KW Hydraulik Dynaset WHU110/200-12VDC User manual

1November 2014 JLe
Water heating unit WHU110/200 -12V_24V
WHU110/200-12_24VDC
WATER HEATER UNIT
MAY CHANGE WITHOUT PRIOR NOTICE
OPERATING INSTRUCTIONS
Note: This manual is valid from WHU serial number 41565118.

2
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
TABLE OF CONTENTS
1.SAFETY PRECAUTIONS AND WARNING STICKERS 3
2.GENERAL INFORMATION 4
3.TECHNICAL SPECIFICATIONS 4
4.OUTLINE DIMENSIONS AND CONNECTIONS 5
5.WHU BURNING PROCESS 6
5.1 Alarm sequence table 6
5.2 Startup sequence 7
5.3 Switch off sequence 7
6.INSTALLATION AND OPERATION 8
7.MAIN ASSEMBLY 9
8.PART LIST 10
9.WIRING DIAGRAM WHU110-200_12V 11
10. WIRING DIAGRAM WHU110-200_24V 12
11. WHU 110/200 -12V_24V BURNER ASSEMBLY 13-17
11.2 WHU Boiler assembly 16
11.3 WHU Electrode cover assembly 16
11.4 WHU Electric motor assembly 17
11.5 WHU Electric motor assembly 17
12. PRODUCT DISPOSAL 18
13. MANUFACTURER’S LIMITED WARRANTY 19
14. DECLARATION OF CONFORMITY 20
November 2014 JLe

3
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
WARNING STICKER
Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product.
Product recipient is obligated to fix determinate warning sticker to Dynaset product.
Fix sticker to visible and appropriate place or close to Dynaset product where it’s easily seen.
Before fixing sticker clean surface with solvent detergent.
READ OPERATION INSTRUCTIONS. RISK OF ELECTRIC SHOCK. BEWARE OF HOT SURFACE.
SAFETY PRECAUTIONS
The hydraulic system is usually pressurized up to 250 bar.
In order to avoid damages and accidents operator and maintenance personal must act in compliance with the
laws, regulations and recommendations issued by local electricity and work safety authorities.
Follow all your local safety instructions related to electric devices and the high-pressure hydraulics.
TECHNICAL CONDITION OF YOUR MACHINERY AND EQUIPMENT MUST BE SUBJECT TO CONSTANT
SURVEILLANCE.
Hydraulic system of a carrier machine should be maintained according to the service program.
All couplings, valves and hoses should be maintained tight and clean as well as kept under constant
observation.
Leaks in the hydraulic system must be fixed immediately to avoid injuries caused by high pressure and oil
blowouts.
Prior to maintenance, detaching from a carrier or disassembling a DYNASET-unit, the hydraulic system of a
carrier machine should be stopped and DYNASET’s hydraulic circuit depressurized.
When operating or maintaining in the immediate vicinity of DYNASET hydraulic unit or accessories, appropriate
protective clothing, safety goggles, gloves, ear and eye protection should be worn.
Do not touch parts heated by hydraulic oil.
EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY SERVICE
DISSASSEMBLING OR REPAIR OF UNIT AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE
SAFE, RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT.
Prevent freezing nozzles, water circuit and pipeline. Draining and air flushing have to perform before
ambient temperature reaches 0°C (32°F).
Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.
Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause
nausea, fainting or death.
Unintentional sparkling can result in fire or electric shock. Unintentional start-up can result in entanglement,
traumatic amputation, or laceration. See appendix engine manual.
All installation and service of both hydraulic and electric equipment must be performing experienced personnel
only.
November 2014 JLe

4
Qw / lpm 10 20 30 40
∆p / bar 1 5 12 21
Pressure drop:
Q water Diesel fuel Supply
15 lpm 30 lpm consumption voltage
110 kW 200 bar
∆t out ∆t out 13,5 l/h 12 / 24 88 kg
96 °C 48 °C diesel VDC
Power C P max Weight
0
5
10
15
20
25
30
35
10 15 20 25 30 35 40 45 50
Δp [bar]
Qw [lpm]
WHU water heater, producing hot water or steam, is ideal in demanding cleaning tasks.
High water temperature greatly enhances impact effect and water jet scouring capacity. The unit is to be connected
to pressure line of Dynaset HPW high pressure pump.
Unit is especially intended for mobile use. It has next connections; Water tank, hot water out and electric power
from vehicles voltage source (12/24VDC).
Control enclosure switches are front mounted and easily operated electrically ignited units functions.
WHU heating capacity is 110 kW. Electric supply 12 or 24 VDC depending on WHU type, equipped with logic
control.
FueI consumption 13,5 l/h diesel .
TECHNICAL SPECIFICATION
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
GENERAL INFORMATION
November 2014 JLe

