Operating Manual Control Panel PU-20-12V PU-20-24V

Operating Manual Control Panel PU-20-12V PU-20-24V
EN
Operating Manual
Control Panel
PU-20-12V PU-20-24V
Ver. 1.0.0.10
Introduction
This operating manual is a component of the documentation for fluid pre-heater type
BINAR-5S and contains all the necessary information about safe operation that is
intended for the users.
In case of any problems, we emphatically recommend that you contact the authorised
service centres, whose addresses and telephone numbers are available from the dealer or at
the website www.autoterm.ru
Before you start using the pre-heater, it is necessary to read this
operating manual and pre-heater operating manual.
Warranty and liability
The manufacturer is not liable for faults and damage arising from failure to observe
the instructions contained in the installation manual and the pre-heater operating manual.
 The control panel may be used only to control the pre-heater.
 It is prohibited to connect and disconnect the socket of the control panel during
operation of the pre-heater.
 After shut-off the pre-heater may not be restarted earlier than after lapse of 5-10
seconds.
 If attempts to start-up the pre-heater fail twice in a row, it is necessary for reason of
safe operation of the pre-heater to contact the service centre, which shall repair such
faults.
The warranty period for operation of the product and the warranty service conditions
are given on the warranty certificate.
2
Safety
.
Do not switch-on and use the pre-heater in places where inflammable vapours and
gases or a large volume of dust may be generated (for instance, fuelling stations,
diesel tanks, fuel, coal, wood or grain storage facilities). Risk of explosion.
Do not start-up and use the pre-heater in confined spaces. There is a risk of poisoning
and suffocation from exhaust gases.
Do not switch-on and use the pre-heater if the exhaust gases flow contains
combustible materials or fluids. Risk of fire.
Do not use a faulty pre-heater. Risk of injury from use of a defective device.
Description of the control panel .
1 – digital display.
2 – light diodes (display of the clock, timers,
adjustment of the clock).
3 and 5 – movement between the main
displays, movement between the
menu items, editing of values (+/-).
4 – ON/OFF switching of the pre-heater and
pump, editing input, confirmation of
selected value, timer activation.
6 – setting of the control panel, return to
main screen.
7 – setting of the pre-heater control
unit, setting of the timers.
Intended use
The panel is intended for:
 start-up and shut-down of the pre-heater in manual mode;
 start-up and shut-down of the pump in manual mode;
 viewing of the values of the coolant temperature and power supply voltage;
 viewing of the actual time data and operating time of the pre-heater/pump;
 timed start-up of the pre-heater;
 setting the coolant heating temperature limit;
 selection of re-heating mode;
 setting of temperature for start-up of the cabin ventilator relay;
 visualisation of the error code in case of product operation failures;
 visualisation of the program version of the control panel and control unit.
3
Time sequence of work with the panel
Upon connection of the pre-heater to the electric circuit of the vehicle, the indicator
shall show the program version of the control panel. Further, the progress of the
installation of the interlink between the control panel and the control unit shall be
displayed (in %). After installation of the interlink, the main screen shall appear (current
time, fluid temperature or power supply voltage, the current time appears by default).
negative temperature will carry a minus sign.1
To enter the menu, press the button
or
or
*.
To move within the menu, press the button
.
The button
confirms the selection resulting in start-up of the pre-heater/pump.
After start-up, the default operating time is displayed within 7-15 s, after which time
count-down starts (visualised on the indicator).
During the operation of the pre-heater, it is possible upon pressing the button
to
quickly jump to the menu for setting of the operating time of the pre-heater / pump.
If during operation of the pre-heater, you press the button
, the pre-heater is
shut-down. The fuel supply is cut and the combustion chamber is purged within 3-5
minutes.
After the last pressing of any arbitrary button, the indicator goes off
after the set period in order to save electric energy. For illumination of the
indicator it is necessary to press an arbitrary button.
Indication of operating modes
Pre-heater operation
Pump operation
Shut-down of pre-heater operation (purging)
Coolant temperature
Power supply voltage at the input of the pre-heater
Error
*According to the type of control panel cover, the signs
4
and
are considered as equal.
Working with the control panel
Pressing of the buttons
on the main screen*:
- viewing the current time;
- viewing of the coolant temperature;
- viewing of power supply voltage.
