Manual Binar 5
Contents
1. 5 General green Revolutions 6 U supply blue PWM 4 ar Le Battery Car alarm system Relay 55 55 1 red Si 8 9 HH 2780 Ey E Kad 1 6 eS s pM Fuses whife black 10 Cut off x black Cabin heater fan contral 2 XSTXS3 TA Page 8 of34 AJIBP 048 00 00 000 XS6 gt at Control panel with timer 12V OUT INP gt 5 NY RA SIS SS m XSI E arcu 6 ll ll r 4 7 Confral Vert electric water pump Fuel pump Cabin heater fan relay 9 9 85 Relay 66 General 70 XP brown General LA N is possible to install modem Entora GSM 1308 and modem harness instead of harness for car alarm system relay Optional Relay Figure 4 1 Electric circuit Control panel Page 9 of 34 AJIBP 048 00 00 000 fo cabin heater A Fan relay 93 vy Fuses Harness AN mu Fuel line Ex 2 E P aS lt gt Fuel pump harness i hot fluid outlet to engine __ Fuel pump S J m w i f i5 fuel P ES 5 L Air intake XS iS ES p e E cS elect2. 5 warranty repair Performed by Withdrawn Name signature Withdrawn Performed by Nou eee Name signature Page 33 of 34 AJIBP 048 00 00 000 Limited Liability Company ADVERS 11 Lesnaya str Samara Russia 443100 tel 846 270 65 09 fax 270 68 65 Warranty service coupon Ne 2 Binar 5 pre heater warranty repair Serial date of manufacturing Date and s le eve Bap eea unt ced Date and place of installation signature of a person in charge The following fault handling activities were performed Performed eto eto reo ed viet Name signature Manager RE stamp 8 maintenance organization Si esa OWNER signature Warranty service coupon 1 Binar 5 pre heater warranty repair Serial date of manufacturing Dateandplaceofsale neenotni na ante dads stamp Date and place of installation YES S Sle T prO OE Ale Var e galee signature of a person in charge The following fault handling activities
3. MANUFACTURER ADVERS Limited Liability Company Sales department 11 Lesnaya str Samara 443100 Russia Tel 846 270 68 64 Fax 846 270 65 09 E mail advers ts yandex ru we 02922 Warranty support department Tel fax 846 266 25 41 266 25 43 Tel 846 266 25 42 266 25 39 E mail garant autoterm ru E mail advers garant yandex ru Technical support E mail support autoterm ru Tel 846 263 07 97 extension 231 Binar 5B Binar 5B C Binar 5D Binar 5D C engine pre heater for vehicles with liquid cooling system User Manual 048 00 00 000 aS E 10 11 12 13 14 Page 2 of 34 AJIBP 048 00 00 000 Table of Contents Introduction TOTNM 3 Technical data and characteristics 4 Safety measures Cc 4 Description of pre heater set up and operation 5 Pre heater 6 The pre heater Control devices according to the choice of the consumer 11 Installation specification for pre heater and its assemblies 21 Post installation checkout e 27 Recommendations 28 Transportation and storage 30 borrada Me S 30 Pre he
4. choice asknowleagement coolant temperature mode of installation of tme setting Figure 6 1 Control panel Page 12 of 34 AJIBP 048 00 00 000 6 1 2 Setting running time on the control panel While first time pre heater is connected to the vehicle electric circuit or after breaks in power supply there s zeroing of the running time on the control panel The indicator looks like fig 6 1 In view of energy saving 30 sec after the last press of the knob the indicator stops lightning To restart lightning it is necessary to press any knob To set or change the running time hour or min it s necessary to press and hold on the knob gt more than 2 sec two first digits of the indicator start blinking Then with continuous or interrupted pressing the knobs or lt set the necessary time Pressing the knob gt leads to time increasing to one hour Pressing the knob lt leads to time decreasing to one hour After setting the necessary time press the knob digits 3 and 4 start blinking With help of the knobs gt or lt set necessary minutes After setting minutes press the knob OK the indicator will show in first digit correction of the clock rate and the 3d and 4 digit of the indicator will be blinking see figure 6 2 Maximum correction of the clock rate is 10 10 sec a min With the knobs gt or lt set the necessary corre
5. Position of the air pump is free Overall and mounting dimensions are given in Figure 7 3 Page 23 of 34 AJIBP 048 00 00 000 23 Figure 7 3 Overall and mounting dimensions 7 2 3 Installation of the air intake The air intake shall be installed on the air pump as per Figure 4 2 Air for combustion shall not be absorbed from the passenger compartment vehicle cab or baggage compartment Suction inlet of the intake shall be assembled so that to avoid its blockage ingress of snow and free drain of water It is prohibited to locate the inlet against the incident flow 7 2 4 Installation of the motor pump The motor pump shall be located in conformity with recommendations given in items 7 1 1 and 7 1 2 Operating position of motor pipe is whatever from horizontal to vertical with the outlet fitting up 7 2 5 Installation of pipes Pipes shall be connected with the pump pre heater and engine as shown in Figures 4 2 7 1 and 7 2 Pipes shall not run in vicinity with the exhaust pipe and engine components having high temperature Pipe junctions with other components shall be fixed with clamps Pipe interconnections shall be fixed with fittings 7 2 6 Installation of the exhaust pipe Note that exhaust pipe has high operating temperature The exhaust pipe flexible corrugated metal hose shall be cut to necessary length Page 24 of 34 AJIBP 048 00 00 000 The exhaust pipe is fixed with clamps slightly downwards in th
