河北宏业YJH系列汽车燃油加热器英文说明书.pdf

HEBEI HONGYE MACHINERY CO.,LTDAdd?No.461 Nancang street,Botou City,HeBei province,ChinaTel?[phone]Fax?[phone]Sales dept.:[phone] 8221410P.C?062150HEBEI HONGYE MACHINERY CO.,LTDRInstallation and OperationManual ofYJH-Q5B Type Oil-fired HeaterPrefaceWelcome to choose our hydronic heaters.This kind of heatercomplies with:GB10907-89?fundamental parameter of oil-fired heater?GB10908-89?technical conditions of oil-fired heater?GB10909-89?test method of oil fired heater?Enquiry Line:[phone]R&D8262234Sales dept.8221410After service dept.ContentsI.Technical parameter and applicant conditions.1II.Structure and work principle.2III.Position of Installation.3IV.Model for actual Installation.4V.Connection to the vehicle cooling system.5VI.Relocating the circulation pump.6VII.Fuel connection.6VIII.Supply of conbustion air.9IX.Exhaust line.9X.Automatic control?function and indication.10XI.Observations for first operation.18-1-YJH-Q5B/1(2)YJH-Q5B/1Rated heat flow5kwFuelDieselPetrolFuel consumption0.56L/h0.65L/hNominal voltage12V(24V)12VWork voltage10-15V(19-32V)10-15VNominal power consumption without circulation pump50wPermissible ambient temperature:Heater:-Operation-40?-+60?-40?-+120?-storage-40?-+40?-40?-+60?Metering pump:-Operation-40?-+120?-40?-+40?Perm.operating pressure(heat carrier)0.4-2.5 barCapacity of the heat exchanger0.16 lMinimum capacity of the circulation4.0 lMinimum flow for the heater250 l/hCO2 in exhaust gas(perm.function range)8-12%Heater dimensions242?139?182Weight3.5KgRemote distance800mtimerThree timer designUsed in car,mini bus,multi-functionalApplicant scopevehicle etc.,for cabine warming,window glass defrosting,and lowtemperature start up of the engineI.Technical parameter and applicant conditionsModelItemParameterCirculation pumpWP-1000/2WP-1000/1Flow rate at 0.1 bar1000 l/hRated voltage24V12VRated power6 wOverall dimension168?55?73mmWeight0.4kg-2-II.Structure and work principle (see Figure I?II)i?Structure1.The main part of heater consists of volatilizing atomization system,glow plug,chamber,heat exchanger,control unit,etc.2.Oil line consists of oil pipe,metering pump,etc.3.Circulating system consists of water pump,water pipe,connection,valve,etc.Figure I1.Type?O?seal2.Base of chamber3.Heat-proof seal4.Heat-proof seal of chamber5.Heat-proof seal of upper body6.Stuff of vitta7.Upper body8.Motor of the wheel9.Seal of air10.Air-wheel base11.Type?O?seal12.Cover of combustion wheel13.Combustion wheel14.Cover of control-assembly15.Control-assembly16.Stator of sensor17.Seal of controller18.Stuff of sensor19.Tmperature sensor20.Overheat cut off21.Heat exchanger22.Casing of heat exchanger23.Root of flame sensor24.Flame sensor25.Chamber26.Glow plug-3-Figure IIii.Work principle1.After the combustion wheel begins to perform under the driving of motor,fuel issupplied by metering pump and atomized in chamber.The atomized fuel will bemixed with air and then ignited by glow plug.Heat generated from the fully faredflame in combustion chamber is transmitted to the coolant in the sandwich of the heatexchanger,through radiator;and the heating purpose will be achieved in theprocedure of heated coolant circulating driven by water pump.And the exhaust gasis released through exhaust pipe.2.Water pump is driven by a separate motor.The coolant will be sucked in through theintake of the pump and come into water intake of the Heater,and gets into the vehiclecirculating system after it is heated by heater.III.Position of Installation(dimension of appearance andinstallation,see Fig.II)The water heater must be installed outside the passenger compartment.The heaters are preferably installed in the engine compartment,under the front fenderwhere they are protected from splashing water or on the splashboard.The heaters must be installed as low as possible to permit automatic bleeding of theheater and circulation pump.This is particularly important as the circulation pump is notself-priming-4-IMPORTANT:The openings of the water ports must not point downwards in any installed position.IMPORTANT:The heater must not be installed:?in the immediate vicinity of or above hot parts,?in areas directly exposed to splashing water from the wheels,?below the fording line of the vehicleRating plateThe rating plate must be positioned so that it cannot be damaged and must still beclearly legible when the heater is installed(otherwise a duplicate rating plate must be used).HolderThe holder must be secured to the car body or an intermediate holder with at least fourM6 screws.Washers with a minimum diameter of 22 mm must be used if the body surfaces areplane.The holder must not be secured to the car body with self-tapping screws.The holder must be correctly machined in compliance with the minimum bending radiiand in accordance with the technical rules.IV.Model for actual Installation.?see Fig.III?Figure III-5-1.Radiator2.Cooling water thermostat3.Water pump(of the engine)4.Engine with standard equipment5.Water