow line running from the vehicle 70 °C the heat of the auxiliary heating is only fed to
engine to the heat exchanger and insert the check the passenger compartment = small cycle, fast heat-
valve. ing up. If the cooling water temperature continues to
Cut open the return line running from the heat rise, the thermostat gradually changes over to the
exchanger to the vehicle engine and insert the large cycle = additional preheating of engine (full
T-piece. Insert the heater, thermostat and water change-over is reached at 75 °C).
pump into the water circulation system as shown
in the drawing.
Please note!
Execute connections 1, 2 and 3 as described in
the drawing.

Thermostat, Ø 18 mm

4 2
(always open)

7
1

6
5

햲 Heater t<70 °C = 3 closed

햳 Water pump 2 open
햴 Check valve
t>75 °C = 3 open
햵 Thermostat
햶 T-piece 2 closed
햷 Vehicle’s heat exchanger
햸 Vehicle engine

GB

F
13

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 4. Water cycle with combination valve Combination valve with 5 connections:
Order No. 330 00 177
Mounting the combination valve – 5 connections and additional
If the water flow pipe and water return pipe from the T-piece Ø 20 for return line:
vehicle engine to the heat exchanger in the engine Order No. 20 1673 80 11 00
compartment have been spaced apart, the combina-
tion valve with 5 connections and one T-piece have Combination valve with 6 connections:
to be used. Order No. 330 00 176
Cut open the inflow line running from the vehicle
engine to the heat exchanger and insert the combina- Characteristic heating curve:
tion valve. With the stationary heating switched on, the heat is
Cut open the return line running from the heat ex- exclusively fed to the passenger compartment =
changer to the vehicle engine and insert the T-piece. small cycle, fast heating up.

Mounting the combination valve – 6 connections Once the vehicle engine is put into operation – at low
If the water flow pipe and water return pipe from the speed – a part of the heat is fed to the vehicle engine
vehicle engine to the heat exchanger in the engine (partial cycle) which leads to a shortening of the
compartment have been installed parallel to each vehicle engine’s warm-up period.
other, the combination valve with 6 connections
(without T-piece) may be used. At increased engine speeds (> 2000 rpm), the entire
Cut open the inflow and return lines running from heat is distributed to the passenger compartment and
the vehicle engine to the heat exchanger and insert vehicle engine = large cycle, auxiliary heating func-
the combination valve. tion, further shortening of the warm-up period.

Combination valve (6 connections)

HYDRONIC

from vehicle to vehicle

engine heat exchanger

to vehicle from vehicle

engine heat exchanger

6
1
D
5
4
S
햲 Heater
햳 Water pump
GB 햴 Combination valve (5 connections)
햵 T-piece
햶 Vehicle’s heat exchanger
햷 Vehicle engine
F
14

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 Conducting the combustion air / exhaust gas