6. SEIS Figure 6 15 The 2d timer activation Repeated pressing of the knob OK will cancel a command of activation Malfunction codes Table 6 1 codes Malfunction description Notes Troubleshooting 1 Check thoroughly the liquid circuit 2 Check circulation pump replace if necessary 3 Check temperature sensor and overheating sensor replace if necessary Overheating is detected Check thoroughly the liquid circuit Difference between 2 Check circulation pump replace if necessary 02 temperatures measured by 3 Check t i d lace if the heat sensorand Check temperature sensor and overheating sensor replace i overheating sensor is too big necessary Check connecting leads Output signal and voltage are in linear dependence from temperature 0 C corresponds to 2 73 V 1 C Faulty temperature sensor 03 1 onthe board sensors rise corresponds 10uV output signal 7 increase Check the sensors and replace the sensor board with a new one if necessary Check connecting leads Output signal and voltage are in linear dependence from temperature 0 C corresponds to 2 73 V 1 C Faulty temperature sensor 04 temperature rise corresponds 10 output signal 2 on the board sensors increase Check the sensors and replace the sensor board with a new one if necessary Check connecting leads Check ohmic resistance between 05 Faulty flame indicator indicator conta
7. of 34 048 00 00 000 Pre heater delivery configuration corresponds to that specified in the packing list 13 Packing and acceptance certificate Binar 5 pre heater serial number Program manufactured and accepted in conformity with Specification TY 4591 012 40991 176 2009 design documentation in force declared serviceable Date of packing Packed by Signature Packed product accepted by Signature Quality Department Stamp 14 Sale and installation certificate Binar 5 pre heater serial number Place and date of sale Commer stamp vendor signature Familiarized with the warranty conditions and operating rules no complaints regarding configuration and outward appearance Commer rere reer buyer signature Binar 5 pre heater serial number was installed and tested on a vehicle class model registration number Page 32 of 34 AJIBP 048 00 00 000 Dy Company enis As Stamp signature of a person in charge Stub of warranty service coupon 1 jo 2 Stub of warranty service coupon 5 warranty repair
8. atmospheric precipitation and climatic factors in conformity with requirements 5 GOST 15150 69 and from mechanical effects in conformity with category C requirements GOST 23216 78 10 3 As concerns the climatic factors transportation and storage conditions of the pre heaters shall correspond to those specified in 5 GOST 15150 69 11 Warranty 11 2 The pre heater warranty life is 18 months from the date of sale 1 e 500h or 50000km haul provided that the User followed the operating rules transportation rules and storage rules foreseen by the present Manual 11 3 In case the vendor stamp and date of sale is missing the warranty life starts from the pre heater date of manufacture 11 4 Production malfunctions that may occur during the warranty life are handled by authorized specialists spare parts are provided by the manufacturer at his expense 11 5 The manufacturer acts onno complaints regarding incompleteness or mechanical damage of the pre heater 11 6 The present warranty does not cover defects occurred as a result of force majeur lightning stroke fire flood inadmissible voltage oscillation traffic accident violation of installation operational transportation and storage rules foreseen by the present Manual installation repair or setup of the pre heater performed by personnel company not authorized by the manufacturer pre heater non dedicated usage 12 Pre heater delivery configuration Page 3
9. avoiding their contact with hot or vibrating components of the vehicle 7 1 9 It is unacceptable to operate the pre heater with the cooling fluid frozen 7 1 10 completion of any activities with the cooling system repair work cooling fluid replacement it shall be purged to remove air blocks as per 7 2 Installation of the pre heater units and assemblies 7 2 1 Installation of the heater The heater shall be installed under the bonnet as shown in Figure 4 It is unacceptable to install the heater on the engine passenger compartment or cab of a vehicle The heater shall be installed with account of its operating positions ref Fig 7 2 items 7 1 1 and 7 1 2 Fuel pipe Coolant circulation Exhaust gas Air supply 1 Heater 6 Fuel pipe 2 Parking heater 7 Fuel pump 3 Control panel 8 Fuel intake Page 22 of 34 AJIBP 048 00 00 000 4 Motor pump 9 Air pump 5 Exhaust pipe 10 Fuel tank Figure 4 Pre heater installation diagram fluid outlet 3142 fluid inlet 110 Figure 7 2 Heater acceptable operating positions Attention In case the heater is tilted to be installed on the vehicle fluid hoses shall be connected to the heater adapters as shown in Figure 7 2 7 2 2 Installation of the air pump It is advisable to install the air pump as close as possible to the heater with the air duct having no unnecessary bends It is unacceptable to install the air pump on the engine
10. functionality of the basic hardware purchased and installed initially It is possible to operate by the heater with control panel with timer hereinafter referred to as control panel installed on the car dashboard It is possible to operate by the pre heater Binar 5B C and Binar 5D C by the control panel or remotely with the help of GSM modem by SMS sent by mobile phone If there s alarm signaling system installed in the car one can use its free channel to operate by the pre heater The pre heater s activation time is possible to be programmed by control panel While operating the control panel indicates the temperature of the cooling system and operation mode of the pre heater In case of failure the code of malfunction is indicated Minor changes performed on the heater structure by the Manufacturer may not be documented in this Operation Manual 2 Technical data and characteristics Page 4 of 34 AJIBP 048 00 00 000 Performance specifications are given with 10 tolerance at 20 C ambient temperature and 12V nominal voltage Characteristic model Binar 5B Binar 5 D Binar 5 B C Binar 5D C Heat productivity kW 50 5 Nominal supply voltage V 12 Acceptable deviation V 9 5 16 Fuel petrol meeting Diesel meeting requirements of requirements of GOST 51105 GOST 305 Fuel consumption 1 h 0 7 0 6 Power consumption with the pump max 80 W Power consumption on s
