Eberspacher Hydronic HS3D5ECS Manual Troubleshooting

Vehicle Heaters | Technical Documentation EN
R EPAI R I NST R UCTION S

HY DRONI C S3 ECO NO MY 12 V C S
HY DRONI C S3 COMME RCIAL 24V C S
These repair instructions are valid for the following

engine-independent water heaters:
Heaters for petrol Order No. Æ 05/2020 05/2020 Æ 09/2020 Æ

B4E – 12 V CS 20.2007.05.0000 20.2050.05.0000
B5E – 12 V CS 20.2008.05.0000 20.2051.05.0000
Heaters for diesel

D4E – 12 V CS 25.2933.05.0000 25.2992.05.0000
D5E – 12 V CS 25.2934.05.0000 25.2993.05.0000
D5L – 24 V CS 25.2696.05.0000 25.3009.05.0000

D6L – 24 V CS 25.2745.05.0000 25.2672.05.0000
D6L – 24 V CS ADR 25.2977.05.0000 25.3004.05.0000
Heaters for diesel

with inlet pressure resistant metering pump
D4E – 12 V CS VDP 25.2943.05.0000 25.2995.05.0000
D5E – 12 V CS VDP 25.2942.05.0000 25.2994.05.0000
Repair instructions | Hydronic S3 CS
Chapter Chapter title Page

Chapter contents
1 Introduction
1.1 Concept of this document 4
1.2 General information 4
1.3 Reference documents 4
1.4 Special text formats and presentations 4
1.4.1 Lists 4
1.4.2 Cross references 4
1.5 Picture symbols 4
1.6 Intended use 5
1.6.1 Range of application of the heater 5
1.6.2 Intended use of the heater (via the vehicle's own heat exchanger) 5
1.7 Non-intended use 5
1.8 Disclaimer 5
1.9 Target groups of this document 5
1.10 Duty to instruct of the target groups 5
1.11 Safety instructions 6
1.12 Warranty and liability 6
1.13 Accident prevention 6
1.14 Functional test following a repair 6
2 Troubleshooting
2.1 What to check first in case of faults 7
2.2 Control box is locked 7
2.3 Unlocking the control box 7
2.3.1 Overview of testing equipment / control units 7
2.3.2 Fault diagnosis using the CAN control unit 7
2.4 Vehicle-specific diagnostic system 7
2.5 Fault code table 8
3 Repair instructions
3.1 Please note 14
3.2 Special tool 14
3.2.1 Control box dismantling kit 14
3.2.2 Release tool 14
3.3 The repair steps at a glance 15
3.4 Dismantle the heater 15
3.4.1 Repair step 1: Remove the control box 15
3.4.2 Repair step 2: Remove the sensor cover and water connection socket 16
3.4.3 Repair step 3: Remove the heat exchanger 17
3.4.4 Repair step 4: Remove the combustion chamber 17
3.4.5 Repair step 5: Remove the lead harness of the heater 17
3.4.6 Repair step 6: Remove the glow plug 18
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3.4.7 Repair step 7: Replace the blower 19

3.4.8 Repair step 8: Remove the blower housing / heat exchanger seal and the fuel connection grommet 19
3.5 Assembling the heater 19
3.5.1 Mount the fuel connection grommet and blower housing / heat exchanger seal 19
3.5.2 Install the glow plug 20
3.5.3 Install the lead harness of the heater / flame sensor 20
3.5.4 Install the combustion chamber 20
3.5.5 Installing the heat exchanger 20
3.5.6 Install the water inlet sensor / water outlet sensor 21
3.5.7 Install water connection socket / sensor cover 21
3.5.8 Mounting the control box 21
3.5.9 Installing the blower cover 22
3.5.10 Measure the fuel quantity 22
3.5.11 Measure fuel quantity with EasyScan 22
3.6 Hydronic S3 Economy component drawing 23
4 Electrics
4.1 Heater wiring 24
4.2 Parts list for circuit diagram, heater and cable harness 24
4.3 Heater circuit diagrams 25
4.3.1 Heater 12V CS 25
4.3.2 Heater 24V CS 26
4.3.3 Cable harness 12V CS 27
4.3.4 Cable harness 24V CS 28
4.3.5 Cable harness 24V CS ADR 29
4.4 Circuit diagrams for control units 30
4.4.1 Easy Start Pro 30
4.4.2 EasyStart Timer 31
4.4.3 EasyStart Web 32
5 Technical data
5.1 Petrol heater 12V CS 33
5.2 Diesel heater 12V CS 34
5.3 Diesel heater 24V CS 35
6 Environment
6.1 Certifications 36
6.2 Disposal 36
6.2.1 Disposal of materials 36
6.2.2 Dismantling the heater 36
6.2.3 Packaging 36
6.3 Technical Support 36
7 Service
7.1 Standard times 37
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1 Introduction 1.4 Special text formats and presentations
Special text formats and picture symbols are used in this document
1.1 Concept of this document to emphasise different situations and subjects. Please refer to the
This document assists the workshop with troubleshooting and repair following examples for their meanings and appropriate action.
of the heater. The document is divided into the following chapters to
1.4.1 Lists
make it easier to find information quickly.
This dot () indicates a list or action step, introduced by a heading.
1 Introduction – If an indented dash (–) follows a “dot”, this list/action step is a
Important, introductory information about use and the structure of sub-section/secondary step of the black dot.
this document
1.4.2 Cross references
2 Troubleshooting
Underlined blue text denotes a cross-reference, which can be clicked
Information about unlocking the control box and the fault codes of
in the PDF format. The part of the document named in the text is then
the heater, their meaning and troubleshooting measures / remedies
displayed.
based on a clear table
3 Repair instructions 1.5 Picture symbols

Information about special tools, dismantling and assembly of the
heater’s components as well as a component drawings Regulation!
This information indicates a statutory regulation. Any violation of
4 Electrics
these regulations results in expiry of the type-approval for the
Information on the electronics, circuit diagrams and components
heater and exclusion of any guarantee and liability claims against
5 Technical data Eberspächer Climate Control Systems GmbH & Co. KG.
Technical data of the petrol and diesel heaters
6 Environment Danger!
Information about certification and disposal “Danger” indicates a situation that can directly result in death or
7 Service serious injuries if not avoided.
Information about setup times and technical support Æ This arrow indicates the appropriate measures to avert the immi-
nent danger.
1.2 General information
This document is used to correct faults and to carry out repairs for Warning!
the heaters listed on the title page, and is valid to the exclusion of “Warning” indicates a situation that can potentially result in death or
all liability claims. The necessary work may only be carried out by serious injuries if not avoided.
appropriately trained personnel of an Eberspächer service partner. Æ This arrow indicates the appropriate measures to avert the
potential danger.
Depending on the version or revision status of the heater, differ-
ences may occur compared to this documentation. Please check this
before carrying out the repair and take any possible differences into Caution!
account. “Caution” indicates a situation that can potentially result in minor or
slight injuries if not avoided.
1.3 Reference documents Æ This arrow indicates the appropriate measures to avert the
potential danger.
Technical description
Describes the function and proper installation and contains all infor-
mation necessary for safe operation of the heater. Note
Spare parts list This note contains recommendations for use and useful tips for the
Contains the information necessary for ordering spare parts. operation, installation and repair of the product.
Installation recommendation
Describes vehicle-specific installation situations.
Installation Instructions Plus
Supplementary information on heaters and control units.
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1.6 Intended use 1.9 Target groups of this document

