MV HEATING Airo 2 Heater Instruction Manual

MV HEATING Airo 2 Heater

Specifications

• Model: MV Airo 2 & Airo 5
• Manufacturer: MV Heating UK Ltd
• Heater Types: 2kW & 5kW Air Heaters
• Contact: +44 (0)2380 522345

Introduction
The MV Airo 2 and Airo 5 are diesel-powered hot air heaters with petrol versions available upon request. These heaters feature a small fuel furnace controlled by a single-chip microprocessor. The cold air is drawn into the air passage, heated by the heat exchanger, and blown out as hot air. The heater can supply hot air independently to various compartments like driver’s cab, passenger’s compartment, campervans, cranes, and marine vessels.

Features

• Compact structure
• Easy installation
• Low running costs
• Easy maintenance
• Safe and reliable operation

Technical Data

• MV Airo 2 Technical Data
  • Output: 2kW
  • Fuel: Petrol
  • Voltage: 12/24V
  • Fuel Consumption: 0.14 – 0.27 l/h
  • Power Consumption: 2.6W
  • Working Temperature: Not specified
  • Weight: Not specified
  • Dimensions: 323x120x121 mm

Working Principle
The main heater body consists of components like Fresh Air Fan, E.C.U., Air Motor, Bottom Case, Insulating Bush, and Heat Exchanger. Combustion air is efficiently fed into the heater via the combustion air pipe and supported by the combustion air fan. Cool air is heated by the heat exchanger and pushed out through the air outlet by the fresh air fan of the air motor assembly.

Product Usage Instructions

Installation Instructions

1. Select a suitable location for installing the heater.
2. Connect the wiring harness following the provided instructions.
3. Ensure proper ventilation for exhaust gases.
4. Connect the fuel pump to the vehicle’s fuel tank securely.
5. Connect the heater to the vehicle’s battery following the correct polarity.
6. Verify all connections before operating the heater.

Operation Instructions

1. Turn on the control switch of the heater.
2. Select the desired output position based on heating requirements.
3. The heater will automatically start heating and blowing hot air.
4. To stop the heater, turn off the control switch.
5. Maintain regular checks and follow maintenance guidelines as per the manual.

Frequently Asked Questions (FAQ)

• Q: Can I use the MV Airo 2/5 in marine applications?
  A: Yes, the MV Airo 2/5 heaters can be used in marine vessels along with other applications like campervans and cranes.

• Q: What is the fuel consumption rate of the MV Airo 2 heater?
  A: The fuel consumption rate of the MV Airo 2 heater is between 0.14 to 0.27 liters per hour.

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. 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.

Note

• This instruction book is subject to revision without notice, but the instruction book is in conformity to the purchased product.
• Our effort is to explain all questions you may have. If you have any doubts or find anything incorrect in this manual, please contact us directly.
• Check the heater for any damage when unpacking and contact the dealer immediately if anything is found.
• If any troubles arise during application, please contact MV Heating or other customer service stations authorized by this company. We shall do our best to provide service to you.

Comply with the operation manual for installation and operation, to ensure prolonged and reliable use.

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 microprocessor. 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 air motor, heated by the heat exchanger and blown out as hot air.
An example of how the heater operates is shown in Figure 1. Hot air is supplied by the heater to the driver’s cab and/or passenger’s compartment independently from the engine. The same theory applies to campervans, cranes, marine vessels etc.
The heater is fully automatically controlled. Its features include a compact structure, easy installation, low running costs, easy maintenance and is safe and reliable.

Technical Data

MV Airo 2 Technical Data

Airo 2 Current Draw

MV Airo 5 Technical Data

MV Airo 5

Heat Power| 5kW
Fuel| Diesel
Rated Voltage| 12V24V
Fuel Consumption| 0.19 – 0.60l/h
Rated Power Consumption| 15 – 90W
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

Working Principle

The structure of the main heater body is shown in Figure 2.

