Orion V20230213 Air Diesel Heater User Manual

Orion V20230213 Air Diesel Heater User Manual

Safety Information

Danger!

• ONLY use this product in accordance with these instructions and AbLL local regulations and guidelines related to the use of diesel fuel and heating equipment. Failure to do so may expose you to legal liability and risk serious property damage and severe personal injury possibly including death.
• DO NOT allow children or those unfamiliar with this product to use or install it. Do not use while under the influence of alcohol, drugs, or any medication that negatively affects your judgment or reflexes. Keep children and bystanders away during installation.
• Keep your work site clean and well lit. Cluttered and dark work areas invite accidents.
• Disconnect the vehicle battery connections before any installation, adjustment, repair, or maintenance.
• ALWAYS turn off the heater before adding any fuel.
• ONLY use DIESEL fuel for the heater. Use of other fuels may cause malfunction or greater risk of fire hazard.
• ALWAYS use personal protective equipment (PPE) suitable to your task. Always wear ANSI-approved eye and hand protection while using this product. Nonslip footwear is also highly recommended. Other equipment such as ear, head, and body protection may also be necessary depending on your work and other equipment.
• Dress properly for the installation of the heater. DO NOT wear loose clothing or jewelry and keep hair, clothing, gloves, hoses, and tools away from any moving parts.
• NEVER operate the heater in a confined space without proper ventilation. This can result in the buildup of harmful gases and pose a risk to human health. If you experience any symptoms such as headaches, dizziness, or unconsciousness while operating the heater, immediately stop using the heater and move to a well-ventilated area. If symptoms persist, seek medical attention promptly. It is important to take these symptoms seriously and prioritize your health and safety.
• The heater and its components can become hot during operation. Avoid touching them to prevent the risk of burns or injury. ALWAYS wait for components to cool down or use protective gear when handling.
• ALWAYS install this heater in a spacious compartment away from any combustible or flammable materials. NEVER use the heater in hazardous locations such as fuel depots, carbon storage, and timber warehouses.
• If a fuel leak occurs, turn off the heater IMMEDIATELY and disconnect the fuel line. ONLY use a trained and licensed technician to repair the leak.
• Maintain this product. Check for misalignment, binding, wear, or other damage before use. If any damage is detected, repair or replace the problematic components before further use. Only replace components with identical parts.

Specifications

Package List

Product Diagram

Main Body

Installation

After drilling the holes necessary for the installation of this heater, it’s important to protect the underlying material from moisture and water damage. If any splintering occurs as the exhaust hole is created, ensure the area is covered with a sealing paint to prevent water and moisture from getting in.

Main Body

1. When installing a diesel heater in a vehicle, it’s important to consider the location and potential impact on surrounding materials and components. Typically, the heater is mounted in a protected area, such as in the storage compartment under a bed in a transport truck or under a seat in a passenger vehicle. It can also be installed on walls or in protected compartments outside the operator’s cabin, as long as all regulations and installation instructions are followed.
   When choosing a location for the heater, ensure that there is sufficient clearance aroundthe heater, ducting, and exhaust to prevent damage to heat- sensitive materials. Ensure the heater is not exposed to outside elements and that it is properly enclosed if mounted outside the vehicle cabin. Ensure the mounting surface will allow for a complete seal between the heater and the floor. Avoid exposing the heater to excessive heat or hazardous chemicals and fuels. Depending on the installation conditions, the acceptable angular range for each side is shown below:
   

2. Use the mounting plate (AA) as a reference to determine the exact positions for each hole. Clearly mark the spot for each hole.

3. Use a hole saw and power drill to cut through the floor of the vehicle. The holes are necessary to allow the pipes and hoses to connect and vent outside of the van, but be careful to minimize any other holes or gaps nearby.
   

4. Apply a generous amount of silicone (not included) around the circumference of the holes and under the mounting plate base. Carefully insert the mounting plate into the holes, ensuring that it sits flat and is centered. Secure the four corners of the mounting plate to the caravan floor using four of the provided M6 screws and nuts (F).

5. Remove the nuts and washers from the bolts at the bottom of the main body and then mount the main body (A) onto the mounting plate. Get under your vehicle and secure the heater unit to the bracket by replacing the washers and nuts, making sure it is properly aligned and secure.

Air Inlet & Outlet Vents

1. Measure the size of the hole required for the air outlet vent (D) to pass through the surface near the front of the diesel heater. Mark the location where the hole is to be cut.
2. Cut the hole using a hole saw.
3. Cut a piece of the air outlet ducting (AC) that is just long enough to reach from the diesel heater to the newly cut hole. Secure one end of the ducting to the outlet vent and insert it into the hole. Use a hose clamp (J) to attach the other end of the ducting to the diesel heater. If necessary, use the inlet/outlet brackets (L) to secure the ducting to the wall or floor.
4. Fix the vent casing in place using M6 screws and nuts and then attach the outside cover. Repeat the process for the air inlet ducting (AD), which will be longer than the outlet ducting.

