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General Components BISON 2000A Owner's Manual

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BISON 2000A OWNER'S MANUAL

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Summary of Contents for General Components BISON 2000A

  • Page 1 BISON 2000A OWNER’S MANUAL...
  • Page 2 Thank you for purchasing the BISON 2000A Air heater. This instruction book describes the structures, working principles, installation and operation of the BISON 2000A. For correct use of the heater, please read this instruction book carefully before installation and use. The instruction book should be saved in a convenient place for reference later.

  • Page 3: Table Of Contents

    Installation of Combustion Air Pipe and Exhaust ........16 Fuel Lines...................... 18 Fuel Standpipe ..................... 21 BISON 2000A Wiring Diagram – Brushless Version ........23 Timer and Rheostat Control Plugs ............25 Wiring Loom Plug for Timer and Rotary Control ........26 Circuit Interfaces ..................
  • Page 4 Pre-setting Starting and Heating Times ........... 30 Checking Temperature ................31 Converting to Thermostatic Mode ............31 Fault Information ..................31 Remote Operation ................... 32 Installation Fuel Priming Feature ............. 32 LCD Digital 7-Day Timer ................33 Changing Language .................. 34 Changing the Date and Time ..............

  • Page 5: Introduction

    Introduction The main equipment of the BISON 2000A air heater (hereinafter 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.

  • Page 6: Technical Data

    Technical Data Output (w) 2000 Fuel Petrol Diesel Voltage 12/24V 12/24V Fuel Consumption (l/h) 0.14 - 0.27 0.12 - 0.24 Power Consumption 14 - 29 Working Temperature -40°C - 20°C Weight (KG) Dimensions (mm) 323x120x121 Variable Output Current Draw (Amps) Position...

  • Page 7: Bison 2000A Internal Structure

    BISON 2000A Internal Structure Figure II 1. Heat exchanger 2. Gasket 1 (4 hole) 3. Combustion chamber 4. Burner Assembly 5. Gasket 2 (5 hole) 6. Air Motor Assembly 7. Insulating bush 8. ECU 9. Air Fan Wheel 10. Glow Pin...

  • Page 8: Structures And Working Principles

    The heat exchanger is made of die-cast aluminium, with radiating fins around the rear. The combustion chamber fits inside the inner cavity of the heat exchanger. The burner assembly and glow pin, fit into the end of the combustion chamber. Fuel comes to the burner assembly through the fuel pipe and is ignited by the glow pin.

  • Page 9: Case Assembly

    Case Assembly Figure IV 12. Junction box cover 13. Top Case 14. Hot air outlet 15. Inlet Cover 16. Outlet Cover 17. Grill...

  • Page 10: Installation

    Installation The kit includes everything necessary for installation.
  • Page 11 Figure V 18. Control Switch/Timer 19. Main Wire Harness 20. Fuel Pump 21. Mounting Gasket 22. Combustion 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.

  • Page 12: Installation Of The Main Heater Body

    Installation of the Main Heater Body 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. Figure VI A. Air heating inlet B.
  • Page 13 35.5 DIMENSIONS: MM A. Mounting Gasket B. Mounting Plate Figure VII Figure VIII If the heater is being reinstalled, a new gasket should be used. 0 - 90° 0 - 90° Figure IX...

  • Page 14: Air Inlet & Outlet

    The direction of the heater for installation is shown in figure IX. Ensure you do not exceed the inclination angle or normal operation will be affected. After installation, make sure there is no friction between the fan and other nearby parts to ensure smooth operation and make sure the heater label is clearly visible for ease of maintenance in the future.

  • Page 15: Additional Ducting (Optional)

    Additional Ducting (Optional) Quantity of ducting can be purchased according to needs. A. Grill or ducting B. Heater Body C. 60mm Hose Clip D. 60mm APK Ducting E. 80-60mm Reducer F. 80mm Directional Vent Figure XI A. Heater Outlet B. 60mm Hose Clip C. 60mm APK Ducting D. 60mm ‘Y’ Branch E. 80- 60mm Reducer F.

  • Page 16: Installation Of Combustion Air Pipe And Exhaust

    Installation of Combustion Air Pipe and Exhaust The combustion 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 bottom of the vehicle, ensuring that the openings are far enough away from any splashing water or dirt that can clog them.
  • Page 17 combustion air pipe and exhaust pipe should be kept in good condition. Do not damage or remove them. Both the combustion air pipe and exhaust pipe should come downward from the heater and face opposite to the vehicle’s direction 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˚...