heater6.Battery7.Fuse holder8.Control unit(in the heater)9.Relay(for vehicle fan)10.Regulating valve for vehicle heating11.Heat exchanger,vehicle heating12.Fan for vehicle heating13.Switch for vehicle heating fan14.Fuse bank in vehicle15.Timer16.Fuel pickup17.Intake silencer,combustion air intake line18.Exhaust muffler19.Circulation pump20.Fuel metering pumpV.Connection to the vehicle cooling systemThe heaters are connected to the vehicle cooling system as shown in Figs.III?IV?V.At least 4litres of coolant must be circulated?1.Equalizing reservoir2.Thermostat3.Engine4.Circulation pump5.Heater6.Heat exchanger7.RadiatorFigure VThe heater must be integrated into the cooling circuit in the feed line to the on-boardheat exchanger.Note:Leaking cooling water must be collected in a suitable container.The water hoses supplied must always be used.If other hoses are used,they must atleast comply vehicle rubber pipe standard.The hoses must be routed without kinking andpreferably uphill to ensure perfect bleeding.Hose connections must be supported by hoseclips so that they cannot slip off.Note:The hose clips on the heater must be fitted between the flared neck and the heater.-6-The hose clips must be tightened with a torque of 2.0+0.5 Nm.Care must be taken to bleed the cooling system before the heater is taken into servicefor the first time or after refilling with fresh cooling water.Heater and lines should beinstalled in such a way as to ensure static bleeding.Malfunctions due to overheating may occur during operation if the heater and lineshave not been bled correctly.VI.Relocating the circulation pumpThe circulation pump can be only installed in the water circulation.Care must be takento ensure without fail that water flows through the heater in the right direction(water outletat the top/water inlet at the bottom),otherwise the heater will malfunction.Figure V Installation positions.VII.Fuel connectionThe following shows the allowed pressure of fuel pick up.The permissible fuel inflow height,H(m)0.001.002.00Max.perm.excess pressure(bar)in the fuel line 10.20.110.03The permissible fuel suction height,S(m)0.000.501.00Max.perm.negative pressure(bar)in the fuel tank-0.10-0.06-0.02-7-Figure VIFigure VII1.Fuel supply A fuel feed line can normally be identified from the installed fuel filter.Fuel may only be taken from the return line with the special fuel pickup(seeFigureVII.)The fuel pickup must be fitted so that any air or gas bubbles are automaticallydischarged in the direction of the tank.(See Figure.III)Air or gas bubbles may arise in the fuel line of the vehicle if there are leaks in thecarburetor or vehicle fuel pump or if the ambient temperature is higher than the evaporationtemperature of the fuel.The fuel pickup should not be located near the engine,as gas bubbles may form in thelines on account of heat radiated from the engine.This may cause problems duringcombustion.When installing the heater in a vehicle with fuel injection system,it is thereforeimportant to establish whether the fuel pump is located inside or outside the tank.If the fuel pump is located inside the tank,fuel can only be withdrawn from the returnline.In this case,it must be ensured that the return line continues almost to the bottom of thetank.The return line must be extended if necessary.2.Fuel linesNote:The hose clips must be tightened with a torque of 1.0+0.4 Nm.Leaking fuel must be removed before starting the engine or heater.-8-Figure VIIIFigure IXImportant:Since the lines normally cannot be routed with a constant uphill gradient,the insidediameter must not be allowed to exceed a certain size.Air or gas bubbles will accumulatein lines with an inside diameter of more than 4 mm and cause malfunctions if the lines sagor run downwards.The diameters specified in Fig VI.will ensure that bubbles do not form.The lines should not be routed downwards from the metering pump to the heater.Unsupported fuel lines must be secured to prevent them sagging.They must beinstalled in such a way that they cannot be damaged by flying chippings and hightemperatures(exhaust line).Connecting two pipes and a hoseThe correct procedure for connecting fuel lines with hosing is illustrated in Fig.VIIIEnsure that there are no leaks.3.Metering pumpThe metering pump is a combined delivery,metering and shutoff system and is subjectto specific installation criteria(see Figs.VI,IX)Installation positionBefore installing the metering pump,ensure that the maximum pressure occuring at thepickup point is less than 0.2 bar.It is advisable to install the metering pump in a cool place.The permissible ambienttemperature must not exceed+40?at any time during operation.Metering pump and fuel lines must not be installed within range of radiated heat fromhot vehicle parts.A heat shield must be used if applicable.The pump should be preferably installed near the tank.