Eberspacher engine preheaters
Auto Terms,  Car device,  Vehicle electrical equipment

Eberspacher engine preheaters

When a car is operated in a region with cold winters, many motorists consider equipping their vehicle with a pre-heater. There are many types of such equipment in the world. Regardless of the manufacturer and model, the device allows you to warm up the engine before starting, and in some models, also the interior of the car.

The heater can be air, that is, designed to heat the interior of the car, or liquid. In the second case, the power unit is pre-heated. Everyone knows that after the machine is idle in the cold, the oil in the engine gradually solidifies, which is why its fluidity is lost. When the driver starts the unit, the engine experiences oil starvation for several minutes, that is, some of its parts receive insufficient lubrication, which can lead to dry friction.

It is clear that in this case the load on the car's internal combustion engine is not recommended. For this reason, depending on the ambient temperature and the idle time of the car without action, heating of the unit is required. For more information on why you need to warm up a car engine in winter, read separately... And about how to properly prepare a gasoline or diesel engine for work, read in another article.

Eberspacher Hydronic preheaters are used to raise the temperature of the internal combustion engine, making it easier to start, especially if it is a diesel engine. The features of the operation of diesel power units are described in another review... But in a nutshell, a cold engine running on diesel fuel does not start well in frost, because the combustion of VTS occurs due to the injection of fuel into compressed air (high compression heats it up to the combustion temperature of the fuel) in the internal combustion engine cylinder.

Eberspacher engine preheaters

Since the chamber in the cylinder after a machine standstill in the cold is very cool, the fuel may not ignite after injection, since the air heating level does not correspond to the required parameter. To ensure the correct start of such a power unit, the engine starting system can be equipped with glow plugs. Their function and principle of operation are described in more detail. here.

Gasoline is much easier to ignite. To do this, it is enough to create a sufficient voltage in the ignition system so that a powerful spark is formed. Details on how the ignition system works is described in another review... However, in cold regions, the temperature of the motor is also important before it is operated with increased loads. Some car manufacturers equip vehicles with a remote start system. How the ICE remote start system works is described in another article.

While the car starts to move, due to the fact that its engine will work for some time in a light mode, the power unit will be correctly prepared for the upcoming trip. About,which is better: engine preheater or unit autostart, read this article. Additionally, the engine preheater is installed as a heater for the passenger compartment. This allows you not to wait until the temperature in the car rises to a comfortable parameter - the driver comes to the car, and the cabin is already warm enough. This mode will be especially useful for truckers. In order not to burn fuel during the night and it is useless not to waste the resource of the power unit, it is enough to set the required temperature, and the system will automatically maintain it.

Let's focus on how it works, and on the features of the device and modifications of the heaters, which were developed by the German company Eberspächer.

Principle of operation

Some motorists may feel that installing a preheater is an unnecessary luxury. In their opinion, you can wait a little while the car warms up. This is true, but for those who live in northern latitudes, this may be associated with some inconvenience. Few people will be pleased to just stand in the cold and wait for the car to prepare for the trip. It is also uncomfortable to be in the car interior, since it is still cold, and if you turn on the stove right away, frosty air will come from the air ducts.

The benefits of pre-heaters will be appreciated only by those who drive every day in severe frosts. But before buying the first available model, you need to make sure that it will meet the required parameters. We will talk about this a little later. Before that, you should understand on what principle the device works.

Eberspacher engine preheaters

Eberspächer Hydronic is mounted in the engine cooling system (the device of this system is discussed in more detail) here). When the device is activated, the working fluid (antifreeze or antifreeze) begins to circulate in a small cooling circle. An identical process occurs when the motor is running until it reaches the operating temperature (read about this parameter separately).

To ensure the movement of antifreeze along the line when the engine is turned off, an individual pump is included in the heater device (in another article read about how the standard water pump of the motor works).

An igniter is connected to the combustion chamber (basically it is a pin that heats up to the ignition temperature of gasoline or diesel fuel). The fuel pump is responsible for the supply of combustible material to the device. This element is also individual.

The fuel line, depending on the type of installation, can be individual or combined with the standard one. In the first case, the fuel pump is connected to the main fuel line immediately after the fuel filter. If the car uses two types of fuel, for example, when installing LPG, then the heater will only operate on one. The safest way is to organize a connection to a gasoline line.

If the system uses an individual fuel system, then in this case a separate fuel tank can be installed (it is necessary when using fuel that is different from the main one filled into the gas tank).

When the system is activated, fuel is supplied to the combustion chamber through an injector. A heat exchanger of the device is installed in the area of ​​the flame. The fire heats up the antifreeze circulating along the line. Thanks to this, the cylinder block gradually heats up, and it is easier for the engine to start in cold weather.

As soon as the coolant temperature reaches the required parameter, the device is deactivated. If the system is combined with the operation of the interior heater, then additionally this equipment will also heat the interior. The combustion power of the mixture of air and fuel depends on the temperature of the antifreeze. While this figure is below 75 degrees, the nozzle operates at maximum mode. After the coolant heats up to +86, the system reduces the fuel supply. A complete shutdown occurs either by the timer program or remotely via the remote control. After deactivation of the combustion chamber, the fan for heating the passenger compartment will continue to operate for a couple of minutes in order to use all the heat accumulated in the heat exchanger.

Eberspacher engine preheaters

The air analogue Airtronic has a similar operating principle. The only difference between this modification is that this heater is intended only for heating the interior of the car. It can be installed in the engine compartment, and it heats only a heat exchanger connected to the air ducts of the interior heating system. The exhaust gases are discharged into the exhaust system of the machine.

The operation of the pump, fan and nozzle is ensured by charging the battery. And this is the main disadvantage of any pre-heaters. If the system runs for an hour or a little less, then a weak battery will very quickly lose its charge (read separately about several ways to start the engine with a completely dead battery).

If the internal combustion engine heating system is integrated into the interior heating, the heater fan will start when the coolant reaches a temperature of +30 degrees. For the device to work correctly, the manufacturer has equipped the system with several sensors (their number depends on the equipment modification). For example, these sensors record antifreeze heating rate. These signals are sent to the microprocessor control unit, which determines at what moment to turn on / off the heating. Based on these indicators, the fuel combustion process is controlled.

Heater action device Hydronic

The installation itself will not work unless a control device is connected to it. There are three modifications of activation systems:

  1. Stationary;
  2. Remote;
  3. Mobile.

The stationary control unit is equipped with an Easystart timer. It is a small panel that is installed on the center panel in the passenger compartment. The location is chosen by the motorist himself. The driver can set the time for turning on the system for each day of the week separately, set it to turn on only on a specific day. The availability of these options depends on the control system model.

Eberspacher engine preheaters

Also, car owners are offered modifications that have feedback (the key fob receives information about the state of the equipment or the heating process), resistance to severe frosts, various display options with several types of control buttons. It all depends on which model is available in the car accessories and accessories store.

The remote control model comes with two remote controls (Remote and Remote +). They differ from each other by the presence of a display on the key fob itself and timer control buttons. This element spreads a signal within a radius of one kilometer (this depends on the battery charge and the presence of obstacles between the key fob and the car).

The mobile type of control operation implies the installation of a special application on a smartphone (Easystart Text +) and a GPS module in the car. This control system can be combined with a stationary panel. In this case, the setting of the pre-heater operation mode is provided both from the panel in the car and from a smartphone.

Types of preheaters Hydronic Eberspacher

All Eberspacher preheater models are divided into three categories:

  1. Autonomous type from the Hydronic category, that is, the coolant is heated, which circulates in a small circle of the cooling system. This category includes models adapted for both petrol and diesel powertrains. Such equipment is located in the engine compartment and is integrated into the cooling system;
  2. Autonomous type from the Airtronic category, that is, the system heats the air in the cabin. This modification does not affect the preparation of the motor for operation in any way. Such equipment is purchased by truck and bus drivers who perform long-distance flights, and who sometimes have to spend the night in the car. The interior heater works separately from the engine. Installation is carried out inside the car (cabin or salon);
  3. Non-autonomous type from the Airtronic category. In this case, the device is an additional sleeve for the interior heating system. The equipment works by heating the motor. For efficient heat intake, the device is mounted as close to the cylinder block as possible. In fact, this is the same water heater, only it works when the engine is started. It does not have an individual pump - only a heat exchanger, which provides an accelerated supply of heat to the air ducts of the car heater.

In addition to these varieties, there are also two categories, differing in the voltage that must be in the on-board system. Most models operate on a 12 volt mains supply. They are installed on cars and small trucks with an engine that does not exceed 2.5 liters. True, more productive models can be found in the same category.

The second category of pre-heaters operates on a 24-volt network. These models generate more heat and are installed on wagons, large buses, and even yachts. The power of the device is measured in kilowatts and is referred to in the literature as "kW".

The peculiarity of autonomous equipment is that it does not increase the consumption of the main supply of fuel, especially if an individual tank is used.

Eberspacher preheater models

Regardless of the device model, it will work in the same way. Only the purpose of the category can be for heating the internal combustion engine and, incidentally, the interior of the car, or exclusively for the interior of the car. The difference is also in the voltage that is required for the operation of the device, and in performance.

The principle of operation of this equipment does not even differ from the functions of analogs produced by other manufacturers. But Eberspacher heaters have one special feature. They are adapted to work with diesel power units. These products are in particular demand among truck drivers.

On the territory of the CIS countries, many options for pre-starting heaters are offered. Let's consider their features.

Liquid type

All models of the liquid type (that is, connected to the cooling system of the internal combustion engine) from Eberspacher are designated Hydronic. The marking contains symbols B and D. In the first case, the device runs on gasoline or is adapted for a gasoline engine. The second type of devices is designed for diesel engines or they run on diesel fuel.

Eberspacher engine preheaters

The group, represented by 4 kW liquid heaters, consists of two petrol and two diesel models:

  1. Hydronic S3 D4 / B4. These are new products from the manufacturer. They work both on gasoline and diesel fuel (you just need to choose a model with the appropriate marking). The peculiarity of the device is low noise level. The heater is economical due to fine atomization (depending on the operating mode, the device can consume up to 0.57 liters of fuel per hour). Powered by 12 volts.
  2. Hydronic B4WSC / S (for a petrol unit), Hydronic D4WSC / S (for a diesel engine). Fuel consumption depends on the type of fuel and heating mode, but does not exceed 0.6 liters per hour.

The first group of devices has a construction weight of two kilograms, and the second - no more than three kg. All four options are designed for heating the engine, the volume of which does not exceed two liters.

Another group of devices has a maximum power of 5-5.2 kW. These models are also designed for preheating small volume internal combustion engines. The voltage in the network is 12 volts. This equipment can have three operating modes: low, medium and maximum. Depending on the pressure of the fuel in the line, the consumption will vary from 0.32 to 0.72 liters per hour.

