Planar PLANAR-9D-12, PLANAR-9D-24 Operating Manual

EN

Air Heater

PLANAR 9D

Operating Manual

ADVR.216.00.00.000 RE

(25.01.2018)

2

Sales department

Autoterm LLC

Trikatas street 4, Riga, Latvia

[phone]

E-mail: sales@autoterm-

europe.com www.autoterm-

europe.com

ADVERS LLC

Russia,

443068, Samara, Novo-

Sadovaya street, 106

[phone]

www.autoterm.ru

Service support

Autoterm LLC

Trikatas street 4, Riga, Latvia

[phone]

Е-mail: service@autoterm-

europe.com

To find nearest service point:

https://autoterm-

europe.com/en/partners

TABLE OF CONTENTS

1 Introduction ..................................................................................................................... 3

2 Basic parameters & specifications .................................................................................. 3

3 Safety Measures............................................................................................................... 4

4 Description of Heater Structure and Operation............................................................... 5

5 Heater control unit........................................................................................................... 6

6 Control panel ................................................................................................................... 6

7 Scope of Supply............................................................................................................... 9

8 Installation requirements ............................................................................................... 10

9 Post-installation testing ................................................................................................. 16

10 Recommendations ......................................................................................................... 17

11 Possible malfunctions during operations and Remedial Procedure for Heater Ignition

Problems......................................................................................................................... 18

12 Transportation & storage............................................................................................... 19

13 Warranty ........................................................................................................................ 19

3

1 Introduction

This operation manual is intended to familiarize the User with salient features,
operation, assembly and operating procedures for PLANAR–9D-12, PLANAR–9D-24,
(hereinafter called «the heater») intended for regulated heating of various compartments of a
motorized vehicles at atmospheric temperatures as low as -45°С (-113F).

Minor changes performed on the heater structure by the Manufacturer may not
be documented in this operation manual.

When placing an order or referring to the heater in documents pertaining to other types
of equipment, the heater codes will read as follows:

«Отопитель воздушный

/

Air Heater

PLANAR–9D-12 TU4591-008-40991176-2005»;

«Отопитель воздушный

/

Air Heater

PLANAR–9D-24 TU4591-008-40991176-2005»;

2 Basic parameters & specifications

The basic heater specifications are quoted in Table 1.

The basic parameters are quoted to a margin of 10% tolerance at a temperature of
20С (68F) at a nominal voltage.

Parameter Code

Version

PLANAR–9D–12

PLANAR–9D–24

Nominal Supply Voltage, V

12

24

Fuel type

diesel

Heating efficiency,
kw / btu

max

min

max

min

8.0 / 27,300

3.2 / 10,900

8.0 / 27,300

3.2 / 10,900

Air flow rate,
m³/h / cfm

max

min

max

min

290 / 170

70 / 41

290 / 170

70 / 41

Fuel consumption,
l/h / gal/h

max

min

max

min

1.0 / 0.26

0.42 / 0.11

1.0 / 0.26

0.42 / 0.11

Power consumption,
w / A

max

min

max

min

215.0 / 17.9

12.0 / 1.0

180.0 / 7.5

12.0 / 0.5

Air temperature control

manual/automatic

manual/automatic

Weight, kg / lb

18.0 / 39.7

4

Table 1

3 Safety Measures

3.1 The installation of the heater and its fittings shall be performed by

authorized organizations only.

3.2 The heater may only be used for the purposes specified herein.

3.3 The fuel supply line shall not be installed inside the passenger compartment

or cabin of a motor vehicle.

3.4 The vehicle electric harness shall not be installed near the fuel supply line.

3.5 A vehicle that uses the heater shall be equipped with a fire extinguisher.

3.6 It is prohibited to use the pre-heater in areas, where highly inflammable vapors or

ample quantity of dust may be generated or accumulated.

3.7 To prevent the possibility of exhaust gas poisoning, the heater shall not be used

when the vehicle is in the closed, not aired rooms (garage, workshop, etc).

