Faultfinding TrumaticC 10 GB

Trumatic C
Design / components
Ignitor
Change in 2004 from 10 Hz to Coil for small setting yellow

20 Hz (2 orange labels on side of Coil for large setting green
green igniter), then to 50 Hz ignitors
Solenoid valve BR 2
(black with 50 Hz lettering) and now
Magnetic coils with
to 35 Hz (white lable with blue lettering).
restraining coil 310-340 Ω
Output side 18000 V Pick-up coil 8-9 Ω
10 / 20 Hz 50 Hz 35 Hz
Low setting Crushing
High setting Designation

punched in
Input side 12 V
TrumaticC_10_GB – 07/10 – rb, Seite 13 Copyright by Truma Gerätetechnik, Putzbrunn Right reserved to make technical modifications
Trumatic C
Design / components Remote control
Electric safety and drain valve Continuous +
connection
Automatic draining of water in boiler

between ambient temperature of 2 °C and 4 °C Close
if C heater is switched off.
Open
Overpressure protection from spring-loaded
solenoid valve > 3.5 bar.
Board
Connection at
Solenoid coil heater
cable harness
Microswitch
Do not kink
drain hose,
Articulated lever route downwards.
Extension cable
Cut off end of drain
hose at an angle
Trumatic C
Design / components
Elasi remote control
Available only as spare part
Locking
indicator
Electric
opener
Pneumatic pump button

for closing Pneumatic cylinder
is attached to Elasi
Operating position
Off position
Trumatic C
Design / components
Control panels
Control panel
as of 05/02
Summer operation
40/60 °C
Off position
Difference between
series 1 and series 2 Winter operation
is lettering without water
reheating
Winter operation
with water
reheating
Room temperature sensor

Absolutely needed for control panel from
Note 05/02, as no integrated sensor exists.
Extending the control panel cable can cause the solenoid valve to switch
Trumatic C
Design / components
Time switch (ZUC 2)
Technical Information:
Lighting:
12 V / 145 mA (Standard)
Replace bulb if voltage is 24V.
Plug-in cable 3 m in length

optional 5 m extension cable
Programming:
3 switch-on times in
7 day period
Switch-on duration max. 2 hours
Time Day of week Manual Modify

setting selection on/off setting
Trumatic C
Design / components
Recirculated air fan
up to 06/01 for External housing
C 3402 / C 6002 separation (old)
Motors for C 3402

and C 6002 up to
06/01 are identical.
34000-70500
Possible production
of odours with
housing up to 06/01
(external separation)
Trumatic C
Design / components Internal housing
Recirculated air fan separation
as of 07/01
(Serial no. 12200001)
Motor for C 3402

34000-70500
(red positive cable)
Motor for C 4002

and C 6002
34000-77300
with more power
(white positive cable).
The first motors C 4002

as of 07/01 had C 6002
a red positive cable
and were marked with a C 3402
C 60 D sticker.
Plastic with neutral odour and

internal separation.
Trumatic C
Design / components
Electronic C 3402
Room sensor
connector
Accessory connector J3
contacts
Electronics designation
Control panel
E/1 = separate voltage
connector J2
connection
C = C 34
weak DC motor
Fuse F2 1,25 AF
status actuell fixed fuse
Cable
Fuse F1 4 AT
harness J9
Connection 12 V
Cable
Voltmeter ground
harness J1
Trumatic C
Design / components
C 3402 electronics overview
DC motor
with red/black
connecting cable
34000-70500
(like C 6002 up to 06/01)
Electronic C 34 E/1
Electronic C 34/2 kW var. /3 /4 as of 05/02
up to 04/02 Spare part for electronics
C 34/2 kW var. /3 /4
Trumatic C
Design / components Room sensor
C 4002 electronics connector contacts
Designation
Control panel
as of 09/06:
connector J2
ROHS
C40E/5/6 = lead-free
BF /
C40E/3/4 = not
lead-free
C40E/1/2 = not
lead-free, no F3
Accessory
connector J3
Control panel fuse