Operation of the clock
Viewing of coolant temperature
Viewing of power supply
voltage
Main
screen
Pressing the button
on the main screen:
- brief pressing - start-up of the pre-heater (count-down of the pre-heater
.
operating time starts). The screen shows the marking
- long pressing – start-up of the pump (count-down of the pump operating time
starts). The screen shows the marking
Pressing the buttons
during operation* of the pre-heater / pump:
- viewing the operating time of the pre-heater / pump;
- viewing of the coolant temperature;
- viewing of power supply voltage.
Operation of the
pre-heater or
pump
Pressing the button
during operation of the pre-heater / pump:
- shut-down of the pre-heater / pump (purging, end of operation).
Shut-down
Operation of the clock
* - Upon pressing the buttons
Viewing of coolant temperature
Viewing of power supply
voltage
the screens are switched continuously.
5
Tasks in the settings menu
- jumping between the menu items;
- switches panel to editing mode:
- change of value (reduction);
- change of value (increase).
- confirmation of selected value;
- return to main screen (last changes not saved).
If during the editing (modification) process there is no activity within 20
seconds in relation to each activity, the panel jumps back to the main screen.
Last changes shall be saved.
Settings menu
The control panel has three types of settings:
1.
Setting of timers is activated by briefly «K» pressing the button
screen.
To switch between the timers, press the buttons
.
Main screen
Timer 1
Timer 2
Timer 3
Main screen
Timer 1
Timer 2
Timer 3
* According to the type of control panel cover, the signs
6
or
* on the main
and
are considered equal.
2.
To change the pre-heater operating mode and setting of the control panel, briefly « K»
press button
on the maín screen. It consists of:
Main screen
Correction of the clock
-59… +59 s every 24 hours.
Pre-heater operating
time
Indicator illumination
time
30 s, 1… 10 minutes,
permanent
Current time and
day of the week
Disconnection of the indicator
during operation
On – goes off during operation.
Off – illuminated during operation.
Main screen
Brightness of
the indicator
1...5
Selection of button pressing for start-up of the pre-heater /
pump
оО – brief pressing – pre-heater ON
long pressing – pump ON
Оо – brief pressing – pump ON
long pressing – pre-heater ON
7
3.
To set the control unit, press and hold « D» the button
on the main screen. It consists of:
Main screen
Temperature maintained in reheating mode
-75... +95 °C
Temperature of
running heater
+30... +60 °C
Service
information
8
Temperature for switching to
standby mode
+20... +95°С
Re-heating mode
О - Off
А - Automatic
Н - Manual
Pump operation in the re-heating
Cabin heater ON
standby mode
Оп – heater automatically starts up,
Оff – heater does not start-up
1 – continuously operating
О – off
Start-up of pump upon start of
engine
1 – pump starts
О – pump does not start
Return to factory settings
th = 88 , HU = 0 . tu = 85
tr = 40 , Pu = Б ; г = Оп
Selection of pump type
А - Elektrus
B- Bosch
Setting the current time
.
The current time is set and displayed only in 24-hour format. After power failure, the
current time is deleted. The day of the week is indicated by the digits 1 to 7. 1 – Monday, 2
– Tuesday, etc., 7 – Sunday.
Current time and
day of the week
Editing the day of the
week
Editing the hours
Editing the minutes
Setting the control timers .
The control panel allows the programming of three automatic start-ups using three
independent timers. Any of the three automatic start-ups runs only upon activation. It is
possible to activate only one timer.
According to the selected timer, the appropriate diode is illuminated. The light diode
starts blinking after activation of timer. After start-up of the pre-heater, the timer activation
is deleted.
To change to timer editing, press and hold the button
. Timer editing is done in
the same manner as editing of the current time.
For automatic start-up of the pre-heater using timers 1 and 2, it is necessary to set the
start-up time. For Timer 3, it is necessary to set the start-up time and day of the week. The
day of the week is set from 0 to 7. If we set “0”, this means that upon activation of the
timer the pre-heater shall start-up regardless of the day of the week (after start-up, the timer
activation is deleted).
Briefly pressing the button
activates the timer; only in timer display mode (the
light diode of the timer starts blinking).
Main screen
Timer 1
Timer 2
Timer 3
К
Timer editing
D
Timer editing
D
Timer editing
D
Timer
activation
K
Timer
activation
К
Timer
activation
К
D - long depression of the button
К – brief depression of the button
11
Setting of pre-heater operating time .
