General Components AIR 2KW HOST User manual

AIR 2KW HOST

Page 2 of 21
Contents
Introducon ..............................................................03
Technical Data ...........................................................03
MV Airo 2 Internal Structure.....................................04
Structures and Working Principles............................04
Case Assembly .............................................. ............04
Installaon.................................................................05
Installaon of the Main Heater Body........................ 06
Air Inlet & Outlet ......................................................07
Addional Ducng (Oponal) ...................................08
Installaon of Combuson Air Pipe and Exhaust......08
Fuel Lines 10
Fuel Standpipe...............................................
.................
..................................................
............12
MV Airo2 Wiring Diagram – Brushless Version.........13
Timer and Rheostat Control Plugs.............................14
Wiring Loom Plug for Timer and Rotary Control.......15
Circuit Interfaces........................................................15
Operaon ..................................................................15
Rheostat Control .......................................................15
Mini Timer .................................................................16
Manual Start Up and Shut Down .............................16
Pre-seng Heang Time...........................................16
Pre-seng Starng and Heang Times ...................... 16
Checking Temperature .................................. ............17
Converng to Thermostac Mode ...........................17
Fault Informaon ......................................................17
Remote Operaon ...................................................17
Installaon Fuel Priming Feature ..............................17
LCD Digital 7-Day Timer.............................................17
Changing Language ...................................................18
Changing the Date and Time.....................................18
Manual On/Off.............................................. ............18
Switching to Thermostac Mode .............................. 19
Fan Mode ..................................................................19
Pre-seng Heang Times.........................................19
Installaon Fuel Priming Feature ..............................20
Checking Error Codes .................................... ............20
Reseng Digital Controller to Factory Sengs ........20
Maintenance ................................................. ............20
Fault Codes ................................................... ............21
Rheostat Control ........................................... ............21
Fault Codes Error! Bookmark not defined. ....................
Timers. ...................................................................... 21

1. Control switch
2. Heater Body
3. Fuel Pump
4. Wiring Harness
5. Vehicle’s Baery
6. Vehicle’s Fuel Tank
7. Exhaust Pipe
8. Combuson Air Intake
Preface
Scope of applicaon:
Figure I
Page 3 of 21
Thank you for purchasing the MV Airo 2 Air heater.
This instrucon book describes the structures,
working principles, installaon and operaon of the
MV Airo 2. For correct use of the heater, please read
this instrucon book carefully before installaon and
use. The instrucon book should be saved in a
convenient place for reference later.
Introducon
Comply with the operaon manual for installaon
and use, to ensure prolonged and reliable operaon.
The main equipment of the MV Airo 2 air heater
(hereinaer referred to as ‘the heater’) is a small fuel
furnace controlled by a single-chip micro-processor.
Its furnace body (the heat exchanger) is located in the
hood shaped case, which serves as an independent
air passage. Cold air is drawn into the air passage by
the fan and blown out when it becomes hot.
The heat can be supplied by the heater to the driver’s
cab and passenger’s compartment independently
from the engine. The schemac diagram is shown in
Fig I.
The heater is fully automacally controlled. It
features a compact structure, easy installaon, low
running costs, easy maintenance and is safe and
reliable.
Aenon



This instrucon book is subject to revision
without noce, but the instrucon book is in
conformity to the purchased product.
Our effort is to explain all quesons you may
have. If you have any doubts or find anything
incorrect in this manual, please contact us
directly.
Check the heater for any damage when
unpacking and contact the dealer immediately if
anything is found.
If any troubles arise during applicaon, please
contact MV Heang or other customer service
staons authorized by this company. We shall do
our best to provide service to you.
Technical Data
Output (w)
1
2
34
5
6
8
7
Fuel
Voltage
Fuel Consumpon (l/h)
Power Consumpon
Working Temperature
Weight (KG)
Dimensions (mm)
Variable Output
Posion
PO1
PO2
PO3
PO4
PO5
PO6
PO7
2000
Petrol Diesel
12/24V 12/24V
0.14 - 0.27 0.12 - 0.24
14 - 29
-40°C - 20°C
2.6
323x120x121
Current Draw
(Amps)
0.9
1.1
1.2
1.3
1.5
1.7
1.9