-9-Figure X Exhaust pipeopening InstallationpositionIX.Exhaust lineThe exhaust line(inside diameter 22mm)can be routed withseveral bends(270?altogether,minimum bending radius 50mm).The total length of the exhaust line must be not less than500 mm.The maximum length equals 1000 mm.The opening of the exhaust pipe must not point in thedirection of travel(see Fig.X)Rigid pips of unalloyed steel with a minimum wall thicknessof 1.0mm or flexible piping of alloyed steel only must be usedas exhaust line.Note:Accumulated condensation in the exhaust line must bedischarged immediately.A condensate drain hole may be drilledif necessary.Installation and attachmentThe metering pump must be secured with a vibration-damping suspension.Its installationposition is limited as shown in Fig.?,in order to ensure effective auto-bleeding.VIII.Supply of combustion airThe intake opening for combustion air must be located so that it cannot become cloggedwith dirt.It must not point in the direction of travel.An intake line is required for combustion air.The withdrawal point for the combustion air must be located in a cool(temperature?20?)place where it is protected from splashing water and above the fording line of the vehicle.Under no circumstances may the combustion air be taken from areas occupied bypeople.A ventilation opening measuring at least 30cm2 is required if the heater is installedin an enclosed box.If the heater is installed in a common installation space near the vehicle tank,thecombustion air must be taken from the outside and the exhaust gas discharged into theatmosphere.The openings must be splash-proof.Installation instructionsConnect the slotted side(approx.18mm)of the combustion air intake line,max.400mm long,to the air intake port of the heater and secure it with the hose clip supplied.Important:Ensure an adequate distance from the exhaust system.-10-X.Automatic control,function and indicationi.Automatic controlWhen equipped cable harness and switch of the heater should be ensured in such amanner that their functions will not be affected in normal work conditions.When arranging the cable harness,Vehicle and heat resource should be kept indistance,meanwhile sealing method(glass cement)shall be used to prevent connections andsockets from mud splash.All sockets and connections should be well connected.Operation instructions:1.Starting upStarting up?After starting up?water pump will work?control unit of the heater willexamine over voltage,and work conditions of glowplug,metering pump,motor,flamesensor,temperature semsor,any abnormal will be warned by the indicator;And if all right,glow plug is electricified-preheating begins,15 seconds after this,motor and meteringpump begin to work,motors starting up need 10 seconds,80 seconds(ahead 40 secondsglowplug working,next 40 seconds no working)after this,when a stable flame emergesdetected by flame sensor,glow plug switches off,indicator lights,and heater comes to anormal work state;If heater fails to ignite,as to petrols heater,the green indicator makesflashing,as to diesels heater,heater should be started again,when a stable flame emergesdetected by flame sensor,heater comes to a normal work state,otherwise the green indicatormakes flashing.2.Automatic control over heating procedureHeater will automatically changes into the setting of turn off as soon as watertemperature reaches 78?,then metering pump stops;and motor of the heater continuesuntill the heater cools down,of which the whole procedure lasts 4 minutes;after this burningindicator turns out.And as soon as water temperature falls to 65?,heater works againautomatically.3.After the heater switches off,metering pump stops;and motor of the heater continuesto work untill the heater cools down of which the whole procedure lasts 4 minutes,then theburning indicator turns out.ii.Function and Indication:1.If heater fails to ignite after 90 seconds fuel supply,motor and metering pump stopworking;Then after15 seconds preheating,metering pump and motor restart.Ifwhen a new 90 seconds fuel supply is finished,heater still fails to ignite,it mustbe the occasion of turning off because of trouble,meantime the green indicatormakes flashing.-11-Serial No.NameVersionQuantityRemarksSOperating unitJK931-0021With burning indicatorEHGlow plugDRS-16 or DRS-8.61YPMetering pump1M1Motor of the water pump48ZW01/021M2Motor of heater35ZY01/021RTIgniting sensor1PT100FOverheat cut off1FUFuseBX2011125A2.If flame turns out abnormally during burning process re-start should be made.3.Turning off of the heater might be caused by mal-circulation of coolant characterizedwith overheat of the heater,warning of the overheat cut-off,stop of fuel supply.Ifthe trouble turn off is caused by overheat,the burning indicator will make acontinuously flashing,and the buzzer howls.After troubles are eliminated,Turn offthe heater and re-start it.4.Any occasion of working voltage below 10V or 19V and above 15V or 32V,will beregarded as abnormal,the burning indicator will warn and for the sake of protection,the heater will be turned off.5.When the heater works in a normal state,control unit