F3 1.6 AT
Input fuse
F1 6.3 AT Cable harness
12 V connection connector J9
Ground for voltmeter Cable harness

connector J1
Trumatic C
Design / components
C 4002 electronics
Electronics must not be interchanged!
Trumatic C
Design / components Room sensor
electronic C 6002 connector contacts
Designation
as of (05/07): Control panel
C60E/5/6 = lead-free connector J2
ROHS
BF /
C60E/3/4 = not
lead-free
C60E/1/2 = not
lead-free, no F3
C60D/1 = more powerful
air circulation motor
C60/2/3/4 = for
motor with red/black
cable
Accessory connectorJ3
Control panel fuse
F3 1,6 AT Cable harnness
Input fuse F1 6,3 AT connector J9
Connection 12 V Cable harness

Ground for voltmeter connector J1
Trumatic C
Design / components
C 6002 electronics
Electronics
C 60 E/5 BF
C 60 / 2 kW electronics C 60 D/1 electronics C 60 E/1/2/3/4
C 60 E/6 ROHS
var. /3 /4 up to 06/01 (for more powerful electronics (for
lead-free
DC motor) more powerful
Must not be replaced from 07/01 to 04/02 DC motor) from 05/02
Must not be used as
with electronics spare part for other
C 60 E/1/2/3/4/5/6 or Spare part for
electronics.
C 60 D/1 C 60 D/1 electronics
Motor with Motor with black/red

black/red connecting connecting cables Motor with black/white Motor with black/white
cables 34000-70500 with C 60 D sticker connecting cables connecting cables
(like C 3402) (34000-77300) (34000-77300) (34000-77300)
Trumatic C
Electronic system, control panel and remote/room sensor combinations
Room sensor needed
Control panel as of 05/02 (Standard as of 05/02)
Connecting Room sensor (FFC 2)
Electronic
system cable
as of 05/02
+
-
The sensor in the control panel

Control panel up to 04/02 deals with temperature control
Electronic
system
as of 05/02
+
-
Trumatic C
Room sensor needed
Control panel as of 05/02
Adapter Room sensor (FFC 2)
Electronic
system
up to 04/02 + Connecting cable
Room sensor accessories

Control panel up to 04/02 Connecting
Room sensor (FFC 2)
Cut off temp. cable
Electronic sensor
system beneath
as of 05/02 transparent
+ cap
-
Trumatic C
Remote sensor accessories
Control panel up to 04/02
Remote sensor old version
Cut off jack
Electronic Cut off temp.
from remote sensor
system sensor beneath
as of 05/02 transparent
and crimp a flat
+ cap
connector onto the
- cable.
Remote sensor needed

Control panel as of 05/02 Remote sensor old version
Electronic
system
up to 04/02
Trumatic C
Room sensor accessories
Adapter Room sensor (FFC 2)
Electronic
system + Connecting
up to 04/02 cable
Remote sensor accessories

(standard up to 04/02)
Electronic Remote sensor old version

system
up to 04/02
Trumatic C
Electronic
system The sensor in the control panel
up to 04/02 deals with temperature control
Standard up to 04/02
Remote sensor needed

Control panel as of 05/02 Old remote sensor
Electronic Cut off jack
system from remote sensor
as of 05/02
and crimp a flat
+
connector onto the
-
cable.
Trumatic C
Connection Drawing
Connection 10 A
+
-
Connecting the 12 V power supply
Attention:
Do not disconnect the connectors from the
electronics until the power supply has been
12 V
Gas pipe switched off. Connect heater to fuse
protected vehicle power supply with a
Pipe clip 2x2.5 mm2 cable (up to 6 m long) or
2x4 mm2 cable (6 m or above in length). Central ground
If the heater is being directly connected
Pressure
to the battery, the positive and negative
regulator
leads must have fuse protection. The
heater must be disconnected from the 12 V
Gas vehicle power supply when welding work
cylinder is being carried out on the body.
Vehicle frame
Ground
Trumatic C
Basics of summer operation Normal Mode
2 Heat up water (2kW setting)
Burner start-up Solenoid valve opens
Room thermostat without function;
Gas flow starts
1 D.C. motor will not start; Ignitor active
undervoltage detection;
Flame created
Pre-purge time - 18 seconds;
Flame monitoring active
Residual gases are blown out
4 6 8 3 Water temperature 40 °C/60 °C