Conducting the combustion air Arrange the exhaust gas outlet in such a manner
The combustion air must be drawn in from the out- that the exhaust gas cannot be immediately drawn
side (not from the passenger compartment in again.
or boot). The exhaust gas outlet must lead out into the open air.
As described in these mounting instructions, the The exhaust gas pipe must be arranged in such a
heater is installed inside the engine compartment. If manner that exhaust gas cannot enter the vehicle,
the air intake fitting for the combustion air is situated be drawn in by the vehicle's fan or by the heater
in an area where the combustion air does not reach fan1), nor must it impair the function of vital vehicle
temperatures exceeding 25 °C, and where neither parts in any way (ensure that an adequate distance
road spray nor dust / dirt are to be expected, the is maintained).
combustion air intake is already complete. If this is Run the exhaust gas pipe in such a manner that
not the case, a flexible hose with an inner diameter of it cannot be clogged up by dirt, snow or water
20 mm and up to 1.5 m long has to be connected to (draining hole). Do not position the outlet opening of
take the combustion air from an area complying with the exhaust gas against the air stream.
this condition. An end sleeve crossed with a web must be mounted
The inlet opening of the combustion air pipe may in on the end of the exhaust gas pipe so that a 16 mm
that case not be built in against the air stream and diameter ball cannot be inserted (requirement of
must be installed in such a manner that it cannot be StVZO “Technical Demands Expected of Heaters”).
clogged by dirt and snow and that penetrated water
1)
may run off. This requirement is considered to be fulfilled when
Push on the end sleeves so that a 16 mm diameter the end of the exhaust gas pipe is run upwards or
ball cannot be inserted (requirement of StVZO to the side, or when the exhaust gas pipe passes
“Technical Demands Expected of Heaters”). underneath the vehicle floor to the vicinity of the
side or rear limits of the driver's cab or the pas-
Conducting the exhaust gas senger compartment.
The items supplied include a flexible exhaust hose
with an inner diameter of 24 mm and 1000 mm long.
It must be cut apart at a suitable place and the ex- ! Danger of poisoning and burns!
haust silencer inserted (compare diagram on page 3);
the exhaust tailpipe 햶 should be much shorter than Every combustion process creates exhaust gas
the exhaust pipe 햴. If necessary, the exhaust hose which contains toxic constituents; for this reason
pipe may be shortened or extended up to a maximum and due to the high temperatures occurring, the
length of 2 m. exhaust gas duct needs to be absolutely carried out
The exhaust gas pipe must not protrude beyond the in accordance with the specifications of these
external limits of the vehicle. mounting instructions.
The exhaust pipe must either slope downwards During heating operation, avoid any work in the area
slightly, or a 5 mm diam. hole must be drilled into of the exhaust gas duct.
the lowest point of the pipe to allow condensate to In such a case, switch off the HYDRONIC
drain off. beforehand and wait until all parts have completely
Always fasten the silencer; longer exhaust pipes must cooled down.
always be fastened at intervals of approx. 50 cm. If necessary, wear protective gloves.

햲 Heater 1
햳 Combustion air hose
햴 Exhaust gas pipe
햵 Exhaust gas silencer D
햶 Exhaust tail pipe

S
2 4
3 5
GB
bis 1,5m

bis 2m
up to 1.5 m
up to 2 m F
15

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 Fuel supply

Operation with bio-diesel (PME) – Danger of fire and explosion!

HYDRONIC D 5 W S - 24 V
! Poisonous fumes!
HYDRONIC D 5 W S - 24 V is certified for operation
with bio-diesel as per DIN V 51606 in free-flowing Caution when handling fuel. Before filling up and
state (decreases at temperatures under 0 °C). when working on the fuel supply, switch off the
vehicle’s engine and the HYDRONIC.
1. Tapping fuel with the T-piece from the fuel Avoid open fire when handling fuel.
supply line Do not smoke; this also applies there where
the presence of fuel is only noticeable on account
Precondition: of its characteristic smell.
Fuel lines must be tight. Do not inhale petrol fumes.
A maximum preliminary pressure of 0.3 bar can
arise in the fuel lines in any operating mode.

Please note!

Deviations from the instructions given here are

impermissible, otherwise functional disorders
can arise.
Tapping fuel from the supply line downstream of the
delivery pump is prohibited in cars, since pressures
of up to 10 bars can occur.
Before the air heater is turned on it is first necessary
to start up the vehicle's engine so that the fuel lines
can be filled.

To engine b
mechanical fuel pump
or injection pump 8

햲 Inflow line running from tank fitting to engine – Permissible line lengths
insert T-piece into inflow line upstream of delivery
pump Suction side
햳 Return line running a = max. 2 m
D 햴 Dosing pump
햵 T-piece Pressure side
햶 Fuel filter – only required if fuel is contaminated b = max. 4 m for petrol
햷 Fuel hose, 5 x 3 (inner diameter = Ø 5 mm) – b = max. 6 m for diesel
S HYDRONIC B 5 W S only
햸 Fuel pipe, 6 x 2 (inner diameter = Ø 2 mm)
햹 Fuel pipe, 4 x 1,25
GB (inner diameter = Ø 1,5 mm)
햺 Fuel hose, 5 x 3 (inner diameter = Ø 5 mm),
approx. 50 mm long
햻 Fuel hose, 3,5 x 3 (inner diameter = Ø 3,5 mm),
F approx. 50 mm long