3.8 When refueling the vehicle, the heater shall be switched off.

3.9 When performing welding operations on the vehicle or repairs on the heater,

disconnect the heater from the vehicle battery.

3.10 When assembling or dismantling the heater, observe the safety measures specified

by electric work regulations for the fuel supply system and the vehicle’s wiring system.

3.11 The heater shall not be connected to the vehicle electric circuit while the engine is

running or the battery is switched off.

3.12 The heater’s electric power supply must not be disconnected before the end

of the purge cycle.

3.13 The heater is powered from the accumulator battery regardless of the availability

of the vehicle frame connection.

3.14 The heater’s connectors must not be connected or disconnected while the heater’s

electric power supply is turned on.

3.15 It is forbidden to step on a heater and to put on it subjects.

3.16 It is forbidden to cover a heater with articles of clothing, pieces of fabric, etc. and

as to place them before its entrance or an exit of heated air.

3.17 Wait 5 to 10 seconds before switching the heater back on.

3.18 In the event of two subsequent ignition failures, contact the maintenance

department to report a malfunction.

3.19 In the event of a failure in heater operation, contact a designated repair

organization authorized by the manufacturer.

3.20 Manufacturer warranty shall not apply if the above requirements are not

adequately met.

5

4 Description of Heater Structure and Operation

The heater operates independently from the vehicle engine.

The fuel and electric power supply is provided by the vehicle. See figure 4.1 for the
heater wiring diagram.

The heater is a self-contained heating device comprising the following:

- heating device (see figure 4.2 for basic components thereof);

- fuel supply pump providing fuel for the combustion chamber;

- ignition and indicator device (control panel);

- wiring harness connecting heater fittings to the vehicle battery.

- fuel tank

The heater’s operating principle is based on heating air driven through the

heater’s

heat exchange system.

The heat sources are fuel combustion gases from the combustion chamber. The
resulting heat warms the walls of the heat exchanger, which is air-blown from the outside. Air
passes through the ribbing of the heat exchanger and enters the passenger compartment or
other compartments of the vehicle.

Upon ignition, control unit of the heater checks the heater to ascertain whether fittings
such as the flame indicator, the overheat sensor, air pump motor, plugs, fuel supply pump
and the electric circuits thereof are working properly.

If no problem is detected, the ignition process starts.

In accordance with the preset sequence, the combustion chamber is fore-purged and the
glow plug warms up to the required temperature. Air and fuel starts to enter the combustion
chamber under the same procedure, whereupon the ignition process is initiated. Once stable
combustion is achieved, the heating plug switches off. Flame control is provided by
the
flame indicator. All processes involved in heater operation are monitored by the
control unit.

The control unit controls heat exchanger temperature and halts the combustion process as
soon as the temperature exceeds the specified limit and the temperature of the heated air. The
heater may be switched off at any time.

Pressing the heater deactivation command stops the fuel entering and the combustion

chamber is purged with air.

During automated operation control of the heater in emergency situations, bear in mind
the following:

1) in the event of ignition failure, the process will be repeated. The heater will switch off
following two consecutive ignition failures;

2) if in a operating time of a heater, a burning stops, then the attempt of starting will be
repeated. In operating time of a heater a flameout is possible till 3 times;

3) if the heat exchanger is overheated (maybe as a result of closure of the heater
inlet/outlet vents), the heater will switch off automatically,

4) if the heated air is overheated maybe as a result of closure of the heater inlet/outlet
vents), the heater will switch off automatically.

5) if voltage drops below 20 V (10 V) or exceeds 30 V (16 V) the heater will switch off;

6) at emergency switching off of a heater on the control panel (CP) the light-emitting
diode blinks. The quantity of blinking corresponds to an error code. Watch an error
code in the manual of control panel.

6

5 Heater control unit

The control unit and the control panel control the heater.

