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B 5 W S and D 5 W S
Technical Description Eberspächer ®
Mounting Instructions

J. Eberspächer
GmbH & Co.

tion
Eberspächerstr. 24

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

www.eberspaecher.com

Engine-independent water heater

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

Order No. Order No.

HYDRONIC B 5 W S – 12 V 20 1793 05 00 00 HYDRONIC D 5 W S – 12 V 25 2100 05 00 00

Universal mounting kit 20 1777 80 00 00 Universal mounting kit 20 1777 80 00 00

HYDRONIC B 5 W S – 12 V 20 1794 05 00 00 HYDRONIC D 5 W S – 12 V 25 2101 05 00 00

As a complete package As a complete package

HYDRONIC D 5 W S – 24 V 25 2146 05 00 00
Universal mounting kit 25 2009 80 00 00

Contents Page Page

Items supplied .......................................................... 2, 3 Permissible mounting positions ............................... 9 D
Control elements, optional ........................................ 2 Connection to the cooling water circuit ..................... 10 – 12
Government regulations and Conducting the combustion air / exhaust gas ........ 13
safety instructions concerning installation .............. 4 Fuel supply ................................................................ 14 – 17 S
Technical data ........................................................... 5 Circuit diagrams ........................................................ 18 – 21
Sectional drawing ..................................................... 6 Function ..................................................................... 22
Principal dimensions / Installation ........................... 7 Controls and safety devices ..................................... 23 GB
Mounting instructions / mounting example ................ 8 ADR / TRS 003 / TMD – mode of operation ............. 23

* Please hand this technical description / mounting instruction

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

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Items supplied Control elements, optional

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

1 HYDRONIC B 5 W S – 12 volt 20 1793 05 00 00 1 Change-over switch 22 1000 31 89 00

‘heating / ventilating’ 12 / 24 volt
To be additionally ordered: Can only be used in combination
1 Universal mounting kit 20 1777 80 00 00 with a control element.

or
1 Mini-clock – 12 / 24 volt 22 1000 31 31 00
1 HYDRONIC B 5 W S – 12 volt 20 1794 05 00 00
As a complete package* The mini-clock can be combined with
the TP 41 / TP 41i radio remote control.
1 HYDRONIC D 5 W S – 12 volt 25 2100 05 00 00
1 Module clock – 12 / 24 volt 22 1000 30 34 00
To be additionally ordered:
with temperature preselection
1 Universal mounting kit 20 1777 80 00 00

or The module clock can be

combined with the TP 4 / TP 4i
radio remote control.
1 HYDRONIC D 5 W S – 12 volt 25 2101 05 00 00
As a complete package*
1 Mounting parts for the 25 1482 70 01 00
module clock – only required
1 HYDRONIC D 5 W S – 24 volt 25 2146 05 00 00
when installed with a shade
To be additionally ordered:
1 Universal mounting kit 25 2009 80 00 00
1 TP 41 radio remote control 22 1000 31 35 00
TP 41i radio remote control 22 1000 31 39 00*
* The complete package consists of:
12 / 24 volt
1 HYDRONIC B 5 W S or D 5 W S
1 Universal mounting kit The TP 41 / TP 41i radio remote control
can be used on its own or in combination
Optional extras with the mini-clock – Order No. 22 1000 31 31 00.
1 Check valve, Ø 18 mm 254 00 070