reached (WTF)
Automatic restart yellow lamp goes out –
in the event of burner shut-off
temperature difference
of 2 - 4 °C to the set
water temperature
Air overtemperature LÜT reached
(LTF) ULM-coasting
5 Burner shut-off at 150 °C
Burner cut-in at 120 °C
Water overheat condition WÜT

7 reached (WTF)
ULM-cont.running
Burner locked at 77 °C
Burner released at 68 °C
Trumatic C
Basics of summer operation Lockout
1 Burner start-up 2 Heat up water (2kW Stufe)
4 6 8 3 Fault no flame
Re-ignite for 10 sec.
Shut-off
Reset fault
manually
Water temperature
5 90 °C – 95 °C (WTS)
Burner safety shut-off
7 Air temperature
190 °C +/- 5 °C (LTS)
Note
The WTS and LTS switches only open if the WTF and LTF sensors are defective.
Trumatic C
Basics of winter operation without controlled water temperature Normal Mode
Burner start-up Heating
Room thermostat 5 – 30 °C;
2 Solenoid valve opens
1 D.C. motor starts; Gas flow starts
Low-voltage detection; Ignitor active; flame created
Pre-purge time 18 seconds; Flame monitoring active
Residual gas is blown out autom. load regulation active:
C 34: 2kW – 3,4 kW
C 40: 2kW – 4 kW
C 60: 2 kW – 4 kW – 6 kW
4 6 8 Automatic
Room temperature 5 – 30 °C
restart
10 reached
when temp. deviates 3
D.C. motor shut off
by 0,5 °C from
burner shut-off
set room temp.
Air overtemperature LÜT reached
5 (LTF) ULM-coasting
Burner shut-off at 150 °C
Water temperature exceeded Water overheat condition WÜT

9 (WTF), ULM after-run 7 reached (WTF)
D.C. motor on at 62 °C ULM-cont.running
D.C. motor off at 60 °C Burner locked at 75 °C
as of year of manufacture 2005 Burner released at 65 °C
Trumatic C
Basics of winter operation without controlled water temperature Lockout
1 2
4 6 8 3 Fault no flame
Shut-off
Reset fault 5 Air temperature

manually 190 °C +/- 5 °C (LTS)
7 Water temperature
90 °C – 95 °C (WTS)
Note
Trumatic C
Basics of winter operation with controlled water temperature Normal Mode
Burner start-up 2 Heating
Room thermostat 5 – 30 °C; Solenoid valve opens
D.C. motor starts; Gas flow starts
1 Ignitor active; flame created
Low-voltage detection;
Pre-purge time 18 seconds; Flame monitoring active
Residual gas is blown out autom. load regulation active:
C 34: 2kW – 3,4 kW
C 40: 2kW – 4 kW
C 60: 2 kW – 4 kW – 6 kW
3 Room temperature 5 – 30 °C
5 7 Automatic reached
restart D.C. motor shut off (LTF)
9
when temp. deviates burner shut-off if
by 2 °C from water temperature reaches (WTF)
set room temp.
or Air overtemperature LÜT reached
water temperature (LTF) ULM-coasting
4
Burner shut-off at 150 °C
8 Water temperature exceeded
6 Water overheat condition WÜT
(WTF), ULM after-run reached (WTF)
D.C. motor on at 62 °C ULM-cont.running
D.C. motor off at 60 °C Burner locked at 77 °C
as of year of manufacture 2005 Burner released at 68 °C
Trumatic C
Basics of winter operation with controlled water temperature Lockout
1 2
4 6 8 3 Fault
no flame
Shut-off
Reset fault
5 Air temperature
manually
190 °C +/- 5 °C (LTS)
7 Water temperature
90 °C – 95 °C (WTS)
Note
Trumatic C
Elasi - + (30)
Wiring diagram
Connector J1
Large magnetic coil
As of 05/02 AW HW
Voltage
connection
on electronics
(parallel to cable - +
harness)
1 2 4 5 7 8 9 10 11 12 14 16 18 20
J1 3 6 13 15 17 19
- +
Ignitor Motor Motor
- +
-
AW HW Recirculated
Combustion
Housing ground air
Small magnetic coil
Trumatic C
Wiring diagram
Connector J9
LTS
190°C
C 4002
bn
bn
2 3 4 6 7 8 9 10 11 12
J9
1 5
gr
ge
ge
gn
gn
or
gr
or
90°C
Water thermostat Water temperature Air temperature Combustion air