16

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 2. Tapping fuel with rising tank connection
installed in the vehicle tank or in the tank
fitting

If it is not possible to install a separate rising pipe in Condition:

cars with fuel injected engines the return line can be • No valve may be installed in the return line
tapped by means of a T-piece. in the tank.
• The pressure inside the return line may reach
a max. of 2 bar. In case of pressures above 0.3
and up to 2 bar a pressure reducer (add-on part,
order No. 20 1645 89 30 00) must be installed
in front of the dosing pump.

b
10

햲 Tank connection for metal tank, Permissible line lengths

inner diameter = Ø 2 mm,
external diameter = Ø 6 mm, Suction side
order no. 25 1226 89 50 00 a = max. 2 m
햳 Tank connection for tank fitting,
inner diameter = Ø 2 mm, Pressure side
external diameter = Ø 4 mm, b = max. 4 m for petrol
order no. 20 1645 89 35 00 b = max. 6 m for diesel
햴 Dosing pump
햵 Fuel filter – only required if fuel is contaminated
햶 Fuel hose, 5 x 3 (inner diameter = Ø 5 mm) –
HYDRONIC B 5 W S only
햷 Fuel pipe, 6 x 2 (inner diameter = Ø 2 mm)
햸 Fuel pipe, 4 x 1 (inner diameter = Ø 2 mm)
햹 Fuel hose, 3,5 x 3 (inner diameter = Ø 3,5 mm),
approx. 50 mm long
햺 Fuel hose, 5 x 3 (inner diameter = Ø 5 mm),
approx. 50 mm long
햻 Fuel pipe, 4 x 1,25 (inner diameter = Ø 1,5 mm)
햽 Connecting piece, external diameter = 4 mm
D

GB

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 Mounting position of the dosing pump
Permissible suction and pressure level
of the dosing pump

Mounting position of the dosing pump

Mount the dosing pump in the vehicle with the pres-
sure side rising by at least 15° and maximum 90°.

If possible the fuel lines from the dosing pump to

pressure side the heater should rise continuously.

Permissible suction and pressure level

Pressure level from the vehicle's tank to the dosing
pump:
a = max. 3000 mm

Suction level with a pressureless vehicle tank:

b = max. 500 mm for petrol
b = max. 1000 mm for diesel

Please note: Check the tank venting.

Suction level with a vehicle tank in which fuel tap-

햲 Dosing pump ping produces a vacuum (valve with 0.03 bar in the
햳 Maximum fuel level tank closure):
햴 Minimum fuel level b = max. 150 mm for petrol
햵 Connection on the heater b = max. 450 mm for diesel

Pressure level from the dosing pump to the heater:

c = max. 2000 mm

GB

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 Please note!

• A pressure reducer (Order No. 20 1645 89 30 00) • Always fasten the fuel pipes at intervals of approx.
or a separate tank connection (see page 13) must 50 cm.
be used if the pressure in the fuel line exceeds
0.2 bar to maximum 2.0 bar. • Always use a rubber hose to connect the fuel
branching piece – never use a plastic pipe.
• A separate tank connection if the pressure in
the fuel line exceeds 2.0 bar or if the return line • The fuel pipe must always be butt-jointed where
incorporates a check valve. there is a connection between fuel pipes and
a fuel hose (see Drawing A).
• Fuel tapping in a car after the conveying pump
is prohibited! • When incorporating a T-piece ensure that the
mounting position indicated on Drawing B is
• Fuel hoses and pipes must be cut to length with observed.
a sharp knife; the cut-off point must not be dented
and must be burr-free. • §§ 45 and 46 of StVZO also apply correspond-
ingly to the fuel lines and additional heater tanks.
• Protect the fuel line, filter and dosing pump
from impermissible heat, and do not mount in
the vicinity of silencers and exhaust gas pipes.