The heat exchanger is made of die cast aluminium with radiating fins around and at the rear end. The combustion tube is located inside the heat exchanger, and the burner assembly is fixed on the front end of the combustion tube. Fuel is fed to the burner assembly through the fuel inlet pipe by the aid of the fuel pump. It is ignited by the glow pin, which also serves as a flame sensor after ignition. The flame is supported in the burner assembly and sealed in the combustion tube. All combustion gases exit the heater through the exhaust outlet.

Combustion air is fed into the heater via the combustion air pipe and is supported efficiently by the combustion air fan, located on the rear of the air motor. 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 Airo 2 Internal Structure

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. Glow Pin
11. Overheat Sensor

MV Airo 5 Internal Structure

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

Heater Cases
Figure 5 shows the heater casing layout for both the MV Airo 2 and 5 heater.

1. Inlet cap
2. Outlet Cap
3. ECU Cover
4. Top Case
5. Bottom Case
6. Grill

Installation Parts

Figure 6 shows the basic principle of parts for installation.

1. Main Heater Body
2. Control Unit
3. Main Wiring Harness
4. To Power Supply
5. Fuse Holder
6. External Temperature Probe
7. Mounting Gasket
8. Combustion Air Pipe Clamp
9. Combustion Air Pipe
10. Combustion Air Pipe Strap
11. Combustion Pipe Silencer
12. Exhaust Pipe Clamp
13. Exhaust Pipe P-Clip
14. Exhaust Pipe
15. Exhaust Silencer*
16. M6 Nut & Washer (x4)
17. Fuel Pump
18. Fuel Pump Mount
19. Fuel Pump Damper
20. Non-Return Valve**
21. Fuel Filter**
22. Fuel Pipe Connector
23. Fuel Pipe Connector Clamp
24. Fuel Pipe
25. Fuel Standpipe

Unsealed in a vehicle application and must be installed outside of the vehicle. When purchased as part of a marine kit, the silencer will be sealed, and attached to the exhaust pipe as part of a single system.
**Not suitable for use with petrol systems
Figure 6 shows the diagram for an Airo installation. The position and ways of fixing of various parts may vary from one vehicle/boat to another, but the general principles remain the same.

Attention:

• Do not mount the heater near any flammable sources.
• 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.

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.

MV Airo 2 Dimensions

• A. Fresh air inlet (60mm)
• B. Hot air outlet (60mm)
• C. Combustion air inlet (22mm)
• D. Fuel inlet (5mm)
• E. Exhaust outlet (22mm)
• F. Non-interference area
• G. Information label
• H. Installation surface
• I. Gasket

MV Airo 5 Dimensions

• A. Fresh Air Inlet (90mm)
• B. Hot air outlet (90mm)
• C. Combustion air inlet (24mm)
• D. Exhaust outlet (24mm)
• E. Fuel inlet (5mm)
• F. Non-interference area
• G. Mounting Gasket

Choose a flat installation surface, any undulations could cause the case to twist and will not ensure an even mount. Make sure there are no foreign bodies between the bottom of the heater and the installation surface itself. 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.

Mounting Gasket and Plate Dimensions
The mounting gasket and mounting plate required in most vehicle installations is shown above. 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.

Angle of Installation
The angle of installation is shown in figure 10. 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 identification and maintenance in the future.

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.

Avoid re-entering of the supplied hot air into the inlet port (as shown in Figure 11). If no inlet pipe is required, make sure the grill is installed at the inlet port (Figure 5 no. 6) to prevent blockages. Ducting can be configured in various ways as shown overleaf. Larger ducting sizes like the Airo 5 can be reduced in some applications but care must be taken not to cause overheating if reduced considerably.

Additional Ducting
Quantity of ducting can be altered according to needs, but over excess will cause poor air flow or possible overheating.