11. heater receives the command start up with answer and failure note request it will start working cycle and send SMS about its state and will be ready to send SMS with malfunction code in case of malfunction Activated pre heater doesn t accept the command start up and the switched off pre heater doesn t accept the command switch off SMS answer if requested will contain information about the pre heater state To protect the pre heater from unauthorized operation SMS must contain password 4 last figures of IMEI are used for this purpose Command format C A NNNN 1 start up 3 switch off 8 state request A parameters 0 command without answer 1 with answer 2 with failure note 3 with answer and failure note NNNN 4 last figures of IMEI The list of commands Start up without answer 1 0 NNNN Start up with answer 1 1 NNNN Start up with SMS failure note request 1 2 NNNN Start up with answer and SMS failure note request 1 3 NNNN Switch off without answer 3 0 NNNN Switch off with answer 3 1 NNNN State of the pre heater 8 0 NNNN Pre heater answer temperature C operation mode Operation modes Stop switched off doesn t work R ignition Lo low mode Hi full mode Prod purging Wait waiting mode V Burning out Page 20 of 34 AJIBP 048 00 00 000 Examples of the answers Answer Answer decoding T 7 stop Temperature 7 C the pre heat
12. vehicle Attention Assembling shall be performed with the safety devices dismantled 7 2 10 Installation of the control panel Control panel is installed in the cabin on the dashboard or any other comfortable for the driver place The control panel is fixed by adhesive tape Degrease the surface before installation of the panel remove protective film from the tape 8 Post installation checkout 8 2 completion of the assembling the following shall be guaranteed leak profess of the fluid system leak profess of the fuel pipes security of the pre heater electric contacts attachment 8 3 Open the heater control valve to full Remove air blocks from the fluid system of the vehicle following instructions of the vehicle manufacturer Put vehicle heater fan switch in position of min rotation 8 4 Install 5 25A and 5A safety devices control panel indicator will light 8 5 To perform the pre heater operation test press the middle button The pre heater shall start combustion the information will be on the indicator Further on the pre heater operates automatically In 40 A5minutes the pre heater stops its operation automatically To stop the work of the pre heater is possible at any time pressing the middle knob on the control panel Page 28 of 34 048 00 00 000 8 6 While performing the pre heater operation test it is necessary to check if heater fan switches on Normally the fan is activated when the co
13. were performed Performed by teet equi dedos Name signature Manager stamp maintenance organization Owner signature
14. which is connected to six pins connector XP4 on the pre heater control unit board see figure 4 1 There s a wire in the harness connecting contacts and 4 of the connector It s necessary for the control unit to identify connected harness of the remote alarm system and to receive its operation signals On closing the relay contacts according to the signal of vehicle alarm system transmitter the command start up is formed when relay contacts are opening the command switch off is formed The operation of the pre heater in this case doesn t differ from starting up by others control devices After start up the pre heater is working for 40 min and then switches off It is possible to stop the operation of the pre heater with the help of the transmitter and from the control panel To start up the pre heater next time with the transmitter it s necessary to switch off the relay and switch it on again If there s a channel of feedback control in the transmitter there will be mark confirming the relay is switched on Type of the transmitter has no significant meaning the only requirement is that the relay current consumption must not exceed current capacity of the remote alarm system channel Connector XS4 which is connected with the harness is used for modem connection The harness XS4 must be disconnected from the control unit and connected with modem Simultaneous use of modem and remote control system is impossible 6 3 The use a
15. 000 Figure 7 7 Installation diagram of storage tank to the fuel drain line and its connection with fuel pump 7 2 8 Fuel pump and fuel pipe installation It is advisable to install fuel pump close to the fuel tank and lower fuel level in the tank Position of the fuel pump is given in Figure 7 8 Preferable position of the pump Maximum level of heater inlet Minimal fuel level in the tank a lifting capacity up to 500 mm in a free flow tank up to 150 mm in case of underpressure in the tank b pump head between the fuel pump and heater up to 1500mm Figure 7 8 Fuel pump acceptable assembling position While assembling the fuel pipe shall be cut only with a sharp knife as shown in Figure 7 9 Cutoffs shall be free of restriction dents and burrs Correct Incorrect Page 27 of 34 AJIBP 048 00 00 000 Figure 7 9 Cutting the fuel pipe before installation Attention The fuel pipe and fuel pump shall be protected from heating It is prohibited to install them close to the exhaust pipe or on the engine 7 2 9 Assembling of the pre heater electrical harness The pre heater wiring harness shall be connected as shown in Figure 1 pre heater electric circuit and Figure 1 While assembling note that heating deformation or displacement of harness during operation of the vehicle is unacceptable The wiring harness shall be fixed with plastic clamps to the components of the
