MV Heating Hydro 55 User manual

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MV Heating UK Ltd
MV Hydro 55
Diesel Powered
Water Heater
Instruction Manual
Ed. 1.00
MV Heating UK Ltd
Unit 6
Second Avenue Business Park
Millbrook
Southampton
SO15 0LP

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MV Heating UK Ltd
Preface
Thank you for purchasing the MV Hydro 55 Water
heater. This instruction book describes the structures,
working principles, installation and operation of the MV
Hydro 55. For correct use of the heater please, please
read this instruction book carefully before installation
and use. The instruction book should be saved in a
convenient place for later reference.
Attention
•This instruction book is subject to revision
without notice, but the instruction book is in
conformity to the purchased product.
•Our effort is to explain all questions the user
may have through this instruction manual. If
you have any doubts or find anything incorrect
in this manual, please contact the company
directly.
•Check the heater for any damage when
unpacking and contact the dealer immediately if
any damage is found.
•If any troubles arise during application, please
contact MV Heating or other customer service
stations authorized by this company. We shall
do our best to provide service to you.

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MV Heating UK Ltd
Contents
No.
Content
Page
No.
1
Introduction
4
2
Technical Data
6
3A
Installation
8
3B
Installation of fuel line
15
4
Operating Instructions
18
5A
Maintenance
19
5B
Fault Finding
21

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MV Heating UK Ltd
1. Introduction
The MV Hydro 55 is a 5kW modulating diesel fired
water heater, which is suitable for providing hot water
for heating purposes via radiators or matrix heaters and
also domestic hot water via a calorifier. The MV Hydro
55 is fully automatic in operation featuring low energy
glow pin ignition and microprocessor control for full
temperature regulation.
Very low servicing costs due to modular construction.
Simple wiring means a variety of controls are available
to operate this heater
It can be applied to various heating purposes, whether
its hot water heating for easier living or engine pre-
heating and demisting.
For both vehicle and marine markets the Hydro 55 is a
great way to efficiently meet your heating needs.
This kit includes everything necessary for installation
excluding plumbing to the radiators and calorifier.

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MV Heating UK Ltd
Included in your Hydro 55 Kit is:
MVHydro 55
Part
Quantity
Heater on bracket with water pump
1
Fuel standpipe
1
Fuel pump on antivibration mount
1
Fuel pipe
1
Rubber coolant hose
2m
Water pipe connections
4
Clips & Fixings
Various
Wiring harness
1
On/off switch with diagnostic light
1
Stainless steel exhaust terminal
1
Stainless steel exhaust clamps
1
Silicone coated exhaust lagging
1
Exhaust support strapping
1
Exhaust with silencer
2.3m

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MV Heating UK Ltd
2. Technical Data
Figure I

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MV Heating UK Ltd
Figure I:
1. Heat exchanger assembly 2. 4-hole combustion
chamber gasket
3. Backing plate 4. 3-hole combustion
chamber gasket
5. Combustion chamber 6. Heat exchanger gasket
7. Housing 8. Combustion air motor
9. Air motor gasket 10. Air fan gasket
11. Combustion air fan 12. Combustion air fan cover
13. Thermistor 14. Glow pin and flame
sensor assembly
15. Overheat sensor 16. Water pump
17. ECU board 18. ECU cover gasket
19. ECU cover with loom

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MV Heating UK Ltd
3A. Installation
Parameter YJH-Q5B/1(2) YJH-Q5B/1
Rated heat flow
Fuel Diesel Petrol
Fuel consumption 0.56L/h 0.65L/h
Nominal voltage 12v(24(v) 12v
Work voltage 10-15v (19-32v) 10-15v
Nominal power consumption without circulation pump
Permissible ambient temperature:
Heater: -Operation -40˚C - 60˚C -40˚C - 120˚C
-Storage -40˚C - 40˚C -40˚C - 60˚C
Fuel Pump: -Operation -40˚C - 120˚C -40˚C - 40˚C
Ideal operating pressure (Heat carrier)
Heat exchanger capacity
Minimum capacity of the circulation
Minimum flow of the heater
CO₂ in exhaust (Allowed range)
Heater dimensions
Weight
Remote distance
Timer
Scope of application
Hydro 55
8-12%
242x139x182
3.5Kg
800m
Three timer design
Used in larger vehicles and
marine craft for cabin warming,
demisting and low temperature
start up of the engine.
5kw
50w
0.4 - 2.5 bar
0.16 1
4.0 1
250 1/h
Parameter WP-1000/2 WP-1000/1
Flow rate at 0.1 bar
rated voltage 24v 12v
Rated Power
Overall dimensions (mm)
Weight
10001/h
6w
168x55x73
0.4g
Circulation Pump