1. Heat exchanger
2. Gasket 1 (4 hole)
3. Combuson chamber
1. Heat Exchanger
2. Heater Case
3. Insulang Bush
12. Juncon box cover
13. Top Case
14. Hot air outlet
15. Inlet Cover
16. Outlet Cover
17. Grill
4. Burner Assembly
5. Gasket 2 (5 hole)
6. Air Motor Assembly
7. Insulang bush
8. ECU
9. Air Fan Wheel
10. Glow Pin
11. Overheat Sensor
MV Airo 2 Internal Structure
Figure II
Structures and Working Principles
The structure of the main heater is shown in Fig. III
Case Assembly
Figure IV
Page 4 of 21
The heat exchanger is made of die-cast aluminium, with
radiang fins around the rear. The combuson chamber
fits inside the inner cavity of the heat exchanger. The
burner assembly and glow pin, fit into the end of the
combuson chamber. Fuel comes to the burner
assembly through the fuel pipe and is ignited by the glow
pin. The flame is passed up the combuson chamber and
returns between the inner walls of the heat exchanger
and discharged through the exhaust outlet vent to the
outside of the vehicle or boat.
The air supporng combuson of the furnace,
comes from the combuson air inlet port and
is sent down the combuson pipe by the
combuson supporng air blades of the fan
motor.
1
7
10
11
2
3
4
5
6
8
9
1 2 3
12 13
17
16
14
15
17

18. Control Switch/Timer
19. Main Wire Harness
20. Fuel Pump
21. Mounng Gasket
22. Combuson Air Inlet Pipe
23. Exhaust Pipe
24. Fuel Pump Extension Loom
25. Fuel Standpipe
26. Fuel Pipe
27. Fuel Pump Bracket
28. Fuel Filter
29. Exhaust Pipe Clip
30. Exhaust Pipe Fixing Clip
31. Air Inlet Fixing Strap
32. Fuel Connector Hose Clip
33. Fuel Line Connector
34. Air Inlet Hose Clip
35. Control Fixing Screw
36. An-Vibraon Mount (M6)
Installaon
The kit includes everything necessary for installaon.
Figure V
Page 5 of 21
Aenon:
Do not mount the heater near any flammable sources
Do not install the heater in closed spaces without venlaon
Do not place the heater near anything that can cause a blockage
Do not mount the heater near any water sources and protect it from any splashing
Figure V shows the diagram for
installaon. The posion and
ways of fixing of various parts
may vary from one vehicle/boat
to another, but the general
principles remain the same.
25 32
33
35
18
19
21
29
23
30
24
20
32
33
26
28
36 22
34
27
31

Page 6 of 21
A. Air heang inlet
B. Air heang outlet
C. Combuson air inlet
D. Fuel inlet
E. Exhaust outlet
F. Non-interference area
G. Informaon label
H. Installaon surface
I. Gasket
Figure VI
For the ease of servicing, fault finding and air flow it’s recommended that the main body is placed in an area with
easy access. Figure VI shows the minimum distances required.
Installaon of the Main Heater Body
Choose a flat installaon surface, any undulaons could cause the case to twist
and will not ensure an even mount. Make sure there are no foreign bodies
between the boom of the heater and the installaon surface itself. This will
ensure a good seal between the two. File down any drill holes to again ensure an
even mounng surface. Tighten the M6 bolts provided to a torque seng of
6Nm+1Nm.
Figure VII shows the posion of the installaon holes. If the installaon area is
less than 1.5mm thick a mounng plate will be required (Figure VIII).
A
C
120
121
120 29
20
5020
155
323
D E G F
B
Figure VII Figure VIII
7.5
26
12 44
18
55
A
148
7.5
170
85
125
2
5
25 35.5
B
A. Mounng Gasket B. Mounng Plate
If the heater is being reinstalled, a new gasket should be used.

