The Beru Diesel Instant Start System ISS - Beru.com

The Beru Diesel
Instant Start System ISS
Forward-looking technology for
Diesel engines of the latest generation
Perfection
built in
www.beru.com

The Diesel engine revs up as
fast as a petrol engine now!
Whether Audi, BMW, Mercedes-Benz or
VW – the Beru ISS is used in more and
more new vehicles ex works. The ISS
components are now on the market for
expert repair of these vehicles: electronically
controlled Beru „GE“ heater plugs
and the matching Beru „GSE“ control
units.
„Otto-engine-like
key-turn start“ – enabled
by the Beru
Instant Start System
with performance-
optimised heater plugs
and electronic control
unit
Beru ISS – the innovation
in Diesel cold-start
technology
The operative characteristics
of the ISS
Approx. 8 million motorcars
(i.e. 17 per cent of the overall
number of vehicles in the
meantime) and 40 per cent of
all new registrations are autoignition
vehicles – a tendency
continuously increasing; a
boom of which you can profit
along with Beru, the innovative
development partner of the
automotive industry.
Experts agree: The future belongs to the Diesel. There will
be more and more Diesel vehicles. The auto engine has
turned into a high-tech drive which is environmentally
friendly, but at the same time strong in performance and
torque. In the meantime, about 40 per cent of all new-car
buyers decide in favor of a Diesel – a trend that will
continue in the near and long-term future (cf. chart
below).
What applies for the whole vehicle, applies also for
the Diesel engine: More and more purely mechanical
components in the vehicle are optimised by electronics.
The heater plug as a starting aid for the Diesel engine, for
example, is now electronically controlled in the vehicles of
the latest generation – an important contribution to more
start comfort and less pollutant emission.
The Beru engineers call their latest innovation in the Diesel
cold-start field the Instant Start System (ISS) or Diesel
quick-start system, which has been developed in close
co-operation with the automotive industry. The system,
consisting of performance-optimised heater plugs and a
control unit, ensures a fast and safe cold start of the Diesel
– even in extremely low outside temperatures. The faster a
Diesel starts up and the faster it runs steadily, the lower
the emissions are.
The electronic control unit comprises a micro-controller,
which controls the heater plug current tuned to the requirements
of the engine. Within three seconds at the latest
the heater plugs reach a temperature of 1,000° Celsius –
even at outside temperatures of -30 °C. At temperatures of
-10 °C upwards, the pre-heating takes less than one second
Diesel vehicles
in thousands
14.000
12.000
10.000
8.000
6.000
4.000
0
3,1
3,6
Diesel vehicles stock
Diesel share
4,9
9,1
13,4
13,7
13,9
15,7
17,0
25,7
1970 1975 1980 1985 1990 1995 2000 2001 2002 2020
Diesel share in
vehicle stock
30 %
25 %
20 %
15 %
10 %
5 %
0 %