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MV Heating UK Ltd
Tools Required:
1. Electric drill with slow speed
2. Crimping pliers
3. Wire cutters
4. Metric spanners 8mm to 13mm
5. Flat blade & posidrive screwdrivers
6. Sharp knife
7. Pipe shears [for plastic & rubber water pipe].
Important Information:
The heater must not be installed:
➢In the immediate vicinity of hot parts
➢In areas exposed to splashing water (vehicle
tyres for example)
➢Below the wading line of a vehicle

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MV Heating UK Ltd
Mounting the heater
The Hydro 55 is ideally installed in the engine room
away from any water that may interfere with the
system whilst still being low enough to allow automatic
bleeding of the heater and circulation pump. This is
particularly important as the circulation pump is not
self-priming.
Figure II
The opening of the ports must not point downward in
any installed position and allow for the rating plate to

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MV Heating UK Ltd
be positioned so that it is clearly legible when the
heater is installed.
Model for installation:
Figure III
1. Radiator 2. Cooling water thermostat
3. Engine water pump 4. Vehicle Engine
5. Water heater 6. Battery
7. Fuse holder 8. Control Unit
9. Relay (for vehicle fan) 10. Regulating valve for
vehicle heating
11. Heat exchanger, vehicle heating 12. Vehicle heating fan
13. Switch for vehicle heating fan 14. Fuse bank in vehicle
15. Timer 16. Fuel pickup
17. Intake silencer, combustion air 18. Exhaust muffler
intake line
19. Circulation pump 20. Fuel metering pump
Connecting to the vehicle’s cooling system

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MV Heating UK Ltd
The heater is connected to the cooling system as shown
here:
Figure IV
1.Equalising reservoir 2. Thermostat
3. Engine 4. Circulation Pump
5. Heater 6. Heat exchanger
7. Radiator
Always use the hoses provided. Ensure they are
installed without kinks and preferably installed uphill to
ensure better bleeding. Use hose clips to support the
hose connections to prevent them from slipping off.
Take care not to over tighten the clips. A torque setting
of 2.0+0.5 Nm is ideal. Secure hose clips on the heater
between the flared neck and the heater.

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MV Heating UK Ltd
Take care to bleed the cooling system before servicing
the heater or after refilling with coolant. Malfunctions
can occur if not bled correctly.
Relocating the circulation Pump
The circulation pump can only be installed in the water
installation. Take care to ensure that the water flows
through the heater in the right direction (water outlet
at the top and inlet at the bottom) the heater will
malfunction if this isn’t done.
Figure V
Installation Positions

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MV Heating UK Ltd
Supply of combustion air
Notes:
Under no circumstance should the combustion air be
taken from areas occupied by people. Make sure that
the opening for the air combustion chamber is in a
position that will not become trapped or clogged with
dirt or in the direction of travel.
It is ideally places in a cool temperature environment
away from splashing water and again above the vehicles
wading line.
Instructions:
Connect the slotted side of the combustion air intake
line (max. 400mm long) to the air intake port of the
heater and secure it with the hose clips provided giving
yourself an adequate distance from the exhaust system.
Exhaust
The supplied exhaust line can be
installed with several bends (270˚
altogether with a minimum bending
radius of 50mm). The total length of the
line shouldn’t be less than 500mm or
larger than 3m and make sure the
exhaust doesn’t point in the direction of
travel.
Figure VI

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MV Heating UK Ltd
3B. Installation of fuel lines
The following shows the ideal pressure of fuel pick up.
Figure VII Figure VIII
Identify the fuel line from the installed fuel filter. Only
take fuel from the return line with the special fuel
pickup (see Figure VII.) The pickup is ideally fitted so
that any air bubbles are discharged in the direction of
the fuel tank (see Figure III).
The allowed fuel inflow height, H(m) 0.00 1.00 2.00
Maximum allowed excess of pressure (bar) in the fuel line 0.2 0.11 0.03
The permittable fuel suction height. S(m) 0.00 0.50 1.00
Maximum permitted negative pressure (bar) in the fuel tank -0.10 -0.06 -0.02