The default pre-heater operating time is 40 minutes. Changing range between 20
minutes to 2 hours in leaps of 5 minutes.
The first position shows the hours, the second and
third show the minutes. (Example: 1 hour 20
minutes)
Pre-heater operating
time
Main screen
Correction of the clock
Editing of the
operating time
.
Due to the action of low temperatures, the precision of the clock may change
somewhat.
The time correction range for the clock is -59…+59 s
for 24 hours. The default time correction is 0 s.
Setting the indicator illumination time
.
The default illumination time of the indicator of the
control panel is 30 seconds.
The duration of indicator illumination can be set at 30 s and from 1 minute to 10
minutes with a leap of 1 minute, or illumination can be set at permanent, where the screen
shows – «- - -».
After lapse of the set time:
 If the pre-heater is in operation, the indicator will show the symbol of the operating
mode. To renew full indication, it is necessary to press an arbitrary button (part from
“3” on the left).
 If the pre-heater is off, the control panel changes to standby mode. The indicator
illumination goes off, the light diodes indicating the timer continue to be illuminated (if
the timer is activated). To renew indication, it is necessary to press the button “4”, “5”,
“6” or “7”.
10
Setting of the disconnection of the indicator during operation.
During operation of the pre-heater, the indicator on
the control panel goes off after the period set in .
During operation of the pre-heater, the indicator on the
control panel shall remain on. Upon end of operation of
the pre-heater, the indicator goes off after the period set
in .
Setting of the indicator illumination brightness
The indicator brightness changes in the range 1 to 5.
Default brightness: 3.
Setting the quick start-up function
The given setting determines the duration of the depression of button
the pre-heater / pump.
Default value:
 brief depression – start-up of pre-heater;
 long – start-up of pump.
to start-up
Brief depression – start-up of pre-heater;
Long depression – start-up of pump.
Brief depression – start-up of pump.
Long depression – start-up of pre-heater.
Setting the temperature for switching to standby mode .
The pre-heater operates at full or low output depending on the coolant temperature.
The pre-heater heats the coolant until it reaches the set temperature and switches to
standby mode (the operation of the heater is interrupted, the pump continues to run). Upon
drop of the temperature, the pre-heater restarts.
The default temperature for switching to standby
mode is +88°С.
The necessary temperature for switching to standby
mode can be set in the range +20 … +95°С.
11
Setting of the activation of the re-heating mode .
In re-heating mode, the pre-heater operates together with the engine and keeps the
coolant temperature in the range 75…95°С.
Automatic mode:
 If the pre-heater is off, then it automatically starts upon engine start.
 If the pre-heater is off, then it automatically jumps to “re-heating” mode upon engine
start.
Manual mode:
 If the pre-heater is off, then it does not start automatically upon engine start (jit is
necessary to start it manually).
 If the pre-heater is off, then it automatically jumps to “re-heating” mode upon engine
start.
Upon switching off the engine, the pre-heater is also shut-down automatically.
The re-heating mode is off.
Re-heating mode (automatic).
Re-heating mode (manual).
Setting of re-heating temperature
The default temperature is +85°С.
The necessary temperature can be set in the range
+75 … +95°С.
Setting of pump in standby mode
In re-heating mode, upon switching of the pre-heater to standby mode, the pre-heater
is shut-down while the pump continues to run (default setting).
According to the given settings:
The pump remains in operation (from the moment of
start-up until shut-down of the pre-heater).
The pump operates simultaneously with the preheater and is inoperational during the standby mode.
12
Setting of cabin heater start-up .
During operation of the pre-heater, depending on the
coolant temperature, the cabin heater is automatically
started*.
The cabin heater shall not be started during operation of
the pre-heater.
* - Subject to the condition that the pre-heater is connected to a relay harness (purchased separately).
Setting of the necessary temperature for start of heater in the cabin
The default relay activation temperature is +40°С.
The necessary activation temperature may be set in
the range +30 … +60°С.
Setting of the start-up of the pump upon engine start.
The pump that is supplied with the pre-heater may be used for ancillary circulation of the
coolant during vehicle engine operation. The pump automatically starts upon engine start
shuts down upon switching off the engine.