Installation of Combustion Air Pipe and Exhaust

The combustion air inlet pipe sucks in combustion air and the exhaust pipe discharges fumes outside of the vehicle. Measures must be taken to avoid the fumes from re-entering the vehicle via the fresh air inlet. 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.

• 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. Do not confuse the two. Use the supplied clamps to fix them securely to the combustion air inlet and the exhaust outlet on the heater. The protective end cap on the outlet of the 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 face 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˚. Figure 15 shows the right and wrong way to install the combustion air intake. Note that it is the same for the exhaust too.

When the heater is operating, the exhaust will get hot, so make sure it is installed away from any parts that could get damaged by high temperatures. In vehicle applications the exhaust vent should also point downward to the road surface with an angle of 90˚±10˚. This is best achieved by fixing a clamp 150mm from the pipe end.

Any exposed exhaust should be covered with a heat shield to prevent scalding.

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.

Installation of Fuel Lines

NOTE: Copper fuel should be used for inland waterways vessels.
The vehicles own fuel tank can be used to supply fuel to the heater, a separate tank can be used if necessary. If a separate tank has been used, please ensure that it is not installed in the driver or passenger cab and is away from anything that could cause a fire risk or inhaling of toxic fumes.

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.

Where possible the fuel line should ideally be placed uphill to the fuel pump to ensure ideal bleeding of the fuel line. Avoid installing the heater below the fuel level to prevent automatic siphoning and flooding of the heater.

The fuel pump’s outlet should tilt upward at an angle between 15˚-35˚. 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.
The fuel filter, fuel pipe and clamps should all be replaced after 2 years of us

When the fuel is being sucked from the vehicle tank, or an independent tank, a fuel standpipe is required. Make sure all the openings are appropriate for the installation and a tight seal is maintained for the base of the standpipe. 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.

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.
Standpipe 1: (Part No: AHZ-034)

Usually supplied in Marine kits and supplied bent, this standpipe is installed like so:

• Drill a hole in the top of the vehicle’s fuel tank Φ22 ± 0.2mm in size. Ensure it is smooth and clean of burrs.
• Remove the top nut and washers and bend the standpipe straight.
• 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.

Standpipe 2 (Sender Unit Pipe): (Part No: AHZ-035)

Supplied mainly in vehicle kits, this standpipe (or sender unit pipe) 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.
• Drill a Φ6 ± 0.2mm hole into the sender unit.
• Remove the nut from the standpipe and feed it through the hole ensuring the rubber ‘o’ ring remains on the standpipe ‘head’ side.
• 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 an O-ring inside.

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. Plug the multiplug (figure 22) into the X6 of the ECU (figure 29) ensuring the long flat tab faces the ECU. WARNING: If inserted incorrectly, the ECU will be destroyed upon initial startup.

Note: The wiring harness for both heaters can exit to the right or left cutout of the heater’s top case. Ensure that the rubber grommet is located inside the top case to prevent water damage.

Airo 5 Main Connector
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. Plug the multiplug (figure 23) into the ECU ensuring the tab faces upward and clips into X7 (figure 33) of the ECU.
WARNING: If inserted incorrectly, the ECU will be destroyed upon initial startup.

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.

Control Unit Connector
Fix the control unit in place using the methods provided in their respective manuals. They are best installed so that they can be seen and operated easily to identify working conditions and for easy access.

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.

Auxiliary Unused Connection
The following plug on the loom can remain safely disconnected.

Temperature Sensor Probe Connector
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.

Installing Temperature Probe
We recommend installing the temperature sensor in the following way to maintain a steady room temperature:

• Do not subject it to direct heat.
• Install it at shoulder height when sat in vehicle
• Install it on a vertical wall. The room temperature sensor must be completely exposed to the ambient air.
• Avoiding any external heat sources like stoves, fridges, or direct sunlight.

1. Drill a 10mm hole.
2. Feed the end of the cable with the one insulated connector through the drill hole.
3. Connect the cable to the sensor, regardless which side, as polarity is not an issue.
4. Insert the room temperature sensor. Plug into the main wiring 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).