Note: The above steps are for reference and installation may differ depending on the specific setup and location.

Air Intake Pipe

1. Attach the air filter (Y) to the end of the air intake pipe.
2. Connect the air intake pipe to the bottom of the diesel heater using a pipe clamp (N).
3. Mount the air intake pipe under the vehicle’s floor using a hose clamp.
4. Position the pipe so it faces towards the rear of the vehicle to prevent dust buildup during transit.
   

Exhaust Pipe

1. Use two M6 screws, washers, and nuts to install the exhaust muffler (G) and muffler bracket (AE) at a suitable position near the heater. Make sure it is directed away from the vehicle to ensure that the fumes do not get trapped underneath the vehicle. Do not point it towards the awning area to avoid inhaling exhaust fumes while sitting outside.
2. Route the exhaust pipe (I) from the heater to the exhaust muffler use the pipe bend (C) if necessary. Fasten it with a pipe clamp. Make sure to position the exhaust pipe on a slight downward slope from the diesel heater unit to allow for any condensation to drain out.

Fuel Assembly

1. Choose the location for the heater’s dedicated fuel tank (AB). The placement is a matter of personal preference and practicality. Consider your specific vehicle setup and choose the location that is most suitable. Aim to maximize stability and minimize spillage and exposure to fumes. Use the M4 screws (P) or similarly strong fasteners secure the fuel tank to the floor or wall through the three holes in the tank body. Use the M4 Washers (K) to prevent any leakage.

2. Open the fuel tank and take out the small bag with accessories. Select a location for the fuel line (B or U) and drill a 0.27 in. (7 mm) hole in either the side or bottom of the tank. Thread a piece of wire (not included), e.g. an unbent wire coat hanger, through the hole and up to the opening at the top of the tank. Place the fuel line nipple (Q) on the end of the wire at the top use the wire to guide it through the hole in the bottom. Secure the nipple in place with an O-ring (AF) and the fuel line nipple nut (N) on the outside of the tank. Connect the fuel line and fasten it with fuel line clamps (R). Use fuel line extensions (S) if needed.

3. Use the fuel pump bracket (T) to install the fuel filter (V) and fuel pump (Z) somewhere under the van and near the fuel tank. Place the fuel filter closer to the fuel tank. Place the fuel pump (W) closer to the diesel heater, using a fuel pump shock clip for secure mounting. Ensure that both the filter and pump are angled between 15 and 30 degrees for best performance.
   

4. Measure three sections of fuel line: one from the fuel tank to the fuel filter, another from the fuel filter to the fuel pump, and the third from the fuel pump to the diesel heater. Cut the fuel line into three separate sections, according to your needs. Connect the fuel line sections between the fuel tank, fuel filter, fuel pump, and diesel heater by attaching the sections at each corresponding point and securing them with jubilee clips.

Wiring

1. Connect the positive and negative wires to the battery terminals.
2. Connect the wiring bundle (H) to the diesel heater.
3. Connect the wiring to the fuel pump.
4. Connect the wiring to the LED control panel (X).
5. If necessary, drill small holes to run the wiring to its desired location, such as the fuel pump under the van. To achieve this, remove the connection casing, run the wiring through the hole, and then reconnect the casing. It is recommended to install the LCD monitor display in a convenient location on the wall, as it will serve as the control center for operating the diesel heater.

Final Installation Diagram

Operation

Priming

1. Push the power button to turn the heater on.
2. Hold down OK and then push ▼. You should see “H OF” flashing on the screen.
3. Push ▲ and you should see “H ON” flashing on the screen.
4. Listen for the fuel pump to start ticking.
5. Keep priming until the fuel reaches the diesel heater unit. If the unit stops priming after 60 seconds, you may need to turn on the “Prime Cycle” via the monitor.

Turning the Heater On/Off

1. You will see the lines across the bottom of the “diesel heater” image on the screen increase as the heater gets to temperature. It’s normal for the heater to be smokey the first time it’s fired up.
2. To view the voltage the unit is running at, click through the OK button until you see a number with a little “v” after it.
3. To view any error codes, click through the OK button until you see an “E”. If there are any errors, it will display “E” with a number after it (e.g. E-07).
4. To turn the diesel heater off, hold the power button until the display shows to indicate the unit is going through a “cool down” cycle. The unit should turn off after the cycle is finished.

Plateau Mode

1. Simultaneously press and OK until the display shows to indicate “Plateau Mode”, which adjusts the wind-to-oil ratio to help your system work in high-altitude areas with less oxygen.
2. Simultaneously press and OK for 2 seconds to exit Plateau Mode.