This document is aimed at the following target groups:
1.6.1 Range of application of the heater
The water heater operating independently of an engine is intended Service company
for installation in the following vehicles: The “service company” target group includes all service companies
All kinds of vehicles trained by Eberspächer that purchase heaters and air-conditioners
Construction machinery and their control units, accessories and spare parts from Eberspächer
Agricultural machinery or the trade and install, repair or service these on behalf of an end
user.
1.6.2 Intended use of the heater (via the vehicle's own heat
exchanger) Installation company
The “installation company” target group includes all companies
Pre-heating, de-misting windows
trained by Eberspächer that purchase heaters and air-conditioners
Heating and keeping the following warm:
and their control units, accessories and spare parts from Eberspächer
– Driver and working cabs
and install, repair or service these on behalf of another company
– Freight compartments
(usually the automotive / body manufacturer).
– Passenger and crew compartments
– Vehicle engines and units End user
The “end user” target group includes all natural persons who operate
Note
a heater or air conditioner with the help of a control unit, regardless
Use with a 230 V connection to the public power system (e.g.
of whether they act as a consumer or as part of their job.
houseboats and camper vans) only with the “CE application”
installation kit.
1.10 Duty to instruct of the target groups
Only use and operate the heater within the scope of the intended
use stated by the manufacturer and in compliance with the docu- Each named target group must fulfil their duty to instruct in full. The
mentation enclosed with each heater. duty to instruct relates to the passing on of technical documents.
Technical documents are all documents published by Eberspächer for

the installation, operation, use, maintenance or repair of heaters and
1.7 Non-intended use
air conditioners and their control units, accessories and spare parts.
On account of its functional purpose, the heater is not approved for
Note
the following applications:
If not explicitly defined in the following, the technical documents
Long-term continuous operation, e.g. for heating:
can be passed on printed out as hard copies, on a data carrier or
– Residential rooms
by internet download.
– Garages
Current technical documents can be downloaded from the
– Work huts, weekend homes and hunting lodges
Eberspächer website.
– Houseboats, etc.
Caution! Responsibility of the installation company

Use, operation and deployment of the product outside the intended The installation company must pass on the following technical docu-
use stated by the manufacturer can cause considerable injuries to ments to the company that employs them, and it in turn is obliged to
people and/or damage to machinery and property. pass on the documents to the end user:
Æ Only use the project for the stipulated purpose and in the Technical description
approved area of use. Operating instructions
Responsibility of the service company

The service company must pass on the following technical docu-
1.8 Disclaimer
ments to the end user, even if they employ a subcontractor:
Technical description
The manufacturer is not liable for damage caused by improper use
Operating instructions
or incorrect operation. Failure to comply with the safety instructions
makes the guarantee null and void and this leads to the exclusion of Note
any liability of Eberspächer Climate Control Systems GmbH & Co. KG. The named target groups must ensure that the operating instructions
produced by the manufacturer for the product are made available to
the end user in printed form and in their own national language. If
necessary this can be a short form of the detailed operating instruc-
tions, which are additionally enclosed with the product on a data
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carrier or are available to download from the internet. 1.12 Warranty and liability
Eberspächer Climate Control Systems GmbH & Co. KG does not
accept any liability whatsoever for defects and damage, which are
1.11 Safety instructions
due to installation or repair by unauthorised and untrained persons.
Danger! Compliance with official regulations and the safety instructions is
Fire hazard. Risk of poisoning due to exhaust gases. prerequisite for liability claims. Failure to comply with official regula-
tions and safety instructions leads to exclusion of any liability of the
Improper repair or installation can result in toxic exhaust gases get- manufacturer.
ting into the interior of the vehicle or a fire.
Æ Repair and installation of the heater by authorised and trained 1.13 Accident prevention
skilled personnel only.
Æ Use original spare parts only. Always follow all accident prevention regulations and shop and oper-
Æ Comply with the official regulations. ating safety instructions.
Æ Take into account and follow this document and all applicable
documentation. 1.14 Functional test following a repair
Vent the coolant circuit and the whole fuel supply system. Comply
Note with the instructions issued by the vehicle manufacturer.
Have the heater installed only by a service partner authorised by Open all heating circuits before the trial run (set the temperature
the manufacturer according to the instructions in this manual, control to “warm”).
possibly according to special installation recommendations; the Switch on the heater at the control unit and during the trial run
same applies to any repairs to be carried out in the case of repairs check all water and fuel connections for leaks and tight fit.
or guarantee claims. Correct any faults during operation with the help of diagnostic
Repairs by third-parties not authorised by the manufacturer and / equipment or the control unit.
or with non-original spare parts are dangerous and therefore not
Note
allowed. They result in expiry of the type-approval of the heater;
The function of the heater is described in detail in the “Technical
and thus, when installed in motor vehicles, they can cause expiry
Description” document.
of the vehicle's operating licence.
The following measures are not allowed:
– Changes to heating-relevant components. Emergency shutdown – EMERGENCY OFF
– Use of third party parts not approved by the manufacturer. In an emergency carry out an emergency shutdown as follows:
– Installation or operation deviating from the statutory regulations, Switch off the heater via the control unit or disconnect it from
safety instructions or specifications relevant to safe operation as the power supply (remove fuse / disconnect battery).
stated in the installation instructions and operating instructions.
This applies in particular to the electrical wiring, fuel supply,
combustion air system and exhaust system.
Only use original accessories and original spare parts for installa-
tion and repairs.
Only use the control units approved by the manufacturer to operate
the heater. Use of other control units can cause malfunctions.
Before the heater is installed again in another vehicle, rinse the
heater parts carrying water with clear water.
When carrying out electric welding on the vehicle, disconnect the
positive cable at the battery and attach it to ground to protect the
control box.
Use only anti-freeze products approved by the vehicle manufac-
turer to top-up; please refer to the vehicle's operating manual.
Blending with unapproved anti-freeze can cause damage to the
engine and heater.
Defective fuses may only be replaced by fuses with the specified
fuse rating.
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2 Troubleshooting Unlocking the control box, reading out, displaying and deleting
the fault memory is possible using the following testing
equipment / control units:
2.1 What to check first in case of faults
Test equipment Order No.
Check EasyScan diagnostic tool 22.1550.89.0000
– Fuel in the tank?
Control unit Order No.
– Fuel lines filled? (Visual check) EasyStart Pro 22.1000.35.2200
– In the case of a diesel heater: summer diesel still in the fuel EasyStart Web 22.1000.34.7800
lines?
– Heater controller (water valve) fully set to “warm”? 2.3.2 Fault diagnosis using the CAN control unit
– Combustion air system or exhaust system damaged or blocked? After activating the control unit, faults are displayed.
Electrical components The current faults and the stored faults can be read out, displayed
– Cables, connections damaged? and deleted by using the workshop menu.
– Contacts corroded?
The fault diagnosis with control units is described in detail in
– Fuses defective?
the reference document “Installation Instructions for Plus –
– Faulty wiring (short circuit, interruption)?
EasyStart / Altitude Kit, Special Functions and Diagnosis”.
Check battery voltage
– Undervoltage protection ON (battery voltage < 10.5 V)? Note
– Overvoltage protection ON (battery voltage > 16 V)? For further information and up-to-date circuit diagrams of the
Check voltage supply UBatt (Terminal 30) control units, see “Installation Instructions Plus” in the Eberspächer
– Unplug the 2-pin connector -XB1 from the heater. Partner Portal.
– Measure the voltage between cable RD (chamber 1) and cable Not only the defective component, but also a defective current
BN (chamber 2) in the 2-pin connector -XB1. circuit results in a fault or error message.
In case of a voltage deviation, check the following components Fault codes, fault descriptions, causes / remedial actions are de
for corrosion or interruption: described from page 8.
– Fuses Ensure adequate battery voltage (> 10.5 V).
– Supply lines
– Earth connections
– Battery terminal posts 2.4 Vehicle-specific diagnostic system
If an external diagnostics system is to be used, contact the vehicle
2.2 Control box is locked
manufacturer.
The control box is locked if the following faults occur:
Unsuccessful start attempts
– After 3 consecutive failed start attempts in succession, see Fault
code P00012B.
Overheating
– After three overheating cutouts, see Fault code P00011A.
2.3 Unlocking the control box