Drawing A: Drawing B:

correct

incorrect

GB

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 Circuit diagram
HYDRONIC B 5 W S / D 5 W S – 12 volt

20 1777 00 96 01 B
Parts list

1.1 Burner motor a) for auxiliary heating option connect to D+ Cable colours
1.2 Glow plug f) cut open wire
1.5 Overheating sensor g) only with petrol sw = black
1.12 Flame sensor h) only with diesel ws = white
1.13 Temperature probe k) switch (auxiliary heating, e.g. outside temperature rt = red
< 5 °C or change-over switch for summer / winter) ge = yellow
D 2.1 Controller gn = green
2.2 Dosing pump vi = violet
2.5.7 Relay, vehicle fan Length ‘plus’ + length ‘minus’: br = brown
2.7 Main fuse 20 A < 5 m: cross section 4 mm2 gr = grey
S 2.7.1 Fuse, actuation 5 A > 5 m < 8 m: cross section 6 mm2 bl = blew
2.7.5 Fuse, vehicle fan 25 A li = purple
2.12 Water pump Cable ends that are not being used must be isolated.
GB
5.1 Battery Plug and socket case are shown from the cable entry
5.1.2 Fuse strip in vehicle side.
F 5.9.1
5.10
Switch, vehicle fan
Vehicle fan
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 Circuit diagram
Control elements – 12 volt

Parts list

2.15.9 Sensor, outside temperature

3.1.9 Change-over switch ‘heating / ventilating’

3.1.16 Key button, radio remote control

3.2.6 Timer, mini-clock

3.2.9 Timer, module clock
3.2.12 Timer, mini-clock

3.3.6 TP 41i radio remote control (receiver)

b) Connect to terminal +15 if heating operation

> 2 hrs (with the ignition switched on) is desired
c) Lighting terminal 58
d) Stationary ventilation (optional)
e) External switch ON / OFF (optional)
i) Connection radio module receiver TP 4i

Length ‘plus’ + length ‘minus’:

< 5 m: cross section 4 mm2
> 5 m < 8 m: cross section 6 mm2

Cable ends that are not being used must be

insulated.

Plug and socket case are shown from the cable

entry side.

Please note!

For vehicles with automatic heating or airconditioning,

vehicle fan control must be in accordance with our
vehicle-related workshop information. If no workshop
information is available, the vehicle manufacturer’s
instructions with regard to the connection and / or point
of intersection for the fan control must be adhered to.
D

S
Cable colours

sw = black vi = violet GB
ws = white br = brown
rt = red gr = grey
ge = yellow bl = blew
20 1777 00 97 01 A gn = green li = purple
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 Circuit diagram
HYDRONIC D 5 W S – 24 volt

Parts list 25 2147 00 96 01

1.1 Burner motor f) cut open wire Cable colours

1.2 Glow plug
1.5 Overheating sensor Length ‘plus’ + length ‘minus’: sw = black
1.12 Flame sensor < 5 m: cross section 4 mm2 ws = white
1.13 Temperature probe > 5 m < 8 m: cross section 6 mm2 rt = red
D 2.1 Controller ge = yellow
2.2 Dosing pump Cable ends that are not being used gn = green
2.5.7 Relay, vehicle fan must be isolated. vi = violet
S 2.7 Main fuse 15 A Plug and socket case are shown br = brown
2.7.1 Fuse, actuation 5 A from the cable entry side. gr = grey
2.7.5 Fuse, vehicle fan 25 A bl = blew
GB 2.12 Water pump li = purple
5.1 Battery Please note!
5.1.2 Fuse strip in vehicle
5.9.1 Switch, vehicle fan The vehicle ventilator runs immediately
F 5.10 Vehicle fan after the heater has been started.

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 Circuit diagram
Control elements – 24 volt

Parts list Please note!