More efficient heaters are models marked M10 and M12. Each of them has a power of 10 and 12 kW, respectively. This is the middle class, which is designed for SUVs and heavy vehicles. Often it can be installed on special equipment. The rated voltage of the on-board network can be 12 or 24 volts. But to work at maximum capacity, a more powerful battery is required.

Naturally, this affects fuel consumption. Depending on the spray mode, the unit requires 0.18-1.5 liters per hour. Before buying a device, you must take into account that it is weighty. In order to properly secure the structure, you need to choose a suitable place so that the mount can withstand such a weight.

Closes the list with the most powerful model of a liquid heater. This is the Hydronic L30 / 35. This equipment works only on diesel fuel. It is intended exclusively for large-sized vehicles and can even be installed in locomotives. The system voltage must be 24V. The installation consumes from 3.65 to 4.2 liters of diesel fuel per hour. The whole structure weighs no more than 18kg.

Air type

Since air heaters are used exclusively as a cabin heater, there is less demand for them, especially among motorists considering cold starting equipment. This category of equipment also runs on either gasoline or diesel fuel.

Eberspacher engine preheaters

While the car owner can install an extra fuel tank, it would be more practical to get a model that runs on the same fuel as the powertrain itself. The reason is that automakers in the design of cars have provided little free space for additional elements of this type. An example of this is the adaptation of a car for a mixed type of fuel (LPG). In this case, a second fuel tank, a cylinder, is often installed instead of a spare tire.

So that when a wheel is cut or punctured, it could be changed to an emergency analogue, you need to constantly carry a parking wheel in the trunk. Often, in a passenger car, there is not much space in the trunk, and such a wheel constantly interferes. Alternatively, you can buy a stowaway (for details on how the stowaway differs from a regular wheel, as well as some recommendations for its use, read in another article).

For these reasons, it would be more practical to buy a heater that runs on the same type of fuel as the power unit. Air models can be installed either in the passenger compartment or in the engine compartment as close to the cylinder block as possible. In the second case, the device is integrated into the air ducts that go to the passenger compartment.

These devices also have different power outputs. Basically, the performance of these modifications is 4 or 5 kW. In the Eberspacher product catalog, this type of heater is called Airtronic. Models:

  1. Airtronic D2;
  2. Airtronic D4 / B4;
  3. Airtronic B5/D5L Compact;
  4. helios;
  5. Zenith;
  6. Xeros.

Eberspächer wiring diagram and operating instructions

The connection diagram for Eberspacher Airtronic or Hydronic depends on the model of the device. Each of them can be integrated in different ways into the air ducts of the passenger compartment heater or the cooling system line. Also, the installation feature depends on the car model, since in each individual case there may be a different amount of free space under the hood.

Sometimes the device cannot be installed in a car without re-equipment. For example, in some models, the driver has to move the washer reservoir to another suitable location, and instead mount the heater housing. For this reason, before buying such equipment, you need to consult a specialist whether it is possible to install it on your car.

Eberspacher engine preheaters

As for the electronic circuit, the user manual indicates how to correctly integrate the device into the on-board system of the car so that the new equipment does not conflict with other systems of the car.

Operating instructions, different wiring diagrams to the electrical system of the machine and to the cooling system of the vehicle - all this is provided with the equipment. If you lose this documentation on the official Eberspacher website, you can download an electronic version for each model separately.

Features of the operation of Eberspacher

Before starting the connection of any heater model, it is necessary to de-energize the vehicle electrical system. To do this, properly disconnect the battery terminals (for the safest way to do this, read in another article).

During the installation process, some nuances should be taken into account:

  1. If a design with an individual fuel tank is used, then it is necessary to take care of its tightness, as well as that it is protected from heating, especially if it is a gasoline version.
  2. Regardless of whether a separate fuel tank will be used or the device will be connected to a standard line, you should make sure that fuel does not ooze out at the hose connections during the heater operation.
  3. The equipment fuel line must be routed through the car so that in the event of a leak, fuel does not enter the passenger compartment (some, for example, install an additional fuel tank in the trunk of a car) or onto hot parts of the power unit.
  4. If the exhaust pipe runs near fuel hoses or a tank, it is imperative that the two do not come into direct contact. The pipe itself will be hot, so the manufacturer recommends laying fuel hoses or installing the tank at least 100mm from the pipe. If this cannot be done, then the pipe should be covered with a thermal shield.
  5. A shut-off valve must be installed in the additional tank. It is necessary in order to prevent the backfire of the flame. When using gasoline, it should be noted that even in a sealed container, this type of fuel will still evaporate. To prevent depressurization of the container, it is necessary to periodically start the heater, or drain the fuel for a while, while it is not in use. It is much more practical in this regard to use a regular gas tank, because all modern cars are equipped with an adsorber. What kind of system it is and how it works is described in detail. separately.
  6. It is necessary to fill the fuel tank with the heater switched off.

Error Codes

Since this category of equipment operates in an autonomous mode, it uses an individual control unit that processes signals from sensors and control elements. Based on these pulses, a corresponding algorithm is activated in the microprocessor. As expected of any electronics, due to power outages, microcircuits and other negative factors, failures may appear in it.

Malfunctions in the electronic part of the equipment are indicated by error codes that appear on the display of the control element.

Ошибки D3WZ/D4WS/D5WS/B5WS/D5WZ

Here is a table with the main codes and their decoding for boilers D3WZ / D4WS / D5WS / B5WS / D5WZ:

Mistake:Explanation:How to fix:
10Overvoltage shutdown. The electronics blocks the operation of the boiler if the voltage surge lasts for more than 20 seconds.Disconnect contact B1 / S1, start the motor. The voltage is measured between pins 1 and 2 on plug B1. If the indicator exceeds 15 or 32V, it is necessary to check the condition of the battery or generator regulator.
11Critically low voltage shutdown. The electronics blocks the device in case of a voltage drop in the on-board network for 20 seconds.Disconnect contact B1 / S1, turn off the motor. The voltage is measured between pins 1 and 2 on plug B1. If the indicator is below 10 or 20V, it is necessary to check the condition of the battery (oxidation of the positive terminal), the fuse, the integrity of the power wires or the presence of oxidation of the contacts.
12Shutdown due to overheating (exceeding the heating threshold). The thermal sensor detects heating above +125 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
14The difference between the readings of the temperature sensor and the overheating sensor. This error appears when the heater is running, when the coolant is heated at least +80 degrees.Possible loss of tightness of hose connections; Check the line through which the coolant circulates; There may be no throttle valve in the line of the cooling system; Check the correspondence of the direction of coolant circulation, the operation of the thermostat and the non-return valve; Possible formation of an air lock in the cooling circuit (may occur during installation of the system ); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
15Blocking the device in case of 10 times overheating. In this case, the control unit itself (brains) is blocked.Clean the error recorder; Possible loss of tightness of the hose connections; Check the line through which the coolant circulates; There may be no throttle valve in the line of the cooling system; Check the correspondence of the direction of coolant circulation, the operation of the thermostat and the non-return valve; Possible formation of an air lock in the cooling circuit (may occur during the installation of the system); Possible malfunction of the boiler water pump.
17Emergency shutdown when the heating temperature threshold value is exceeded (the brain detects overheating). In this case, the temperature sensor records an indicator above +130 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
20,21Glow plug breakage; Glow plug breakage (wire breakage, wiring short circuit, shorted to ground, due to overload).Before checking the working order of the electrode, it is necessary to remember: the 12-volt model is checked at a voltage of no more than 8V; the 24-volt model is checked at a voltage of no more than 18V. If this indicator is exceeded during diagnosis, it will lead to the destruction of the electrode. It is also necessary to take into account that the power supply does not tolerate short circuits well. Diagnostics: Wire 9 is removed from contact block No. 1.52ws and from chip number 12 - wire 1.52br. 8 or 18 volts are supplied to the electrode. After 25 seconds. the voltage across the electrode is measured. As a result, there should be a current value of 8A + 1AА In case of deviations, the glow plug must be replaced. If this element is working properly, it is necessary to check the wires going from the electrode to the control unit - a break or destruction of the cable insulation is possible.
30The speed of the electric motor forcing air into the combustion chamber exceeds the permissible value or is critically low. This can happen when the impeller of the motor is blocked due to contamination, freezing of the shaft, or as a result of the cable snagging on the shank mounted on the shaft.Before carrying out diagnostics, it is necessary to take into account: the 12-volt model is checked at a voltage of no more than 8.2V; the 24-volt model is checked at a voltage of no more than 15 V. The power supply does not tolerate a short circuit; It is extremely important to observe the pinout of the cable (pole). First, the reason for the impeller blockage is found out and eliminated. The electric motor is supplied with a voltage of 8 or 15 volts. To do this, remove the 14 wire from contact No. 0.752br, and from contact No. 13 - wire 0.752sw. A mark is applied to the shaft end. The measurement of the number of revolutions is carried out using a non-contact photoelectric tachometer. The norm for this element is 10 thousand. rpm. If the value is higher, then the problem is in the control unit, and the "brains" should be replaced. If the speed is insufficient, replace the electric blower. It is usually not repaired.
31Open circuit in the electric motor of the air blower.  Before carrying out diagnostics, it is necessary to take into account: the 12-volt model is checked at a voltage of no more than 8.2V; the 24-volt model is checked at a voltage of no more than 15 V. The power supply does not tolerate a short circuit; It is extremely important to observe the pinout of the cable (pole). The integrity of the electrical line is checked. The electric motor is supplied with a voltage of 8 or 15 volts. To do this, remove the 14 wire from contact No. 0.752br, and from contact No. 13 - wire 0.752sw. A mark is applied to the shaft end. The measurement of the number of revolutions is carried out using a photoelectric type tachometer. The norm for this element is 10 thousand. rpm. If the value is higher, then the problem is in the control unit, and the "brains" should be replaced. If the speed is insufficient, replace the electric blower.
32Air blower error due to short circuit, overload, or short to ground. This can occur when the impeller of the motor is blocked due to contamination, freezing of the shaft, or as a result of the cable snagging on the shank mounted on the shaft.Before carrying out diagnostics, it is necessary to take into account: the 12-volt model is checked at a voltage of no more than 8.2V; the 24-volt model is checked at a voltage of no more than 15 V. The power supply does not tolerate a short circuit; It is extremely important to observe the pinout of the cable (pole). First, the reason for the impeller blockage is found out and eliminated. Next, the resistance between the wiring and the body of the device is measured. This parameter should be within 2kO. A smaller value indicates a short to ground. In this case, the supercharger is replaced with a new one. If the device shows a value higher, then further procedures are carried out. The electric motor is supplied with a voltage of 8 or 15 volts. To do this, remove the 14 wire from contact No. 0.752br, and from contact No. 13 - wire 0.752sw. A mark is applied to the shaft end. The measurement of the number of revolutions is carried out using a non-contact photoelectric tachometer. The norm for this element is 10 thousand. rpm. If the value is higher, then the problem is in the control unit, and the "brains" should be replaced. If the speed is insufficient, replace the electric blower.
38Breakage of the relay control of the air blower. This error may not be displayed in all models of pre-starting car boilers.Replace relay; In case of wire breakage, repair the damage.
39Blower relay control error. This can happen with a short circuit, overload, or a short to ground.The relay is dismantled. If after this the system shows error 38, then this indicates a malfunction of the relay, and it must be replaced.
41Breakage of the water pump.The integrity of the wiring suitable for the pump is checked. To "ring" the circuit, you must remove the wire 0.52br from pin 10 and wire 0.52 vi from pin11. If the device does not detect a break, then the pump must be replaced.
42Water pump error due to short circuit, short to ground, or overload.The cable is disconnected from the pump. If error 41 appears on the display of the device, this indicates a breakdown of the pump, and it must be replaced.
47Dosing pump error due to short circuit, short to ground or overload.The cable is disconnected from the pump. If error 48 appears, you need to replace this device with a new one.
48Dosing pump breakDiagnostics of the pump wiring is carried out. If damage is found, it is repaired. Otherwise, the pump must be replaced.
50Blocking the device due to 10 attempts to start the boiler (each attempt is repeated). At this moment, the "brains" are blocked.The blockage is removed by clearing the error logger; The presence of fuel in the tank is checked, as well as the supply force. The amount of supplied fuel is measured as follows: The hose going to the combustion chamber is disconnected and lowered into a measuring container; The heater turns on; After 45 seconds. the pump starts pumping fuel; During the procedure, the measuring container must be kept at the same level with the heater; The pump will turn off after 90 seconds. The boiler is turned off so that the system does not try to start again. The norm for the D5WS model (diesel) is a volume of 7.6-8.6 cm3, and for B5WS (petrol) - 10.7-11.9 cm3
51Cold blowdown error. In this case, after turning on the boiler, the temperature sensor for 240 seconds. and more fixes the indicator above +70 degrees.The exhaust gas outlet is checked, as well as the supply of fresh air to the chamber; The serviceability of the temperature sensor is checked.
52Safe time limit exceededThe exhaust gas outlet is checked, as well as the supply of fresh air to the chamber; The filter of the dosage pump may be clogged; The serviceability of the temperature sensor is checked.
53, 56The torch was cut off at the maximum or minimum stage. If the system still has a reserve of test runs, the control unit will try to start the boiler. If the launch is successful, the error disappears.In case of an unsuccessful attempt to start the device, it is necessary to: Check the exhaust gas outlet, as well as the efficiency of supplying fresh air to the combustion chamber; Check the flame sensor (corresponds to codes 64 and 65).
60Breakage of the temperature sensor. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is dismantled, and the integrity of the wires going to the sensor is checked. If no damage is found, it is necessary to short-circuit the temperature sensor by moving the wire in the 14-pin chip from position 3 to 4. Next, turn on the boiler: Appearance of code 61 - it is necessary to dismantle and check the operability of the temperature sensor; Code 60 does not disappear - possible breakdown of the control unit. In this case, it must be replaced with a new one.
61Temperature sensor error due to short circuit, short to ground, or overload. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is removed, the presence of damage to the wires is checked; In case of cable integrity, the wires in the 14-pin plug are disconnected 0.52bl from pins 3 and 4; The control unit is connected and the heater is activated. When code 60 appears, it is necessary to check the functionality of the temperature sensor. If the error code does not change, this indicates a problem with the control unit and must be checked for damage or replaced with a new one.
64Breakage of the combustion sensor. The check should be carried out only on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is dismantled, the sensor wire is checked for damage. If there is no damage, you need to short-circuit the sensor by swapping wires 14 and 1 in the 2-pin chip. The device turns on. When error 65 appears, remove the sensor and check its performance. If the error remains the same, the control unit is checked for damage or replaced with a new one.
65Flame sensor error due to short circuit, short to ground or overload. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is dismantled, the sensor wire is checked for damage. If there is no damage, disconnect the 14 wires from the 0.5-pin chip.2bl (contact 1) and 0.52br (pin 2). The plug is connected and the device is turned on. When error 64 appears, remove the sensor and check its performance. If the error remains the same, the control unit is checked for damage or replaced with a new one.
71Breakage of the overheating sensor. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is dismantled, the sensor wire is checked for damage. If they are absent, you need to short-circuit the sensor by swapping wires 14 and 5 in the 6-pin chip. The device turns on. When error 72 appears, remove the sensor and check its performance. If the error remains the same, the control unit is checked for damage or replaced with a new one.
72Overheating sensor error due to short circuit, short to ground, or overload. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is dismantled, the sensor wire is checked for damage. If they are absent, you need to disconnect the 14 wires from the 0.5-pin chip.2rt (pin 5) and 0.52rt (pin 6). The plug is connected and the device is turned on. When error 71 appears, remove the sensor and check its performance. If the error remains the same, the control unit is checked for damage or replaced with a new one.
90, 92-103Breakdown of the control unitThe item is being repaired or replaced with a new one.
91Interference due to external voltage. The control unit is malfunctioning.Causes of interference voltage: Low battery charge; Activated charger; Interference from other electrical devices installed in the car. This malfunction is eliminated by correctly connecting the additional car equipment and fully charging the battery.

