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Advers PLANAR 2D Repair Manual

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ООО"ADVERS"
Russia, 443068, Samara,
Novo-Sadovaya Str., 106А
Factory
+7(846)263-07-97
Sales Department
www.autoterm.ru
+7(846)270-68-64; 270-65-09
E-mail: sales@autoterm.ru
Service Department
ООО"Servisnaya Kompaniya"
Russia, 443100, Samara,Lesnaya Str., 11А
+7(846)266-25-39; 266-25-41
+7(846)266-25-42; 266-25-43
Е-mail: garant@autoterm.ru
Е-mail: support@autoterm.ru
Air Heaters
PLANAR
Repair Manual
March 2016

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  • Page 1 ООО"ADVERS" Russia, 443068, Samara, Novo-Sadovaya Str., 106А Factory +7(846)263-07-97 Sales Department www.autoterm.ru +7(846)270-68-64; 270-65-09 E-mail: sales@autoterm.ru Service Department ООО"Servisnaya Kompaniya" Russia, 443100, Samara,Lesnaya Str., 11А +7(846)266-25-39; 266-25-41 +7(846)266-25-42; 266-25-43 Е-mail: garant@autoterm.ru Е-mail: support@autoterm.ru Air Heaters PLANAR Repair Manual March 2016...

  • Page 2: Table Of Contents

    Page. 2 of 29 March 2016 Edition 1 PLANAR Contents Technical Specifications ....................4 Safety ..........................5 Troubleshooting......................5 Heater Dismounting and Disassembly................11 Heater Components - Repair and Replacement............14 Functions, Removal and Replacement of Glow Plug..........14 Functions, Removal and Replacement of Glow Plug Screen ........
  • Page 3 PLANAR Edition 1 March 2016 Page. 3 of 29 This Repair Manual is intended for service personnel performing maintenance and repairs of PLANAR air heaters (hereinafter - "the heater") and their modifications. It describes methods of determining possible faults, how to determine the working condition of components and parts, and how to identify the need to replace them.

  • Page 4: Technical Specifications

    Page. 4 of 29 March 2016 Edition 1 PLANAR Technical Specifications Table1shows the Technical Specifications of the heater. The Specifications are given with the tolerance of 10%, obtained at 20С and rated voltage. Table 1 PLANAR 4DM2 Rated voltage, V: 12 / 24 12 / 24 12 / 24...

  • Page 5: Safety

    PLANAR Edition 1 March 2016 Page. 5 of 29 Safety 2.1. Repairs should be conducted in compliance with applicable occupational safety instructions. 2.2. Violation of the rules of operation of the air heater may cause a fire. 2.3. The workplace should be provided with fire-fighting implements. 2.4.
  • Page 6 Page. 6 of 29 March 2016 Edition 1 PLANAR Table2 Fault Description Fault Cause Recommended Solutions Code Check the intake and outlet of the heating unit for unobstructed entry and exit of heated air. The sensor sends a Check the integrity of the fan and its signal to shut down the performance.
  • Page 7 PLANAR Edition 1 March 2016 Page. 7 of 29 Table2 Fault Description Fault Cause Recommended Solutions Code Increased friction in the Electric motor of bearings or contact Check electric motor, if possible the air blower does between the impeller correct the fault; replace air blower not develop the and fan shroud in the if necessary (see item5.6).
  • Page 8 Page. 8 of 29 March 2016 Edition 1 PLANAR Table2 Fault Description Fault Cause Recommended Solutions Code Insufficient pre- Check the plug, replace if heating of the glow necessary (see item5.1). plug, faulty control Check voltage supplied by control unit, replace if necessary. unit.
  • Page 9 PLANAR Edition 1 March 2016 Page. 9 of 29 Table2 Fault Description Fault Cause Recommended Solutions Code Check connectors and wiring leading to the electric motor board Damaged bearing or rotor, Motor does and the control unit. Eliminate the not rotate foreign objects, etc.
  • Page 10 Page. 10 of 29 March 2016 Edition 1 PLANAR Table2 Fault Description Fault Cause Recommended Solutions Code Faulty Check connecting wires. temperature Faulty temperature Check sensor (item 5.4). sensor at air sensorat air intake. only PLANAR-8DM intake. See instructions for unblocking the Heater control Error "Overheating"...