The control box can be unlocked with testing equipment / a control
unit. For the procedure and description for testing equipment and for
control units see “Installation Instructions Plus – EasyStart / Altitude
Kit, Special Functions and Diagnosis”.
2.3.1 Overview of testing equipment / control units

The electronic control box can store up to 10 faults.
The current faults and the stored faults can be read out, displayed
and deleted.
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2.5 Fault code table

Fault code P000… Error description Cause Error class
Remedial action for control ele-
ments TP7.1:
EasyStart Web
EasyStart Pro
Water outlet sensor Check the water outlet sensor. 1: Service
P000100 – Interruption – Check cables for continuity, short circuit and damage.
P000101 – Short circuit – Unplug connector XB4, measure resistance between
P000102 – Short circuit after Ub+ cable RD (chamber 9) and cable RD (chamber 10).
– Measured values see page 18, deviating values –>
renew lead harness of heater.
P00010A Cold air – timeout The combustion chamber has not cooled sufficiently for a 1: Service
restart.
Check whether hot combustion air is drawn in. If not –>
check flame sensor, see Fault code P000120 and Fault
code P000121.
Water inlet sensor Check the water inlet sensor. 1: Service
P000110 – Interruption – Check cables for continuity, short circuit and damage.
P000112 – Short circuit after Ub+ cable BU (chamber 5) and cable BU (chamber 6).
P000114 Possible risk of overheating Too large temperature difference between the water inlet and 1: Service
(implausible signal) water outlet sensor.
For remedial action, see Fault code P000115.
Note!
Check the water inlet sensor.
Fault code P000114 is only
– Unplug connector XB4, measure resistance between
displayed if
cable BU (chamber 5) and cable BU (chamber 6).
the heater is in operation
Temperature reached at water
outlet sensor at least 80 °C.
P000115 Overheating – software thresh- Temperature at the water outlet sensor >125 °C. 5: Water Circuit or
old exceeded Check water circuit for leaks (heater controller in warm Pump
position)
If non-return valve / thermostat in the water circuit, check
the flow direction.
Check water throughput rate.
Vent water circuit.
Check the water outlet sensor
– Check cables for continuity, short circuit and damage.
cable RD (chamber 9) and cable RD (chamber 10).
Check water pump, see Fault code P000253 to Fault code
P000258.
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ments TP7.1:
EasyStart Web
EasyStart Pro
P000116 Overheating – hardware thresh- Temperature at the water outlet sensor >130 °C. 5: Water Circuit or
old exceeded For remedial action, see Fault code P000115. Pump
Check the water outlet sensor.
– Check cables for continuity, short circuit and damage.
P00011A Operating lock-out – too many The control box is locked due to too frequent consecutive 6: Overheat.
overheating events detected overheating (Fault code P000114, Fault code P000115). Heater locked
For remedial action, see Fault code P000114, Fault code
P000115.
Unlock control box, see page 7.
Flame sensor Check flame sensor. 1: Service
P000120 – Interruption – Check cable for continuity, short circuit and damage.
P000122 – Short-circuit to Ub+ cable BN (chamber 7) and cable BN (chamber 8).
Next display Fault code P000120, Fault code P000121
–> Renew control box, see repair step 1, see page 15.
P000125 Flame cutout from start process Check exhaust and combustion air system. 1: Service
P000126 Flame cutout within the control Check fuel quantity and fuel supply, see page 22.
range 0% – 25% Check flame sensor, see Fault code P000120 and Fault
P000127 Flame cutout within the control code P000121.
range 25% – 50%
P000128 Flame cutout within the control
range 50% – 75%
P000129 Flame cutout within the control
range 75% – 100%
Note!
In case of flame cutout during
the start phase or in normal
operation the heater is restarted
(max. 5 times). If the restart was
successful, the fault code display
is deleted.
P00012A Unsuccessful start procedure Check exhaust and combustion air system. 4: Fuel Supply or
Check fuel quantity and fuel supply, see page 22. Pump
Renew the fuel filter.
Clean the fuel filter in the connection socket of the meter-
ing pump.
P00012B Operation inhibit, too many Following five unsuccessful start attempts the control box is 1: Service
unsuccessful start procedures locked.
Check fuel quantity and fuel supply, see page 22.
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ments TP7.1:
EasyStart Web
EasyStart Pro
P000143 Air pressure sensor Heater in emergency mode. The air pressure is outside the 7: Restricted
– implausible signal characteristic curve for the altitude adjustment (P < 598 hPa Operation
or P > 1106 hPa).
12V: Check connection to the CAN BE. Delete error.
24V: Delete error. If the fault persists, replace the control
box
Circuit board temperature sensor Replace control box, see repair step 1, Page 15 1: Service
P000150 – defective (voltage too high)
P000151 – defective (voltage too low)
P000152 – Overtemperature detected
P000200 Metering pump interruption Check metering pump lead harness for continuity, short 4: Fuel Supply or
P000201 Metering pump – short circuit circuit and damage. Pump
– Lead harness ok –> renew the metering pump.
P000202 Metering pump – short circuit Check cables for continuity, short circuit and damage. 4: Fuel Supply or
downstream of +Ub or transistor – Unplug the connector at the metering pump. Pump
error Display Fault code P000200 metering pump defective –>
renew metering pump.
P0002a1 Water pump – Control / Diagno- Check lead harness of the water pump: 5: Water Circuit or
sis pin interruption – Unplug connector -XB3 at the heater Pump
– Unplug connector -XB8/2 at the water pump
– Check water pump lead harness for continuity, short
circuit and damage
– If water pump lead harness ok –> renew the water
pump
P000210 Glow plug – interruption Check glow plug. 1: Service
P000211 Glow plug – short circuit – Check cables for continuity, short circuit and damage.
P000212 Glow plug – short circuit down- – Unplug connector -XB4, unclip cable WH (chamber 3)
stream of +Ub or transistor error and cable WH
(chamber 4).
Caution!
– Apply max. 9.5 V / 18 V voltage to the glow plug and
Damage to unit in case of
after 25 sec measure the current intensity.
overvoltage
– Measured value 9.5 A / 4.75 A (+1 / –1.5) the glow
Voltage > 9.5 V / 18 V irreparably
plug is ok
damages the glow plug.
– Deviating values –> renew the glow plug.
Æ Test function with
max. 9.5 V / 18 V.
Note
Note the short-circuit withstand
capability of the power pack.
P000213 Glow plug – ignition energy too Glow plug energy input is too low. 1: Service
low Check cables for continuity, short circuit and damage.
Check glow plug, see Fault code P000210 to Fault code
P000212.
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ments TP7.1:
EasyStart Web
EasyStart Pro
P000220 Electric motor – interruption Visual inspection of electric motor / control unit 1: Service
P000221 Electric motor – short circuit (contacting).
P000222 Electric motor – short circuit Check electric motor for dirt / corrosion, clean if necessary.
downstream of +Ub or transistor Check blower wheel for blockage, remove blockage if
error necessary.
Replace electric motor if necessary.
P000223 Electric motor – blocking Impeller blocked (frozen, soiled, sluggish, ...). 1: Service
P000224 Electric motor – current input Remove blockage.
too high – Check electric motor for smooth and easy running by
turning the impeller manually.
Next display Fault code P000223 / Fault code P000224
–> renew the blower, see repair step 7, Page 19.
P000250 Water pump – interruption Check lead harness of the water pump: 5: Water Circuit or
P000251 Water pump – short circuit – Unplug connector -XB3 at the heater Pump
– Unplug connector -XB8/2 at the water pump.
– Check cable for continuity, short circuit and damage.
– Lead harness of the water pump ok –> renew the
water pump.
P000252 Water pump - short circuit Unplug connector -XB8/2 at the water pump. 5: Water Circuit or
downstream of +Ub or transistor – Display Fault code P000250 Water pump defective –> Pump
error renew water pump.
P000253 Water pump – blocking Water hoses laid free from kinks? 5: Water Circuit or
Pump
P000254 Water pump – overcurrent Water pump / water circuit dirty? 5: Water Circuit or
cutout Pump
P000255 Water pump – speed below Water pump / water circuit dirty? 5: Water Circuit or
minimum Pump
P000256 Water pump – dry running Check the coolant liquid level in the water circuit. 5: Water Circuit or
Vent the water pump / water circuit. Pump
P000257 Water pump – overheating Water pump ambient temperature too high. 5: Water Circuit or
Position the water pump at an adequate distance from hot Pump
vehicle parts.
P000258 ADR water pump Check lead harness of the water pump: 5: Water Circuit or
– Undervoltage / Overvoltage – Unplug connector -XB3 at the heater Pump
– Unplug connector -XB8/2 at the water pump.
– Check cable for continuity, short circuit and damage.
– Lead harness of the water pump ok –> renew the
water pump.
P000259 ADR water pump / vehicle Check the cables to the water pump and to the vehicle 5: Water Circuit or
blower blower for continuity, short circuit and damage. Pump
– Short circuit Check the coolant circuit.
Check blower relay.
P000260 Universal output Check cable for continuity and damage. 1: Service
Interruption If necessary, check coding for universal outlet.
P000261 Vehicle blower – short circuit Check electric motor cover for damage and correct fit. 1: Service
– Electric motor cover ok –> renew blower relay -K1.
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ments TP7.1:
EasyStart Web
EasyStart Pro
P000262 Universal output Check cable for continuity, short circuit and damage. 1: Service
Short circuit downstream of Ub+
or transistor fault
P000300 Overheating detection Check the water outlet sensor. 1: Service
Metering pump hardware or – Check cables for continuity, short circuit and damage.
cutout circuit defective – Unplug connector XB4, measure resistance between
Next display Fault code P000300 –> renew lead harness of
the heater.
P000301 Watchdog reset Delete errors, the heater remains ready for operation. 1: Service
P000302 Too many watchdog resets Replace control box, see repair step 1, Page 15
P000303 Operating lockout: Too frequent Replace control box, see repair step 1, Page 15 1: Service
output stage errors
P000304 Too many resets (loose contact) Replace control box, see repair step 1, Page 15 1: Service
P000305 Control box not calibrated Replace control box, see repair step 1, Page 15 1: Service
P000306 Second cutout circuit is Replace control box, see repair step 1, Page 15 1: Service
defective
P000307 CAN communication error Delete error, if it occurs repeatedly check the CAN connec- 1: Service
control unit tion between heater and control unit
P00030A CAN communication error Delete error, if it occurs repeatedly check the CAN connec- 1: Service
tion between heater and control unit
P000310 Control box cutout due to Overvoltage applied at the control box without interruption for 3: Overvoltage
overvoltage at least 20 seconds.
P000311 Heater cutout due to overvoltage Unplug connector -XB1 at the heater.
Start the vehicle engine.
Note!
Measure voltage between cable RD (chamber 1) and cable
Heater is not functioning.
BN (chamber 2).
– Voltage >15 volt
– Check alternator controller
– Check the battery.
P000312 Control box cutout due to Undervoltage applied at the control box without interruption 2: Undervoltage
undervoltage for at least 20 seconds.
P000313 Heater cutout due to Unplug connector -XB1 at the heater.
undervoltage Start the vehicle engine.
Measure voltage between cable RD (chamber 1) and cable
Note!
BN (chamber 2).
Heater is not functioning.
– Voltage < 10 volt
– Check the fuses, the supply cables, the ground connec-
tions and the positive terminal post at the battery for
voltage drop (corrosion).
P000315 Implausible air pressure Check connection to the control unit. If fault persists, use 1: Service
information EasyScan to test the control unit.
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ments TP7.1:
EasyStart Web
EasyStart Pro
P000316 Insufficient heat dissipation via Too many consecutive short heating mode operations. 5: Water Circuit or
the coolant Check coolant circuit Pump
P000330 Control box defective Replace control box, see repair step 1, Page 15 1: Service
P000342 Invalid configuration 12V / 24V: Too many CAN components connected. Check 1: Service
the configuration.
24V ADR: Use one CAN control unit only, check the connec-
tion to the control unit if necessary.
P000394 ADR button Check the cable and button for continuity, short circuit, 1: Service
– Short circuit damage. Replace if necessary.
P000500 Fault memory entry Withdrawal of the active request (fault remains active as 0: No message
ErrorState_GSC. long as heating or diagnosis request still exists).
Fault response: Heating or venti- Delete fault memory.
lation mode is continued.
P000A00 Communication is ended by Reset the fault by withdrawing the active request (fault 0: No message
the heater. EasyFan does not remains active as long as heating or diagnosis request
respond to the coded number of exists).
messages. Delete fault memory.
P000E01 Runtime limit exceeded Coded runtime end reached. 1: Service
25.2696.95.2682.0D | EN | 05.2020 13
3 Repair instructions 3.2 Special tool
3.2.1 Control box dismantling kit