16. ater delivery configuration 30 Packing and acceptance certificate 3l Sale and installation 31 Page 3 of 34 AJIBP 048 00 00 000 1 Introduction The present User Manual gives information on set up operation and servicing of Binar 5 and Binar 5D starting pre heaters and their modifications hereinafter referred to as pre heater which are used for start heating and warming up of vehicles with liquid cooling system and engine displacement up to 3 51 at ambient temperature as low as minus 45 C Fuel used for Binar 5B starting pre heater operation is petrol for Binar 5D diesel fuel is used Binar 5B C and Binar 5D C have the lead for connection with vehicle alarm system or for GSM modem mounting The pre heater functions are following 1 Fail safe starting engine operation under low ambient temperature conditions 2 Additional heating of engine and passenger compartment with the engine running under hard frost conditions 3 Heating of passenger compartment and windshield at low subzero temperatures to remove icing with the engine inactive These functions are supported by the pre heater basic hardware Its modular structure makes it feasible to connect with devices supporting the other functions thus improving
17. ction of the clock rate Figure 6 2 Clock rate correction After clock rate correction press the knob OK to come back to the mode of clock setting see figure 6 3 6 1 3 Manual pre heater start up Initial state of the indicator see figure 6 3 shows running time or the temperature of the cooling liquid Figure 6 3 Running time the indicator When pressing the knob the pre heater is activated the indicator shows operation mode P ignition counting time of operation in minutes on the 3d and 4 digits the LED is lightning constantly see fig 6 4 the indicator shows that since the moment of start up the pre heater is in operation for 2 minutes th Page 13 of 34 AJIBP 048 00 00 000 PIL 612 Figure 6 4 When the pre heater is activated the first digit shows the mode of operation see figure 6 5 6 6 6 7 6 8 6 9 0 e Figure 6 5 Full mode ELI 5 Figure 6 6 Middle mode ELI 0235 Figure 6 7 Low mode LL BI Figure 6 8 Cooling down mode To switch off the pre heater press the knob OK the indicator will show operation mode IT purging time counting of the pre heater operation and frequent blinking of the LED see figure 6 9 UN Figure 6 9 Indicator after the pre heater switching off Page 14 of 34 AJIBP 048 00 00 000 Attention Any information is on the indicator for 30 sec and then the digits will go out the LED is lightni
18. cts it must be not more 10 Ohm Replace the indicator if necessary Page 17 of 34 AJIBP 048 00 00 000 Faulty temperature sensor 06 Replace control unite of the pre heater Table 6 1 07 Flame failure in low mode See the description of malfunction code 08 Check air duct exhaust gas escape channel and fuel supply 08 Flame failure in full mode correct troubles replace fuel pump and flame indicator if necessary 09 Glos plus malae on Check the glow plug replace if necessary 10 Air pump motor Check the electric wiring of the air pump motor replace the air malfunction pump if necessary 1 Check thoroughly the liquid circuit airlock is possible before Overheating Heating rate the air pump cooling liquid cannot be pumped through the 11 is too high heater 2 Check cooling liquid for fluidity at low temperatures 3 Check the pump replace if necessary This malfunction is possible if the pre heater is switched on 12 Shutdown voltage boost when vehicle engine is running The possible reason of the trouble is vehicle voltage regulator failure In case there are no more tries to start the pre heater left check 13 No more tries to start the fuel supply and amount of fuel supplied Check the air supply pre heater are left system to the combustion and exhaust gas escape channel check ignition plug Circulation pump Check circulation pump wiring for short circui
19. ding electric circuits In case ofnonfailed status there starts ignition Simultaneously the circulation pump is also activated conformity with the preset program is performed preliminary purging of the combustion chamber and glow plug warming up to the desired temperature Then there starts fuel and air supply and combustion process is initiated in the combustion chamber The flame detector controls combustion of the fuel blend in the combustion chamber Hot gasses heat the walls of the heat exchanger which warm up the liquid in the engine cooling system The control unit controls temperature of the coolant fluid by two sensors The sensors are installed close to inlet and outlet nozzles of the heat exchanger The control unit sets operation mode for the pre heater according to the temperatures full duty low duty or cooling down The full duty mode means that the coolant fluid is heated up to 75 C and in case of overheating the pre heater is switched to the low duty mode The low duty mode means that the coolant fluid is heated up to 85 C in case of overheating more than 85 C the pre heater is switched to the cooling down mode The cooling down mode means that combustion stops the pump continues its operation When the temperature of the coolant fluid gets below 70 C and the total cycle 40 min hasn t finished yet the pre heater automatically starts the full duty mode When the coolant fluid has been heated more tha
