Autoterm Marine Fuel Kit User Manual
- June 6, 2024
- Autoterm
Table of Contents
MARINE FUEL KIT
User’s manual
v10.2021
Manufacturer: AUTOTERM LLC
Paleju 72, Marupe, Latvia, LV-2167
Warranty Department [email protected]
Technical Support [email protected]
www.autoterm.com
INTRODUCTION
Dear Customer!
Thank you for choosing AUTOTERM Marine fuel kit! We are doing everything to
make this product meet your requirements, so
its quality satisfies every customer.
This manual is intended for organizations that specialize in the installation
and maintenance of heaters AUTOTERM AIR, AUTOTERM FLOW and users of the
product after installation. The document covers the main rules of installation
of the product on different small maritime transport (e.g., yacht, boat,
cutter).
Please read carefully this manual before installing and operating the product.
This manual contains needful information in order to use this product
correctly.
Disregarding of these instructions can void the warranty of the product, lead
to damage of product and/or property and be a risk to health.
If the product is handled and/or installed
improperly, there is a possibility of a fire hazard and damage of property
because of high temperatures and electrical components are being used. That is
why all safety precautions, operation and installation instructions must be
observed.
For other languages of this manual, please see
www.autoterm.com/manuals.
SAFETY INSTRUCTIONS
Risk of damage due electrical nature
– Disconnect the product from the power supply before working on the product.
– Electric wiring, the air intake, and the fuel pipe must be protected from
contact with sharp edges of vessel structures.
Risk of fire and explosion
– Switch off the heater, when the vessel is being re-fuelled.
– The installation arrangement must exclude the possibility of contact of the
exhaust pipe with the air intake, fuel pipe, or other flammable objects.
– The vessel where the heater is installed must be equipped with a fire
extinguisher.
Personnel certified by AUTOTERM is needed
– For safety reasons, contact the service shop to troubleshoot the heater if
it fails to launch two times in a row.
– In case of faults in the operation of the product, contact specialized
repair organizations authorized by AUTO THERM.
– Repairs and works not described in this manual should be done only by
certified professional
LIABILITY
IN THE CASE OF NON-COMPLIANCE with the requirements, the persons who installed
the heaters assume all risks and any responsibility for the occurrence of
adverse consequences and related damage resulting from installing and
repairing by personnel not having AUTOTERM certification, and/or using non-
original spare parts for repair.
In case of any problems, we strongly recommend contacting certified service
centers. Contact information and location of certified service centers can be
found at our website www.autoterm.com.
GENERAL INFORMATION
The AUTOTERM Marine fuel kit is designed to be used only with AUTOTERM AIR and
AUTOTERM FLOW heaters.
This fuel kit meets the requirements of ISO 7840 – MARINE FUEL A1 standard. It
applies to hoses for small craft with permanently installed fuel systems. It
does not apply to hoses entirely within the splash well at the stern of the
craft connected directly to an outboard engine.
This fuel kit is installed and used in place of a standard fuel kit supplied
with heaters.
GENERAL FUEL SYSTEM INSTALLATION
Do not operate the heater using biofuel.
Use only diesel fuel standard EN590 for diesel operated heaters and
gasoline EN 228 for gasoline operated heaters, depending on the ambient
temperature.
Act as instructed on Fig.1 and Fig.5 to install the fuel system. The fuel pump
and the fuel supply line must be protected from heating.
Do not take fuel from fuel filter or it’s casings, because doing so
causes fuel leaks.
** Do not take fuel from the fuel line between the fuel filter and fuel
pump of the vessel’s engine, the return line of the engine or after the high-
pressure pump of the vessel.
Heater is not designed to work with pressure over 0.2 bar.
Recommended length of the fuel line is 5m. If possible, it is advised not to
cut fuel lines to shorter lengths. Distance between the fuel tank and fuel
pump should not exceed 1m and distance between the fuel pump and the heater
should not exceed 4m (see Fig.1 and Fig.5)
FUEL SUCTION HOSE INSTALLATION.
** Before installing a fuel suction hose in a fuel tank of the vessel, make
sure that the fuel level is high enough to ensure the operation of the heater
and low enough to easily remove the fuel tank if needed.
Fuel is taken directly from the fuel tank of the vessel or an additional tank.
Drill a hole Ø16mm in the fuel tank to install a fuel suction hose. When
drilling the hole in the fuel tank, follow safety precautions that should be
observed when working with a transport, which is filled with fuel or explosive
substance.