Setting the Temperature

1. To adjust the diesel heater temperature, push ▲ and at the same time.
2. Use ▲ and ▼︎ to increase/decrease the temperature. You can set the temperature between 5 °C. and 30 °C.
3. Push OK to set the temperature and to view the current temperature inside the vehicle in Celcius degrees. Push OK again to see what temperature the heater is set to run at.

Setting the Timer

1. To set the clock on the diesel heater control panel, push .
2. The first number will flash. Use ▲ and ▼ to change the number up or down.
3. Push OK to move to the next number, then use ▲ and ▼ to set the correct digit.
4. Push OK to get to the “Timer” screen.
5. Push ▲ turn the timer on and then push OK.
6. Set the “Start Time” using ▲ and ▼, then push OK.
7. Set the “End Time” using ▲ and ▼, then push OK.
8. You may add an additional timer by using the Timer screen again. If not, the screen will return to the original “Clock” screen.

Pairing the Remote

1. To pair the remote control (W) with the LCD monitor, press and hold ▲ for 5 seconds.
2. After 5 seconds, you should see “HFA” displayed on the screen.
3. To complete the pairing process, press the “ON” button on the remote control.

Note: Removing this product from power does reset its control system, causing it to forget previously paired remotes. To continue using your remote control(s), simply restore power and pair them again.

Maintenance

Poorly ventilated exhaust can KILL. Carefully follow ALL aspects of ventilation maintenance.

• Periodically inspect the electrical connections for loose connections and tighten if needed.
• Regularly check the fuel levels in the heater’s fuel tank to make sure there’s enough diesel to keep the heater running. If the fuel level is low, top off the tank with diesel while being careful to avoid overfilling.
• lean the air filter regularly by removing it from the heater and gently tapping it against a hard surface to remove any loose debris. Using a clean cloth or brush, remove any smaller dirt or debris. Finally, reattach the air filter to the heater. It’s recommended to clean the air filter every few months during normal use and more often in polluted areas or during heavy use.
• Check the fuel lines and connections for any signs of leaks, such as fuel spots on the floor or a strong diesel odor. If there are leaks, tighten the connections to prevent further leaks. If you are unsure how to tighten the connections, consult your vehicle’s manual or a trained and licensed diesel heating technician.
• Check the exhaust pipe regularly for blockages, clearing and cleaning the line if needed.
• If the heater has not been used for a long period of time, it’s important to perform a test run before using it again. This will ensure that the heater is functioning properly and that there are no leaks or other issues that could cause harm. To perform a test run, turn on the heater and let it run for a few minutes, observing the fuel and air levels, the temperature, and the exhaust pipe. If everything appears to be working properly, the heater is ready for use. If you notice any issues, such as dirty or broken components, clean or replace them as needed. For serious issues, seek assistance from a trained and licensed diesel heating technician.

Troubleshooting

E-4  Oil Pump FailureCheck for damage, looseness, oxidation, short circuits, and breaking of oil pump connections and connectors. Repair or replace the oil pump as necessary.   E-5  Hig Temperature Alarm(Intake over 50°C or case over 230°C)Ensure that the heating duct is not obstructed.       E-6       Fan FailureClear any obstructions from the fan blades if they are stuck. E-8      No CombustionVerify the oil level and add oil as needed to prevent oil shortage. Take steps to prevent oil from solidifying at low temperatures. Unsuccessful StartupWait until the shell temperature has cooled down to a safe level if it is too high to activate the cooling shell for three minutes after starting.

generator to ensure it is functioning properly, replace the battery or generator if necessary.
Check the fuse and replace it if it is aging.
E-3| Ignition Plug Failure| Tighten the ignition plug connector if it is loose.
Check and repair the wire and housing if they are shortcircuited.
Replace the ignition plug if it is damaged.
Check the fan and repair or replace it if it is not working properly.
Check the temperature sensor. Replace if it is damaged or broken.
Make sure the connection between the fan and plug is secure by tightening it if it is loose.
If there is too much space between the magnet on the wind turbine and the Hall sensor on the controller, adjust it to reduce the gap.
Check the wiring for the fan for any short circuits or open connections and repair them as necessary. If the motor is damaged, repair or replace it.
Ensure that the oil pipeline and pump are clear of any blockages to ensure proper operation.
Make sure that there are no obstructions in the air intake and exhaust ducts.
Verify that the shell temperature sensor is in full contact with the shell and that the pressure spring is strong.
Check the filter near the ignition plug and clean or replace it if there is an excessive amount of white smoke in the exhaust gases.

Contact Us

Thank you for choosing our products! If you have any questions or comments, contact us at
[email protected] and we’ll resolve your issue ASAP!

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