2.15.9 Sensor, outside temperature For vehicles with automatic heating or airconditioning,
vehicle fan control must be in accordance with our
3.2.9 Timer, module clock, TRS vehicle-related workshop information. If no workshop
3.2.12 Timer, mini-clock information is available, the vehicle manufacturer’s
instructions with regard to the connection and / or
b) Connect to terminal +15 if heating operation point of intersection for the fan control must be
c) Lighting terminal 58 adhered to.
e) External switch ON / OFF (optional)
i) Connection radio module receiver Cable colours D
Length ‘plus’ + length ‘minus’: sw = black
< 5 m: cross section 4 mm2 ws = white
> 5 m < 8 m: cross section 6 mm2 rt = red S
ge = yellow
Cable ends that are not being used gn = green
must be insulated. vi = violet GB
br = brown
Plug and socket case are shown gr = grey
from the cable entry side. bl = blew
li = purple
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 Circuit diagram
HYDRONIC D 5 W S – 24 volt, GGVS / TRS 003 / ADR / ADR 99

25 2147 00 97 01 C

D Cable colours

sw = black
ws = white
S rt = red
ge = yellow
gn = green
GB vi = violet
br = brown
gr = grey
bl = blew
F li = purple

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 Circuit diagram
Control elements – 24 volt, GGVS / TRS 003 / ADR / ADR 99

Parts list

1.1 Burner motor m) if only one control element is used for items 5.2.1
1.2 Glow plug and 5.2.2, it must be ensured that, if the function
1.5 Overheating sensor ‘opening of battery separating switch’ is
1.12 Flame sensor actuated (emergency shutdown-function in the
1.13 Temperature probe case of GGVS / TRS 003 / ADR / ADR 99) and
similar), the switch always breaks contact
2.1 Controller without delay (without consideration for the
2.2 Dosing pump heater mode) and breaks all of the heater’s
2.5.7 Relay, vehicle fan circuits from the battery.
2.7 Main fuse 15 A
2.7.1 Fuse, actuation 5 A Length ‘plus’ + length ‘minus’:
2.7.5 Fuse, vehicle fan 25 A < 5 m: cross section 4 mm2
2.12 Water pump > 5 m < 8 m: cross section 6 mm2

3.2.9 Timer, module clock, TRS Cable ends that are not being used
must be isolated.
5.1 Battery Plug and socket case are shown
5.1.2 Fuse strip in vehicle from the cable entry side.
5.2.1 Battery operating switch m)
(operation e.g. controlled
via ignition lock) Please note!
5.2.2 Battery separating switch m)
(Emergency-shutdown function in the case The cables drawn in as dashed lines have to be
of GGVS / TRS 003 / ADR / ADR 99) additionally laid and connected. Prior to doing so,
5.3 Accessory drive HA+ disconnect the wire harness at the positions marked
5.3.1 Switch auxiliary drive with f). Cable seals and push-on contacts for the
5.5 Generator D+
5.9.1 Switch, vehicle fan
connector B1 and the ventilator relay are contained
in the installation kit.
D
5.10 Vehicle fan The vehicle ventilator runs immediately after the
heater has been started.
b) Connect to terminal +15 S
c) Lighting terminal 58 For vehicles with automatic heating or airconditioning,
f) Cut open wire vehicle fan control must be in accordance with our
g) Insulate cable and tie back vehicle-related workshop information. If no workshop GB
information is available, the vehicle manufacturer’s
instructions with regard to the connection and / or
point of intersection for the fan control must be
adhered to.
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 Function Check the following points in the event of faults:

Depending on the wiring, the heater can be operated The heater does not start when it is switched on:
as purely stationary heater or as combined stationary
and auxiliary heater to compensate for an insufficient Turn-off the heater and then switch it on again,
output of heat by the vehicle engine. but not more than twice in succession.