If needed, cut the immersible tube of the fuel suction hose shorter before
installation. Its bottom end must be located about 10-15 mm above the bottom
of the tank, or at the height to provide fuel for the engine in the fuel tank
at any time. The cut at the end of the fuel suction hose must be made at a 45°
angle to the axis of the tube. Remove all burrs from the cut after the work is
done.
Install the fuel suction hose in the fuel tank as per Fig.2a. Install the
special washer of the fuel suction hose in the tank hole as per Fig.2b. Apply
a fuel-proof sealant on the threaded surface of the fuel suction tank to
properly seal the connection between the fuel suction hose and the fuel tank.
**** Never install the suction hose on the side of the fuel tank. It must be
installed on the top side of the fuel tank.
ADDITIONAL FUEL TANK INSTALLATION
Consider the convenience of fuelling, when installing the fuel tank (Fig.3).
Install the fuel tank in such a way that the amount of fuel and its potential
leaks from the inlet, fuel suction nozzle or connections can be visually
controlled.
When filling the fuel tank, be careful not to spill any of the fuel on the
exhaust system, wiring, or other objects, which can be damaged due to their
contact with fuel.
Fuel tank must be installed with its wide side perpendicular to the direction
of the movement of the vessel (see Fig. 3).
INSTALLATION OF THE FUEL PUMP AND FUEL LINE
The fuel pump is connected to the heater through its own harness and supplies
fuel depending on the required heat capacity to the combustion chamber of the
heater. The fuel pump is operated by electrical impulses sent by the control
unit. When running, the fuel pump makes a characteristic metallic clicking
noise. It is recommended to install the fuel pump close to the fuel tank
(distance should not exceed 1 meter (see Fig.1 and Fig.5)) and below the low
level of fuel in the fuel tank, but not lower than 70cm of the minimal fuel
level (see Fig.5, point a)). But the height between the fuel pump and the
heater cannot be greater than 1,5 meters (see Fig.5, point b)). The fuel pump
should be positioned with a slight angle pointing upwards (see Fig.4)
If for some reason the sealing of the fuel pump is compromised, it is advised
to install the fuel pump lower than the heater in order to avoid leaks and
overflooding the heater with fuel due to gravity.
Remember to properly bleed the “silent” TH11 fuel pump. If it’s not properly
bled it will be as loud as a standard fuel pump.
To bleed it start the heater and position the fuel pump with its outlet
upwards till there are no air bubbles in the fuel line and only then secures
the fuel pump in its recommended position.
1 – Fuel tank
2 – Heater
3 – Fuel pump| 4 – Clamp
5 – Shut off valve
6 – Copper O-ring gasket| 7 – Fitting
8 – Sleeve
9 – Copper fuel pipe
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MARINE FUEL KIT INSTALLATION
Assemble the marine kit according to the diagram (see Fig. 6) following the steps described below:
- Assemble the shut-off valve (5) and both fittings (7) together. Put copper O-rings (6) at the fitting thread side
- Put rubber sleeves (8) with clamps (4) to both fittings.
- Connect the fuel pump incoming line to the shut-off valve outgoing side sleeve. Tighten sleeve clamps.
- Mount fuel tank or fuel pick up tube (included in the heater installation kit) according to Fig.2 or Fig.3
- Fasten the fuel pump (3) to the surface with a clamp. Don’t overtake 1m maximum distance from the fuel tank (1).
- Connect fuel pick-up tube/fuel tank to the shut-off valve (5) using 1m copper pipe (9) piece and sleeves (8). Push copper pipe (9) into the sleeve (8) as deep as possible to avoid air bubbles occurrence during operation. Do not cut the pipe. Fasten copper fuel pipe (9) to surface with P-type clamps every 50-80 centimetres.
- Connect 4m copper pipe piece (9) to the fuel pump outgoing side sleeve (8).
- Fasten fuel pipe to the surface. It is preferable to lay the fuel supply line on a straight line and with a small inclination upwards in the direction of the heater. The fuel supply line should be fastened every 50-80 cm to prevent sagging, prevent effects of vibrations and avoid fractures. Do not cut the copper pipe.
- Connect fuel pump wiring harness to the fuel pump socket. Check if the shut-off valve (5) is open. Start the heater several times until the fuel removes air from the fuel pipe.
- Put rubber sleeve (8) with clamps (4) to the heater (2) fuel intake pipe and connect the end of 4m copper pipe (9) to the heater (2). Push the copper pipe into the sleeve (8) as deep as possible to avoid air bubbles occurrence during operation Retighten all clamps (4). Start the heater (2) and check fuel lines for leakage during operation.