20. e direction of exhaust Round holes 3mm in diameter for moisture drain shall be made at bends in the lowest points of the pipe To optimize connection with the heater fitting and to guarantee better sealing there shall be done a lengthwise cut about 15mm long on the exhaust pipe The cut shall be the same length as the male fitting The exhaust pipe shall not transcend the overall dimensions of the vehicle Discharge gas shall be vented out The exhaust outlet and combustion air inlet shall be located so that to avoid resuction of discharge gas As well there shall be taken measures to avoid penetration of this gas inside the passenger compartment or their absorption by the fan Moreover discharge gas shall not affect operation of the other assemblies of the vehicle The exhaust outlet shall be assembled so that to avoid its blockage ingress of snow and free drain of water It is prohibited to locate the outlet against the incident flow 7 2 7 Installation of the fuel supply system of the pre heater Failure to comply with the following recommendation will cause to malfunctions Fuel supply of the pre heater with fuel intake Fuel intake is installed to the fuel tank according to figure 7 5 a fuel intake and special washer installation in the fuel tank is performed according to figure 7 5 b installation of fuel supply line from fuel intake to the pre heater is performed according to figure 7 6 The fuel pipe from the fuel pump to the heat
21. er from starting or cause it to stall in mid operation To fix breakdowns proceed to the following steps a change the fuel in the fuel tank as according to the ambient temperature b If the heater does not operate properly once the fuel was changed according to the temperature check the fuel supply pump filter as follows Outlet remove the fuel supply pump from the vehicle using a wrench F A 17 fix the pump in place unscrew the pipe stub and remove the filter see Figure 10 1 Do not fix the pump in place using surfaces other than Surface A when removing and installing the pipe stub rinse the filter in gasoline and blast it with compressed air install the filter into the fuel supply pump use sealant when installing the pipe stub install the fuel supply pump and Pd if the heater works Filter Pype Stub 17 Figure10 1 9 12 Use engine oil cooling fluid that correspond to the season of the year and ambient temperature 9 13 Check the battery charge level on a regular basis Page 30 of 34 AJIBP 048 00 00 000 9 14 While long storage of the vehicle it is recommended to switch off the heater from the vehicle battery to avoid its discharging current consumption in non operation mode 30 40 mA 10 Transportation and storage 10 2 The pre heaters are safe for transportation and may be transported with any vehicles including air and rail transport provided thatthe packaged products are protected from
22. er is switched off T 3 R Time 0 25 Temperature 3 Ignition Time of operation 25 sec T 15 H1 Time 6 Temperature 15 C Full mode Time of operation 6 min T 63 Prod Time 35 Temperature 63 C Pyrging Time of operation 35 min T 75 Prod Time 35 Error 17 10 20 Temperature 75 C Pyrging Time of operation 35 min Malfunction code 17 Time of malfunction origin in 10 min 20 sec after start up of the pre heater The modem is put in case with dimensions 70 70 25mm There are 2 connectors on the back wall power supply connector and information connector on the front wall there s a socket for SIM antenna connector and LED indicator There s harness for connection with the pre heater from one end of the harness there are 2 connectors which are connected to the modem from the other end there s flat six pin connector for connection with control unit of the pre heater Remove plastic cover from the pre heater to connect the harness There s XP4 connector on the control unit board it is with harness XS4 to be connected with relay operated by remote alarm system This harness must be disconnected There s detachable antenna witch is fixed to the windscreen of the vehicle This antenna provides the connection with cellular operator After installation and fixation of SIM antenna and cable the modem must be installed in car cabin in the glove compartment or under the dashboard After connection of the pre heate
23. er shall have no slope Attention While making the inlet in the fuel tank follow safety measures for activities with tanks which were used for inflammable and explosive fuel A SESS Wall of a fuel tank OSS Ie 77797976 oF lt LI Ly Ly Us lt 4 a 7 1 Fuel supply intake 4 washer 8 2 Nut M8 5 special washer 3 enlarged washer 8 6 seal ring Figure 7 5 Fuel intake installation Page 25 of 34 AJIBP 048 00 00 000 to fuel intake of heater Uf 1 fuel tank of the vehicle 4 connecting pipe fuel supply line 2 fuel supply line of the vehicle 5 fuel pump 3 fuel supply intake 6 rubber or polyurethane sleeve Figure 7 6 Installation diagram for the pre heater connection with fuel supply line Intake of the fuel for the pre heater is allowable to perform from fuel drain line from engine to tank on condition that storage tank is installed Fuel drain line shall have end at the bottom of the fuel tank It is advisable to install the tank in engine area close to the pre heater fuel pump Installation shall be performed according to figure 7 7 to engine fuel dran line 1 vehicle fuel tank 5 storage tank 2 fuel drain line from the vehicle engine 6 connecting pipe fuel pipe line to the tank 3 adapter 7 rubber or polyurethane sleeve 4 fuel supply line 8 fuel pump Page 26 of 34 AJIBP 048 00 00