monitor sensor sensor temperature sensor
Trumatic C
Pre-purge flow diagram
J1-1
J1-4
F1
J1-8 Pre-purge time

18-20 sec.
F2 1 Hz
clock
J2-10 J2-4 Undervoltage

Water temp. VBLM
10.5V
sensor
J9-11 J9-4
Combustion air
temperature sensor
J9-12 J9-6 J1-11
Trumatic C
Summer operation flow diagram
J1-1 Fault signal Flame
5-10 sec. monitoring
J1-4
-0,65 V
F1
J1-7 J1-19
J1-8 Pre-purge time
Ignitor
18-20 sec.
F2 1 Hz
clock Speed Solenoid valve
monitor shutt-off
J2-10 J2-4 Under-
Water VBLM
voltage 10,5V temperature J9-2
sensor
Water temperature
monitor (WTW)
J9-11 J9-4 90-95 °C
J9-3
Combustion air
temperature sensor
J9-5
(bei C 4002
J9-12 J9-6 J1-11 Air temperature J9-7)
switch (LTS)
190 °C
J9-1
J1-14 Restraining J1-16
Changeover
coil
2 kW
310-340 Ω
J1-12
Attracting
coil 8-9 Ω
Trumatic C
Winter Operating Heating Flow Diagram
J1-1 Fault Flame
signal monitoring
J1-4 5-10 sec.
-0,65 V
F1
J1-7 J1-19
J1-8 Pre-purge time
Ignitor
18-20 sec.
F2 1 Hz
clock Speed Solenoid
monitoring valve shut-off TIST-
TSOLL
VBLM
10,5 V J9-2 Motor
control
Water temperature
J2-7 monitor (WTW)
Activating
winter operating
J9-11 90-95 °C
J9-10
J9-3
Combustion air LTF
temperature sensor
J9-5
(bei C 4002
J9-12 J1-11 J9-8
Air temperature J9-7)
switch (LTS)
190 °C
J1-18
J9-1
J1-14 Restraining J1-16 J1-17 Restraining
J1-15 Umluft-
Changeover Changeover
coil coil motor
2 kW 3,4 / 4 kW
310-340 Ω 310-340 Ω
J1-12 J1-13 J1-20

Attracting Attracting
coil 8-9 Ω coil 8-9 Ω Power monitoring
Trumatic C
Flow diagram, heating and hot water re-heating in winter operation
J1-1 Fault Flame
signal monitoring
J1-4 5-10 sec.
-0,65 V
F1
J1-7 J1-19
J1-8 Vorspülzeit
Ignitor
18-20 sec.
F2 1 Hz
clock Drehzahl- Magnetventil-
überwach. abschaltg. TIST-
TSOLL
Water VBLM
10,5 V
temperature J9-2 Motor
sensor control
Water temperature
J2-7 monitor (WTW)
Activating
winter
J9-11 J9-4 90-95 °C
operating
J9-10
J9-3
Combustion air LTF
temperature sensor
J9-5
(bei C 4002
J9-12 J9-6 J1-11 J9-8
Air temperature J9-7)
switch (LTS)
190 °C
J1-18
J9-1
J1-14 Restraining J1-16 J1-17 Restraining
J1-15 Umluft-
Changeover Changeover
coil coil motor
2 kW 3,4 / 4 kW
310-340 Ω 310-340 Ω
J1-12 J1-13 J1-20