3.1 Please note
Eberspächer Order No. 25.2652.81.0000
This chapter describes the permitted repair work on the heater. The dismantling kit is required to unlock the control box and consists
Note! of a lever (1) with two release wedges (2). To use the wedges, break
The heater must be removed from the vehicle for the repair work them off at the connection pins.
to be carried out. 2 1 2
After completing all the work and installing the heater in the vehi-
cle, perform a functional test of the heater, see page 6.
Assembly of the heater is described from page 19.
Danger!
Risk of injury, burns and poisoning! 3.2.2 Release tool
Ensure the following before carrying out any work on the heater: The release tool is used to release contacts in the connectors. The
Æ Switch off the heater and leave it to cool. tool can be ordered directly from the manufacturer HERTH+BUSS
Æ Disconnect the battery. ELPARTS.
Æ Do not operate the heater in enclosed spaces (garage / work-
for tab connector 1.2 mm Order No. 959.45.400
shop). Exception: use of an exhaust extractor.
for tab connector / tab receptacle 2.8 mm Order No. 959.45.402
Caution!
Possible unit damage
Æ Always renew the seals and O-rings of dismantled components.
Æ Check all components for damage and replace if necessary.
Æ Check plug-in contacts, plug-in connections and cables for corro-
sion and damage, and repair if necessary.
Æ Use original spare parts only.
Æ After working on the coolant circuit, check the coolant level and
if necessary top up according to the vehicle manufacturer's
instructions.
Æ Then vent the coolant circuit.
Æ Operation and after running of the heater may only be stopped in
an emergency (see “EMERGENCY OFF” on page 20) by interrupt-
ing the battery current (risk of heater overheating).
Note!
Thread-forming screws are used to fix the components in the
factory. In case of repair the thread is already pre-cut by the initial
installation.
Installation instructions
Position screw by hand and screw in.
Always keep to the given tightening torque.
When screwing for the second time also position by hand and do
not cut a new thread.
The thread-forming screw is suitable for max. 6 installation
attempts.
14 25.2696.95.2682.0D | EN | 05.2020
3.3 The repair steps at a glance 3.4 Dismantle the heater
Note! Caution!
These repair instructions describe how to dismantle the heater in Unit damage due to unbalance!
individual repair steps. Reference is made to the necessary preceding
The impeller is pressed on precisely. If the heater is put down on the
steps to be carried out at the relevant repair steps.
blower it can cause damage to the blower.
Æ Do not lay heater on its impeller.
Repair step 1 Æ Always put down heater to the side.
Remove the control box Page 15
Renew electric motor cover Page 16
3.4.1 Repair step 1: Remove the control box
Repair step 2
Remove sensor cover / water connection socket Page 16 Note!
Use the dismantling kit to remove the control box. Do not undo the
Repair step 3 bottom snap connections on the control box.
Remove the heat exchanger Page 16
Repair step 4 1
Remove the combustion chamber Page 17
Repair step 5 6
2
Remove lead harness of the heater Page 17
Check the flame sensor Page 18 5
Check the water inlet sensor Page 18
Check the water outlet sensor Page 18
Repair step 6 3
Dismantle glow plug Page 18
Check glow plug Page 18
Repair step 7 4
Replace the blower housing Page 19
Repair step 8
Remove the blower housing / heat exchanger seal and fuel Undo both screws (4) from the control box (3).
connection grommet Page 19 Undo the screw (1) of the sensor cover (2) by 3 turns and lift up the
sensor cover (2).
Release both snap connections (5) on the blower cover (6).
Lift up the blower cover (6).
6 9 10
7 3
Insert both wedges (9) between the blower cover (6) and the snap
catches (10) of the control box (3), release the snap catches.
Insert the lever (8) in the snap catches (7) of the control box (3)
and unlock the control box. To do this press the lever (8) up to the
25.2696.95.2682.0D | EN | 05.2020 15
blower cover (6). Pull the electric motor cover (15) carefully off the connection pins
(18).
19
17
13 11 18
12
16
15
Push the new electric motor cover (15) carefully onto the connec-
tion pins (18) and press on lightly.
3
Note!
Do not change the position of the connection pins.
Pull off the control box (3) carefully, at the same time remove the
electric motor cover (11) and the ground cable (12). Screw in the 3 screws M3 × 12 (16). Tightening torque
Unlock and unplug connector -XB4 (13). 1.5±0.1 Nm.
Hook the flame sensor (19) connection cables into the guide hook
Renew the electric motor cover
(17).
Caution!
Note!
Damage to the unit caused by leak or dirt
Mount the control box, see page 21.
The seals on the electric motor cover are permanently deformed
following removal of the control box. An integral seal with the control 3.4.2 Repair step 2: Remove the sensor cover and water
box is not ensured on re-installation. connection socket
Æ Always replace the electric motor cover.
Æ If the electric motor cover is renewed, dirt particles and metal
parts can get inside the motor. 1
Æ Install the new electric motor cover immediately.
3
Æ For installation details, see point 12 onwards.
The electric motor cover is included in the

