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Summary of Contents for MV Heating Airo 2
- Page 1 MV Airo 2 & 5 LPINE NSTRUCTION ANUAL 1.00 MV Heating UK Ltd Unit 6 Second Avenue Business Park Millbrook Southampton SO15 0LP 2 & 5kW Air Heaters MV Heating UK LTD +44 (0)2380 522345...
- Page 2 +44 (0)23 8052 2345 Preface Thank you for purchasing the MV Airo 2 and/or Airo 5 diesel powered hot air heater (petrol versions of the MV Airo 2 are available upon request). This instruction book describes the structures, working principles, installation, and operation of the MV Airo 2/5.
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Page 3: Table Of Contents
+44 (0)23 8052 2345 Contents Introduction ....................... 4 Technical Data ....................5 MV Airo 2 Technical Data ................5 Airo 2 Current Draw ..................5 MV Airo 5 Technical Data ................6 MV Airo 5 Current Draw ................6 Working Principle ....................7 MV Airo 2 Internal Structure ................ - Page 4 Installing Temperature Probe ..............31 ECU Connections – Airo 2 ................32 ECU Connections – Airo 5 ................33 MV Airo 2 Alpine Auto Wiring Diagram ............34 MV Airo 5 Alpine Auto Wiring Diagram ............35 Maintenance ....................37 Fault Codes .......................
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Page 5: Introduction
+44 (0)23 8052 2345 Introduction The main parts of both the MV Airo 2 and Airo 5 air heaters (hereinafter referred to as ‘the heater’) are 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. -
Page 6: Technical Data
+44 (0)23 8052 2345 Technical Data MV Airo 2 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) -
Page 7: Mv Airo 5 Technical Data
Working Temperature -40°C ― 20°C Weight of Main Heater 5.9Kg Dimensions 425X148X162mm Mobile Phone Control (Optional) No limitation Remote Control (Optional) Without obstacles ≤800m MV Airo 5 Current Draw Variable Output 12V Current Draw Position (Amps) MV Heating UK Ltd... -
Page 8: Working Principle
Cool air enters the fresh air inlet, is heated by the heat exchanger, and is pushed out the air outlet by the fresh air fan of the air motor assembly. MV Heating UK Ltd... -
Page 9: Mv Airo 2 Internal Structure
+44 (0)23 8052 2345 MV Airo 2 Internal Structure Figure 3 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. Fresh Air Fan 10. -
Page 10: Mv Airo 5 Internal Structure
+44 (0)23 8052 2345 MV Airo 5 Internal Structure Figure 4 1. Heat Exchanger 2. O-ring 3. Combustion Chamber 4. Burner Assembly 5. Gasket 6. Air Motor Assembly 7. ECU 8. Glow Pin 9. Overheat Sensor 10. Insulating Bushes MV Heating UK Ltd... -
Page 11: Heater Cases
+44 (0)23 8052 2345 Heater Cases Figure 5 shows the heater casing layout for both the MV Airo 2 and 5 heater. Figure 5 1. Inlet cap 2. Outlet Cap 3. ECU Cover 4. Top Case 5. Bottom Case 6. Grill... -
Page 12: Installation Parts
+44 (0)23 8052 2345 Installation Parts Figure 6 shows the basic principle of parts for installation. Figure 6 MV Heating UK Ltd... - Page 13 Do not install the heater in closed spaces without ventilation. • Do not place the heater near anything that can cause a blockage. • Do not mount the heater near any water sources and protect it from any splashing or road debris. MV Heating UK Ltd...
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Page 14: 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 7 shows the minimum distances required on the MV Airo 2 and Figure 8 shows the distances for the larger Airo 5 model. -
Page 15: Mv Airo 5 Dimensions
This will ensure a good seal between the two. File down any drill holes to again ensure an even mounting surface. Use the mounting gasket and plate provided, particularly if the mounting surface is less than 1.5mm thick. Tighten the M6 nuts provided to a torque setting of 6Nm+1Nm. MV Heating UK Ltd... -
Page 16: Mounting Gasket And Plate Dimensions
Marine and other applications may require a bulkhead (‘L’ shaped) mounting bracket. The heater’s main footprint remains the same. If the heater is being reinstalled, a new mounting gasket should be used. MV Heating UK Ltd... -
Page 17: Angle Of Installation
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 identification and maintenance in the future. MV Heating UK Ltd... -
Page 18: Air Inlet & Outlet
+44 (0)23 8052 2345 Air Inlet & Outlet Ducting Size Airo 2 – 60mm Ducting Size Airo 5 – 90mm Make sure that the hot air outlet does not exit onto any parts affected by heat and that it isn’t directed toward the flow of anything that can cause a blockage, near splashing water or near the vehicles exhaust. -
Page 19: Additional Ducting
Quantity of ducting can be altered according to needs, but over excess will cause poor air flow or possible overheating. A. Inlet Grill or ducting B. MV Airo 2 Heater Body C. 60mm Hose Clip D. 60mm APK Ducting E. 80-60mm Reducer F. -
Page 20: Installation Of Combustion Air Pipe And Exhaust
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. Figure 14 shows the right and wrong way to install the pipework. A. Correct B. Wrong Figure 14 MV Heating UK Ltd... - Page 21 +44 (0)23 8052 2345 Airo 2 Combustion and Exhaust Pipe Size – 22mm Airo 5 Combustion and Exhaust Pipe Size - 24mm Only use the inlet pipe and exhaust provided with the kit for installation. The exhaust pipe is made of corrugated stainless steel while the combustion pipe is aluminium wrapped in paper and plastic.