5
WATER PORTS
Water in 1. Water out 2. Over flow 3.
R 1/2” R 1/2” R 3/8”
OUTLINE DIMENSIONS AND CONNECTIONS
3
1 2
A
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
FOOT (3.1) INSTALLATION DIMENSIONS:
WATER PORTS INSTALLATION DIMENSIONS:
November 2014 JLe
A
630
440
900
390
39
330

6
Controls water heater burn process according to the measured exhaust gas and water output temperatures
and water flow sensor.
If at any time water flow is stopped the burner will stop after a delay of 4 seconds if the water flow is not
restored within that time.
Burner will stop immediately and the failure indicator light will start indicating if one or several of the following
conditions is met:
A. Water temperature >110C (Alarm 3),
B. Exhaust gas temperature > 300C (Alarm 4),
C. Exhaust gas temperature drops more than 15°C after burning sequence has started (Alarm 2), if
ignition sequence has failed (Alarm 1), or if emergency stop button has been pressed indicator light
burns continuously. See TABLE 1.
After failure is resolved, Press the Reset button for 2 seconds to reset the fault.
Fan motor has a 15 seconds cooling sequence after burner has stopped.
WHU BURNING PROCESS
Alarm 1 0.5s/0.5s
Alarm 2 1s/1s
Alarm 3 2s/1s
Alarm 4 3s/1s
Emergency Stop
Continues
ALARM SEQUENCE TABLE 1.
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
November 2014 JLe

7
1. Fan motor starts.
2. Fife (5) second delay.
3. Ignition spark and fuel switched on.
4. Wait for exhaust gas temperature to rises for min 15°C in 10 seconds. If the temperature is reached
sequence will continue, otherwise sequence will restart from the beginning for maximum of 4 times.
If the temperature level is not reached, the sequence will abort and fault indicator light will light up.
After failure is resolved, the sequence can be reset by pressing reset button for 2 seconds/until failure
indicator light will go off.
5. Wait for exhaust gas temperature to rises 10°C for maximum of 15 seconds. If the temperature is
reached, sequence will continue, otherwise re-ignition will take place maximum of 5 times. If the
temperature level is not reached, the sequence will abort and fault indicator light will light up.
6. After failure is resolved, the sequence can be reset by pressing reset button for 2 seconds/until failure
indicator light will go off.
STARTUP SEQUENCE
Heater cuts the fuel flow if determinate temperature has reached and performs exhaust gas
ventilation (10 sec).
Water runs normally through heater unit without warming. Blower starts automatically before ignition
transformer and solenoid ignited the heating process. WHU heating stays on until water flow is stopped or
unit is turned off.
Any time water flow is stopped the heater will stop after set delay provided the water flow be not restarted
within delay. After water flow is continued, WHU automatically starts ignition sequence.
Heater has equipped with the safety function, which stop heater immediately.
The failure indicator light will light up if one or several of the following conditions are met:
1. Water temperature >110°C.
2. Exhaust gas temperature Stays up and flame is on.
3. Exhaust gas temperature <300°C.
Fan motor has a 15 sec cooling sequence after burner has stopped.
SWITCH OFF SEQUENCE
WHU BURNING PROCESS
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
November 2014 JLe

8
WHU CONTROL BOX
Emergency stop reset,
Emergency stop button,
WHU main switch
Water supply, Drain , Hand spray gun
FRONT PANEL CONNECTIONS:
Install WHU unit firmly onto its chassis. Ensure electric supply 12VDC or 24VDC is connected to WHU
control box. Fuel is enough in the WHU fuel tank.
1. Attach water supply to the water supply connection (front panel).
2. Attach hand spray gun to the hand spray gun (outlet) connection.
3. Switch water faucet (ball valve) on at water supply network or PTO (power take off) driven Dynaset
HPW pump pumping water to the WHU unit.
If the water system has mixing valve between WHU supply and outlet lines, it is possible to adjust
water temperature accordingly.
4. Switch WHU main switch on.
5. Point the hand spray gun to the target and press the handle.
6. Release hand spray gun handle -> water flow stops and the heater burner will stop after a delay of
four (4) seconds if the water flow is not restored (handle pressed) within that time.
Finally heater performs exhaust gas ventilation (10 seconds).
7. Turn WHU main switch off.
8. Switch water supply to WHU off, faucet (ball valve) or PTO.
INSTALLATION AND OPERATION
Water heating unit WHU110/200 -12V_24V
MAY CHANGE WITHOUT PRIOR NOTICE
November 2014 JLe

MAIN ASSEMBLY
1.1
2.0
2.7
2.6
2.11
3.1
3.2
3.3
3.5
3.11
Water heating unit WHU110/200 -12V_24V
9
MAY CHANGE WITHOUT PRIOR NOTICE
November 2014 JLe
2.14