Kit – control box
2
Kit – glow plug
Kit – heater lead harness.
17 19
Undo the screw (1).
Remove the sensor cover (2) and water connection socket (3).
Note!
Mount the sensor cover and water connection socket, see page 21.
16
15 18
16
Unhook the flame sensor (19) connection cables at the guide hook
(17).
Undo three screws (16) from the electric motor cover (15).
16 25.2696.95.2682.0D | EN | 05.2020
3.4.3 Repair step 3: Remove the heat exchanger

Carry out repair step 1, Page 15 and repair step 2, Page 16
first.
4
2
3
4 3
5
5
6
Pull the combustion chamber (3) together with the glow plug off
the blower housing.
Undo the screw (1), remove the compression spring (2). 4

Use pliers to pull out the water inlet sensor (3) and water outlet
sensor (4).
Undo the screws (5), pull off the heat exchanger (6).
Note!
Install the heat exchanger, see page 20.
Repair step 1 is not necessary if the heat exchanger is replaced
Pull out the glow plug (4).
3.4.4 Repair step 4: Remove the combustion chamber Note!

Firstly, carry out repair step 1, Page 15 up to repair step 3, Install the combustion chamber, see page 20.
Page 17.
3.4.5 Repair step 5: Remove the lead harness of the heater
2
Note!
If the lead harness of the heater (4) is renewed, unplug the glow
plug connection cables from the connector -XB4 (Chamber 3 and
1
4), see Repair step 6, Page 18.
Apart from the flame sensor (3), the other components on the lead
harness of the heater (4) (ground cable (5), water inlet sensor (2)
and water outlet sensor (1)) have already been removed from the
heater.
Unlock the snap connections (1) on the blower cover (2) and
remove the blower cover.
1
2
4
5
Carry out Page 15 to Page 17 first.
25.2696.95.2682.0D | EN | 05.2020 17
Table of values
1 - [°C] R [kΩ] - [°C] R [kΩ]
– 50 657 ±80 kΩ 80 1.26 ±100 Ω
2
– 40 330.6 ±33 kΩ 100 0.677 ±60 Ω
3 – 20 96.3 ±8 kΩ 120 0.389 ±38 Ω
0 32.55 ±500 Ω 150 0.183 ±20 Ω
25 10* ±11 Ω 180 0.095 ±12 Ω
40 5.33 ±320 Ω 200 0.064 ±0 Ω
60 2.49 ±175 Ω
Note!
Unhook the flame sensor connection cables (1) from the guide
Install the lead harness, see page 20.
hook (3) on the electric motor.
Remove the flame sensor (2) on the blower housing.
3.4.6 Repair step 6: Remove the glow plug
Check flame sensor
Firstly, carry out repair step 1, Page 15 up to repair step 5,
The sensor test is performed in Page 17.
liquid at temperatures up to max.
200 °C.
Sensor insertion depth

1
X = 15 mm
Use a multimeter to measure the resistance in connector -XB4

between cable BN (chamber 7) and cable BN (chamber 8). If the value
lies outside the values table, replace the lead harness of the heater. 2
Table of values
Unplug the WH connection cables from the glow plug (1) at the
- [°C] R [Ω] - [°C] R [Ω]
– 50 830 ±11 50 1194 ±12 connector -XB4 (2) (chamber 3 and 4).
0 1000 ±10 100 1385 ±15 Check glow plug
20 1078 ±11 150 1573 ±20
25 1097 ±11 200 1758 ±24 Danger!
Risk of burns and fire due to glowing component.
Note!
After the operating voltage is applied the glow plug becomes very hot
Install the lead harness, see page 20.
and can cause burns.
Æ Insert glow plug in combustion chamber or jig.
Check the water inlet and outlet sensor
The sensor test is performed in Apply 9.5±0.1 volt voltage to the glow plug
liquid at temperatures up to max. After 25 sec. measure the current intensity and then disconnect
200 °C. from the power supply.
– Measured value 9.5 A (+1 / –1.5) the glow plug is ok
Sensor insertion depth – Deviating values –> renew the glow plug.
X = 50 mm ±5 mm
Note!
Install the glow plug, see page 20.
Check the water inlet sensor

between cable BU (chamber 5) and cable BU (chamber 6). If the value
lies outside the values table, replace the lead harness of the heater.
Check the water outlet sensor
between cable RD (chamber 9) and cable RD (chamber 10). If the value
lies outside the values table, replace the lead harness of the heater.
18 25.2696.95.2682.0D | EN | 05.2020
3.4.7 Repair step 7: Replace the blower 3.5 Assembling the heater
Page 17. Caution!
Then replace the blower. Damage to unit caused by third party, damaged or deformed
components
3.4.8 Repair step 8: Remove the blower housing / heat
exchanger seal and the fuel connection grommet Installing third party, damaged or deformed components has a nega-
tive effect on the function of the heater.
Æ Replace damaged, deformed or defective components.
Page 17.
Æ Use original Eberspächer spare parts, see spare parts list.
Æ Use all the components included in spare parts kits.
1.1
1
3.5.1 Mount the fuel connection grommet and blower housing /
heat exchanger seal
1.2 1.3
2
1
Remove the seal (1) from the combustion chamber. 1.
Note!
Push on the fuel connection grommet (1). Bottom edge of the
The folding seal can be cut for easier removal.
grommet is flush with the combustion chamber flange (2).
6 5
3.
3 4
Pull off the fuel connection grommet (2) from underneath. 4. 2.