  • Page 18: Fuel Lines

    Fuel Lines 500-1200mm 2000-6800mm 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 Always fit the fuel pump on the anti-vibration mount securely onto the vehicle.
  • Page 19 90° 0° 1. Heater Body 2. Max. Fuel Level 3. Min. Fuel Level 4. Fuel Pump Fuel Pump Angle & Suction Height A. 3000mm B. 500mm C. 2000m D. Not acceptable E. Acceptable (between 15-90°) F. Not acceptable Figure XVII Figure XVII shows the ideal way to mount the fuel pump The fuel pump’s outlet should tilt upward at an angle between 15˚-35˚...
  • Page 20 Only use the fuel line provided, ensure the pipe is placed away from any possible debris and avoid any sagging in the line. Make sure the fuel line does not flow downward toward the fuel pump. This will prevent correct fuel flow and produce air bubbles in the line.

  • Page 21: Fuel Standpipe

    Fuel Standpipe A fuel standpipe (or suction pipe) will need to be installed in the vehicle’s fuel tank or an independent fuel tank depending on what the installation calls for. Sealant is not required to fit the standpipes. Depending on the standpipe provide in the kit you will need to install the standpipe in one of two ways.
  • Page 22 Stand pipe 2: (Part No: AHZ-035) Figure XX Supplied mainly in vehicle kits, this standpipe is installed like so: • If possible; remove the sender unit from the vehicle’s fuel tank, this will make it easier to attach the nut securely back onto the standpipe •...

  • Page 23: Bison 2000A Wiring Diagram - Brushless Version

    BISON 2000A Wiring Diagram – Brushless Version Figure XXI...
  • Page 24 The previous page shows the wiring diagram for the heater. The wires of the main heater have been made into bundles. They can be laid according to the positions of various components and should be fixed to the proper locations. The distance between two fixing points should not exceed 300mm.

  • Page 25: Timer And Rheostat Control Plugs

    Timer and Rheostat Control Plugs Use a single screw to fix the timer control or rheostat control in place. They are best installed so that they can be seen and operated easily to identify working conditions and for easy access. The black and clear plugs connect to the corresponding plugs on the loom (below).

  • Page 26: Wiring Loom Plug For Timer And Rotary Control

    Wiring Loom Plug for Timer and Rotary Control BLUE BLUE/WHITE RED/WHITE BLACK GRAY RED/YELLOW BROWN To Main Wiring Harness Figure XXIV Any surplus wires should be kept in good condition and wrapped in electric tape to avoid short circuiting. External Remote Temperature Sensor Probe The remote temperature sensor probe is best installed at shoulder height whilst sat down, ensuring ample air flow and a clear ambient temperature reading...

  • Page 27: Circuit Interfaces

    Circuit Interfaces The connection parts on the controller case are designed in such a way that wrong connections are impossible to make. The following circuit interfaces can be found on the controller case; these are: • X1: Fan motor • X2: Glow plug •...

  • Page 28: Operation

    Operation Rheostat Control °C 1. Variable Output Button and Indictor Light 2. Temperature Button and Indicator Light 3. Fan Only (Cold Air) Button and Indicator Light 4. Control Knob 5. Fixing Screw Hole (Located underneath control knob) Figure XXVI The rheostat (or rotary) control works by twisting the control knob to the desired heat setting, and using the buttons listed to determine the heaters function.

  • Page 29: Mini Timer

    Mini Timer 1. Display 2. Up Arrow Key 3. ‘P’ Icon 4. ‘Heating’ Icon 5. Down Arrow Key 6. Fixing Screw Hole Figure XXVII Functions • Adjustable thermostatic mode from 5°C to 35°C • Adjustable 7 step heating mode from <1kW to your heaters full output •...

  • Page 30: Manual Start Up And Shut Down

    Manual Start Up and Shut Down For immediate start-up press the heating icon to change the standby mode into the heating mode and the heater will start up immediately. To adjust the heating temperature in the heating mode simply press the up or down arrow keys.