24. f poisoning with the toxic exhaust gas generated by the operating pre heater it is prohibited to use the pre heater in enclosed car parks having no ventilation garage workshop and etc 3 9 It 15 prohibited to use the pre heater in areas where highly inflammable vapors or ample quantity of dust may be generated or accumulated 3 10 While fueling the truck the pre heater shall be switched off 3 11 Itis prohibited to se battery master switch in the pre heater electric circuit 3 12 The pre heater shall be disconnected from the accumulator battery when welding is performed with the vehicle 3 13 It is prohibited to connect the pre heater to the electric circuit of the vehicle with the engine running and accumulator battery missing 3 14 It is prohibited to switch off pre heater power before ending of the purging cycle 3 15 It is prohibited to connect and disconnect the pre heater plug when the pre heater power is on 3 16 It is recommended to restart the pre heater after it s switching off not earlier than in 5 10 sec 3 17 In case of malfunctioning the pre heater shall be repaired in service centers authorized by the manufacturer 4 Description of pre heater set up and operation The pre heater runs independently of the vehicle engine The pre heater is fueled and powered from the vehicle The pre heater electric circuit is given in Figure 4 1 The pre heater is an autonomous heater main components are given in Figure 4 2 con
25. gure 6 12 setting the 1st timer To correct start up time it s necessary to press the knob gt while this two first digits will be blinking hours After the necessary time setting with the help of the knobs gt and lt press the knob after this digits 3 and 4 will be blinking and it s possible to set the necessary time in minutes and then to press the knob to confirm the time set To set or correct time in the second timer it s necessary to press the knob lt the indicator will look like on the figure 6 13 Set time for the pre heater automatic start up in sequence described for the 1 timer Figure 6 13 Setting the 2d timer To set or correct time for the 3d timer it s necessary to press the knob lt and the indicator will look like on the figure 6 14 Set time for the pre heater automatic start up in sequence described for the 1 timer Figure 6 14 setting the 3d timer Page 16 of 34 AJIBP 048 00 00 000 To activate one of the three automatic starts only one start up may be active for example timer 2 it s necessary to choose the number of the timer pressing the knob lt and the knob While this timer will be switched over to the mode of preparation to the pre heater automatic starts up The indicator will be looked like on the figure 6 15 The LED of the activated timer in time mode will be blinking rarely
26. n 40 C the pre heater control unit switches on the relay and the passenger cabin heater fan is activated in case it is switched on The air in the cabin is warming up and provides comfortable conditions for the passengers When the coolant fluid temperature goes down 30 C the control unit switches the fan relay off Duration of the total cycle is 40 minutes Moreover there is a possibility to switch of the pre heater any time during the cycle off When the pre heater is switched off manually or automatically as preset time expires the fuel supply stops and the combustion chamber is purged with air Peculiarities of the pre heater automatic control under emergency conditions and in contingencies Page 7 of 34 AJIBP 048 00 00 000 1 If the pre heater has not started for some reason starting process will be repeated automatically After two successive failed starts the pre heater is switched off 2 If combustion stops when the pre heater operates the pre heater stops its operation 3 in case of the pre heater overheating ex abnormal coolant fluid circulation air block etc it automatically switches off 4 in case of voltage drop below 9 5V or voltage surge above 16V the pre heater switches off 5 In case of the pre heater emergency shutdown a corresponding code of malfunction is indicated on the control panel Refer to table of malfunctions codes Attention 1 It is allowable to operate the pre heater with the
27. nd installation of modem for the pre heater activation You can operate the pre heater by the mobile phone In the easiest case you can send SMS with command start up Activation of the pre hater will be fulfilled automatically The car will be warmed up by your coming To control the pre heater operation remotely there s possibility to connect GSM modem to the control unit Activated SIM card 15 necessary to operate the pre heater with the modem IMPORTANT It is necessary to cancel the protection of the SIM with PIN The are three commands start up switch off state request There are 4 variants of the 1 command command without answer command with answer request and failure note command with answer and command with failure note request Page 19 of 34 048 00 00 000 The 2 variants of the second command Command with answer and command without answer The 3d command is a request of the answer When the pre heater receives the command start up without answer it is activated and if there s no malfunctions it will be switched off in 40 min When the pre heater receives the command start up with answer it will start working cycle and after checking of the equipment sends SMS about the pre heater state When the pre heater receives the command start up with failure note request it will be ready to send SMS with malfunction code in case of malfunction during the operation When the pre
28. ng or blinking till the pre heater is switched off To restart indication of the information presses any knob While the pre heater operation pressing the knob gt will show the information about the temperature of the cooling liquid temperature 76 is the temperature repeat pressing of the knob will show the operation mode of the pre heater See figure 6 10 ELI 276 ELI 5j Figure 6 10 Information after pressing the knob 6 1 4 Malfunction code indication in case of the pre heater failure During start up or operation of the pre heater the may be malfunctions In case of malfunctions the control unit automatically sends command to switch off the pre heater Every malfunction is coded and is shown on the indicator see figure 6 11 While this the code of the malfunction and the LED indicating the activity of the pre heater are blinking rarely See the codes of malfunctions in table 6 1 Figure 6 11 indicator shows the pre heater fault Page 15 of 34 AJIBP 048 00 00 000 6 1 5 The pre heater automatic activation To activate the pre heater automatically it s necessary to set up time of automatic start up Control panel lets to record three automatic starts Any of the three will be initiated on condition of activation One may set up the pre heater activation time from the mode Running time pressing the knob lt The indicator will look like on the figure 6 12 08 5 Fi