The control unit performs the following functions:
а) initial diagnostics (serviceability check) of heater fittings during ignition,
b) diagnostic of heater elements throughout operation,
c) heater activation/deactivation by command from control panel;
d) combustion process control;
e) automated switching of ventilation after the combustion process stopped;
f) automated deactivation of the heater occurs:

- in the event of failure of one of the controlled elements,

- when any parameter exceeds the specified limit (heat exchanger temperature, air
temperature, supply voltage)

- combustion chamber flame failure (more than 3 times)
6 Control panel

On the front panel of the control panel are located:

1 – Button on/off ventilation mode;
2 – Button on/off heater;
3 – Light-emitting diode to display of working
of heater;
4 – Light-emitting diode to display of the mode of
ventilation;
5 – Potentiometer handle.

The light-emitting diode pos. 3 shows a mode

of working of a heater:

- shines yellow – the heating mode;

- blinks often yellow – during a purge;

- blinks seldom red – at malfunction of heater;

- doesn't shine – at an not working heater.

The light-emitting diode pos.4 shows a condition of the mode of ventilation:

- shines green – if the cabin temperature sensor isn't connected and the heater works
in the ventilation mode;

- blinks green – switching off of the mode of ventilation;

- shines yellow – if the cabin sensor is connected and the heater works at the heating
mode with ventilation function;

- doesn't shine at an idle heater and at the switched-off ventilation mode.

Work with the control panel is described in manual on the control panel.

7

1. View of connector (XS1, XS3, XS7, XP1, XP3, XP7) is shown from contact side (not
from wires side).

2. *color of a tag on wires

3. **to buy in addition

1. Figure. 4.1- Wiring diagram

Figure 4.2 – Basic heater components

8

9

7 Scope of Supply

See figure 7.1 for scope of supply and connection diagram of basic heater components

PLANAR-9D-12, PLANAR-9D-24.

Figure 7.1 – Connection diagram of basic heater components

10

8 Installation requirements

8.1 Heater installation

Install the heater according to figure 8.1. Peace of installation for the heater should be

flat. Position the heater’s inlet vent in such a way to prevent absorption of vehicle/heater

exhaust gas in normal operating conditions. The distance between the walls/partitions and
the edge of the inlet vent shall be at least 100 mm (see figure 8.1). The distance between the
walls/partitions and the edge of the outlet vent shall be at least 250 mm. When assembling or
operating the heater, ensure that no foreign objects enter the inlet/outlet vents. Prior to
assembly, ensure availability dismantlement requirements, as this will permit easier
maintenance in future.

See figure 8.1b how to position mounting holes to install the heater into the
motor

vehicle casing.

ATTENTION!!! To ensure reliable performance, follow the above

recommendations carefully. Install the heater horizontally as shown on the figure 8.1.

Figure 8.1 – Variants of installation of a heater.

11

At installation of the heater check that
its case had no contact both with a floor
and with other parts of a cabin or a manned
compartment. Non-performance of this
requirement can lead to deformation of the
heater case, jamming of the air fan and
a possible overheat.

Fig. 8.1a - reserve free space

Figure 8.1b– Mounting holes used for heater installation

8.2 Air inlet installation

Air necessary for burning, should not be soaked up from salon or a cabin and a car

luggage space. Position the pipe’s air inlet vent to prevent snow entering or choking

the
pipe and to allow incoming water to run off. The entrance aperture of an air inlet
is forbidden to have against a running air stream at car movement.

8.3 Exhaust pipe installation

When installing the exhaust pipe, be mindful of its high operating temperature.
Exhaust pipe is fixed with clamps.

Direct exhaust gas outside. Position the gas outlet vent and the air inlet vent in such a
way as to prevent exhaust gas from entering the combustion chamber.

Ensure that exhaust gas does not enter the passenger compartment of the vehicle and that
it does not get sucked in through the vehicle fan. Do not allow exhaust gas to affect the
performance of vehicle components. Position the exhaust pipe outlet vent so as to prevent
snow entering or choking the pipe and to allow incoming water to run off. The
exhaust outlet of an exhaust pipe is forbidden to have against a running air stream at car
movement.

At the vent of the exhaust pipe the screen is installed, this is necessary for stable
operation of the heater while working low idle.