PART LIST
No CODE DESIGNATION DETAILS QUANTITY
1 D210107010 WHU110/200-12V COMPLETE 1
1 D210107011 WHU110/200-24V COMPLETE 1
1.1 6306695000 WHU200 BURNER 110kW 12VDC 1
1.1 6306695100 WHU200 BURNER 110kW 24VDC 1
2.0 D100105181 ELECTRIC CABINET WHU110 12VDC 1
2.0 D100105182 ELECTRIC CABINET WHU110 24VDC 1
2.1 4405262000 ENCLOSURE 1
2.2 4405168250 CAN I/O-MODULE 12I/8O 1
2.3 4405168230 CAN I/O-MODULE 12I/12O 1
2.4 4405433000 RELAY 12Vdc 2
2.5 4405442000 RELAY 12Vdc 70A 1
2.6 4405361700 MAIN SWITCH 1
2.7 4405371100 E-MERGENCY STOP BUTTON 1
2.8 4405366000 ADAPTER 2
2.9 4405367500 CONTACT ELEMENT NO 2
2.10 4405367000 CONTACT ELEMENT NC 1
2.11 4405359110 LIGHT BUTTON 1
2.12 4405365200 LED ELEMENT 1
2.13 4605642100 DIODE 1
2.14 4605748000 SENSOR PT-100 1
2.15 4605749010 SENSOR, ROD PT-100 1
2.16 4805964530 RECEPTACLE MALE M12 1
2.17 6306696200 IGNITION WIRES WHU200 1
2.18 4405304000 ENCLOSURE 1
2.19 4405433010 RELAY SOCKET 12V/24V, 30A 1
2.20 4405359600 SPLASH GUARD 1
2.21 4404979010 FUSE BOX 1
2.22 4806040005 TERMINAL BOARD 1
2.23 4404985000 FUSE 10A 1
2.24 4806026000 TERMINAL BLOCK L 2,5mm2 14
2.25 4806026100 TERMINAL BLOCK L 6mm2 1
2.26 4806026020 TERMINAL BLOCK PE 2,5mm2 1
2.27 4806027000 TERMINAL BLOCK 1
2.28 4806003100 MOUNTING RAIL EN 35x7,5mm 1
2.29 8500056500 ALLEN SCREW M6x25 8.8 2
2.30 8500880700 NUT M6 2
2.31 8501200500 LOCKING WASHER A6,4x11 4
2.32 8500403800 ALLEN SCREW M4X35 8.8 2
2.33 8501710910 SCREW COUNTERSINK M4X16 8.8 4
2.34 8500406600 ALLEN SCREW M5X30 8.8 4
2.35 8501200400 LOCKING WASHER A5,3x10 4
2.36 8501950200 NUT M5 4
3.1 0709015902 FOOT WHU110/250 1
3.2 0709015904 FRONT PLATE 1
3.3 0709015906 FASTENING PLATE CABINET 1
3.4 1702470000 FITTING R1/2u-R3/8s 2
3.5 6306376000 OVER FLOW VALVE 30lpm 200bar 1
3.6 1702577000 SVIWEL ELBOW FITTING R1/4 1
3.7 1702474900 LINK FITTING R3/8u-R1/4s 1
3.8 1702502000 JOINT FITTING R3/8 1
3.9 1702445000 LINK FITTING R3/8u-R3/8s 1
3.10 1702185000 SEAL USIT R3/8 3
3.11 6306703000 FLOW SWITCH 250bar R3/8 1
3.12 1701920000 FITTING 15L R1/2 2
3.13 1701915000 FITTING 15L R3/8 1
3.14 1702190000 SEAL USIT R1/2 3
3.15 1702400000 ELBOW FITTING R1/2-R1/2 u/s 2
3.16 1702090000 SVIWE T- FITTING L15 1
3.17 1702520000 SLEEVE R1/2 1
3.18 1702165000 PLUG L15 1
3.19 1701860000 FELLURE L15 4
3.20 1701870000 NUT 15L M22x1,5 5
3.21 1702085000 LINK FITTING L15 2
3.22 1702500000 LINK FITTING R1/2s 1
3.23 8500015300 ALLEN SCREW M10x40 8.8 3
3.24 8501126100 WASHER A10,2x18 6
3.25 8501168410 SPRING WASHER 10,2x18 6
3.26 8500881000 NUT M10 3
3.27 8500005900 ALLEN SCREW M6x16 8.8 6
3.28 8500406100 ALLEN SCREW M5x12 8.8 6
Water heating unit WHU110/200 -12V_24V
10
MAY CHANGE WITHOUT PRIOR NOTICE
November 2014 JLe