29. oling liquid reaches 40 C 8 7 Ifthe pre heater demonstrates faulty operation during its switching on or in the process of operation malfunction code will be on the indicator 8 8 The productivity of the fuel pump is not big that s why when the fuel line is empty and it is filled slowly The pre heater performs 2 tries of ignition and if there s no fuel yet stops the activity with malfunction code 13 No more tries to start the pre heater are left There s need to switch on the pre heater until the fuel fills the fuel pipe line 8 0 Start the pre heater with the vehicle engine on and verify its operation Attention Note that cooling fluid temperature readings displayed on the vehicle instrument panel and control panel may vary as temperature is measured in different parts of the fluid system of the vehicle 9 Recommendations 9 2 Ifthe pre heater won t start after switching on check the fuel in the tank the battery charged connectors and fuse 254A are in order 9 3 Ifcontrol panel won t work indicator is not lighting check fuse 5A 9 4 If vehicle heater fan won t start automatically when the temperature of cooling liquid over 40 C check fuse 15A and relay 9 5 If the pre heater won t switch on and switch off or after purging of the combustion chamber the fan motor will rotate take off fuses 5A 25A and then install them again in sequence first 25A then 5A 9 6 All the rest malfunctions are identified automatically and are sh
30. own on the control panel indicator 9 7 Seethe list of malfunctions and troubleshooting in the Table 6 1 of the present manual 9 8 In case of malfunction while operation except those described in item 9 1 9 2 and 9 3 consult with repair centers 9 9 To ensure consistent performance the heater should be switched on for up to 5 minutes each month throughout the year warm seasons included This procedure is necessary to remove sticky film deposited on moving parts of the fuel pump and other units Ignoring this operation may cause the pre heater failure 9 10 Safe performance of the pre heater depends on the fuel that shall correspond to the season of the year and ambient temperature See recommended fuel types for diesel pre heater in the table 6 2 Table 6 2 Ambient temperature C Fuel type or blend Page 29 of 34 AJIBP 048 00 00 000 0 C and above 0 C Diesel JI 0 2 40 Or JI 02 62 305 82 0 C 5 Diesel 3 0 2 mines 45 305 82 5 C 20 C Blend diesel 3 0 2 mines 45 TOCT305 82 50 with petrol P511050 97 50 Lower then 20 C Diesel A 0 4 305 82 or blend diesel 3 0 2 mines 45 305 82 50 and petrol P51105 97 50 9 11 An untimely switch to a winter type of fuel may cause a paraffin blockage in the fuel inlet tube filter if applicable located in the fuel tank and in the fuel supply pump filter which may prevent the heat
31. passenger compartment heater control valve open to full 2 With the purpose of energy saving the heater fan speed switch shall be in Minimal ventilation position 3 Itis advisable to direct the passenger compartment heater steam line in the face and not on the windshield 5 Pre heater control unit Control unit operates the activity of the pre heater according to the set program and fulfill the following functions a pre heater starting and switching off according to control panel or other control devices modem remote control device command b pre heater basic components diagnostics before and during the operation pre heater work control and choice of the pre heater operation mode according to the temperature of the cooling liquid d connection of control unit microprocessor with control devices identification of active device and information transmission pre heater switching off when operation cycle is finished 40 min when one ofthe controlled basic components failed when the parameters are out off tolerable limits temperature voltage flame blow off in combustion chamber Harness Heater par Grcut by Control fuel pump 1 22008 2 Output data p NE Input data p EN X 2 Grete U supply red white mea ellow XS4AXP4 Control electric pump ooo Control Relay C AP3 X 3 brown 05 cs 22 BEEN m gt brown Air pump 3 7 L 4 RTS General
32. r to the source of power the modem start the search of the cellular net the indicator is blinking When the connection is set the indicator is lightning constantly Commands to start up and switch off the pre heater are send from the control panel and from the modem independently The pre heater switched on by SMS can be switched off pressing the middle knob on the control panel and vice versa Attention Please be aware of the fact that SMS can be received with delay because of technical problems of cellular operator To be sure that command is received by the pre heater in time adjust your mobile phone so to get the note about SMS delivery or use command with answer Page 2 of 34 AJIBP 048 00 00 000 If SMS with start up command is not delivered because of cellular connection operator fault send SMS to switch off the device It will prevent the pre heater start up when you don t need it 7 Installation specification for pre heater and its assemblies 7 General 7 1 5 Heater shall be located lower the radiator overflow tank Motor air pump shall be installed lower the radiator overflow tank and the heater 7 1 6 Check up fluid flow in the heater and the engine cooling system be sure it has the same direction 7 1 7 Remove air blocks from the engine cooling system and the heater on completion of the heater installation All the pipe junctions shall be leak proof 7 1 8 Fuel and coolant pipes shall be assembled in a way