12

Attention! At installation of a heater into the volume of vans (isothermal boxes,
minibuses, etc.) the arrangement of an exhaust pipe and an air inlet on opposite boards is
inadmissible. Installation of exhaust and air intake pipes through one board is correct. The
distance between them has to exclude repeated absorption of exhaust gases through an air
inlet (not less 200mm).

Non-performance of the listed recommendations under adverse conditions (a strong
wind, of pressure differences) not only interferes with an exit of exhaust gases, but
also creates additional discharge in an air intake zone. As a result normal work of a burner is
at a loss, there is its contamination soot and heater service life is reduced.

In rare instances non-performance of this recommendation can lead to hit of a flame in
the blower of air pump.

Fig.8.3a – recommended position.

13

8.4 Installation of heater fuel supply system

To prevent emergency situations, follow these instructions carefully

8.4.1 Installation of heater fuel pump and fuel tank

A fuel tank it is necessary to fix so that the exit of fuel which can flow out from its bulk
mouth, on the earth was provided.

The bulk mouth of a fuel tank should not be in salon, a luggage carrier, in a motor
compartment. If the bulk mouth is located on a vehicle lateral face the filler cap in

the closed position should not support car’s body dimensions. Fuel which can spill at filling

of a fuel tank, should not get on exhaust systems and electro wires. It should be taken away
on a ground.

The fuel supply pump should be mounted as close to the fuel tank as possible

and
positioned below the tank’s lower fuel level.

For the purpose of an exception of leak of fuel from a fuel tank by gravity at
infringement of tightness of the fuel pump, a fuel tank it is preferable to have so that the fuel
maximum level was below a cut of a fuel tube of a heater.
ATTENTION!

Before a heating season it is necessary to check a fuel tank. If the fuel was stored long
time in a tank (for example from last heating season), it needs to be removed! To wash out
a tank with gasoline or kerosene and to fill in new diesel fuel. This procedure is intended for
removal of a deposit in fuel at long storage. Not performance of this procedure can lead to a
contamination or failure of the fuel pump and the raised sooting in the combustion chamber.

Heaters of PLANAR-9D-12, PLANAR-9D-24 it is completed with the fuel pump for

which mounted position has to be correspond to fig. 8.4a, i.e. ± 5 ˚ from horizontal

position.

Figure 8.4a- Permissible mounting position of fuel pump

8.4.2 Installation a fuel supply intake in a regular tank of the car

Fuel supply intake must be installed into regular fuel tank of the car according
to figure 8.5.

a) Perform installation of special washer with fuel supply intake to the tank

inlet
according to figure 8.5

b) Perform installation of the fuel supply line from fuel supply intake to the
heater according to figure 8.6.

14

Attention!!! While manufacturing a hole in a regular fuel tank of the car it is
necessary to fulfill safety requirements for works with tank which was filled with
combustible and explosive fuel.

1- fuel supply intake 4- washer 8
2- nut M8 5- special washer
3- washer 8 6- gasket

Figure 8.5 – Fuel supply intake installation in a regular tank of the car

1 – regular fuel tank of the car 4 – fuel pump
2 – fuel supply intake 5 – sleeve
3 – fuel supply line d=4 mm 6 – fuel supply line d=5mm

7 – fuel supply line d= 2mm

Figure 8.6 – Installation diagram for heater fuel supply system using a fuel supply intake

15

8.4.3 Fuel intake from return fuel pipe with T-connector

Allowed fuel intake from the return fuel pipe (unloading fuel from the engine to the
tank) with T-connector. Return fuel pipe should be free of pressure and goes at the bottom
of the fuel tank. The installation of the T-connector according to Fig. 8.7;

1 - regular fuel tank 4 - fuel supply line dу = 2мм
2 - return fuel line from engine to tank 5 - T-connector
3 - sleeve 6 - fuel pump

Рис. 8.7 – Installation diagram for heater fuel supply system using return fuel pipe.