The weakest point in such models is the temperature sensor. This element quickly becomes unusable due to natural wear and tear (they are destroyed due to sudden changes in temperature). There are two of these sensors in the boiler, and usually they are changed in pairs. Water and dirt often get under the cover that protects these sensors. The reason is that in the cold it deforms, and in some cases it disappears altogether.

Most often, the service includes those models of boilers that are installed at the factory under the bottom of the car, for example, in a Mercedes Sprinter or Ford Transit. In this case, the device suffers from constant contact with moisture, which causes the contacts to deteriorate. This problem can be prevented by installing an additional protective casing on top of the boiler or moving it to the engine compartment.

Here is a table of errors that may not appear on the display:

Mistake:How does it manifest:How to fix:
Failure to start an independent heaterThe electronics turn on, the water pump is activated, and with it the interior heater fan (standard), but the torch does not ignite. After the boiler is turned on, the interior fan is turned on (autonomous interior ventilation mode).The control unit is dismantled and the operability of the temperature sensor is checked. If it is defective, the microprocessor considers it as hot coolant and the boiler does not need to be turned on. The cabin heater must be set to heating mode.

The control values ​​of sensors and other elements of the preheater electrical system are shown in the table below:

System component:The norm of indicators at a temperature of +18 degrees:
Candle, glow plug, pin0.5-0.7 Ohm
Fire sensor1Om
Temperature sensor15 kΩ
Overheating sensor15 kΩ
Fuel supercharger9 ohm
Air blower motorIf it is dismantled, when connected to a network of 8V, it should consume approximately 0.6A. If assembled in a structure (housing + impeller), then at the same voltage it consumes within 2 amperes.
Water pumpWhen connected to 12V, it consumes approximately 1A.

D5WSC / B5WSC / D4WSC errors

Compared to previous modifications, these boilers are easier to install on a car, because the water pump and the fuel supercharger are located inside the heater body (C - Compact). Most often, the "brains" of the device and sensors fail.

Here is a table of error codes for Hydronic D5WSC / B5WSC / D4WSC models:

Mistake:Explanation:How to fix:
10The mains voltage indicator has been exceeded. The control unit fixes the indicator for more than 20 seconds, after which the device turns off.Disconnect contacts B1 and S1, start the car engine. The voltage is measured at pin B1 between the first chamber (red wire 2.52) and the second chamber (brown wire 2.52). If the device detects a voltage exceeding 15 and 32V, respectively, then you need to check the condition of the battery or generator.
11Voltage critically low. The control unit detects a low voltage for more than 20 seconds, after which the boiler turns off.Disconnect contacts B1 and S1, start the car engine. The voltage is measured at pin B1 between the first chamber (red wire 2.52) and the second chamber (brown wire 2.52). If the device detects a voltage below 10 and 20V, respectively, then you need to check the fuses, power wires, ground contact, as well as the condition of the positive terminal on the battery (due to oxidation, the contact may disappear).
12Exceeding the heating threshold (overheating). The temperature sensor records a reading above +125 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
14A difference was found between the readings of the overheating sensor and the temperature (the indicator exceeds 25K). In this case, when the boiler is running, the overheating sensor can record an indicator of more than 80 degrees, and the system does not turn off.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
15Blocking of the control unit due to 10 times overheating of the device.Check the line through which the coolant circulates; Possibly leaking of the hose connections (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the correspondence of the coolant circulation direction, thermostat operation and non-return valve; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Unlock the controller by clearing the error logger.
17Emergency shutdown due to critical overheating. The corresponding sensor records the temperature rise to more than +130 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones.
20,21Broken spark plug due to short circuit, short to ground, or overload.A 12 volt device should be tested at a maximum voltage of 8 volts. If this figure is exceeded, there is a risk of spark plug breakage. Before diagnosing an element, you must make sure that the power supply is protected against short circuits. Diagnostics of the spark plug is carried out when it is installed in the heater. The procedure is as follows: In a 14-pin chip, the white wire of the 9th chamber with a cross section of 1.5 is disconnected2, as well as a brown analogue from the 12th chamber. A voltage of 8 (or for a 24-volt installation of 18V.) volts is connected to the candle. Current measurements are made after 25 seconds. The normal value should correspond (for 8V version) 8.5A +1A / -1.5AIf the value does not match, the plug must be replaced. If it is serviceable, then you need to check the integrity of the wiring.
30Air blower motor speed is critically high or low. This happens due to contamination of the shaft, its wear, icing or deformation of the impeller.If the impeller or shaft is blocked, the obstacle is removed. Check the integrity of the power wires. When carrying out diagnostics, the motor must be connected to a voltage of 8V. To check the speed of the motor, you must disconnect the brown wire 0.752 from the 14th camera of a 14-pin chip, as well as a black wire 0.752 from the 13th camera. A mark is applied to the end of the shaft. The device turns on. To measure this indicator, you must use a non-contact photoelectric tachometer. The normal value of revolutions is 10 thousand. rpm With a lower value, the motor must be replaced, and with a higher value, the controller.
31Air blower motor breakage. It can occur due to damaged power wires or mismatched pinout (pole matching).Check the integrity of the wires. Check pinout. When carrying out diagnostics, the motor must be connected to a voltage of 8V. To check the speed of the motor, you must disconnect the brown wire 0.752 from the 14th camera of a 14-pin chip, as well as a black wire 0.752 from the 13th camera. A mark is applied to the end of the shaft. The device turns on. To measure this indicator, you must use a non-contact photoelectric tachometer. The normal value of revolutions is 10 thousand. rpm With a lower value, the motor must be replaced, and with a higher value, the controller.
32Air blower motor error due to overload, short circuit, or short to frame. This can also happen when the spark plug breaks down due to increased voltage. Malfunctions in the operation of the electric motor can occur due to wear on the shaft or blocking of the impeller (dirt has entered, icing has formed, etc.).If the impeller or shaft is blocked, the obstacle is removed. Check the integrity of the power wires. Before diagnosing the motor, you need to check the resistance to ground. To do this, the tester is connected with one probe to the power wire, and the other to the body. When carrying out diagnostics, the motor must be connected to a voltage of 8V. To check the speed of the motor, you must disconnect the brown wire 0.752 from the 14th camera of a 14-pin chip, as well as a black wire 0.752 from the 13th camera. A mark is applied to the end of the shaft. The device turns on. To measure this indicator, you must use a non-contact photoelectric tachometer. The normal value of revolutions is 10 thousand. rpm With a lower value, the motor must be replaced, and with a higher value, the controller.
38Breakage of the fan relay in the passenger compartment.Check the integrity of the wiring or replace the relay.
39Interior blower relay error due to short circuit, overload or short to ground.Dismantle the relay. If error 38 appears in this case, then it must be replaced. Otherwise, it is necessary to eliminate the short circuit.
41Breakage of the water pump.Check the integrity of the power wires. If damage is found, repair it. You can "ring" the wiring if you disconnect the brown wire 0.52 10th camera in a 14-pin chip, as well as a similar wire for the 11th camera. In the event of a break, the wiring is restored. If it is intact, then the pump must be replaced.
42Water pump error due to overload, short circuit, or ground.Disconnect the pump supply wires. Error 41 indicates a pump malfunction. In this case, it needs to be replaced.
47Metering pump error due to overload, short circuit or ground fault.Disconnect the pump supply wires. If error 48 appears, the pump is faulty and must be replaced.
48Dosing pump breakage.Check the power wires for damage. Eliminate them. If there is no damage, the pump must be replaced.
50The control unit has blocked due to 10 attempts to start the boiler (each attempt is accompanied by a restart).Unlock the control unit by clearing the error logger; Recheck that the fuel supply is sufficient. The amount of supplied fuel is measured as follows: The hose going to the combustion chamber is disconnected and lowered into a measuring container; The heater turns on; After 45 seconds. the pump starts pumping fuel; During the procedure, the measuring container must be kept at the same level with the heater; The pump will turn off after 90 seconds. The boiler is turned off so that the system does not try to start again. The norm for the D5WSC model (diesel) is a volume of 7.8-9 cm3, and for B5WS (petrol) - 10.4-12 cm3 The norm for the D4WSC model (diesel) is the volume of 7.3-8.4 cm3, and for B4WS (petrol) - 10.1-11.6 cm3
51Exceeding the allowed time. At this moment, the temperature sensor records an unacceptable temperature for a long time.The tightness of the air supply and exhaust gas outlet is checked; The fire sensor is checked. If the control values ​​do not match, the element is changed to a new one.
52Safety time exceeded critical.Check the tightness of the air supply and exhaust; Recheck the correctness of the fuel supply (see solution to error 50); Possible clogging of the fuel filter - clean or replace.
53,54,56,57The torch was cut off at the maximum or minimum stage. The fire goes out before the device enters the desired mode. If the system still has a reserve of test runs, the control unit will try to start the boiler. If the launch is successful, the error disappears.On successful launch, the error code is cleared and the number of trial runs is reset to zero. The tightness of the air supply and exhaust is checked; Recheck the conformity of the fuel supply (see the solution to error 50); The fire sensor is checked (errors 64 and 65).
60Breakage of the temperature sensor. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is disconnected; The integrity of the temperature sensor wiring is checked. If the cable is not damaged, you need to check the sensor itself. For this, the wires of the 14rd and 3th cameras are removed in the 4-pin chip. The wire from the third camera is inserted into the 4th connector. The heater turns on. The appearance of error 61 indicates a sensor malfunction - replace it. If the error does not change, then there is a problem with the controller. In this case, it must be checked and, if necessary, replaced.
61Temperature sensor error due to overload, short to ground, or short circuit. The check should be carried out only on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is disconnected; The integrity of the temperature sensor wiring is checked. If the cable is not damaged, you need to check the sensor itself. For this, in the 14-pin chip, the wires of the 3rd (blue with a cross section of 0.52) and 4th (blue with a cross section of 0.52) cameras. The heater turns on. The appearance of error 60 indicates a sensor malfunction - replace it. If the error does not change, then there is a problem with the controller. In this case, it must be checked and, if necessary, replaced.
64Flame sensor breakage. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The controller is disconnected. The integrity of the sensor power wires is checked. If there is no damage to the wires, the fire sensor must be short-circuited. To do this, disconnect wire 0.52 from the first camera and is connected instead of the similar wire of the second camera. The heater turns on. The appearance of error 65 indicates a sensor malfunction - check its operability and, if necessary, replace it with a new one. If the error does not change, then there is a malfunction in the control unit. In this case, it must be checked or replaced.
65Flame sensor error due to short circuit, overload or short to ground. The check should be carried out only on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is disconnected. The integrity of the sensor power supply wires is checked. If no damage is found, you need to disconnect the two blue wires in the 14-pin chip 0.52 from the first and second cameras. The chip is connected in place, and the boiler turns on. If the error changes to 64, then the sensor needs to be checked or replaced. If error 65 remains unchanged, it is necessary to check the functionality of the controller and replace it if necessary.
71Breakage of the overheating sensor. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The controller is disconnected. The integrity of the sensor power wires is checked. If there is no damage to the wires, the sensor must be short-circuited. To do this, disconnect wire 0.52 from chamber 5 and is connected instead of a similar wire of chamber 6. The heater is turned on. The appearance of error 72 indicates a sensor malfunction - check its operability and, if necessary, replace it with a new one. If the error does not change, then there is a malfunction in the control unit. In this case, it must be checked or replaced.
72Overheating sensor error due to overload, short to ground or short circuit. The check should only be carried out on a test bench or using a jumper for a 14-pin plug if the device is installed in a car.The control unit is disconnected. The integrity of the sensor power wires is checked. If no damage is found, you need to disconnect the two red wires in the 14-pin chip 0.52 from the 5th and 6th chambers. The chip is connected in place, and the boiler turns on. If the error changes to 71, then the sensor needs to be checked or replaced. If error 72 remains unchanged, it is necessary to check the functionality of the controller and, if necessary, replace it.
90,92-103Breakdown of the control unit.Repair or replace the control unit.
91Interference due to external voltage. The control unit is malfunctioning.Causes of interference voltage: Low battery charge; Activated charger; Interference from other electrical devices installed in the car. This malfunction is eliminated by correctly connecting the additional car equipment and fully charging the battery.

Here are some parameters that may not appear on the display of the device:

Mistake:How does it manifest:How to fix:
Failure to start an independent heaterWhen the heater is switched on, the pump and the fan in the passenger compartment work slowly. After switching on the boiler, cold air enters the passenger compartment from the air ducts.The controller is removed and the performance of the temperature sensor is checked. If it is defective, the microprocessor interprets it as hot coolant and the boiler does not need to be turned on. It is possible that the interior fan is set to ventilation rather than heating.

The control values ​​of the various electrical assemblies and boiler sensors are as follows:

System component:The norm of indicators at a temperature of +18 degrees:
Candle, glow plug, pin0.5-0.7 Ohm
Fire sensor1 kΩ
Temperature sensor15 kΩ
Overheating sensor15 kΩ
Fuel supercharger9 ohm
Air blower motorIf it is dismantled, when connected to a network of 8V, it should consume approximately 0.6A. If assembled in a structure (housing + impeller), then at the same voltage it consumes within 2 amperes.
Water pumpWhen connected to 12V, it consumes approximately 1A.

D5Z-H errors; D5S-H

For models of prestarting boilers D5Z-H; D5S-H basically the same error codes as the previous category. The following errors are exceptions:

Code:Explanation:How to fix:
16Big difference between readings of temperature sensors.Check sensors for resistance. This parameter at an ambient temperature within +20 degrees should be in the region of 12-13 kOhm.
22Glow plug output error.The spark plug wire is checked for damage. If the insulation is damaged, a short circuit (+ Ub) can occur. If there is no short circuit, it is necessary to check if the device has a short circuit to ground. If this was not a problem, then there may be a problem with the controller, and it must be replaced.
25A short circuit has formed in the diagnostic bus (K-Line).The cable is checked for damage.
34Burner blower drive error (motor output).Check the motor wire for damage. If the insulation is damaged, a short circuit can form. If there is no short circuit, it is necessary to check if the device has a short circuit to ground. If this was not a problem, then there may be a problem with the controller, and it must be replaced.
36Interior fan output error (applies only to preheaters, not interior heaters).Check the fan wire for damage. If the insulation is damaged, a short circuit (+ Ub) can occur. If there is no short circuit, it is necessary to check if the device has a short circuit to ground. If this was not a problem, then there may be a problem with the controller, and it must be replaced.
43Water pump output error.The pump drive wire is checked for damage. If the insulation is damaged, a short circuit can form. If there is no short circuit, it is necessary to check whether the device has a short circuit to ground (in the 10-pin chip, the wire of the B1 connector). If this was not a problem, then there may be a problem with the controller, and it must be replaced.
49Error in the output signal at the dosing pump.Check the pump wire for damage. If the insulation is damaged, a short circuit can form. If there is no short circuit, it is necessary to check if the device is shorting to ground (in a 14-pin chip). If this was not a problem, then there may be a problem with the controller, and it must be replaced.
54Flame breakage in the "Maximum" mode.In this case, an automatic restart will be triggered. On a successful attempt, the error is cleared from the error logger. In the event of repeated flame breaks, the quality of the fuel supply, the air blower, and the exhaust system are checked.
74Control unit error: overheating.If the breakdown can be repaired, then it can be repaired or replaced.

 To determine the quality of the fuel supply, you must perform the following operation:

  1. The hose leading to the combustion chamber is disconnected and lowered into a measuring container;
  2. The heater turns on;
  3. After 20 seconds. the pump starts pumping fuel;
  4. During the procedure, the measuring container must be kept at the same level with the heater;
  5. The pump will turn off after 90 seconds. work;
  6. The boiler is turned off so that the system does not try to start up again.

The norm for these models of boilers is a flow rate of 11.3-12 cm3 fuel.