ECU Connections

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. If force is required, then it is not located correctly!
Figure 29 shows the correct connections and their wire colours:

• X1: Air motor (red, yellow, brown, blue)
• X2: Glow pin/flame sensor (yellow, brown)
• X3: Overheat sensor (Blue x 2)
• X4: Leads to fuel pump (Black x 2)
• X5: Unused
• X6: Main Wiring Harness (See figure 22)

ECU Connections – Airo 5
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. If force is required, then it is not located correctly! Figure 30 shows the correct connections and their wire colours:

• X1: Air motor (red, yellow, brown, blue)
• 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)

Wiring Diagram

MV Airo 2 Alpine Auto Wiring Diagram

MV Airo 5 Alpine Auto Wiring Diagram

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. The distance between two fixing points should not exceed 300mm.
The wiring harness for both heaters can exit to the right or left cutout of the heater’s top case. Ensure that the rubber grommet is located between the heaters top case and ECU cover to prevent water damage.

A fuse will already be inserted into the fuse holder (20A for 12V heaters and 15A for 24V versions).

Connect the 2.5mm² red wire and the 2.5mm² brown wire in the wire harness to the positive and negative of the vehicle’s battery respectively. Straighten the fuel pump leads coming from the heater body (two 0.6mm² black wires) and put them through the opening on the wall of the air inlet pipe. They can then be connected to the fuel pump by pushing the spring clip down on the plug and pushing shut. Use the fuel pump extension loom if more length is required to reach the fuel pump from the heater.
Note: Any exposed wire outside the vehicle should be protected so as not to be ripped by any road debris or similar.

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:

• Check the air inlet and outlet for any pollution or foreign objects.
• Clean the externals of the heater.
• Check for corrosion or loose connections of the circuits and connections.
• Check the combustion air inlet and exhaust pipe for damage and clogs.
• Check the fuel line for leaks.

To ensure a long life of the heater it is advised that you run it for at least 10 minutes on the highest output every month, to prevent malfunction of mechanical parts. 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.

Fault Codes

Code on Digital Timer| Error Description| Error Light (Flashing Light) on Rotary Control
---|---|---
00| No Fault| F01
10| Second start failure|
20| Heater does not light in time| F02
21| Combustion termination|
30| Voltage too high| F03
31| Voltage too low|
A9| Voltage too low|
41| Overheated| F10
50| Flame sensor open circuit| F05
51| Flame sensor short circuit|
52| Hot air sensor open circuit|
53| Hot air sensor short circuit|
54| Hot air sensor overheated|
65| Inside temperature sensor broken circuit| F06
66| Inside temperature sensor short circuit|
68| Outside temperature circuit broken circuit|
69| Outside temperature circuit short circuit|
70| Fuel pump short circuit| F07
71| Fuel pump broken circuit|
80| Fan broken circuit| F08
81| Fan short circuit|
82| fan speed too low|
83| Fan speed too high|
84| Fan speed measurement fault|
90| Glow pin open circuit| F09
91| Glow pin short circuit|
92| Glow pin high resistance|
93| Glow plug drive open circuit|
a2| Overheating| F10
b4| Overheating or sensor fault| F11
b5| Overheat sensor fault|
c0| Hydro only – blower relay open circuit| F12
c1| Hydro only – blower relay short circuit|
c4| Preheating temperature broken circuit|
c5| Preheating temperature short circuit|
d0| Crystal oscillator in ECU broken| F13
d1| Fault information storage failure|
d3| Maintenance reminder|
–| Earthing Issue| Constant Flash
–| Connection Issue| Traffic Light

MV Heating UK Ltd
Unit 6
Second Avenue Business Park
Millbrook
Southampton
SO15 0LP
MV Heating UK LTD
+44 (0)2380 522345

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