  • Page 11: Heater Dismounting And Disassembly

    PLANAR Edition 1 March 2016 Page. 11 of 29 Heater Dismounting and Disassembly. Replacement or checking of the heater components requires its partial disassembly. Partial disassembly of the mounted heater is allowed, if there is an access to the dismounted components. 4.1.
  • Page 12 Page. 12 of 29 March 2016 Edition 1 PLANAR - remove glow plug and bushing (use S=27 to hold bushing, and S=12 to turn glow plug out); Fig. 3 – Plug with Installation Kit. - remove secure screw of CUand dismount it; - remove screws fastening AB to heat exchanger and disconnect AB;...
  • Page 13 PLANAR Edition 1 March 2016 Page. 13 of 29 4.3. – Dismounting and Disassembly of PLANAR-44D - remove heater from VEH; - remove upper and lower casing shells (Fig.1); - disconnect contacts from CU, remove fastening screw of CU, dismount it; - turn out glow plug;...

  • Page 14: Heater Components - Repair And Replacement

    Page. 14 of 29 March 2016 Edition 1 PLANAR Heater Components - Repair and Replacement. 5.1 Functions, Removal and Replacement of Glow Plug. The glow plug provides ignition of fuel mixture during start-up of the heater. Removal and replacement of glow plug is described in Section 5. Glow Plug Heater Model...

  • Page 15: Functions, Removal And Replacement Of Glow Plug Screen

    PLANAR Edition 1 March 2016 Page. 15 of 29 5.2 Functions, Removal and Replacement of Glow Plug Screen The screen is designed for uniform fuel supply to the CC. When replacing or checking glow plug, it is necessary to check the screen for carbon deposits or clogging. If there are carbon deposits, the screen should be replaced.

  • Page 16: Functions, Removal And Replacement Of Overheat Sensor

    Page. 16 of 29 March 2016 Edition 1 PLANAR Ra 1,6 Ra 1,6 10±0,1 19±0,1 1. MATERIAL STEEL 40XH GOST 4543-71 or similar 1 Материал. Сталь 40ХН ГОСТ 4543-71 и.т.п. 2. HRC 45-50 2. НRC 45..50 Fig. 6- Mandrel Dimensions. Attention! The screen should be installed with interference fit until it stops.
  • Page 17 PLANAR Edition 1 March 2016 Page. 17 of 29 Fig.7 – Overheat sensor Fig.7а – Closed Wires Install replacement heat sensor in reverse order. Remove dirt or oil from contacts with a clean cloth soaked with degreaser. Upon detection oxidation on contacts, clean them with fine sandpaper, wash with degreaser, and tighten for proper connection.
  • Page 18 Page. 18 of 29 March 2016 Edition 1 PLANAR Check the sensor for open circuit with a tester. If there is an open circuit fault, the sensor is defective. Check insulation resistance between the terminals and the housing. The resistance should be not less than 100 MOhm at 100V.Ambient temperature during resistance measurements must be between 15 and 35°C, relative humidity less than 80%.

  • Page 19: Functions, Removal And Replacement Of Temperature Sensors (Planar-8Dm)

    PLANAR Edition 1 March 2016 Page. 19 of 29 5.4 Functions, Removal and Replacement of Temperature Sensors (PLANAR-8DM). 5.4.1 Since January 2015, PLANAR-8DM heaters are equipped with a temperature sensor for heated air. The sensor is installed at the heated air outlet and is connected to the CU. Disassembly is performed in accordance with Section 5.