Attracting Attracting
coil 8-9 Ω coil Power monitoring
8-9 Ω
Trumatic C
Measuring Sheet with J1 connector disconnected
Electrical consumer measurement (heater switched off)
Component Measuring point, Function Remark
contact plug J1 Setpoint (Ohms)
Ignitor Apply 12 V between Ignitor operates If ignitor cannot be
J1-7(+) ws/rt and Audible ignition heard, replace
J1-5(-) ws/bl sparks
VBL Motor Apply 12 V between Motor runs at full If motor does not run,
J1-8(+) sw and speed replace
J1-11(-) bl
UML Motor Apply 12 V between Motor runs at full If motor does not run,
J1-18(+) rt and speed replace
J1-20(-) sw
Small magnetic Apply 12 V between Solenoid valve If small solenoid valve
coil, attracting coil J1-12(+) bl/rt and opens audibly does not open, replace
J1-14(-) bl/sw coil
large magnetic coil, Apply 12 V between Solenoid valve If large solenoid valve
attracting coil J1-13(+) sw/rt and opens audibly does not open, replace
J1-15(-) sw/ws coil
Small magnetic Measure resistance 8-9 If resistance value out
coil, attracting coil between J1-12 bl/rt of range, replace coil
and J1-14 bl/sw Connectors J1-1 to J1-20
Small magnetic Measure resistance 310-340 If resistance value out
coil, restraining coil between J1-14 bl/sw of range, replace coil
and J1-16 bl/gn
Large magnetic Measure resistance 8-9 If resistance value out
coil, attracting coil between J1-13 sw/rt of range, replace coil
and J1-15 sw/ws
Large magnetic Measure resistance 310-340 If resistance value out
coil, restraining coil between J1-15 sw/ws of range, replace coil
and J1-17 sw/gn
Trumatic C
Measuring Sheet with J9 connector disconnected - measurement
of temperature monitors and switches (Heater switched off)
Component Contact plug J9 measuring Setpoint (kOhms) Remark
point
LTS (190 °C) Measure and check for Connection / 0 Switch must
Air temperature connection between J9-1 bn be closed
switch and J9-5 bn
WTW (95 °C) Measure and check for Connection/ 0 Switch must
Water temperature connection between J9-2 ge be closed
switch (yellow and J9-3 ge
strand)
WTF Measure resistance between 0 °C = 35,563 Resistance
Water temperature J9-4 or and J9-6 or 10 °C = 20,860 value (NTC)
sensor (orange 20 °C = 12,683 is
strand) 25 °C = 10,000 temperature-
30 °C = 7,942 dependent Connectors J9-1 to J9-12
40 °C = 5,074
50 °C = 3,336
LTF Measure resistance between 0 °C = 326,500 Resistance LTF
Air temperature J9-8 gn and J9-10 gn 10 °C = 199,000 value (NTC) LTS
sensor 20 °C = 124,900 is
25 °C = 100,000 temperature-
30 °C = 80,570 dependent
40 °C = 53,270
50 °C = 36,030
VBLTF Measure resistance between 0 °C = 28,250 Resistance VBLTF
Combustion J9-11 gr and J9-12 gr 10 °C = 18,361 value (NTC)
temperature 20 °C = 12,161 is
25 °C = 10,000 temperature-
30 °C = 8,276 dependent WTW
40 °C = 5,736
50 °C = 4,067 WTF
Trumatic C
Measuring Sheet with J1 connector connected
Electrical consumer measurement (heater switched on)
Component Measuring Point Function Remark