  • Page 31: Checking Temperature

    Step 4: Next step is adjusting the heating time. You can adjust this in the same way using the arrow keys. The hour first followed by the minutes, pressing the ‘heating icon’ again to confirm and the ‘P’ key for the final time to complete the task.

  • Page 32: Remote Operation

    Remote Operation When the remote signal had been received, the timer will automatically switch to the thermostatic mode, with a default temperature of 25°C, the confirmation dot will appear in the meantime. To return to the standby mode, press the heating icon. The confirmation dot will continue to appear until the remote shutdown signal has been received.

  • Page 33: Lcd Digital 7-Day Timer

    LCD Digital 7-Day Timer Figure XXVIII 1. LCD Screen a. Days of the week 2. Left Arrow Button b. Heating Symbol 3. Right Arrow Button c. Fan Symbol (later models only) 4. Power/Back Button d. ‘P’ (Timer) Symbol 5. OK Button e.

  • Page 34: Changing Language

    Changing Language 一 一 一 二 二 二 Ih i Ih i Ih i The language should be set to English. However, if it 三 三 三 四 四 四 五 五 五 六 六 六 isn’t or the control has been reset to default settings 日...

  • Page 35: Changing The Date And Time

    Changing the Date and Time 1. To change the date and time, navigate to the 18:30 18:30 18:30 clock face symbol and press ok. 2. Select the day of the week it is first using the arrow keys, and pressing ok to confirm. 3.

  • Page 36: Manual On/Off

    Manual On/Off 1. To switch the power on manually, navigate to the heating icon, and press ok 18:30 18:30 18:30 18:30 2. The heater will start automatically. 3. Use the arrow keys to adjust the output of the heater from high to low (07 to 01 respectively) 07 07 07 07 4.

  • Page 37: Switching To Thermostatic Mode

    Switching to Thermostatic Mode To switch to thermostatic mode, turn the heater on manually, as stated in the previous step. 07 07 07 07 1. Once the heater is on, press and hold the ok button for three seconds and then release it. °c °c °c...

  • Page 38: Pre-Setting Heating Times

    Pre-setting Heating Times The digital control can be used as a 7-Day timer, and is able to be preset to switch on up to three times a day. 1. Navigate to the ‘P’ symbol, and press OK. 18:30 18:30 18:30 18:30 2.
  • Page 39 6. Select the minutes in the same way, and press OK to confirm. 7. The next step is choosing which day of the week you want the heater to run. 06:30 06:30 06:30 06:30 06:30 06:30 Starting with Monday, use the arrow keys to change from ‘OFF’...

  • Page 40: Installation Fuel Priming Feature

    Installation Fuel Priming Feature ATTENTION: 18:30 18:30 18:30 • Not to be used in normal heater operation • Disconnect the fuel line from the heater first, to prevent flooding of the heater and place in a suitable receptacle. P 1 P 1 1.

  • Page 41: Checking Error Codes

    Checking Error Codes Once an error code has been displayed, and Ie 3 1 Ie 3 1 Ie 3 1 the problem has been amended, follow these steps to reset it. 1. Check the error using the arrow keys. Exit by pressing either OK or the power button.

  • Page 42: Resetting Digital Controller To Factory Settings

    Resetting Digital Controller to Factory Settings 1. Navigate to the clock face on the menu and simultaneously press both arrow buttons. 18:30 18:30 18:30 2. P1 should appears on the screen. 3. Using the left arrow key select ‘—01’, confirm by clicking the ‘OK’ button. P 1 P 1 4.

  • Page 43: Maintenance

    Maintenance Once the heater is installed, it should ideally be turned on a few times to remove any air trapped in the fuel lines. Also ensure there is no leaking from the lines and that all electric terminals fit securely together. You should also regularly: •...

  • Page 44: Fault Codes

    Fault Codes Rheostat Control When the ECU had discovered a fault, the rheostat control will flash a fault code. The control should therefore be ideally placed where it can be clearly seen and accessed. The faults will be displayed as short flashes followed by long flashes. To determine the code, you must count the number of long flashes.

  • Page 45: Timers

    1E-31 : Voltage too low – check battery or voltage drop in supply cable 1E-52 : Overheat sensor failure 1E-70 : Fuel pump open circuit or ECU failure 1E-80 : Air motor failure 1E-90 : Glow pin failure 1E-d3: Maintenance Reminder Thank you for purchasing the BISON 2000A...

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