Diesel plus electronics: The Beru Diesel instant start system ISS
consists of electronically controlled steel heater plugs and a control
unit, and thus permits an „Otto-engine-like key-turn start“ by the
Diesel engine.
ISS heater plugs
The ISS components for
the automotive parts
trade and workshops
Beru Beru Designation Use As from
order No. short No. quater
0 100 266 008 GE 100 VW/Audi four- VW Touran, 4/02
cylinder 1.9 l TDI Audi A3, 4/02
with pump nozzle Golf V 4/03
Audi three-cylinder Diesel 1.4 l Audi A2 4/03
0 100 266 009 GE 101 VW/Audi four-cylinder VW Touran, 4/02
2.0 l TDI – four valves Audi A3 4/02
with pump nozzle Golf V 4/03
0 100 266 002 GE 102 BMW four and six 318 d (4 cil.) 3/01
cylinder Diesel 320 d (4 cil.)
330 d (6 cil.)
530 d (6 cil.)
730 d (6 cil.)
0 100 266 003 GE 103 BMW eight-cylinder Diesel 740 d 3/02
0 100 266 010 GE 104 AMG five-cylinder Diesel AMG C 30 3/02
(which means that the driver notices virtually nothing
anymore). Thus, the target of producing an „Otto-enginelike
key-turn start“ for the Diesel has been achieved.
At temperatures above 0 °C, pre-heating is not required
any more at all. In this case the heater plugs are used
exclusively for after glowing and thus for ensuring a
smooth run of the engine without jerking, stable idling,
and an instantaneous load assumption as well as optimization
of the environmental protection by reducing the
particle and HC ejection.
The operative characteristics of the ISS: The electronic
control permits intentional intermediate heating – in
idling or after longer trailing throttle, for example. Thus,
the ISS contributes to a permanently safe combustion
process – and prevents to the greatest possible extent
warm-up problems, out-of-true engine run, Diesel rattle,
and excessive vibrations.
The consumption and exhaust optimization obtained by
the Beru ISS contribute to the adherence to the Euro 3 and
Euro 4 emission regulations as well as to the American Tier
2, LEV II.
More and more automotive manufacturers have decided to
fit Beru ISS to their direct injection Diesel engines. The ISS
components are now available for the automotive parts
trade and workshops.
ISS heater plug control units
Beru Beru Designation Use
order No. short No.
0 522 120 701 GSE 101 BMW four-cylinder Diesel 318 d (E 46)
320 d (E 46)
0 522 140 701 GSE 102 BMW six-cylinder Diesel 330 d (E 46)
530 d (E 60)
730 d (E 65)
0 522 150 701 GSE 103 BMW eight-cylinder Diesel 740 d (E 65)
0 522 130 702 GSE 104 AMG five-cylinder Diesel AMG C 30
0 522 120 702 GSE 100 VW/Audi four-cylinder Diesel VW Touran,
Audi A3, Golf V
0 522 110 702 GSE 105 VW/Audi three-cylinder Diesel Audi A2
www.beru.com

Standard heater plug (left):
• glows almost in the entire heater plug area
Performance-optimised heater plug (GE, right):
• concentrated energy utilization at the tip of the heater plug
• new kind of material combination of the current-carrying filament
• improved heat transmission between heater filament and heater plug
surface
• improved heating voltage compared to the design voltage
The ISS control unit (GSE):
• the power consumption of each plug is set by clocking the heating current
• when the vehicle is started again, a plug already heated does not receive
the complete heating voltage
• in case of a short-circuit, the electric circuit of the plug concerned is
interrupted
• after heating, the plug afterglows until the combustion is ideal in the
cylinder
• if the plug is cooled down by intake air, for example, the control unit will
increase the voltage of the plug again
• if the engine temperature drops – in case of longer trailing throttle – this
can be compensated by so-called intermediate heating
• the onboard electrical system is relieved by time-delayed switching of the
heater plugs
BERU Aktiengesellschaft
Mörikestraße 155
D-71636 Ludwigsburg
Telephone: ++49-7141-132-0
Fax: ++49-7141-132-350
info@beru.de
www.beru.com
The operative characteristics of the ISS heater plugs
The heater plugs of the Instant Start System glow only
at the heater plug tip projecting into the combustion
chamber (cf. illustration – right heater plug). Thus the
power consumed is transformed more effectively, which
means: Compared to conventional heater plugs, only half
the energy is required to reach and upkeep the required
temperature.
In the process, the control unit controls the voltage of each
heater plug. Thus, not only an extremely short heating
up time of two seconds maximum is achieved, but a controlled
after and intermediate heating is possible as well.
Result: Immediate stable idling, clean load and thus low
emissions.
The ISS system contains the heating requirement of the
engine in a characteristics map. It compensates the load
and speed influences of the engine.
The individual control permits separate monitoring of each
heater plug circuit and thus extensive diagnostic and
protective functions. The system is suitable for OBD units,
and thus the workshop can read out the errors from the
memory.
Printed in Germany • 2,5.3.04 • Order No. 5 000 001 080