Errors Hydronic II D5S / D5SC / B5SC Comfort

Key errors of prestarting boilers Hydronic II D5S / D5SC / B5SC Comfort are the same as described for models D3WZ / D4WS / D5WS / B5WS / D5WZ and D5WSC / B5WSC / D4WSC. Since this group of heaters contains an additional element (burner heater), additional errors may appear among the errors. They are shown in the table below:

Code:Explanation:How to fix:
9Incorrect signals from the sensor measuring the pressure of the air entering the chamber. This may be the result of a break in the electrical line from the sensor to the controller.A visual inspection of the wires is carried out. If damage to the insulating layer or a break is found, the problem is eliminated. The sensor is diagnosed only with special equipment - EdiTH Basic, in which the S3V7-F software is flashed. If a malfunction is detected, the sensor is replaced with a new one.
13,14Possible overheating; large temperature difference recorded by sensors of one system. Code 14 appears on the display when the boiler is on, and in the cooling system, when overheating is detected, antifreeze has reached a temperature of more than +80 degrees.Check sensors for resistance. This parameter at an ambient temperature within +20 degrees should be in the region of 13-15 kOhm. Check the integrity of the sensor wires. Diagnostics of sensors is carried out only with special equipment - EdiTH Basic, in which the S3V7-F software is flashed.
16Exceeding the differential value of indicators between the temperature sensor and the heating sensor of the device body. Code 16 appears on the display when the boiler is on, and in the cooling system, antifreeze, when overheating is detected, has reached a temperature of more than +80 degrees.Check sensors for resistance. This parameter at an ambient temperature within +20 degrees should be in the region of 13-15 kOhm. Check the integrity of the sensor wires. Diagnostics of sensors is carried out only with special equipment - EdiTH Basic, in which the S3V7-F software is flashed.
18,19,22Low current consumption of glow plugs; spark plug short circuit (+ Ub); control unit transistor error; too low current to ignite fuel.Check the spark plug as follows. For 12 volt model: 9.5 volt applied after 25 seconds. the consumed current is measured. The norm is the current strength of 9.5A. The permissible deviation in the direction of increase / decrease is 1A. In case of a larger deviation, the plug must be replaced. For 24V model: 16V applied after 25 seconds. the current consumed by the candles is measured. The norm is the current strength of 5.2A. The permissible deviation in the direction of increase / decrease is 1A. In case of a larger deviation, the plug must be replaced.
23,24,26,29Open or short circuit of the heating element; low value of the ignition current of the heating element; control unit error.Diagnostics of the heating element in the ignition chamber is carried out: The wires of the B2 connector (14-pin chip) are checked: 12th pin, wire 1.52sw; 9th contact wire 1.52sw. If the insulation is not damaged or the wires are not broken, then the controller must be replaced.
25Short circuit of the diagnostic bus K-LineThe integrity, short circuit of the diagnostic wire is checked (it is blue with a cross section of 0.52 with a white stripe). If there is no damage, replace the controller.
33,34,35The signal wire contact has disappeared; blocking of the electric motor of the air blower; slow rotation of the blades; short circuit in the + Ub bus, transistor error of the controller.Eliminate possible blockage of the impeller or shaft of the air blower motor. Check the blades for ease of rotation by hand. Check burner wire for continuity. Replace the controller if there is no damage or short circuit.
40Short circuit in the bus + Ub (interior fan), controller error.The fan relay is dismantled. If error 38 appears, the relay must be replaced.
43Short circuit in the bus + Ub (water pump), controller error.Disconnect the signal and supply wires of the pump. If error 41 appears, replace the pump.
62,63Open or short circuit of the printed circuit board sensor.Repair or replace the controller.
66,67,68Open or short circuit of the battery disconnector; short circuit in the bus + Ub; control unit error.The integrity of the battery breaker is checked. If there is no damage, check the contacts of connector B1 (8th and 5th), as well as wire 0.52ws and 0.52rt. - a short circuit or a wire break may occur in them.
69JE diagnostic cable error.The integrity of the blue wire with a white stripe 0.5 is checked2... the contact of all equipment connected to the cable is checked. If not, replace the controller.
74Breakage due to overheating; equipment malfunction.The performance of the overheating sensor is checked: The integrity of the cable; The resistance of the wire is measured 0.52Bl sw (pin 10 and 11) as well as wires 0.52B. The resistance indicator should be within 1kOhm. Error 74 does not disappear - replace the controller. The boiler is unlocked by clearing the error logger.

Errors Hydronic 10 / M

The following errors may appear on the Hydronic 10 / M preheater model:

Mistake:Explanation:How to troubleshoot for version 25208105 and 25204405:How to troubleshoot for version 25206005 and 25206105:
1Warning: high voltage (more than 15 and 30V).The voltage of the controller is checked on pins 13 and 14 in chips B1 and S1 when the motor is running.The voltage on the controller is checked (external chip B1) - on contacts C2 and C3.
2Warning: low voltage (less than 10 and 20V)The vehicle's alternator or battery charge is checked.The vehicle's alternator or battery charge is checked.
9Disable TRSSwitch the boiler off and on again. The fault is cleared by D + (generator positive) or HA / NA (main / auxiliary).Switch the boiler off and on again. The fault is cleared by D + (generator positive) or HA / NA (main / auxiliary).
10Exceeding the permissible voltage threshold (above 15 and 20V).The controller voltage is checked on pins 13 and 14 in chips B1 and S1.The voltage on the controller is checked (external chip B1) - on contacts C2 and C3.
11Critically low voltage (less than 10 and 20V).The controller voltage is checked on pins 13 and 14 in chips B1 and S1.The voltage on the controller is checked (external chip B1) - on contacts C2 and C3.
12Exceeding the overheating threshold. The overheating sensor detects temperatures exceeding +115 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the coolant line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible air lock in the cooling circuit may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller and measure the resistance indicator on the internal chip. The norm of resistance between contacts 10/12 of the internal chip B5 is 126 kOhm (+20 degrees) and 10 kOhm (+25 degrees).Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the coolant line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible air lock in the cooling circuit may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller and measure the resistance indicator on the internal chip. The norm of resistance between contacts 11/17 of the internal chip B5 is 126 kOhm (+20 degrees) and 10 kOhm (+25 degrees).
13Critical increase in temperature, which is recorded by the fire sensor. The temperature is higher than +700 degrees or the resistance of the device exceeds 3.4kOhm.The controller is disconnected, and the resistance is measured on the internal B5 chip between pins 10/12. The resistance norm is 126 kOhm (+20 degrees) and 10 kOhm (+25 degrees).The controller is disconnected, and the resistance is measured on the internal B5 chip between pins 11/17. The resistance norm is 126 kOhm (+20 degrees) and 10 kOhm (+25 degrees).
14Overheating warning based on the differential readings of the temperature and overheating sensors (the difference is greater than 70 degrees).Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the coolant line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible air lock in the cooling circuit may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller and measure the resistance indicator on the internal chip. The resistance norm between contacts 9/11 of the internal chip B5 is 1078 Ohm (+20 degrees) and 1097 Ohm (+25 degrees).  Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the coolant line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible air lock in the cooling circuit may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller and measure the resistance indicator on the internal chip. The resistance norm between contacts 15/16 of the internal chip B5 is 1078 Ohm (+20 degrees) and 1097 Ohm (+25 degrees).
15Boiler shutdown due to 3 times overheatingThe same diagnostic procedures are carried out as for errors 12,13,14. To unlock the controller, the error logger must be cleared.The same diagnostic procedures are carried out as for errors 12,13,14. To unlock the controller, the error logger must be cleared.
20Broken candle.Without dismantling the candle, its diagnostics is carried out. For this, the controller is turned off, and the resistance between contacts 3-4 in the internal chip B5 is measured.Without dismantling the candle, its diagnostics is carried out. For this, the controller is turned off, and the resistance between contacts 2-7 in the internal chip B5 is measured.
21Spark plug error due to short circuit, overload, or short to ground; failure due to increased voltage. The 12-volt model is diagnosed at 8V, and the 24-volt model is diagnosed at 18V. Before making any changes, make sure that the power supply is protected against short circuits.The corresponding voltage is applied to the candle. After 25 seconds. current is measured: Norm for 12-volt: 12A+ 1A / 1.5ARate for 24-volt: 5.3A+ 1АЛ1.5А Deviations from the norm indicate a malfunction of the plug and must be replaced. If the element is in good condition, check the integrity of the wires.Identical to versions 25208105 and 25204405.
33Air blower fan motor error due to overload, short circuit, short to ground, failure of the speed controller, breakdown of the glow plug. The 12-volt model is diagnosed at 8V, and the 24-volt model is diagnosed at 18V. Before making any changes, make sure that the power supply is protected against short circuits.The error appears when the required number of revolutions does not match for one minute. Norm for shaft revolutions: Maximum load - 7300 rpm; Full load - 5700 rpm; Average loads - 3600 rpm; Minimum loads - 2000 rpm. The number of revolutions of the engine is checked as follows. Power is connected to the positive wire of the burner 1.5sw and to the negative wire 1.5g. A speed sensor is integrated in the motor. If the engine does not respond during diagnostics, it must be replaced along with the sensor. The performance of the speed sensor is checked by measuring the voltage on the internal chip of the control unit between the 0.25vi-0.25gn outputs. The device should show 8V. If it does not match, the device is replaced.Identical to versions 25208105 and 25204405.
37Breakage of the water pump.Check the functionality of the device and the integrity of the wiring.Identical to versions 25208105 and 25204405.
42Water pump error due to overload, short circuit, short to ground.Contact 0.5swrt (on the controller) is checked for a short to ground, short circuit. The water pump and the integrity of the wires are checked.Identical to versions 25208105 and 25204405.
43Short circuit of external elements. In the external chip of the control unit, pin 2 (1gr) is checked. The connected elements are checked for a short circuit or damage to the wires. The maximum current should be 6A. in case of deviations, the components are replaced with new ones.Identical to versions 25208105 and 25204405.
47,48Open or short circuit of the dosing pump.The performance of the dosing pump is checked for resistance. The allowed value must correspond to 20 Ohm. Eliminate the presence of a short circuit, damage to the wires.Identical to versions 25208105 and 25204405.
50The control unit has blocked due to 20 attempts to turn on (10 attempts, and one more test run for each) - the flame sensor does not detect the presence of fire.Make sure that the glow plug is supplied with electricity, the fuel pump is supplying fuel, that the air blower and exhaust gas are operational. The controller is unlocked by clearing the error logger.Identical to versions 25208105 and 25204405.
51Flame sensor error.An incorrect flame temperature reading indicates a sensor malfunction - replace it.Identical to versions 25208105 and 25204405.
52Exceeding the value of the safe period - at start-up, the flame sensor does not register the appearance of fire.The resistance of the flame sensor is measured. When heating below +90 degrees, the value of the diagnostic tool should be within 1350 Ohm. The cleanliness of the air supply and exhaust pipes is checked. The fuel supply is checked (the procedure is described below this table). The fuel filter may be clogged. The glow plug is checked (errors 20,21). The flame sensor is checked (error 13).Identical to versions 25208105 and 25204405.
54,55Breakage of fire at the maximum or minimum stage. The fire sensor detects the appearance of a flame, but the heater indicates the absence of fire.The operation of the air blower, the fuel pump, and the air supply and exhaust pipes are checked. If the flame is correct, check the serviceability of the flame sensor (error 13).Identical to versions 25208105 and 25204405.
59Fast heating of antifreeze.Carry out the procedures required for errors 12 and 60,61.Identical to versions 25208105 and 25204405.
60,61Breakage of the temperature controller sensor, error due to short circuit, overload or short circuit to ground. The temperature controller sensor indicates parameters that are out of range.The controller is disconnected. The internal counter measures the resistance between pins 9/11. At an ambient temperature of +25 degrees, the device should show 1000 Ohm.The controller is disconnected. The internal counter measures the resistance between pins 14/18. At an ambient temperature of +25 degrees, the device should show 1000 Ohm.
64,65Breakage of the fire indicator. The sensor reports the combustion temperature above +700 degrees, and its resistance is above 3400 Ohm.The control unit is turned off. The resistance is measured between pins 10/12 in the internal chip B5. The norm at an ambient temperature of +20 degrees is 126 kOhm, and at +25 degrees - 10 kOhm.The control unit is turned off. The resistance is measured between pins 11/17 in the internal chip B5. The norm at an ambient temperature of +20 degrees is 126 kOhm, and at +25 degrees - 10 kOhm.
71,72Open or error of the overheating sensor due to a short circuit. The sensor records the overheating temperature above +115 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller, and measure the resistance indicator on the internal B5 chip between pins 10/12. The norm at an ambient temperature of +20 degrees is 126 kOhm, and at +25 degrees - 10 kOhm.  Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the temperature and overheating sensor. In the event of a malfunction, both sensors are replaced with new ones. To check the sensors, you will need to disconnect the controller, and measure the resistance indicator on the internal B5 chip between pins 11/17. The norm at an ambient temperature of +20 degrees is 126 kOhm, and at +25 degrees - 10 kOhm.  
93,94,97Control unit malfunction (RAM - memory device defect error); EEPROM; general controller defect.Microprocessor defects are not eliminated. In this case, the control unit is replaced with a new one.Identical to versions 25208105 and 25204405.