  • Page 20: Functions, Removal And Replacement Of Flame Indicator

    Page. 20 of 29 March 2016 Edition 1 PLANAR 5.5. Functions, Removal and Replacement of Flame Indicator. Flame indicator is used to monitor presence of flame in the combustion chamber. It is a metal tube with a built-in thermocouple. If an error is displayed when the heater is turned on, check the flame indicator for continuity with a tester.

  • Page 21: Functions, Removal And Replacement Of Air Blower

    PLANAR Edition 1 March 2016 Page. 21 of 29 5.6 Functions, Removal and Replacement of Air Blower. The blower (Fig.11) consists of an electric motor with a volute.The motor shaft carries an impeller on the volute side (for air supply into the combustion chamber), and a fan on the other side (for heated air supply).

  • Page 22: Functions, Removal And Replacement Of Control Unit

    Page. 22 of 29 March 2016 Edition 1 PLANAR 4) Check the performance of the speed measurement channel. To do this, connect the contacts of blue and black wires (Figure 12), and measure the pulse frequency on the green wire with a digital tester. When the AB is gaining speed, the pulse frequency should increase.

  • Page 23: Functions, Removal And Replacement Of Combustion Chamber

    PLANAR Edition 1 March 2016 Page. 23 of 29 5.8 Functions, Removal and Replacement of Combustion Chamber. The combustion chamber of evaporative type is designed for air-fuel mixture combustion. Signs of CC malfunction are: failure of the heater to start (if all other heater elements are in good condition), reduced heat output, burnout of the housing or internal parts of the camera, flameout.
  • Page 24 Page. 24 of 29 March 2016 Edition 1 PLANAR Fig.14–Combustion Camera in PLANAR-4DM2. Fig.15– Combustion Camera in PLANAR-8DM. Heaters PLANAR-2D had combustion cameras of two types. 1 type (till January 2015) – screen is attached directly to the CC; 2 type (after January 2015) – screen is attached through a bushing. Fig.16 - Bushing...

  • Page 25: Functions, Removal And Replacement Of Heat Exchanger

    PLANAR Edition 1 March 2016 Page. 25 of 29 Before January 2015. After January 2015. Fig.15–Combustion Chamber of PLANAR-2D heaters. 5.9 Functions, Removal and Replacement of Heat Exchanger. The heat exchanger is designed to transfer heat from hot gases generated by the combustion of air-fuel mixture in the CC to radiators, which in their turn, heat up the air stream passing along the edges of radiators.

  • Page 26: Functions, Removal And Replacement Of Controller

    Page. 26 of 29 March 2016 Edition 1 PLANAR Troubleshooting and determination of productivity of the FP are performed as follows: - before starting troubleshooting, check availability and quality of fuel in the tank; - make sure that the wiring and connectors are in good condition; - make sure that the FP works when the heater is turned on, and the characteristic knocking sound of piston movement inside the pump can be heard;...

  • Page 27: Functions, Troubleshooting And Replacement Of Cabin Sensor

    PLANAR Edition 1 March 2016 Page. 27 of 29 If when you press a button, the indicator on the controller does not light up, check the wiring, the power supply voltage of the controller, and electrical contacts of the terminals. Any dirt or oil should be wiped off the contacts with a clean cloth soaked in gasoline.

  • Page 28: Tools And Equipment For Maintenance And Repairs

    6.1 Test Stand. Maintenance and repair of liquid and air heaters is carried out on the stationary test stand DV 1105.000 (Figure 19) manufactured by OOO ADVERS. The stand is designed for the following operations: a) testing liquid and air heaters using a diagnostic device and determination of their faults;...

  • Page 29: Heater Check After Repair

    PLANAR Edition 1 March 2016 Page. 29 of 29 Heater Check after Repair. 7.1 After repair, the heater should be tested for efficiency on the DV1105.000 stand, and after that it can be installed on the vehicle. (The heater can also be tested on the vehicle on which it will be used).

This manual is also suitable for:

Planar 44dPlanar 4dm2Planar 8dm

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