When installing the fuel supply line, do not allow connecting sleeves to bend. Use a
sharp knife to cut the fuel tube as in figure 8.8. The cutting location shall be free of
indentations, hairs and must not restrict flow through the tube.

Correct Incorrect

Figure 8.8 – Pipe cutting prior to installation

ATTENTION.

1. Do not allow the fuel supply line or fuel supply pump to overheat. Do not install

the fuel supply line and fuel supply pump near the exhaust pipe or on the engine.

2 The fuel supply line connecting the fuel supply pump to the heating element of

the heater should be installed at the same lifting angle.

16

8.5 Installation of heater electric circuit

Heater wire harnesses shall be installed in compliance with the heater wiring system as
shown in figure 4.1. When installing, do not allow the wire harnesses to become
overheated, deformed or dislodged during vehicle use. Attach the harnesses to the vehicle
fittings using plastic clamps.

If it is necessary to truncate length of a harness of the fuel pump, it is allowed to cut out
unnecessary part from the middle of a harness. The junction needs to be closed with a
thermoshrinkable tube.

Attention! We recommend to cut a harness at distance of 500-700 mm from any of end
of a corrugated tube of a harness and to cut out unnecessary part. To take wires, to
remove isolation from the ends of all connected wires, to put a thermoshrinkable tube on
wires and to twist wires of identical color. To establish a thermoshrinkable tube so that twist
appeared in the middle of a tube. To heat a tube and to set it on wires. To put wires in a
corrugated tube and to close a junction with an insulating tape.

Attention! Installation should be performed with the fuse disconnected.

Figure 8.9 - Block and nest arrangement before installation

8.6 Control Panel installation and connection
Control Panel is installed in cabin or passengers compartment on the dashboard or any

other comfortable for the driver place.

The connection of the Control panel to the heater is performed according wiring

diagram (fig. 4.1)

9 Post-installation testing

9.1 When installing, ensure that:

- the fuel supply system is leak-proof

- the electric contacts of the harnesses and heater elements are securely installed

9.2 Install fuse 25А .

9.3 Fill the fuel pipe system with fuel with the help of fuel pumping device (fuel

pumping device can be ordered at manufacturer).

9.4 Check that the heater is working :

- in ventilating mode,

- in heating mode.

The process of activation begins with purging of the combustion chamber. After
purging the process of combustion begins and the heater goes on working in operation
mode.

9.5 Deactivate the heater. While switching off the heater the fuel stops entering and the

process of ventilation of the combustion chamber and heat exchanger starts.

9.6 Activate the heater while the vehicle engine is running and ensure that the heater is

operational.

17

ATTENTION!

1. When performing initial ignition following installation, the fuel supply line
should be filled with fuel using a fuel pumping device until the fuel level reaches the
inlet plug of the heater. If there is no pumping device, restart the heater as many times
as necessary to fill the fuel supply line.

2. Remember that each time the heater fails to start at the first attempt, the
heater will be restarted automatically by the control unit.

10 Recommendations

10.1 To ensure consistent performance, the heater should be switched on for up to 5-10
minutes each month throughout the year (warm seasons included). This will prevent the
moving parts of the fuel supply pump from sticking. Failure to comply with this advice
may cause malfunctions in heater operation.

10.2 Reliable operation of heater depends on the type of fuel used. Type of fuel should
be in accordance with GOST 305-82, depending on the ambient temperature
(see Table 10.1). May be used and the mixture of fuel according to Figure 10.

Table 10.1

Ambient temperature,

°C

Fuel type or blend

0°С and above 0°С Diesel L-0, 2-40 Or L-02-62 GOST 305-82
0°С – -5ºС (32°F – 23°F) Diesel Z-0,2 mines 35 GOST 305-82

-5ºС - 20ºС (23°F - -4°F)

Blend diesel Z-0,2 mines 45 GOST 305-82(50%) with
petrol GOST Р511050-97(50%)

Lower than -20ºC (-4°F)

Diesel A-0.4 GOST 305-82 or blend diesel З-0,2 mines 45

GOST 305-82 (50%) and petrol GOST Р51105-97(50%)

Figure 10 - Amount of kerosene mixed with diesel fuel, depending on the ambient

temperature.