It is necessary to check the quality of the fuel supply by the fuel pump as follows:

  • Before proceeding with the diagnosis, you must make sure that the battery is fully charged;
  • During the test, the controller must be supplied with voltage within 11-13V (for 12-volt version) or 22-26V (for 24-volt version);
  • The preparation of the device is carried out as follows. The fuel hose is disconnected from the boiler, and its end is lowered into the measuring container. The heater turns on. After 63 seconds. During pump operation, the fuel line fills up and gasoline / diesel fuel begins to flow into the vessel. When fuel begins to flow into the measuring vessel, the device turns off. This procedure is necessary to remove all air from the line before starting the measurement. The incoming fuel is removed into the beaker.
  • The measurement of the quality of the fuel supply itself is carried out in the following order. First, the boiler starts up. After about 40 seconds. fuel begins to flow into the vessel. We leave the device turned on for 73 seconds. After that, the electronics switches off the heater, since the sensor does not detect a flame. Next, you need to wait until the electronics initiates a restart. After switching on, 153 seconds are waited. turn off the boiler if it does not turn off by itself.

The norm for this model of the preheater is 19 milliliters. A deviation of 10 percent in the direction of increasing / decreasing the volume is acceptable. If the deviation is greater, the dosing pump must be replaced.

Hydronic errors 16/24/30/35

Here are the errors that can occur in the Hydronic 16/24/30/35 pre-heaters:

Code:Explanation:How to fix:
10Critically high voltage - shutdown. The control unit registers an increase in voltage (above 30V) for at least 20 seconds.Disable 18-pin chip; start the car engine; measure the voltage on the wires 2.52rt (15th pin) and 2/52br (16th pin). If the value is higher than 30V, it is necessary to check the performance of the generator (there is A separate article).
11Critically low voltage - shutdown. The control unit registers a voltage value of less than 19V for more than 20 seconds.Disable 18-pin chip; start the car engine; measure the voltage on the wires 2.52rt (15th pin) and 2/52br (16th pin). The voltage on the wires must match the value of the battery. If these indicators differ, it is necessary to check the integrity of the wiring of the power wires (due to the destruction of the insulating layer, a leakage current may appear); circuit breakers; the quality of the positive terminal on the battery (contact may be lost due to oxidation).
12Shutdown due to overheating. The control unit receives a signal from the temperature sensor that the indicator has exceeded 130 degrees.Check the line through which the coolant circulates; Hose connections may have leaked (check the tightening of the clamps); There may be no throttle valve in the cooling system line; Check the direction of coolant circulation, thermostat and non-return valve operation; Possible formation of an air lock in the cooling circuit ( may occur during the installation of the system); Possible malfunction of the boiler water pump; Check the serviceability of the valves installed in the system; Check the temperature difference on the supply and return parts of the cooling line. If the differential value is more than 10K, then clarify the minimum flow rate of the coolant volume (indicated by the manufacturer in the technical literature for the car); Check the performance of the water pump. Replace if defective; Check the coolant temperature sensor for serviceability. The resistance on it should be within 100 Ohm (at an ambient temperature of +23 degrees). In case of deviations, the sensor must be replaced.
12Large differential value of the overheating and combustion sensor.The installation of sensors is checked. If necessary, tighten the thread tightening by 2.5 Nm. using a torque wrench, the resistance of both sensors is checked. For a flame sensor, the norm is 1 kOhm, and for a flame sensor - 100 kOhm. Measurements must be carried out at ambient room temperature. Check the minimum volume flow rate of the coolant (specified by the manufacturer in the technical literature for the vehicle).
15The control unit has locked out due to a functional error. This code appears on the display when error 12 occurs three times.You can unlock the device by clearing the error logger. Repeat the steps that are necessary for the appearance of code 12.
16The control unit has locked out due to a functional error. This code appears when error 58 occurs three times.You can unlock the device by clearing the error logger. Repeat the steps required when code 58 appears.
20Loss of signal from the ignition current generator or coil. Danger: critically high voltage reading. It appears as a result of a device failure or a break in the signal wire going to the controller.Check the integrity of the supply and signal wires of the setpoint. Replace the wire if damaged. If there is no damage to the wiring, the control unit must be replaced.
21Error in the ignition current generator due to a short circuit. Danger: critically high voltage reading. It appears as a result of the fact that the wire going to the controller is shorted to ground.Check the integrity of the wires going from the device to the controller. If there is no damage, check the function of the dial. This requires a diagnostic tool. If the device breaks down, it must be replaced. If problem persists, replace controller.
25Diagnostic output: short circuit.Check wire 1.02bl and analogue ws in an 18-pin chip (goes to the control unit); the presence of a short circuit of the 2nd contact; as well as the wire from the 12th pin to the 8th pin of the plug. Insulation damage or wire breakage must be repaired.
32The air blower does not rotate when the burner is started.Check if the impeller is blocked. Check the serviceability of the electric motor.
33No rotation of the burner motor. May occur when the mains voltage is too low. When performing diagnostic procedures, it is necessary to supply a maximum of 12V to the device.Make sure that the blower impeller is not blocked. If an obstacle is detected, release the blades or shaft. Check the performance of the electric motor. To do this, use a diagnostic tool. In the event of a malfunction, the motor is replaced with a new one. If the error persists, the control unit needs to be replaced. If the fuel pump is blocked, make sure that its shaft turns freely. If not, the burner must be replaced.
37Error: breakdown of the water pump.Before repairing, make sure that: The Bus2000 / Flowtronic6000S pump is installed; The diagnostic cable from the Bus2000 water pump is connected; The Bus2000 pump is energized. In this case, disconnect the Bus2000 diagnostic cable and turn on the heater. If: The error has disappeared, check whether the pump shaft is blocked, and whether it turns freely on dry; The error has not disappeared, then replace the pump or eliminate the damage that has formed in it. When using a standard hydraulic pump / Flowtronic5000 / 5000S, you must: Disconnect the water pump cable; Apply voltage to the two-pin connector of the pump cable, and check if the device works. In case of normal operation, check the fuse (15A), pump wiring for damage and contacts in the chip. If the error persists, replace the controller.
39Interior fan error due to short circuit.Check the connection in the 18-pin controller connector pin 6 and the 8-pin cable. Check the continuity of the wire between the 7th track and the fan relay. There may be a short circuit between these wires. The integrity of the wires is checked; The correct installation of the fan relay is checked; If the relay fails, replace it; If the error persists, replace the controller.
44,45Open or short circuit in the relay coil.Check the correct installation of the relay on the controller; If the relay is faulty, replace it; If the error persists, replace the controller.
46,47Solenoid valve: open or short circuit.In the section in the cable between the solenoid valve and the control unit (chip D), a wire break or short circuit has formed. Check: The integrity of the wiring between the valve and the controller; The coil of the solenoid valve has become unusable - replace. If the error persists, replace the controller.
48,49Relay coil: open or short circuit.The correct installation of the relay on the control unit is checked. The relay should be replaced if necessary.
50Locked controller due to functional error. Occurs after 10 attempts to restart (the flame sensor does not detect the appearance of fire).Unlocking the control unit by clearing the error logger. The malfunction is eliminated in the same way as when error 52 appears.
51The flame controller detects the formation of a fire before fuel is supplied.The burner must be replaced.
52Failure to start due to exceeded safe start limit. During ignition, the flame sensor does not detect the appearance of fire. When checking the ignition current selector, take into account that the mains voltage is high!Check: Air supply to the combustion chamber; Exhaust gas discharge; Fuel supply quality; Is the flame tube connected to the heat exchanger correctly; Functionality of the current generator. To do this, use the burner diagnostic tool exclusively. If the dial is defective, it must be replaced; Condition of the ignition electrodes. In case of breakdown - replace; Integrity of the wiring and reliability of contacts; Component that controls the quality of the flame - possibly clogging; Serviceability of the coil in the solenoid valve. In case of malfunction, replace. If the error persists, the controller must be replaced.
54The flame is extinguished during burner operation. The error appears when the torch is cut off twice in 60 minutes of device operation.Check: The efficiency of the fuel supply; Is there a good exhaust gas discharge, as well as the CO level2; Serviceability of the coil in the solenoid valve. If the error persists, the controller needs to be replaced.
5830 seconds after the afterburner is activated, the flame control element gives a signal that the flame has not been extinguished.Check and, if necessary, clean the heat exchanger from contamination; Measure CO level2 in the exhaust tract; Check the serviceability of the solenoid valve (for this, only diagnostic equipment is used). Replace in case of malfunction; During coasting, the fuel must stop flowing. If this does not happen, you need to check the condition of the fuel pump; Replace the controller if the above steps did not help.
60,61Short circuit or interruption in the signal from the temperature sensor.Check the integrity of the wires going from the control unit to the temperature sensor; Check the resistance of the sensor, provided that the ambient temperature is +20 degrees, the resistance should be within 1 kOhm; If there are no faults in the sensor or wiring, the controller should be replaced.
71,72Short circuit or interruption of the signal from the overheating sensor.Check the integrity of the wires going from the control unit to the overheating sensor; Check the resistance of the sensor, provided that the ambient temperature is +20 degrees, the resistance should be within 100 kOhm; If there are no faults in the sensor or wiring, the controller should be replaced.
81Combustion indicator: short circuit.A short has occurred between the control box and the burner indicator. Check wire 1.02ge / ws, which connects the 8th pin of the 18-pin controller chip and the 3rd pin of the 8-pin torch harness plug. If the wires are damaged, they must be replaced or insulated. Check the burner indicator is working.
83Fault indicator: short circuit.Check wire integrity 1.02gr, which connects the 5th pin of the 18-pin controller chip and the 6th pin of the 8-pin harness plug (burner indicator wire). If damage is found, eliminate it and check the indicator's performance.
90Breakdown of the control unit.The controller needs to be replaced.
91The appearance of interference from the voltage of external equipment.Check the adjustment of the ignition electrodes; Check which equipment is the source of interference, eliminate the spread of this interference by shielding the wires; The control unit has become unusable - replace if the above steps did not help.
92,93,94,97Controller malfunctions.The control unit must be replaced.