Note!
Illustration shows the combustion chamber of a diesel heater. Before installing fold the blower housing / heat exchanger seal (3)
Install the blower housing / heat exchanger seal and fuel connec- at the connecting web (4).
tion grommet, see page 19, point 1–32. Push the top part of the seal over the flame tube (5) up to the
combustion chamber flange (2).
Fold the bottom part of the seal up over the fuel connection (6).
25.2696.95.2682.0D | EN | 05.2020 19
3.5.4 Install the combustion chamber
Caution!
Unit damage due to unbalance
The impeller is pressed on precisely. If the heater is put down on the

blower it can cause damage to the blower.
2 Æ Do not lay heater on its impeller.
1
Æ Always put down heater to the side.
5.
3
Hold both seal parts together and push them upwards between the 6
combustion chamber flange (2) and the fuel connection grommet
(1). The drillholes in the seal and combustion chamber lie above 2
each other. 1 5
Note!
5
Figures: Diesel heater combustion chamber.
7 4
3.5.2 Install the glow plug

Insert the glow plug (2) in the combustion chamber (1). The con-
Note!
nection cables (3) point towards the middle of the unit.
Do not twist the glow plug connection cables.
Place the combustion chamber on the blower housing, at the same
time
feed the flame sensor (4) and guide pins (5) into the drillholes in
the combustion chamber flange.
1 Push the glow plug grommet (6) and fuel connection grommet (7)
into the corresponding recesses in the blower housing.
Check the fit of the grommets. The grommets must be completely
pushed in.
3.5.5 Installing the heat exchanger
2 2
2
After replacing the glow plug (1) or lead harness of the heater 3
(2), plug the glow plug connection cables onto connector -XB4 in
chamber 3 and 4. 1
3.5.3 Install the lead harness of the heater / flame sensor

2
2
3 Position the heat exchanger (1) on the flame tube and guide pins.
4 Fix heat exchanger with thread-forming screws (2) M5 × 65.
Tightening torque 7.5+0.7 Nm.
1
Lay the glow plug connection cables (3) parallel in the guides, do
not twist.
Insert the flame sensor connection cables (1) in the blower housing
(2).
Push in the flame sensor (3).
Hook the connection cables in the guide hook (4) on the electric
motor.
20 25.2696.95.2682.0D | EN | 05.2020
3.5.6 Install the water inlet sensor / water outlet sensor 3.5.7 Install water connection socket / sensor cover
Note! Note!
If the lead harness of the heater is re-used, always renew the The sensor cover together with the screw is not a tool for pushing
O-rings of the sensor. the water connection socket into the heat exchanger.
If the lead harness of the heater has been renewed, grease the Replace the O-rings.
O-rings of the sensor.
3 4
5
Insert the water connection socket (1) in the sensor cover (2). The
5 1 2 4 3 teeth (3) engage in each other.
Insert the water connection socket in the holders (4) on the heat
Insert the water inlet sensor (1) (cables BU) in the holder (2). exchanger and press in, until the teeth sit on the heat exchanger.
Insert the water outlet sensor (3) (cables RD) in the holder (4).
Lay the sensor connection cables (5) in the guides as shown. Note!
If using an elbow socket, set the required direction.
Push the sensor cover downwards and readjust the connection

socket position until the teeth (3) engage once again.
Fix the sensor cover with thread-forming screw (5) M5 x 18.
Tightening torque 6.5+0.5 Nm.
3.5.8 Mounting the control box
Caution!
7 6 Damage to unit due to overload
Check the sensor compression spring (6) for damage and deforma- An excessive tightening torque on the screw (12) overloads and
tion. Renew damaged or deformed compression spring. damages the control box housing and causes malfunctions.
Position the compression spring as shown and fix with Æ Keep to the specified tightening torque.
thread-forming screw (7) M4 × 10. Tightening torque 3.8 ±0.4 Nm.
10 3 11
9
5
2 1
12
7 4 6
Insert the ground cable (1) in the holder (2) on the control box (3).
Push the connector (4) of the heater lead harness into the control
box connection (5), until the locking device (6) snaps into position.
Feed the guides (7) on the electric motor into the rails (8) on the
25.2696.95.2682.0D | EN | 05.2020 21
control box. start repeats must take place to obtain sufficient fuel for the
Push the control box (3) upwards. The snap connections (10) latch measurement.
onto the blower housing (11). After measuring, switch off the heater.
Fix the control box with 2 thread-forming screws (12) M4 × 10. Read off the quantity of fuel in the measuring cylinder.
Tightening torque 2.8±0.3 Nm.
Evaluation
Stow away the cables and push in the electric motor cover (9) from
Compare the measured quantity of fuel with the values in the
above.
following table.
3.5.9 Installing the blower cover Measured fuel quantity above the maximum value or below the
minimum value –> replace the metering pump.
1
Heater type Hydronic S3
Heater version B 4 E/B 5 E D 4 E/D 5 E
3 Discharge period
3 one-off start 75 sec. 86 sec.
Fuel quantity
3
nominal [cm³] 8.9 7.0
Max. fuel quantity [cm³] 9.8 7.35
2
Min. fuel quantity [cm³] 8.0 6.65
Place the blower cover (1) on the blower housing (2) and push Note!
downwards, until the snap connections (3) latch into position. The given fuel quantities result from the initial start of the heater.
3.5.10 Measure the fuel quantity Carry out the fuel measurement only if the battery is sufficiently
Preparing for the measurement charged. During the measurement at least 12 volt or max. 13 volt
Pull off the fuel pressure line from the heater and insert in a should be applied to the control box.
measuring cylinder (size 25 cm³).
Switch on heater. 3.5.11 Measure fuel quantity with EasyScan
Depending on the heater type, the metering pump starts pumping Preparation / measurement / evaluation
fuel after 17 to 20 sec. If the fuel comes out uniformly and free of Pull off the fuel line at the heater and insert it into a measuring
bubbles, the fuel line is filled and vented. cylinder (size 25 cm³).
Switch off heater and empty measuring cylinder. Make the connection between the heater and EasyScan diagnostic
interface VCI. To do this, connect the EasyScan to the diagnostics
connector of the cable harness.
Start the EasyScan diagnostics software.
In the “Diagnosis” menu, open the [Component activation] tab.
Call up the [External components] submenu.
Enter this test parameter in the [Metering pump] menu:
– Frequency: 7 Hz
– Duration. 60 seconds
Press the [Start metering pump] button to start the measurement.
Wait until the measurement process has ended, then read off the
2 pumped quantity of fuel in the measuring centre.
1 If the measured quantity of fuel lies outside the values listed in the
table, the metering pump must be replaced.
1 from the fuel tank
2 to the heater Heater type Hydronic S3 Economy
Heater version B 4 E/B 5 E D 4 E/D 5 E
Measurement
Delivery period in sec. 60 sec. 60 sec.
Switch on heater.
Fuel quantity, nominal [cm³] 11.4 12.4
Depending on the heater type, the metering pump starts pumping
Fuel quantity - max. [cm³] 12.5 13.6
fuel after 17 to 20 sec. Fuel quantity - min. [cm³] 10.3 11.2
During the measurement, hold the measuring cylinder at the level
of the heater.
In the case of petrol heaters, because of the delivery rate, it is
sufficient to start once to measure the fuel quantity.
In the case of diesel heaters, after starting once, two automatic
22 25.2696.95.2682.0D | EN | 05.2020
3.6 Hydronic S3 Economy component drawing