Pump does not start-up.
Pump starts upon start of engine.
Setting of the pump mode
According to the assembly, the pre-heater may be equipped with a pump from “Bosch” or
“Elektrus”.
Pump manufactured by “ADVERS”.
Pump manufactured by “Bosch”.
Service information
The given menu shows the program version information. The menu is opened by pressing
the button
.
Resetting the control unit .
Reject resetting.
Reset to factory mode.
13
Faults .
Faults that arise during operation of the pre-heater are
coded and automatically displayed on the control panel
indicator in the form of an error code, which shall blink
slowly.
After the indicator goes off, the display
shows a symbol
WARNING
Technical service and repair must be done only by trained and qualified
staff!
Code
01
02
03
04
05
Description of the fault
Overheating.
High heating rate of temperature
sensors.
Potential overheating identified.
Difference between temperatures
measured by the overheating
sensor and heat sensor is too big
Commentaries
Solution of the fault
1. Check the full coolant circuit thoroughly.
2. Check the pump and replace it if necessary.
3. Check the temperature sensor and overheating sensor,
replace if necessary.
4. Check the quality of the Tosol (anti-freeze), which must be
used according to the ambient temperature.
Failure of temperature sensor 1.
Failure of temperature sensor 2.
Flame indicator failure.
Replace sensors if necessary.
Check connecting cables. Check the ohmic resistance between
the indicator contacts and it must not be more than 10 . In
case of failure, replace the flame indicator.
Failure of temperature sensor in
control unit.
Replace heater control unit.
Glow plug failure.
Check the glow plug, replace if necessary.
10
Air blower failure. The rpm
is lower than the nominal
value.
Check the electric wiring of the motor. Repair the fault,
replace the air blower if necessary.
12
Shut-down, voltage rise above
16V (30.8V).
13
Start-up attempts exhausted.
14
Pump failure.
06
09
14
This fault may occur if the pre-heater is switched on when the
vehicle engine is running. The cause may be vehicle voltage
regulator failure.
If the permissible number of permissible start-up attempts has
been exhausted – check the fuel level and fuel supply. Check
air trap, filter and exhaust pipe. Check the ignition plug.
Check the electric leads of the circulation pump for shortcircuit or breakage, check the pump and replace if necessary.
15
16
17
20
22
Shut-down, voltage drop below
10V (20V).
Ventilation time exceeded.
Fuel pump failure.
Connection failure between
control unit and control desk.
Fuel pump failure.
Check the voltage on connector ХS2 of the heater. Check
battery, vehicle voltage regulator and power supply wiring.
Flame detector not adequately cooled during purging. Check air
trap, filter and exhaust pipe. Check flame detector and replace
it if necessary.
Check the electric leads of the fuel pump for short-circuit,
replace if necessary.
Check connecting cables, connectors. Control panel does not get
data from control unit
Check the electric leads of the fuel pump for breakage, replace
if necessary.
Overheating of one of the
sensors.
Refer to error codes 01 and 02.
26
Air blower overload.
Check the air blower. The impeller of the air blower could have
come into contact with the cover of the heater resulting in
deformation of the fixtures.
27
Air blower failure. Motor is not
running.
24
28
29
30
37*
Air blower failure. Motor running
uncontrollably.
Re-heating attempts during
operation of the pre-heater
exhausted.
Connection failure between
control unit and control
desk.
Pre-heater locked.
Check the electrical leads, air blower and control unit, replace if
necessary.
Check the heating system. Check for the tightening of
clamps on the fuel line, leakproofness of the fuel line,
tightness of the fittings on the fuel pump, output of the fuel
pump.
Check connecting cables, connectors. The control unit is not
getting any data from the control panel.
Contact the service centre to unlock the pre-heater.
50
Connection failure between
control panel and modem.
Check connecting cables and connectors.
78
Flameout detected during
operation.
Stated for customer information.
Check for the tightening of clamps on the fuel line,
leakproofness of the fuel line, tightness of the fittings on
the fuel pump.
* WARNING! If error 13 consecutively occurs three times during start-up of the preheater, the pre-heater locks up. The purpose of this blocking is to prevent leak of the
residual fuel into the combustion chamber. Blocking will be indicated by display of error
code 37 on the control panel. To unlock the heater you need to contact the service centre.
15
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