Stationary heating operation If the heater still does not start:

Switching on
The pilot lamp in the control unit lights up when the Is there fuel in the tank?
heater is switched on (switch, timer ...). The water pump
starts and after a fixed programme with prerinsing and Has the fuse blown?
preheating, combustion air fan, glow plug and fuel dos-
ing pump set combustion going. Once a stable flame Are all electrical lines and connections ok?
has formed, the glow plug is switched off by a timer.
Is the combustion-air duct or exhaust-gas duct
Heating operation blocked?
Depending on the heat requirement, the heater may
be adjusted to the following levels:
“LARGE” or “SMALL”. Conduct a diagnostic test with the JE diagnostic
instrument or the module clock as described in
The temperature thresholds have been fixed pro- “Trouble Shooting and Repairs Instructions”
grammed in the electronic control device. If the heat for the HYDRONIC B 5 W S / D 5 W S.
requirement at level “SMALL” is so low that the cool-
ing water temperature reaches 85 °C, the device
goes into the control interval. This is followed by the
fan continuing to run for approx. 130 seconds. The
pilot lamp also lights up during the control interval
and the water pump continues to run up to the next
controlled start.

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 Controls and safety devices

• If the heater does not ignite within 90 seconds Stationary ventilation with change-over switch
after fuel pumping has started, then the start ‘heating / ventilating’
procedure must be repeated in the described Stationary ventilation means that it is possible to
manner. directly control the vehicle fan by means of the heat-
A fault shut-down is effected if the air heater once ing device preselector or – even more effectively – via
again fails to ignite after 90 seconds of fuel the radio remote control TP4i / TP41i, thus bypassing
pumping. the heating operation. This serves the purpose of
After an excessive number of unsuccessful ventilating the passenger compartment shortly before
attempts to start the heater, the control will be departure with fresh air as it often heats up consider-
locked*. ably during summer time (separate wiring).

• A renewed start must be completed if the flame

extinguishes itself during operation. A fault shut-
down is effected if the air heater fails to ignite GGVS / TRS 003 / ADR / ADR 99 –
within 90 seconds after renewed fuel pumping or mode of operation
if it does ignite but then extinguishes itself within
the next 15 minutes. Please note!
It is possible to override a fault shut-down by
briefly switching the heater off and then on again. The HYDRONIC D 5 W S – 24 volt is suitable and
Do not repeat this more than twice certified for installation in vehicles used to transport
in succession! dangerous substances according to the regulations
in accordance with GGVS / TRS 003 / ADR / ADR 99
• In case of overheating (lack of water, badly vented (detailed information is contained in an information
cooling water cycle), the overheating sensor will sheet with print no. 25 2069 95 13 50).
respond, the fuel supply will be interrupted and a
fault shut-down is effected. Once the cause of Forced cut-off in GGVS / TRS 003 / ADR / ADR 99
overheating has been eliminated, the device can mode
be restarted by switching it off and on again When vehicles are used to transport dangerous
(condition: device has sufficiently cooled down, substances (e.g. road tankers), the heater must be
cooling water temperature < 70 °C). switched off before entering the hazardous area
After an excessive number of switching-offs due (refinery, petrol station, etc.). If this is not observed,
to overheating the control will be locked*. then the heater will automatically shut-down when:
– The vehicle's engine is turned off.
• A fault shut-down is effected when the upper – An accessory unit is switch on (e.g. auxiliary drive
or lower voltage limit is reached. for the unloading pump).
– A vehicle door is opened (TMD regulation; only in
• The air heater will not start if the glow plug is France).
defective or if the electrical line to the dosing After shut-down the fan will continue to run for max.
pump is interrupted. 40 seconds.

• The rotating speed of the fan motor is continuously

monitored. A fault shut-down is effected after
60 seconds if the fan motor does not start, if it is
blocked or if the rotating speed drops below 40 %
of the desired speed.

* Reading off errors and cancelling of locking: D

1. by means of the built-in module clock
(3.2.9 in the circuit diagram) Please note!
2. if other control elements have been built in, S
by means of connecting the diagnostic device • To prevent corrosion, the coolant must contain
22 1512 89 00 00 instead of these other control at least 10 % antifreeze all the year round.
elements.
Operation and list of errors see operating instructions • The controller must be protected while electric
GB
for the diagnostic device and / or the trouble-shooting welding work is being completed on the
and repair instructions HYDRONIC B 5 W S / vehicle by disconnecting the “plus” pole from
D 5 W S. the battery and connecting it to the chassis. F
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