Parts list
16
1 Jacket and heat exchanger
6
2 Control box
3 Blower
5
4 Combustion chamber
13 5 Blower cover
6 Cover, sensor
7 10
7 Water connection socket, straight
15
7 8 Glow plug
15 14 9 Heater lead harness with water inlet
11 sensor, water outlet sensor, ground
14
cable, flame sensor
11
10 Compression spring
14
11 Screw, thread-forming,
11 M5×65 (3x)
14
8 12 Cover, electric motor
13 Screw, thread-forming,
1 M4×10 (2x)
4
14 O-ring, 16×2
15 Water connection socket, angled
16 Screw, thread-forming, M5×18
17 O-ring, 7.5×2 (2x)
17 18 Heat exchanger / blower seal
3 19 Fuel pipe grommet
17
19 20 Electric motor cover
9
21 Screw, M3×12 (3x)
20 18
21
21
21
2
12
13
13
25.2696.95.2682.0D | EN | 05.2020 23
4 Electrics 4.2 Parts list for circuit diagram, heater and cable
harness
4.1 Heater wiring -A10 Control box
-A30 Fuse holder 3-pin
Caution! -B5 Flame sensor
Unit damage due to improper electrical connection -B10 WAF (water outlet sensor)
The heater is to be connected up electrically according to the EMC -B11 WEF (water inlet sensor)
directives. Improper interventions can affect the EMC. -F1 Fuse, heater
Æ Do not damage the insulation of electrical cables. -F2 Fuse, control unit
Æ Avoid chafing, kinking, jamming or exposure to heat. -F3 Fan relay fuse
Æ Close off unused chambers of watertight connectors with filler -K1 Fan relay
plugs. -M3 Burner motor
Æ Make the electrical corrosion-free and securely. -M10 Water pump
Æ Lubricate electrical connections outside the interior with contact -R1 Glow plug
grease. -R2 Terminating resistor 120 Ω
-R3 Terminating resistor 9.2 kΩ
-W1 Cable loom, water pump
Note!
-W2 Cable loom, metering pump
Note the following for the electrical wiring of the heater and the
-X1 Ring terminal end
control unit:
-XB1 Bush housing, heater power supply
Position electrical cables and components in the vehicle so that
-XB2 Bush housing, heater signals
they can function properly under normal operating conditions with-
-XB3 Bush housing, heater water pump
out impairment (e.g. due to heat exposure, moisture, etc.).
-XB6/1 Bush housing, tester / EasyScan
Use correct cable cross-section between the battery and heater.
-XB6/2 Bush housing, control unit
For a cable length up to 6 m (positive and negative cable) the
-XB7 Relay block
minimum cable cross-section is 4 mm².
-XB8/1 Bush housing, metering pump plug-in connection
If the positive cable is connected to the fuse box (e.g. terminal 30),
-XB8/2 Bush housing, water pump
the vehicle's cable from the battery to the fuse box must be
-XS6/1 Mating connector with terminating resistor
included in the calculation of the total cable length.
-XS8 Connector housing, metering pump plug-in connection
Insulate unused cable ends.
-Y1 Fuel metering pump
For circuit diagrams for the EasyStart control unit refer to the
a to the heater
installation instructions of the control unit or the “Installation
b Activation, vehicle fan
Instructions plus – EasyStart / Altitude Kit, Special Functions and
c to the CAN control unit
Diagnosis”, which are available to read and download from
c1 to the LIN control unit
www.eberspaecher-standheizung.com/download.
d ADR acknowledgement button
n Generator input D+
o Input, power take-off NA+
Note
It must be ensured that if the battery isolating switch is pressed
due to EMERGENCY STOP, all the heater's electric circuits are dis-
connected from the battery immediately (without any consideration
of the heater's status).
If the battery isolating switch is pressed to disconnect the battery
from all electric circuits, the heater must be switched off first and
if applicable you must wait until the heater's afterrun has finished.
x insulate and tie back any cables that are not needed
Cable colours
RD red GR grey BK black
BU blue YE yellow GN green
WH white VT violet BN brown
24 25.2696.95.2682.0D | EN | 05.2020
4.3 Heater circuit diagrams
4.3.1 Heater 12V CS

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25.2696.95.2682.0D | EN | 05.2020 25
4.3.2 Heater 24V CS

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26 25.2696.95.2682.0D | EN | 05.2020
4.3.3 Cable harness 12V CS

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25.2696.95.2682.0D | EN | 05.2020 27
4.3.4 Cable harness 24V CS
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28 25.2696.95.2682.0D | EN | 05.2020
4.3.5 Cable harness 24V CS ADR

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25.2696.95.2682.0D | EN | 05.2020 29
4.4 Circuit diagrams for control units
4.4.1 Easy Start Pro

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30 25.2696.95.2682.0D | EN | 05.2020
4.4.2 EasyStart Timer

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25.2696.95.2682.0D | EN | 05.2020 31
4.4.3 EasyStart Web
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32 25.2696.95.2682.0D | EN | 05.2020
5 Technical data
5.1 Petrol heater 12V CS

Heater type Hydronic S3 Economy 12V CS
Heater version B 4 E CS B 5 E CS
Mixture of water and anti-freeze
Heating medium
(Proportion of antifreeze at least 10 % up to 50 % maximum)
Fuel Petrol – standard commercially available (DIN 51600 and
EN 228)
Rated voltage 12 volt
Control of the heat flow Maximum Minimum Maximum Minimum
Heat flow (watt) 4300 1800 5000 1800
Fuel consumption (l/h) 0.57 0.23 0.67 0.23
Average electrical power consumption (watt) during operation 24 7 32 7
without water pump, without vehicle fan relay while starting 135
Operating range
Lower voltage limit:
10.5 volt
An undervoltage protection installed in the control box switches off the
heater if the lower voltage limit is reached.
Upper voltage limit:
An overvoltage protection installed in the control box switches off the 16 volt
heater if the upper voltage limit is reached.
Allowable operating pressure up to 2.5 bar overpressure max.
Water volume in the heater approx. 0.09 l
Minimum water flow rate of the heater 300 l/h
during operation –40 °C to +60 °C
Heater
not in operation –40 °C to +105 °C, short-term +125 °C (5 x 2 h)
Allowable ambient temperature
(Also note and follow the information for Metering during operation –40 °C to +20 °C
installation of the heater and metering pump!)
pump Storage –40 °C to +105 °C
drawn-in combustion air max. +25 °C, short-term +45 °C (15 minutes)
Interference suppression class 5 (EN 55025)
Weight – without coolant and attachments 2 kg
Heater (in operation) IP5K6K1)
Degree of protection DIN 40050, Part 9 Heater (not in
IP5K9K1)
operation)
Technical data, water pump

Nominal current max. 1.6 A
Nominal delivery pressure 0.2 bar
Delivery rate ≥ 500 l/h
1) The heater is protected against harmful quantities of dust, powerful water jet under increased pressure and water during high-pressure/steam cleaning (provided it is not in
operation). The control box is dustproof, completely protected against powerful water jet under increased pressure and water during high-pressure/steam cleaning (provided it is
not in operation).
Caution! Note
Operating the heater outside the specified technical data can If no other values are given, the technical data listed include the
cause malfunctions. usual heater tolerances of ± 10 % at nominal voltage, 20 °C ambi-
Æ The technical data must be complied with at all times. ent temperature and Esslingen reference altitude.
25.2696.95.2682.0D | EN | 05.2020 33
5.2 Diesel heater 12V CS

Heater type Hydronic S3 Economy 12V CS
Heater version D 4 E CS D 5 E CS
Heating medium
Diesel – standard commercially available (EN 590)
Fuel Blending with max. 30 % FAME according to EN 14214 is
permitted.
Working range Maximum Minimum Maximum Minimum
Heat flow (watt) 4300 1300 5000 1300
Operating range
10.5 volt
An overvoltage protection installed in the control box switches off the heater 16 volt
if the upper voltage limit is reached.
Heater
not in operation –40 °C to +105 °C, short-term +125 °C (5 x 2h)
pump not in operation –40 °C to +105 °C
IP5K9K1)
operation)

Nominal current max. 1.6 A
Delivery rate ≥ 500 l/h
not in operation).
Caution! Note
cause malfunctions. usual heater tolerances of ± 10 % at nominal voltage, 20 °C ambient
Æ The technical data must be complied with at all times. temperature and Esslingen reference altitude.
34 25.2696.95.2682.0D | EN | 05.2020
5.3 Diesel heater 24V CS

Heater type Hydronic S3 Commercial 24V CS
Heater version D5L D6L
Heating medium
Diesel – standard commercially available (EN 590)
Fuel Blending with max. 30 % FAME according to EN 14214 is
permitted.
Working range Maximum Minimum Maximum Minimum
Heat flow (watt) 5000 1300 5600 1300
Operating range
20.4 volt
An overvoltage protection installed in the control box switches off the heater 32 volt
if the upper voltage limit is reached.
Heater
not in operation –40 °C to +105 °C, short-term +125 °C (5 x 2h)
pump not in operation –40 °C to +105 °C
IP5K9K1)
operation)

Electrical power consumption max. 35 W
Delivery rate 1400 l/h
not in operation).
Caution! Note
cause malfunctions. usual heater tolerances of ± 10 % at nominal voltage, 20 °C ambient
Æ The technical data must be complied with at all times. temperature and Esslingen reference altitude.
25.2696.95.2682.0D | EN | 05.2020 35
6 Environment
6.1 Certifications
The high quality of Eberspächer products is the key to our success.