1 Check valve, Ø 20 mm 254 00 074

1 TP 4 radio remote control 22 1000 30 63 00
1 Comfort mounting kit for engines from 2.5 l
TP 4i radio remote control 22 1000 30 99 00*
cubic capacity 24 0132 00 00 00
12 / 24 volt
The comfort mounting kit includes the following:
1 thermostat, Ø 18 mm The TP 4 / TP 4i radio remote control can only
be used in combination with the module clock.
1 T-piece, Ø 18 mm
1 check valve, Ø 18 mm
1 water hose, Ø 18 mm
* Outside Germany only the I-version radio remote
10 hose clamps
controls may be permissible
D Please refer to the Extra Parts Catalogue for other
additional parts.
Please note!
Control elements must be selected in accordance
S Attention!
with the intended use of the HYDRONIC and on the
Before switching on or preprogramming the heating, put
basis of the distinction: air or water heater, simple
the vehicle’s heating lever (provided the vehicle is
switching on and off, programme preselection and /
equipped with one) to “HOT” (maximum position) and
GB the fan to “slowest speed” (low current consumption).
or radio remote control. The control elements are
supplied with operating instructions. These are
For vehicles with automatic heating, put the heating
intended to be handed over to the customer together
lever to “MAX.” and the desired damper position to
with the mounting and operating instructions for the
F “OPEN” before switching off the ignition.
HYDRONIC.

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Scope of the delivery

S
햲 Heater HYDRONIC B 5 W S / D 5 W S * Part only contained in scope of supply of
햳 Dosing pump HYDRONIC 24 V and in kit 25 2009 80 00 00.
햴 Water pump ** Part only contained in scope of supply of
HYDRONIC 12 V.
GB
Parts without drawing number are included in the
universal mounting kit. a = drive control elements
b = drive fan F
3

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§ Statutory regulations concerning

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

HYDRONIC B 5 W S S 288
HYDRONIC D 5 W S S 274

• The mounting requirements associated with the Gene- Important instructions for
ral Design Certification (AGB) and further statutory ATTENTION ! the installation and repair
regulations have been printed in the corresponding of the HYDRONIC
sections of these mounting instructions.
• When the air heater is installed in special vehicles, the When mounting or repairing the heater, only original
regulations governing such vehicles must be taken into accessories and original spare parts may be used.
account (e.g. ADR / TRS 003 / TMD for vehicles used to Changes to the HYDRONIC or to components relevant to
transport dangerous substances). the heating, the use of outside parts not approved by
• The year in which the air heater was operated for the Eberspächer as well as an installation or operation
first time must be permanently recorded on the type differing from the statutory, safety and /or function rel-
plate. To this end, 3 different years have been printed evant specifications contained in the mounting instruc-
on the corresponding field of the type plate. The valid tions and in the operating instructions are not permissi-
year is to be identified by removing (detaching) those ble:
two years which are not applicable. this applies in particular to the electric wiring (circuit
• Subsequent installation of the heater must be carried diagrams), the fuel supply, the combustion air and ex-
out in conformity with these mounting instructions and haust gas duct.
must be examined and certified in writing by an Fuel pipes and exhaust pipes must be safely fastened, to
officially approved vehicle specialist or inspector or avoid damage from vibrations (recommendation: at
employee (Section 7.4a of Annex VIII to the StVZO) in intervals of approx. 50 cm).
conformity with § 19 Section 3 StVZO. The Ensure that the insulation of electrical lines cannot be dam-
effectiveness of the design certification (ABG) for the aged due to abrasion, kinking, squeezing or by exposure
heater is dependent on this. to heat.
At the discretion of the vehicle owner, the certificate
can be issued as follows: Only the control elements provided and / or approved by
– As separate ‘Certificate of Approval’ which must us, either on their own or in a given combination, may be
always be kept in the vehicle. A blank form for this used to operate the HYDRONIC. The use of other control
‘Certificate of Approval’ is attached at the end of the elements may lead to malfunctions of the heater / heating
operating instructions for the heater. Neutral operation.
certificates of approval available to the motor vehicle
specialist are also permissible. Non-compliance with the statutory, safety and / or
In both cases, the vehicle manufacturer, vehicle function relevant specifications leads to the lapse of the
model and vehicle identification number must be General Design Certification (ABG) of the HYDRONIC
entered. and to the exclusion of guarantee and liability on the part
– As entry in the vehicle registration document (asses- of the company J. Eberspächer GmbH & Co.
sing authority) and in the vehicle identification card
(licencing authority.) Please note!
• For vehicles not subject to the StVZO (e.g. ships), it is Further ‘Safety instructions concerning the installation
necessary to observe the specific regulations and and repair of the HYDRONIC’ as well as ‘Important
mounting instructions applicable to the given vehicle; instructions concerning the installation’ have been
these may difffer regionally. printed directly in the corresponding sections of these
D • The heater may only be installed or repaired - in case
of the heater being handed in for repair or guarantee
mounting instructions.