10.3 An untimely switch to a winter type of fuel may cause a paraffin blockage in the
fuel inlet tube filter (if applicable) located in the fuel tank and in the fuel supply pump filter,
which may prevent the heater from starting or cause it to stall in mid-operation.

18

To fix breakdowns, proceed to the following steps:

1) remove the fuel supply pump from the vehicle; using a wrench (F/A 17), fix
the pump in place, unscrew the pipe stub and remove the filter (see figure 10). Do
not
fix the pump in place using surfaces other than surface A when removing
and installing the pipe stub;

2) rinse the filter in gasoline and blast it with compressed air;

3) install the filter into the fuel supply pump; use sealant when installing the pipe stub;

4) install the fuel supply pump and check if the heater works.

Figure 10. Fuel pump

10.4 Check the battery charge level on a regular basis.

10.5 It is recommended to switch on the heater with vehicle ground breaker closed.

10.6 While long storage of the vehicle it is recommended to switch off the
heater from the vehicle battery to avoid its discharging (current consumption in non­operation mode 30-40 mA).

11 Possible malfunction during operations and Remedial Procedure for Heater

Ignition Problems

11.1 Certain problems may be solved without contacting a maintenance station.

If the heater does not operate when switched on, proceed to the following steps:

1) check the fuel level in the tank and in the fuel supply line beyond the fuel
supply pump,

2) check fuse 25А,

3) check to see that all the contacts of the connectors and the fuse block are
securely joined (contact corrosion is possible),

11.2 All other arisen malfunctions can be determined by quantity of blinkings of

a
light-emitting diode on the control panel (CP). The quantity of blinkings and codes
of malfunctions are specified in manual of the control panel.

11.3 If there are malfunctions except those specified in 11.1, please contact an

authorized maintenance station.

19

12 Transportation & storage

12.1 The heaters are safe to transport and may be transported by any means of
transport, including air and rail transport providing the packed products are protected from
atmospheric precipitations and climatic factors as per requirements specified in section 5 of
GOST 15150-69 and mechanical effects as per requirements specified in category C
of GOST 23216-78.

12.2Storage conditions of heaters in packing of manufacturer have to correspond to

storage conditions of 2 GOST 15150-69.

12.3 The period of storage heaters in packing of manufacturer order of 24 months.

13 Warranty

13.1The warranty term of exploitation of heater outflows under reaching one of next
terms:

- the term of exploitation attained 24 months after the sale of good;

- good worked a warranty resource - 1000 hours;

- mileage with established heater exceeds 50,000 km.

13.2 Appointed tenure of employment of heater - 3000 hours.

13.3 In default of stamp of organization with naming the date of sale a warranty term
is calculated from the date of making of heater.

13.4 A manufacturer does not accept claim on incompleteness and mechanical
damages after sale of heater.

13.5 A producer guarantees normal work of the heater on condition of observance by
the consumer of all rules of exploitation, transportation and storage, indicated in this
guidance. If a malfunction was found out during a warranty term, then she will be set free
of charge. Installation of heater the organizations authorized by a producer must conduct. In
this case, the warranty card is filled column «Information on installation.»

Warranty obligations do not spread to the defects arising up as a result:

- force-majeure circumstances: shots of lightning, fire, flood, impermissible violations

of supply voltage,

- road a transport incident;

- failures to observe of rules of exploitation, storage and transporting;

- repair or adjusting, if they are conducted by the organizations, not authorized by a

producer on installation of the heater and warranty repairing;

- refuse of work of heater by reason of contamination of combustion chamber;

- violations of work of electrical equipment of car;

- independent repair of heater or the use of unoriginal spare parts.

Look www.autoterm-europe.com for the list of organizations performing

warranty repair of Autoterm products.

Please contact Autoterm company [phone], Е-mail: service@autoterm-

europe.com in Riga, Latvia regarding any issues of technical service.