Contact plug J1 Setpoint
Ignitor Measure between At least 10 V If no voltage (or less than
J1-5(-) ws/bl and voltage 10 V) after pre-purge
J1-7(+) ws/rt time, replace controller
UML Motor Measure between 3-12 V voltage If no voltage present (or
J1-20(-) sw and Speed less than 5 V), replace
J1-18(+) rt controlled by controller
LTF
Small magnetic coil Measure between At least 10 V If no voltage present (or
Restraining coil J1-14(-) bl/sw and voltage less than 10 V), replace
J1-16(+) bl/gn controller Connectors J1-1 to J1-20
Large magnetic coil Measure between At least 10 V If no voltage present (or
Restraining coil J1-15(-) sw/ws and voltage less than 10 V), replace
J1-17(+) sw/gn controller
(Measurement only
possible during operation
C 6002 stage 4000 W
and 6000 W Attention:
C 3402 stage 3400 W Make sure before measures that
all fuses, WTW and
LTS have a passage!
Trumatic C
Values of resistance of the room temperature sensor
(Do not measure while wired)
Temperature in °C Resistance in kOhm

- 30 215,67
- 25 156,41
- 20 114,66
- 15 84,51 Please disconnect the cable to the
- 10 62,93 electronic during measurements.
-5 47,077
0 35,56 Possible errors:
+5 27,12
+ 10 20,86 Short circuit
+ 15 16,20 Heater does not work
+ 20 12,68
+ 25 10,00 Cable interruption
+ 30 7,94 Heater runs always with full power
+ 35 6,33
+ 40 5,07
+ 45 4,10
+ 50 3,34
Trumatic C
DC motor C 4002 / C 6002 (EH)
A free-wheeling diode is used in the DC motor of the

Trumatic C 4002 und 6002 (EH) to protect the electronics from
voltage spikes.
A blown diode will result in the destruction of a transistor on the electronics!

Symptom: The DC motor starts up as soon as voltage is applied to
the unit. If such a defect occurs, the electronics and the DC motor
must always be replaced.
In the event of a free-wheeling diode short circuit, input fuse F1

is activated in winter mode. The DC motor must be replaced.
The transistor is defective if the

Transistor
heat sink is matt and tarnished.
soldering
Also evident from the soldering
points
points on the back of the
electronics

Faultfinding TrumaticC 10 GB

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Faultfinding TrumaticC 10 GB

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Available Formats

Trumatic C

Change in 2004 from 10 Hz to Coil for small setting yellow

High setting Designation

Automatic draining of water in boiler

Available only as spare part

Pneumatic pump button

Room temperature sensor

Plug-in cable 3 m in length

Time Day of week Manual Modify

Motors for C 3402

Motor for C 3402

Motor for C 4002

The first motors C 4002

Plastic with neutral odour and

Control panel fuse

Ground for voltmeter Cable harness

Electronics must not be interchanged!

Connection 12 V Cable harness

Motor with Motor with black/red

The sensor in the control panel

Room sensor accessories

Remote sensor needed

Remote sensor accessories

Electronic Remote sensor old version

Remote sensor needed

4 6 8 3 Water temperature 40 °C/60 °C

Water overheat condition WÜT

Water temperature exceeded Water overheat condition WÜT

Reset fault 5 Air temperature

Water thermostat Water temperature Air temperature Combustion air

J1-8 Pre-purge time

J2-10 J2-4 Undervoltage

J9-12 J9-6 J1-11

J1-12 J1-13 J1-20

J1-12 J1-13 J1-20

Component Measuring Point Function Remark

Temperature in °C Resistance in kOhm

A free-wheeling diode is used in the DC motor of the

A blown diode will result in the destruction of a transistor on the electronics!

In the event of a free-wheeling diode short circuit, input fuse F1

The transistor is defective if the

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