reasons - by a specialist workshop approved by the

manufacturer (service partner) in keeping with these
S mounting instructions and possible special installation
recom-mendations.
• The information sticker ‘Switch off heater before
refuelling’ suppplied with the heater must be attached
GB in a suitable position on the vehicle (close to the fuel
filler neck).

F
4

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Technical data

Heater B5WS D5WS

Heating medium Water, glycol compounds

Heat flow settings Large Small Large Small

Heat flow (watt) 5000 1500 5000 2300

Fuel consumption (l/h) 0.69 0.20 0.62 0.27

Electrical input (watt) During operation 37 10 37 10

When starting < 110 < 100

During after running 8 8

Rated voltage 12 V 12 V 24 V

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

Upper voltage limit 16 V 16 V 32 V

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

Permissible working pressure up to 2.5 bar excess pressure

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

Electric power consumption water pump 16 W 16 W 12 W

Min. water flow rate of heater 300 l/h

Fuel Commercial petrol Commercial diesel fuel

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

Permissible ambient temperature

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

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

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

Degree of radio interference suppression 5 for VHF / SW / MW
2 for LW S
Weight
without water and add on pieces approx. 2.3 kg
including water pump and dosing pump approx. 2.9 kg
GB
All technical data ± 10 %
F
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Sectional drawing (shown here is the HYDRONIC B 5 W S)

from vehicle engine

to heat exchanger

D 1 Combustion air blower 10 Combustion air tube A = Exhaust gas

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

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Principal dimensions

HYDRONIC

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

Water pump - 12 volt Water pump - 24 volt

Mounting the heater and water pump Type plate

Point of installation is the engine compartment. Mount

the heater as deeply as possible so that heat ex-
The type plate must be clearly visible after the D
heater has been installed. If necessary, a second
changer and water pump can deaerate automatically. type plate (duplicate) with the same details as the
Observe permissible mounting positions as well as original one can be mounted at a clearly visible
operating and storage temperatures. point on the air heater or a cover in front of the air S
heater.
Installation of the heater in the passenger compart- A second type plate is not necessary if the original
ment, driver’s cab, working cabin, seating compart- type plate is clearly visible under a cover that can GB
ment and generally in rooms used by people is not be removed without having to use tools. The type
permissible. When installing the heater in special- plate is mounted on the basic unit.
purpose vehicles (e.g. ambulance) valid regulations
have to be complied with.
F
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Mounting instructions

The heaters are used in combination with the in- ATTENTION!

vehicle heating system to preheat the engine, to
defrost the windows. The proposed points of installation given in these
They are connected to the vehicle's cooling water mounting instructions are examples.
system, electrical system and fuel system. Other points of installation are also permissible
if they comply with the installation requirements
The heaters can be wired to operate as add-heaters, specified in these mounting instructions.
thereby raising the heating capacity of the vehicle's
own heater to a comfortable level – especially in Please note!
vehicles whose engines have been optimized in Further information concerning the installation
terms of combustion. (e.g. for boats and ships) may be obtained from
the manufacturer on request.

Mounting example

11

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

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

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Permissible mounting positions

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

HYDRONIC

Normal position horizontal (exhaust pipe to the

bottom) with permissible swivel range.

or

Water pump

Normal position horizontal with permissible swivel

range.
Note:
The outlet nozzle must be pointing 5° upward,
as shown in the drawing.

GB

F
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Connection to the cooling water circuit Please note!