Figure IX
Page 7 of 21
Aer installaon, make sure there is no fricon
between the fan and other nearby parts to ensure
smooth operaon and make sure the heater label is
clearly visible for ease of maintenance in the future.
Avoid re-entering of the supplied hot air into the inlet
port (as shown in Figure X). If no inlet pipe is
required, make sure the grill is installed at the inlet
port instead (Figure IV no. 17).
The direcon of the heater for installaon is shown in
figure IX. Ensure you do not exceed the inclinaon
angle or normal operaon will be affected.
Make sure that the hot air outlet does not exit onto
any parts affected by heat and that it isn’t directed
toward the flow of anything that can cause a
blockage, near splashing water or near the vehicles
exhaust.
Correct
Wrong
Figure X
Air Inlet & Outlet
0 -90°
0 -90°

A
B C D E F
Page 8 of 21
A. Grill or ducng
B. Heater Body
C. 60mm Hose Clip
A. Heater Outlet
B. 60mm Hose Clip
C. 60mm APK Ducng
D. 60mm ‘Y’ Branch
E. 80-60mm Reducer
F. 80mm Direconal Vent
G. 80mm Open/Close Vent
D. 60mm APK Ducng
E. 80-60mm Reducer
F. 80mm Direconal Vent
Quanty of ducng can be purchased
according to needs.
Figure XI Figure XII
Addional Ducng (Oponal)
The combuson air inlet pipe sucks in fresh air from
outside of the vehicle and the exhaust discharges
fumes outside of the vehicle. Measures must be
taken to avoid the fumes from re-entering the
vehicle.
The pipes should exit at the boom of the vehicle,
ensuring that the openings are far enough away from
any splashing water or dirt that can clog them. Figure
XIII shows the right and wrong way to install the
pipework.
Figure XIII
Installaon of Combuson Air Pipe and Exhaust
6
A
B
C
D
E
F
F
A
B C D
E
G
F
A
B
C
D
E
F
G

Page 9 of 21
Correct
Direcon of Travel
Direcon of Air Flow
A & B – Correct C & D - Wrong
Only use the inlet pipe and exhaust provided with the
kit for installaon. The exhaust pipe is made of
corrugated stainless steel while the combuson pipe
is aluminium covered in paper and plasc. Do not
confuse the two. Use the supplied clamps to fix them
securely to the combuson air inlet and the exhaust
outlet on the heater. The protecve end cap on the
outlet of the combuson air pipe and exhaust pipe
should be kept in good condion. Do not damage or
remove them.
Both the combuson air pipe and exhaust pipe should
come downward from the heater and face opposite to
the vehicle’s direcon of travel. If the pipe cannot
avoid a curve, make sure the radius is no smaller than
50mm and the sum of all curves does not exceed
270˚. Figure XIII shows the right and wrong way to
install the combuson air intake. Note that it is the
same for the exhaust too.
A
A
Wrong
B
B
ABC D

Page 10 of 21
Figure XV
When the heater is operang, the exhaust will get
hot, so make sure it is installed away from any parts
that could get damaged by high temperatures. The
exhaust vent should also point downward to the road
surface with an angle of 90˚±10˚ This is best achieved
by fixing a clamp 150mm from the pipe end.
Any exposed exhaust should be covered with a heat
shield to prevent scalding.
10°
10°
2
3 4
5 6
7
8
1
2000-6800mm
500-1200mm
Fuel Lines
Figure XVI
1. Fuel Tank
2. Fuel Standpipe
3. Fuel line Hose Clamp
4. Fuel Line
5. Rubber Fuel connector
6. Fuel Filter
7. Fuel Pump
8. To Heater
Where possible the fuel line is ideally placed uphill to
the fuel pump to ensure ideal bleeding of the fuel
line.
Always fit the fuel pump on the an-vibraon mount
securely onto the vehicle. Ensure the outlet of the
fuel pump lts upward. The correct angle is shown in
Figure XVII.
2
3
4
5 6
7
8
1