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MV Heating UK Ltd
Air or gas bubbles can arise in the vehicles fuel line if
there are leaks in the carburettor or fuel pump or if the
ambient temperature is higher than the fuel’s
evaporation temperature.
Do not place the fuel pickup near the engine, as the
radiating heat can also cause gas bubbles to arise in the
fuel line, again causing problems with combustion.
If the fuel pump is located inside the tank (due to a fuel
injection system) the fuel can only be withdrawn from
the return line. Ensure that the return line continues to
the bottom of the tank and extend it if necessary.
Fuel lines
Important:
➢Tighten hose clips to a torque setting of 1.0+0.4
Nm.
➢Ensure that no fuel is leaking before starting the
vehicle or the heater.
➢Air bubbles will likely occur in fuel lines with an
inside diameter greater than 4mm
➢Secure unsupported fuel lines to prevent
sagging
➢Install away from high temperatures and road
debris

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MV Heating UK Ltd
Connecting fuel pipes with a hose
This shows the correct procedure for fitting fuel lines
with a hose. Prevent air bubbles from forming by
minimising gaps and kinks in the lines.
Figure IX Figure X
Fuel Pump
The fuel pump is a combined delivery, metering and
shutoff system and thus subject to specific installation
criteria (see Figures VI and IX).
It is advised to install the fuel pump on its anti vibration
mount near the fuel pump in a cool place away from the
engines radiated heat, use a heat shield if applicable.
Figure IX shows its ideal installation position to
guarantee effective automatic bleeding.

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MV Heating UK Ltd
4. Operation Instructions
Before starting up, make sure the main wiring harness is
away from any direct heat source and that all sockets
are well connected.
DO NOT attempt to adapt the wiring harness in anyway.
It is all ready for installation straight out of the box.
Starting up
Once turned on the water pump will begin to start. The
ECU will then examine all necessary faults such as flame
sensor or over-voltage. Any anomaly will be warned by
the indicator. If everything is correct the glow pin will
be activated and pre heating will begin.
Approximately 15 seconds after this the motor and fuel
pump will begin. The flame sensor will soon detect a
stable flame and the glow pins will switch off. The
heater will now come to a normal working state.
If the heater fails to ignite, the sequence will begin
again. If it fails to ignite for a second time, the green
indicator will flash a fault code (see page 19: Fault
Finding).
Turning off
The heater will automatically turn off when the water
temperature reaches 78˚C, at which point the fuel
pump will stop. The heater motor will continue until the
heater cools down. This process takes around 4
minutes. The heater will automatically switch itself back
on when water temperature falls below 65˚C.

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MV Heating UK Ltd
5A. Maintenance
In a normal working state the ECU will automatically
examine voltage, glow plug, fuel pump, motor and
flame sensor. Any trouble with any of these will be
displayed by the burning indicator.
If the heater fails to ignite after 90 seconds of the start
up procedure, it will automatically restart the process
after a further 15 seconds. If it fails to ignite again it will
turn itself off and the fault code will begin to flash (see
Fault Finding, page 19).
If the flame burns out abnormally while the heater is
running, simply re-start it and try again.
A premature shut down of the heater can be caused by
poor circulation of coolant causing the heater to
overheat. The burning indicator will continuously flash
and the buzzer will howl. After trouble shooting, simply
turn off the heater and re-start.
Any voltage below 10v or above 19v (on a 12v model) or
below 15v and above 32v (on the 24v version) will be
considered abnormal and the indicator will flash the
relevant code. For the sake of protection the heater will
also switch itself off.

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MV Heating UK Ltd
Electrical connections and circuit diagram
Before starting the heater for the first time, make a final
check around the installation to ensure that all circuits
are well connected, fuel lines aren’t sagging or leaking
and whether any dirt is clogging any parts.
Ensure the wiring harness is well away from direct heat
and possible water sources and that there are no loose
plugs and fittings.
Figure XI: Circuit Diagram