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

There are several possibilities: Characteristic heating curve:

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

1 Heater
2 Water pump
2 3 Vehicle’s heat exchanger
4 Vehicle engine

S
4
1
GB
3

F
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2. Inserting the check valve into the inflow line Check valve Ø 18 mm – Order No. 254 00 070
Check valve Ø 20 mm – Order No. 254 00 074
Cut open the inflow line running from the vehicle
engine to the heat exchanger and insert the check Characteristic heating curve as for water cycle “1”
valve.
Insert the heater and the water pump into the water Advantage:
circulation system as shown in the drawing. No loss of efficacy of engine heating with the station-
ary heating switched off.

1 Heater
3 2 Water pump
3 Check valve
4 Vehicle’s heat exchanger
5 Vehicle engine

5
1

3. Integrating the deluxe installation kit Characteristic heating curve:

into the water circulation system First, up to a cooling water temperature of approx.
70 °C the heat of the auxiliary heating is only fed to
Deluxe installation kit, Order No. 24 0132 00 00 00 the passenger compartment = small cycle, fast heat-
ing up. If the cooling water temperature continues to
Cut open the inflow line running from the vehicle rise, the thermostat gradually changes over to the
engine to the heat exchanger and insert the check large cycle = additional preheating of engine (full
valve. change-over is reached at 75 °C).
Cut open the return line running from the heat
exchanger to the vehicle engine and insert the
T-piece. Insert the heater, thermostat and water Please note!
pump into the water circulation system as shown Execute connections 1, 2 and 3 as described in
in the drawing. the drawing.

Thermostat, Ø 18 mm

4 2
D
(always open)

S
7
1 Heater 5 T-piece 1
2 Water pump 6 Vehicle’s
3 Check valve heat exchanger t<70 °C = 3 closed
GB
4 Thermostat 7 Vehicle engine 6
5 2 open
t>75 °C = 3 open
2 closed F
11
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4. Water cycle with combination valve Combination valve with 5 connections:

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

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

Combination valve (6 connections)

HYDRONIC

from vehicle to vehicle

engine heat exchanger

to vehicle from vehicle

engine heat exchanger

6
1
D
5
4
S
1 Heater
2 Water pump
GB 3 Combination valve (5 connections)
4 T-piece
5 Vehicle’s heat exchanger
6 Vehicle engine
F
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Conducting the combustion air / exhaust gas

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

1 Heater 1
2 Combustion air hose
3 Exhaust gas pipe
4 Exhaust gas silencer D
5 Exhaust tail pipe

S
2 4
3 5
GB
bis 1,5m

bis 2m
up to 1.5 m
up to 2 m F
13
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Fuel supply

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

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

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

To engine b
mechanical fuel pump
or injection pump 8

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

installed in the vehicle tank or in the tank • No valve may be installed in the return line
fitting in the tank.
• The pressure inside the return line may reach
If it is not possible to install a separate rising pipe in a max. of 2 bar. In case of pressures above 0.3
cars with fuel injected engines the return line can be and up to 2 bar a pressure reducer (add-on part,
tapped by means of a T-piece. order No. 20 1645 89 30 00) must be installed
in front of the dosing pump.

b
10

햲 Tank connection for metal tank, Permissible line lengths

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

GB

F
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Mounting position of the dosing pump

Permissible suction and pressure level
of the dosing pump
Mounting position of the dosing pump
Mount the dosing pump in the vehicle with the pres-
sure side rising by at least 15° and maximum 90°.
If possible the fuel lines from the dosing pump to
pressure side the heater should rise continuously.

Permissible suction and pressure level

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

Suction level with a pressureless vehicle tank:

b = max. 1500 mm for petrol
b = max. 1000 mm for diesel
Please note: Check the tank venting.

Suction level with a vehicle tank in which fuel

tapping produces a vacuum (valve with 0.03 bar in
the tank closure):
b = max. 150 mm for petrol
햲 Dosing pump b = max. 400 mm for diesel
햳 Maximum fuel level
햴 Minimum fuel level Pressure level from the dosing pump to the heater:
햵 Connection on the heater c = max. 2000 mm

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Important!