33. ric pump exhaust pipe is fluid intake from engine uuu E P 9 exhaust outlet Figure 4 2 Pre heater basic components Page 10 of 34 AJIBP 048 00 00 000 Control unit cover Control unit Glow plu Flame indicator Combustion chamber cover Combustion chamber Cover Heat exchanger N 1 Sensor board Heat exchanger 2 Cover Figure 4 3 Heater basic components Page 1 of 34 AJIBP 048 00 00 000 6 The pre heater Control devices according to the choice of the consumer 6 1Control panel with timer is in set with pre heater 6 1 1 Control panel is provided for indication of running tome the pre heater switch off and switch on in manual mode operation mode indication ignition full mode low mode cooling down mode purging and time of the pre heater operation setup ofthe timer for starting up the pre heater in automatic mode vehicle cooling liquid temperature indication malfunction code indication during the pre heater operation parameters view version number of the set program On the surface of the timer there are four digit LED indicator four LEDs and three knobs Functionality of the knobs and LEDs see on the figure 6 1 Sign of working of a heater LEDs fimer activation scrolling number of timer setting hme input in Service menu heater ON OFF knob timer activation
34. sisting of Heater main components are given in Figure 4 3 Air pump for air supply to the heater combustion chamber Fuel pump for fuel supply to the combustion chamber Circulation pump for forced circulation of cooling system liquid through the heat exchanging system of the pre heater and the vehicle Control unit part of the heater to coordinate operation of the above mentioned systems Pre heater control panel with timer for manual or automatic start up of the pre heater Wiring harness for connection of the pre heater components to the vehicle systems The pre heater is integrated to vehicle cooling system with its hydraulic frame so that the pre heater s pump provides circulation of cooling liquid in the engine and in the heater Page 6 of 34 048 00 00 000 The pre heater principle of operation is based warming up of liquid in the engine cooling system with its further forced pumping through the heat exchanging system of the heater Gases generated because ofthe fuel blend combustion in the combustion chamber warm up the liquid The heat is transmitted through the walls of the heat exchanger to the coolant fluid which in its turn is pumped through the cooling system of the vehicle engine When the pre heater is switched on first of all there is performed functional test of its components such as flame detector heat and overheating sensors pump airpump motor glow plugs fuel pump and correspon
35. t fault or 14 malfunction disconnection fault Replace the pump if necessary Shutdown low voltage Check voltage on XS2 connector of the pre heater Check the 15 less then 9 5 V battery regulator and power supply wiring The pre heater is not cooled enough during purging Check the 16 Excessive ventilation time air duct and exhaust gas escape channel Check the combustion detector and replace if necessary Check the electric wiring of the fuel pump for the short circuit 17 Fuel pump malfunction check the pumping capacity and replace the fuel pump if necessary No connection between 20 control unit ant control Check fuses 5A Check wiring and connectors panel Flame failure at warming TM 21 See the description of malfunction code 08 up mode 27 Air pump failure Motor Check the wiring of the air pump Control unite and motor won t rotate replace if necessary Page 18 of 34 AJIBP 048 00 00 000 28 Air pump failure The motor rotates without control Check the wiring of the air pump control unite replace if necessary 6 2 Use and connection to the vehicle remote alarm system for activation and switching off the pre heater with the help of transmitter You can use vehicle remote alarm system to control the pre heater operation if there is an additional channel The relay with normally open contact is connected to output of the channel contacts must be connected with harness XS4
36. tart mode 100 100 sec W Maximum liquid heating temperature 85 Cabin heater fan switching at liquid 40 temperature Start mode Manual or automatic Time of one working cycle min 40 Pre heater mass in full configuration kg 8 max 3 Safety measures 3 1 The pre heater and its components shall be installed only by authorized companies by reason of it complicated structure there s a combustion chamber where fuel burns a heat exchanger which provides heat transfer to the cooling liquid fuel pump air pump control unit which control and operate the work of the heater according to the program heat sensors etc 3 2 While installation or dismantling the pre heater safety measures specified for activities with car wiring harness and fuel supply line must be observed 3 3 The pre heater shall be used only for purposes described in the present User Manual 3 4 It is prohibited to lay thefuel pipe inside the passenger compartment or driver s cab 3 5 Itis prohibited to use the pre heater in case of leaky fuel system 3 6 Vehicle with the pre heater shall be equipped with a fire extinguisher Page 5 of 34 AJIBP 048 00 00 000 3 7 To avoid possibility of poisoning with the toxic exhaust gas generated by the operating pre heater the exhaust pipe shall be set in a manner preventing discharge gas ingress into the driver s cab or its intake by the heat exchanger fan 3 8 avoid possibility o
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