Errors M-II M8 / M10 / M12

Here is a table of possible errors of models of preheaters Hydronic M-II M8 / M10 / M12:

Code:Explanation:How to fix:
5Anti-theft system: short circuit.Eliminate possible damage to the wires.
9ADR / ADR99: disable.Restart the heater.
10Overvoltage: shutdown. The control unit detects the excess of the voltage limit for more than 6 seconds.Disconnect the plug from the heater; Start the car engine; Measure the voltage indicator in the B2 chip - contacts A2 and A3; With increased voltage (exceeds 15 or 30V for a 12 or 24-volt model, respectively), check the serviceability of the voltage regulator in the generator.
11Voltage Critical: Shutdown. The control unit records a critically low voltage indicator for more than 20 seconds.Disconnect the plug from the heater; Start the car engine; Measure the voltage indicator in the B2 chip - contacts A2 and A3; If the voltage is below 10 or 20V for a 12 or 24-volt model, respectively, check the quality of the positive terminal on the battery (due to oxidation, the contact may disappear ), the power wires for corrosion on the connections, the presence of good ground wire contact, as well as the serviceability of the fuse.
12The overheating sensor detects temperatures over +120 degrees.Remove the air plug from the cooling system circuit or add antifreeze; Check the mass flow rate of water with the throttle open; Measure the resistance of the overheating sensor (chip B1, pins 2/4). The norm is from 10 to 15 kOhm at an ambient temperature of +20 degrees; "Ring" the wiring to detect a short circuit, an open circuit, and also check the integrity of the insulation of the wires.
14High differential value of temperature sensor and overheating sensor. The difference in sensor readings exceeds 70K.Remove the air plug from the cooling system circuit or add antifreeze; Check the mass flow rate of water with the throttle open; Measure the resistance of the overheating sensor (B1 chip, pins 2/4), as well as the temperature sensor (B1 chip, pins 1/2). The norm is from 10 to 15 kOhm at an ambient temperature of +20 degrees; "Ring" the wiring to detect a short circuit, an open circuit, and also check the integrity of the insulation of the wires.
17Blocking of the control unit due to overheating. The overheating sensor records an indicator exceeding +180 degrees.Remove the air plug from the cooling system circuit or add antifreeze; Check the mass flow rate of water with the throttle open; Check the overheating sensor (see code 12); Check the control unit for proper operation.
19Glow plug 1: Failure due to too little ignition energy. Glowing electrode 1 consumes less than 2000 Ws.Make sure there is no short circuit in the electrode, its damage or check its continuity (see code 20). Check the functionality of the control unit.
20,21,22Glow plug 1: short circuit to + Ub, open circuit, overload, short circuit to ground.The indicator of the cold resistance of electrode 1 is checked: the ambient temperature is +20 degrees, chip B1 (contacts 7/10). For a 12-volt network, the indicator should be 0.42-0.6 Ohm; for a 24-volt - 1.2-1.9 Ohm. In the case of other indicators, the electrode must be replaced. In the absence of a malfunction, check the integrity of the wiring, the presence of damage to the insulation.
23,24Glowing electrode 2: open circuit, overload or short circuit.The indicator of the cold resistance of electrode 2 is checked: the ambient temperature is +20 degrees, chip B1 (contacts 11/14). For a 12-volt network, the indicator should be 0.42-0.6 Ohm; for a 24-volt - 1.2-1.9 Ohm. In the case of other indicators, the electrode must be replaced. In the absence of a malfunction, check the integrity of the wiring, the presence of damage to the insulation.
25JE-K line: error. The boiler remains ready.The diagnostic cable is checked for damage (open circuit, short to ground, damaged wire insulation). This is the wire that comes from the B2 chip (pin B4). If there are no faults, check the controller.
26Glow plug 2: short circuit to + UbThe steps are the same as for error 23,24.
29Glow plug 2: Failure due to too little ignition energy. Glowing electrode 2 consumes less than 2000 Ws.The operability of the electrode is checked (throughput, damage or short circuit), see code 23. If there are no faults, check the controller.
31,32,33,34Burner motor: open circuit, overload, short circuit to + Ub, short circuit to ground, inappropriate motor shaft speed.Check the integrity of the wires going to the electric motor (B2 counter, pins 3/6/9); Check the free rotation of the blades of the air blower. If foreign objects are found that prevent rotation, they must be removed and also checked for damage to the shaft or bearing. If no faults are found, the main controller or fan control unit must be replaced.
37Water pump failure.Check the functionality of the water pump. For this, current is supplied to the B1 chip, contacts 12/13. The maximum power consumption should be 4 or 2A. If the pump shaft is blocked, the pump must be replaced. If there are no problems, replace the controller.
41,42,43Water pump: failure due to breakage, overload on + Ub or short circuit.Check the operation of the water pump (see code 37); Check the integrity of the wires (break or damage to the insulation) connected to the B1 chip, pins 12/13; Check the impeller shaft for lubrication; Remove the air lock in the cooling system circuit, and measure the mass flow rate antifreeze with an open throttle.
47,48,49Dosing pump error due to broken wires, overload on + Ub or short circuit.The integrity of the wires going to the pump is checked (chip B2, contact A1). If there is no damage, measure the resistance of the pump (approx. 20 kOhm).
52Safe time limit: exceeded. During the boiler start-up process, the flame is not detected. The combustion sensor gives a signal for heating below +80 degrees, which causes an emergency deactivation of the heater.It is checked: The quality of the fuel supply; The exhaust system; The system for pumping fresh air into the combustion chamber; The operability of the pin electrodes (see code 19-24 / 26/29); Serviceability of the combustion sensor (see code 64,65).
53,54,55,56,57,58Flame loss: Stage “Power”; Stage “High”; Stage “Medium” (D8W / D10W); Stage “Medium1” (D12W); Stage “Medium2” (D12W); Stage “Medium3” (D12W); Stage “Small ". The boiler starts to work, but the flame sensor in one of the stages detects an open fire.Check the fuel supply; Check the number of revolutions of the air blower engine; The quality of the exhaust gas removal; Check the serviceability of the combustion sensor (see code 64,65).
59Antifreeze in the cooling system heats up too quickly.Remove a possible air lock from the cooling system; Replenish the lack of coolant volume; Check the mass flow rate of antifreeze with an open throttle; Check the serviceability of the temperature sensor (see code 60,61).
60,61Temperature sensor: open circuit, short circuit. The temperature sensor is either not sending signals or is reporting a critical high or too low temperature.Check the resistance of the temperature sensor. Chip B1, pins 1-2. The norm is from 10 to 15 kOhm (ambient temperature +20 degrees). In case of serviceability of the temperature sensor, it is necessary to check the integrity of the wires leading to this element.
64,65Combustion sensor: open or short circuit. The combustion sensor is either not sending signals or is reporting a critical high or too low temperature.Check the resistance of the temperature sensor. Chip B1, pins 5/8. The norm is within 1kOhm (ambient temperature +20 degrees). In case of serviceability of the temperature sensor, it is necessary to check the integrity of the wires leading to this element.
71,72Overheating sensor: open circuit, short circuit. The overheating sensor either does not send signals, or reports a critically high or too low temperature.  The steps are the same as for error 12.
74Functional error of the control unit, as a result of which the controller is locked; the equipment that detects overheating is faulty.The control unit or air and fuel pump needs to be replaced.
90Reset of the control unit due to external interference voltage.It is checked: Serviceability of the equipment installed in the immediate vicinity of the boiler; Battery charge; Condition of fuses; Damage to the wiring.
91Resetting the control unit due to an internal error. The temperature sensor is not working properly.The controller of the boiler or blower unit must be replaced.
92;93;94;95;96;97;98;99.ROM: Error; RAM: Error (at least one cell is inoperative); EEPROM: Error, checksum (operating parameters area) - error, calibration values ​​- error, diagnostic parameters - error; Control unit checksum: Error, invalid data; Block overheating control, temperature sensor error; Internal device error; Main relay: Error due to malfunction; Functional blocking of the ECU, a large number of resets.The control unit needs repair or replacement.

Errors Hydronic S3 Economy 12V CS/Commercial24V CS

Here is a table of possible errors of preheaters (economical and commercial) S3 Economy 12V CS / Commercial24V CS:

Code (starts with P000):Explanation:How to fix:
100,101,102Antifreeze output sensor: open circuit, short circuit, short circuit to + Ub.Check the integrity of the wires; Measure the resistance of the RD wire (between pins 9-10). The norm is from 13 to 15 kOhm at a temperature of 15 to 20 degrees.
10АCold purge time exceeded. A new start is not possible due to too high temperature in the inoperative combustion chamber.Make sure that the exhaust gases are drawn into the exhaust system of the machine. Otherwise, it is necessary to check the fire sensor (see code 120,121).
110,111,112Antifreeze input sensor: open circuit, short circuit, short circuit to + Ub. Attention: codes 110 and 111 are displayed only when the boiler is on, as well as when the coolant temperature sensor detects a temperature above +80 degrees.Check the integrity of the wiring; Measure the resistance of the BU wire (between pins 5-6) in the XB4 chip. The resistance rate is from 13 to 15 kOhm at a temperature of 15 to 20 degrees.
114High risk of overheating. Attention: code 114 is displayed only when the boiler is on, as well as when the coolant temperature sensor detects a temperature above +80 degrees. The error appears when there is a large difference between the readings of the two temperature sensors: inlet / outlet (in the line of the engine cooling system).Check the sensor installed at the coolant inlet to the boiler heat exchanger. Measure the resistance of the BU wire (between pins 5-6) in the XB4 chip. The resistance rate is from 13 to 15 kOhm at a temperature of 15 to 20 degrees. Follow the same steps as for error 115.
115Exceeding the threshold of the programmed temperature. A critically high indicator is recorded by a temperature sensor at the outlet of the antifreeze from the heat exchanger of the heater. The sensor records the coolant temperature above +125 degrees.It is checked whether there are any leaks in the cooling system line (when the boiler is operating, the thermostat in the machine must be set for heating in the "Warm" mode); Check the thermostat's serviceability; Check the correspondence between the coolant circulation direction and the direction of rotation of the hydraulic pump blades; Make sure that the cooling system is not ventilated; Check the efficiency of the coolant circulation (valve capacity); Check the operability of the temperature sensor installed at the outlet of the heat exchanger (see code 100,101,102).
116Exceeding the hardware limitation of the coolant heating temperature - overheating. The temperature sensor detects an increase in the temperature of the coolant (exit from the heat exchanger) more than +130 degrees.For corrective action see code 115; Measure the resistance of the RD wire (between pins 9-10). The norm is from 13 to 15 kOhm at a temperature of 15 to 20 degrees.
11АLarge amount of overheating: functional blocking of the controller.Eliminated in the same way as in the case of errors 114,115. The controller is unlocked with: EasyStart Pro (control element) EasyScan (diagnostic device) EasyStart Web (software for diagnostic device).
120,121,122Open circuit, short circuit or short circuit on + Ub of the combustion sensor.The integrity of the wiring is checked. The BN cable in the XB4 chip (between pins 7-8) is tested for resistance. At an ambient temperature of 15 to 20 degrees, the indicator should be in the range of 1-1.1 kOhm.
125;126;127;128;129.Flame breakage at the stage: Adjustments 0-25%; Adjustments 25-50%; Adjustments 50-75%; Adjustments 75-100%. Attention! When the flame is cut off, the controller will try to ignite the boiler three times. A successful start removes the error from the error logger.The efficiency of exhaust gas removal is checked; The efficiency of the fresh air supply to the combustion chamber is checked; The quality of the fuel supply is checked; The operability of the fire sensor is checked (see code 120,121).
12АThe safe time limit has been exceeded.The quality of the air supply / removal from the chamber is checked; The efficiency of the fuel supply is checked; Change the fuel filter; Change the mesh filter in the metering pump.
12VThe operating mode is blocked due to exceeding the safety time limit (the device tried to start three times). The controller is blocked.Check the quality of the fuel supply. The controller is unlocked using: EasyStart Pro (control element); EasyScan (diagnostic device); EasyStart Web (diagnostic device software).
143Air sensor signal error. The boiler goes into emergency mode. The air pressure does not match the program.For the 12-volt model, it is necessary to check the connection of the boiler to the CAN bus. Reset error (see code 12V). For a 24-volt analog, you need to reset the error. Otherwise, replace the control unit.
200,201Open or short circuit of the metering pump.The wiring is checked for damage. If the wires are intact, the metering fuel pump needs to be replaced.
202Metering pump transistor error or short circuit to + Ub.Make sure the cable is not damaged or broken. The counter of the metering pump is disconnected from the blower. If the error persists, the blower must be replaced with a new one.
2a1Lost contact or breakage of the water pump.It is necessary to check the integrity of the pump wires. To do this, you need to disconnect the XB3 chip (heater) and the XB8 / 2 chip (connected to the water pump). The wires should not have any damage to the insulating material and gaps. If there is no damage, the pump must be replaced.
210,211,212Glow electrode error: open circuit, short circuit to + Ub, short circuit, transistor defective. Attention! Before carrying out diagnostics, you need to take into account that the device will fail if the voltage is too high. The electrode collapses when the voltage is higher than 9.5V. It is also necessary to take into account the resistance of the power supply to the resulting short circuits.The wires are checked for damage. If the cable is intact, then it is necessary to check the electrode. For this, the XB4 chip is disconnected (the 3rd and 4th pins of the WH cable). A voltage of 9.5V is applied to the electrode (permissible deviation is 0.1V). After 25 seconds. current strength is measured. The device is considered serviceable if the device showed a value of 9.5A (permissible deviation in the direction of increasing 1A, and in the direction of decreasing 1.5A). In the event of a discrepancy between the indicators, the electrode is defective and must be replaced.
213Glow electrode error due to low glow energy.The integrity of the wires going to the electrode is checked. The performance of the electrode is checked (see code 210,212).
220,221,222Air blower motor: open circuit, short circuit, short circuit to + Ub, transistor defective.The number of shaft revolutions is measured. To do this, you need to use the EasyScan diagnostic device (how it works is described in the operating instructions).
223,224Air blower motor error due to impeller or shaft blocking. The electric motor is consuming too little power.Eliminate impeller or shaft blockage (dirt, foreign matter or icing). Check the free rotation of the device shaft by hand. If the blower fails, it must be replaced.
250,251,252Water pump: open circuit, short circuit, faulty transistor or short circuit to + Ub.Diagnostics of the cable harness is carried out. To do this, disconnect the XB3 chip from the heater, and disconnect the XB8 / 2 chip from the water pump. The condition of the insulating layer of the wires and the integrity of the cores are checked. If the cable is not damaged, then the pump needs to be replaced. The same outcome, if you turn off the XB8 / 2 chip, and the error code does not disappear.
253The water pump is blocked.A branch pipe is bent in the cooling system line.
254,255Excess current to the water pump - device shutdown; the pump shaft is turning too slowly.There may be dirt in the cooling system line or there is a lot of dirt inside the pump.
256Running the water pump without lubrication.Check the level of antifreeze; It is possible that air has entered the pump or small circulation circle and formed a plug.
257,258Water Pump Error: Low / High Voltage (ADR); Overheated.Overheating of the pump due to high temperatures outside. In this case, you should install the pump away from hot units, mechanisms or the exhaust pipe; Check if the wiring to the pump is intact. This is the cable connecting the XB3 (heater) and XB8 / 2 (the pump itself) chips; If there is no damage in the wiring, the pump should be replaced.
259Short circuit in the passenger compartment fan or water pump.Make sure that the wiring to which the pump or the interior fan is connected is not damaged or broken; Check the air blower relay; Check the coolant circulation.
260Broken universal output connection.Check output coding; Check wires for damage.
261Interior fan short circuit.Make sure that the cover of the electric motor is not damaged and correctly installed; If the cover is not damaged and properly closed, then it is necessary to replace the fan relay (K1).
262Short circuit to + Ub in the universal output or faulty transistor.Make sure the cable is not damaged.
300Hardware malfunction, overheating, dosing pump shutdown circuit malfunction.Check the sensor downstream of the heat exchanger. Measure the resistance of the RD wire coming from the XB4 chip (between pins 9-10). The norm is from 13 to 15 kOhm at a temperature of 15 to 20 degrees. The controller is unlocked using: EasyStart Pro (control element); EasyScan (diagnostic device); EasyStart Web (diagnostic device software).
301;302;303; 304;305;306.Control unit malfunction.The control unit needs to be repaired or replaced.
307Incorrect data transfer on the CAN bus.Reset the error, and if it appears, you must re-check the bus connection to the device.
30АCAN bus: error in data transmission.Reset the error, and if it appears, you must re-check the bus connection to the device.
310,311The control unit has shut down due to overload caused by high voltage. In this case, the indicator of high voltage is recorded for more than 20 seconds.Disconnect the XB1 chip from the boiler; Start the engine of the machine; Measure the voltage between the wires RD (1st contact) and BN (2nd contact). If, as a result of diagnostics, the device showed a voltage higher than 15V, then it is necessary to pay attention to the serviceability of the voltage regulator on the generator, as well as the condition of the battery terminals.
312,313The control unit and completely the boiler shut down due to a critically low voltage.Disconnect the XB1 chip from the boiler; Start the engine of the machine; Measure the voltage between the wires RD (1st contact) and BN (2nd contact). If, as a result of diagnostics, the device showed a voltage below 1oV, then it is necessary to pay attention to the serviceability of the fuses, as well as the condition of the battery terminals (especially the positive terminal).
315Incorrect data regarding fresh air pressure.Check the contacts of the connection with the control device. If the error persists, you need to diagnose with EasyScan.
316Poor heat exchange in the cooling system line. The boiler will often initiate short heating cycles with minimal pause in between.Check the line through which the coolant circulates.
330,331,332Control unit malfunction.The controller requires repair or replacement.
342Incorrect hardware configuration.For 12 and 24 volt models: a large number of components are connected to the CAN bus. Check the configuration of the required hardware. Exclusively for 24V ADR model: use only a control element connected to the CAN bus. If necessary, you need to check the quality of the equipment connection.
394Short circuit of the ADR button.Check the integrity of the wiring and, if damaged, replace the damaged components.
500The "ErrorState GSC" entry appears in the error logger. Heating or ventilation does not turn off.Return an active request (the system continues to send a request for heating or hardware diagnostics). Clear error logger.
A00No response from EasyFan to a specific number of signals. Communication with the boiler is lost.Return an active request (the system continues to send a request for heating or hardware diagnostics). Clear error logger.
E01Exceeding the temporary working limit.The device has fulfilled the programmed time threshold.

Price

New thermosensors cost within 40 USD. For light vehicles, the manufacturer offers equipment starting at $ 400, but the price of some kits can reach $ 1500. The kit includes the boiler itself, a control device, a mounting kit, with which the heater is correctly installed on the vehicle, and also connected to the exhaust system.

Some models powered by diesel fuel, intended for heating the car interior, can also cost more than one and a half thousand cu. The main thing in the selection process is to correctly calculate the power of the device, as well as its purpose. An important point is also compatibility with the vehicle's on-board electronics.

Where to install

Since this category of equipment is very complex, and has a large number of components, it is not recommended to install a pre-starting car boiler in the garage of a friend according to the instructions from YouTube. This should be done by professionals who already have enough knowledge and experience. To find a suitable workshop, enter "Eberspacher preheater installation" in the search engine.

Advantages and differences from competitors

The most famous manufacturers of preheaters are the German companies Webasto and Eberspacher. About how the analogue from Webasto is arranged, there is A separate article... In short, the difference between Eberspacher and its related counterpart is:

  • Less kit cost;
  • Smaller boiler dimensions, which makes it easier to find a place where to install it. In many cases, drivers install this equipment in the engine compartment, and larger options - under the car, if an appropriate niche is provided in the body structure;
  • The device has a protective cover that can be easily removed, thanks to which there is good access to all elements of the automobile boiler;
  • The design of the heater, especially the air heater, includes fewer parts, which greatly simplifies the repair and maintenance of the system;
  • Compared to similar models (consuming the same amount of fuel), this product has a higher efficiency - by about half a kilowatt;
  • The hydraulic pump is already installed in the boiler, which makes it easy to install on the vehicle.

In many countries of the post-Soviet space, a network of service stations specializing in car pre-heaters is already slightly developed. Thanks to this, the driver does not need to travel across the country to get his car repaired.

In conclusion, we offer a short video instruction on how to adjust the pre-heater using a standard control module that is installed in the car's interior:

Video instruction on how to use the Eberspacher EasyStart Select control.

Questions and answers:

How to reset eberspacher errors? Some people prefer to do this by removing the battery terminal. After a while, most errors are erased. Or this is done through the service menu on the device panel.

How do I view eberspacher errors? To do this, press the menu, select the "service" mode, the flashing clock symbol and is delayed until the service menu is activated and then scrolls to the list of errors.

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