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

Drawing A: Drawing B:

correct

incorrect

GB

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

20 1777 00 96 01 B
Parts list

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

Parts list

2.15.9 Sensor, outside temperature

3.1.9 Change-over switch ‘heating / ventilating’

3.1.16 Key button, radio remote control

3.2.6 Timer, mini-clock

3.2.9 Timer, module clock
3.2.12 Timer, mini-clock

3.3.6 TP 41 / TP 41i radio remote control (receiver)

b) Connect to terminal +15 if heating operation

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

Length ‘plus’ + length ‘minus’:

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

Cable ends that are not being used must be

insulated.

Plug and socket case are shown from the cable

entry side.

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

S
Cable colours

sw = black vi = violet GB
ws = white br = brown
rt = red gr = grey
ge = yellow bl = blew
20 1777 00 97 01 A gn = green li = purple
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Circuit diagram
HYDRONIC D 5 W S – 24 volt, ADR / TRS 003 / TMD

25 2147 00 97 01 B
Parts list

1.1 Burner motor a) for auxiliary heating option connect to D+ Cable colours
1.2 Glow plug d) Secondary drive input for TRS units
1.5 Overheating sensor h) external water pump sw = black
m) if only one control element is used for items 5.2.1 ws = white
1.12 Flame sensor and 5.2.2, it must be ensured that, if the function rt = red
1.13 Temperature probe ‘opening of battery separating switch’ is actuated ge = yellow
(emergency shutdown-function in the case of gn = green
2.1 Controller ADR, TRS 003, TMD and similar), the switch vi = violet
2.2 Dosing pump always breaks contact without delay (without br = brown
2.7 Main fuse 15 A consideration for the heater mode) and breaks all gr = grey
D 2.7.1 Fuse, actuation 5 A of the heater’s circuits from the battery. bl = blew
2.12 Water pump li = purple
Length ‘plus’ + length ‘minus’:
S 5.1 Batterie < 5 m: cross section 4 mm2
5.2.1 Battery operating switch m) > 5 m < 8 m: cross section 6 mm2
(operation e.g. controlled
via ignition lock) Cable ends that are not being used must be isolated.
GB 5.2.2 Battery separating switch m)
(Emergency-shutdown Plug and socket case are shown from the cable
function in the case entry side.
F of ADR / TRS 003 / TMD)

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

25 2147 00 97 01 B

Parts list

3.2.9 Timer, module clock, TRS Please note:

For vehicles with automatic heating or airconditioning,
b) Connect to terminal +15 vehicle fan control must be in accordance with our
c) Lighting terminal 58 vehicle-related workshop information. If no workshop
e) External switch ON / OFF (optional) information is available, the vehicle manufacturer’s
instructions with regard to the connection and / or
Length ‘plus’ + length ‘minus’: point of intersection for the fan control must be
< 5 m: cross section 4 mm2 adhered to.
> 5 m < 8 m: cross section 6 mm2

Cable ends that are not being used must be Cable colours
D
insulated.
sw = black
Plug and socket case are shown from the cable ws = white S
entry side. rt = red
ge = yellow
gn
vi
=
=
green
violet
GB
br = brown
gr = grey
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Function Check the following points in the event of faults:

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

Stationary heating operation If the heater still does not start:

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

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Controls and safety devices

• If the heater does not ignite within 90 seconds Stationary ventilation with change-over switch
after fuel pumping has started, then the start ‘heating / ventilating’
procedure must be repeated in the described Stationary ventilation means that it is possible to
manner. directly control the vehicle fan by means of the heat-
A fault shut-down is effected if the air heater once ing device preselector or – even more effectively – via
again fails to ignite after 90 seconds of fuel the radio remote control TP4 / TP41, thus bypassing
pumping. the heating operation. This serves the purpose of
After an excessive number of unsuccessful ventilating the passenger compartment shortly before
attempts to start the heater, the control will be departure with fresh air as it often heats up consider-
locked*. ably during summer time (separate wiring).

• A renewed start must be completed if the flame

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

• The rotating speed of the fan motor is continuously

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

* Reading off errors and cancelling of locking: D

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

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