To guarantee this quality, we have organised all work processes
in the company along the lines of quality management (QM). Even
so, we still undertake a large number of activities for continuous
improvement of product quality in order to keep pace with the grow-
ing requirements of our customers.
All the steps necessary for quality assurance are stipulated in inter-
national standards. This quality is comprehensive. It affects products,
procedures and customer / supplier relationships. Officially approved
public experts assess the system and the corresponding certification
company awards a certificate.
Eberspächer Climate Control Systems GmbH & Co. KG has already

qualified for the following standards:
Quality management in accordance with

EN ISO 9001:2000 and ISO / TS 16949:1999
Environmental management system in accordance with

EN ISO 14001:1996
6.2 Disposal
6.2.1 Disposal of materials
Old units, defective components and packaging materials can be

separated into their individual materials so that if necessary all parts
can be disposed of in an environmentally friendly way or can be
recovered and reused. Electric motors, control boxes and sensors
(e.g. temperature sensors) are deemed to be “electronic scrap”.
6.2.2 Dismantling the heater
The heater is dismantled according to the repair steps in this

documentation.
6.2.3 Packaging
The packaging of the heater can be kept in case the heater has to be
sent back.
6.3 Technical Support
If you have any technical questions or problems with the unit, the
control unit or the operating software, please contact the following
service address:
support-UK@eberspaecher.com
36 25.2696.95.2682.0D | EN | 05.2020
7 Service
7.1 Standard times
The standard times important for the guarantee are summarised in

the following overview. The standard times are given as a work value.
1 work value (AW) = 6 minutes
The standard times are based on well-equipped garages/workshops

and include all material and personal allowances taking into account
the safety regulations.
Guarantee / warranty work must be carried out within these standard

times.
Parts to be removed
Water inlet and outlet sensor/O-ring

Water connection socket / O-ring
Combustion chamber seal

Combustion chamber
Electric motor cover
Heater lead harness

Compression spring
Fuel pipe grommet

Work value (AW)
Heat exchanger
Blower cover
Sensor cover
Control box
Glow plug
Blower
Defective component
Control box 1.0 • •
Electric motor cover 1.0 • •
Sensor cover 1.0 •
Water connection socket / O-ring 1.0 • •
Compression spring 1.0 • • •
Water inlet and outlet sensor / O-ring 1.0 • • • •
Heat exchanger 1.0 • • • • •
Combustion chamber 2.0 • • • • • • • • • • •
Blower cover 2.0 • •
Heater lead harness 2.0 • • • • • • • •
Glow plug 2.0 • • • • • • • • • • • • •
Blower 2.0 • • • • • • • • • • •
Combustion chamber seal 2.0 • • • • • • • • • • •
Fuel pipe grommet 2.0 • • • • • • • • • •
Peripheral repair work

Diagnosis, fault memory, functional check 4.0
Fuel metering pump 2.0
Control unit 3.0
Water pump 4.0
Exhaust pipe 1.5
Exhaust silencer 2.5
Combustion air silencer 2.0
Combustion air hose 2.0
Replace the main fuse 1.0
Replace the combination valve 4.0
Replace the non-return valve 4.0
25.2696.95.2682.0D | EN | 05.2020 37
38 25.2696.95.2682.0D | EN | 05.2020
© Eberspächer Climate Control Systems GmbH & Co. KG
Subject to change without notice
05.2020
EN
Eberspächer Climate Control

25.2696.95.2682.0D
Systems GmbH & Co. KG

Eberspächerstraße 24
73730 Esslingen
Germany
info@eberspaecher.com
www.eberspaecher.com

Eberspacher Hydronic HS3D5ECS Manual Troubleshooting

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Vehicle Heaters | Technical Documentation EN

R EPAI R I NST R UCTION S

These repair instructions are valid for the following

Heaters for petrol Order No. Æ 05/2020 05/2020 Æ 09/2020 Æ

Heaters for diesel

D5L – 24 V CS 25.2696.05.0000 25.3009.05.0000

Heaters for diesel

Chapter Chapter title Page

3.4.7 Repair step 7: Replace the blower 19

1 Introduction 1.4 Special text formats and presentations

3 Repair instructions 1.5 Picture symbols

1.6 Intended use 1.9 Target groups of this document

Technical documents are all documents published by Eberspächer for

Caution! Responsibility of the installation company

Responsibility of the service company

2.3 Unlocking the control box

2.3.1 Overview of testing equipment / control units

2.5 Fault code table

Fault code P000… Error description Cause Error class

Fault code P000… Error description Cause Error class

Fault code P000… Error description Cause Error class

Fault code P000… Error description Cause Error class

Fault code P000… Error description Cause Error class

3 Repair instructions 3.2 Special tool

3.2.1 Control box dismantling kit

3.3 The repair steps at a glance 3.4 Dismantle the heater

The electric motor cover is included in the

3.4.3 Repair step 3: Remove the heat exchanger

 Undo the screw (1), remove the compression spring (2). 4

3.4.4 Repair step 4: Remove the combustion chamber Note!

 Carry out Page 15 to Page 17 first.

Sensor insertion depth

Use a multimeter to measure the resistance in connector -XB4

 Check the water inlet sensor

 Pull off the fuel connection grommet (2) from underneath. 4. 2.

3.5.4 Install the combustion chamber

The impeller is pressed on precisely. If the heater is put down on the

3.5.2 Install the glow plug

3.5.5 Installing the heat exchanger

3.5.3 Install the lead harness of the heater / flame sensor

 Push the sensor cover downwards and readjust the connection

3.5.8 Mounting the control box

3.6 Hydronic S3 Economy component drawing

4.3 Heater circuit diagrams

4.3.1 Heater 12V CS

Parts list see page 24 25.2691.00.9601.0A

4.3.2 Heater 24V CS

Parts list see page 24 25.2696.00.9601.0A

4.3.3 Cable harness 12V CS

$       5'  

Parts list see page 24 25.2691.00.9602.0A

4.3.4 Cable harness 24V CS

 5'  %1 $QVFKOXVV(DV\6FDQ

Parts list see page 24 25.2696.00.9602.0A

4.3.5 Cable harness 24V CS ADR

 5'  %1 $QVFKOXVV(DV\6FDQ

Parts list see page 24 25.2696.00.9603.0A

4.4 Circuit diagrams for control units

4.4.1 Easy Start Pro

4.4.2 EasyStart Timer

Undo the screw (1), remove the compression spring (2). 4

Carry out Page 15 to Page 17 first.

Check the water inlet sensor

Pull off the fuel connection grommet (2) from underneath. 4. 2.

Push the sensor cover downwards and readjust the connection

$ 5'

5' %1 $QVFKOXVV(DV\6FDQ

5' %1 $QVFKOXVV(DV\6FDQ