- Page 22 In marine application the exhaust will exit out of the hull of the vessel via the skin fitting. It is important that the end of the exhaust exits in a ‘swanneck’ to prevent any water from traveling up the exhaust and into the heater. MV Heating UK Ltd...
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Page 23: Installation Of Fuel Lines
Always fit the fuel pump on the anti-vibration mount securely onto the vehicle. Ensure the outlet of the fuel pump tilts upward. The ideal angle is shown in figure 18. MV Heating UK Ltd... - Page 24 1. Heater Body 2. Max. Fuel Level 3. Min. Fuel Level 4. Fuel Pump Fuel Pump Angle & Suction Height A. 3000mm B. 500mm C. 2000mm D. Not acceptable E. Acceptable (between 15-35°) F. Not acceptable Figure 18 MV Heating UK Ltd...
- Page 25 The bottom of the standpipe should be about 30-40mm from the bottom of the fuel tank so as to avoid sucking impurities or sediment from the bottom of said tank. MV Heating UK Ltd...
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Page 26: Fuel Standpipe
Cut the standpipe down to size if necessary. • Fit the standpipe by tilting it into position into the newly drilled hole. • Place the rubber and metal washers back on top followed by the nut and tighten it securely on top. MV Heating UK Ltd... - Page 27 Replace the nut on the standpipe to secure it safely to the sender unit. • Replace the sender unit into the fuel tank. • Alternatively, to use in a marine application, simply tap an M6 hole into the fuel tank, and screw the fuel standpipe with O-ring inside. MV Heating UK Ltd...
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Page 28: Main Wiring Harness Connections
Main Wiring Harness Connections Airo 2 Main Connector The main connector of both the Airo 2 & 5 heaters inserts into the ECU of the main heater body. To install the main multi plug into the heater, first remove the ECU cover (figure 5 no. 3) using a small flat bladed screwdriver to allow access to the ECU. -
Page 29: Airo 5 Main Connector
At the same time insert the temperature probe plug into X5 (figure 33) of the ECU paying attention to the orientation (cut-outs) of the plug. 2 Way Plug (Female) - From Main Wiring Harness Brown Blue/Purple Figure 24 MV Heating UK Ltd... -
Page 30: Accessory Plug Connector
The accessory plug is used for optional parts like the mobile phone GSM module. If no such accessory is being used, then this can remain safely unplugged. 4 Way Plug (Male) - From Main Wiring Harness Brown Accessory Yellow Figure 26 MV Heating UK Ltd... -
Page 31: Auxiliary Unused Connection
The temperature probe is for use in the controller’s thermostatic mode. It measures the ambient temperature and relays the information to the control unit. 2 Way Plug (Male) 2 Way Plug (Female) - From Temperature Probe - From Main Wiring Harness Brown Black Blue/Purple Black Figure 27 MV Heating UK Ltd... -
Page 32: Installing Temperature Probe
Plug into the main wiring Figure 28 harness as per figure 25. If necessary, the connector cable can be extended using cables (2 x AWG 20 (2 x 0.5 mm²)). However, the overall length must not exceed 10m (33ft). MV Heating UK Ltd... -
Page 33: Ecu Connections - Airo 2
+44 (0)23 8052 2345 ECU Connections – Airo 2 The plug sockets on the ECU are designed in such a way that wrong connections are difficult to make. Pay attention to the tabs (cut-outs) on each plug to ensure correct orientation and proper location. Each plug should require a smooth push fit. -
Page 34: Ecu Connections - Airo 5
X2: Glow plug/flame sensor (brown, yellow) • X3: Overheat sensor (blue x 2) • X4: Fuel pump (black x 2) • X5: Temperature sensor (brown, blue/purple) • X6: Unused • X7: Main wiring harness (see figure 23) Figure 30 MV Heating UK Ltd... -
Page 35: Mv Airo 2 Alpine Auto Wiring Diagram
+44 (0)23 8052 2345 MV Airo 2 Alpine Auto Wiring Diagram Figure 31 MV Heating UK Ltd... -
Page 36: Mv Airo 5 Alpine Auto Wiring Diagram
+44 (0)23 8052 2345 MV Airo 5 Alpine Auto Wiring Diagram Figure 32 MV Heating UK Ltd... - Page 37 +44 (0)23 8052 2345 Figures 31 and 32 show the wiring diagram for the Airo 2 & Airo 5 heaters. 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.
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Page 38: Maintenance
After 10 years the heat exchanger, overheat sensor and exhaust should be replaced by a professional. If any welding is being attempted on the vehicle, please remove the positive power supply wire and earth it to protect and damage to the heater and controller. MV Heating UK Ltd... -
Page 39: Fault Codes
Hydro only - blower relay open circuit Hydro only - blower relay short circuit Preheating temperature broken circuit Preheating temperature short circuit Crystal oscillator in ECU broken Fault information storage failure Maintenance reminder Earthing Issue Constant Flash Connection Issue Traffic Light MV Heating UK Ltd... -
Page 40: Notes
+44 (0)23 8052 2345 Notes ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. ……………………………………………………………………………………………………………………….. MV Heating UK Ltd...
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