MV Heating Airo 5, Workshop Manual

Page 1: ...MV Heating UK Ltd Unit 6 Second Avenue Business Park Millbrook Southampton SO15 0LP MV Heating UK LTD 44 0 2380 522345 MV Airo 5 WORKSHOP MANUAL ED 1 02 ...

Page 2: ...nd MV Heating will not be liable for any losses and damages in connection with the use of this information Under no circumstances shall MV Heating or its affiliates suppliers or installers be liable for any indirect incidental consequential special or exemplary damages arising out of or in connection with these manuals We do not take any warranties about the completeness reliability and accuracy o...

Page 3: ...at Sensor 9 Part 3 The E C U 10 Part 4 The Air Motor 11 Part 5 The Burner and Glow Pin Assembly Removal 12 Part 5 Cont d The Burner and Glow Pin Assembly Refit 13 Part 5 Cont d The Burner and Glow Pin Assembly Refit 14 Part 6 The Combustion Chamber 15 Part Numbers 16 Notes 17 Note The following flow charts will refer to the exploded diagrams or figures as F P where F donates the figure and P donat...

Page 4: ...m the bottom of the heater 8 Remove the four M6 nuts and washers from the base of the heater 9 Remove the heater and discard the mounting gasket Heater Installation To reinstall the heater back into position follow these steps 1 Locate heater into position with a new mounting gasket and secure with the four M6 nuts and washers to 6 1 Nm 2 Connect and secure fuel supply line to the heater s fuel in...

Page 5: ... 44 0 23 8052 2345 4 MV Heating UK Ltd Heater Cases Diagram 3 1 6 4 2 5 Figure 1 1 Inlet Cap 2 Outlet Cap 3 E C U Cover 4 Top Cover 5 Bottom Cover 6 Grill ...

Page 6: ...ng UK Ltd Internal Structure Diagram Figure 2 1 Overheat Sensor 2 E C U 3 Air Motor Assembly 4 Air Motor Gasket 5 Burner 6 Glow Pin Flame Sensor 7 Combustion Chamber 8 O Ring 9 Heat Exchanger 10 Insulating Bush 2 6 7 5 4 3 1 9 8 10 ...

Page 7: ... 44 0 23 8052 2345 6 MV Heating UK Ltd E C U Connections Diagram 1 2 7 6 5 4 3 Figure 3 1 Overheat Sensor 2 Glow Pin 3 Fuel Pump 4 Temperature Sensor 5 Main Wiring Harness 6 Empty 7 Air Motor ...

Page 8: ...ld be cleaned with appropriate cleaning fluid and blown dry with pressurized air Any sealing compound on parts must be carefully and completely removed before attempting to refit All disassembled parts should be Inspected for damage cracks distortion wear etc and replaced as required You should also regularly inspect all electrical connectors and wiring for corrosion loose contacts or wrong crimpi...

Page 9: ...er 1 3 and top case 1 2 together by sliding away from the bottom case 5 Remove the bottom 1 5 case by pulling away from air motor lugs first Refitting the Cases 1 Ensure all four rubber insulating bushes 2 9 are located on the tabs of the heat exchanger 2 8 first before refitting the cases 2 Replace bottom case 1 5 ensuring the air motor lugs sit inside the appropriate holes 3 Replace top case 1 4...

Page 10: ...2 1 from the E C U two blue wires 3 Slide the overheat sensor off the heat exchanger 2 9 It can be a tight fit and a small flat bladed screwdriver can be used to ease it off as necessary Refitting the Overheat Sensor 1 Replace the overheat sensor onto the heat exchanger 2 Plug the overheat sensor back into the E C U 2 2 paying attention to its correct orientation 3 Replace the cases Part 1 ...

Page 11: ...move the 2 x 3mm hex bolts from the top of the E C U 5 The ECU can now be removed allowing the final four pin connector to also be fully disconnected Refitting the E C U 1 Insert the four pin connector 3 7 into the appropriate slot in the ECU paying attention to its orientation 2 Reinstall the E C U securing it in place with the 2 x hex bolts located on top Tighten to 3 0 0 3 Nm 3 Reconnect the re...

Page 12: ... air motor by tilting it to one side so that the combustion intake clears the heat exchanger 4 The air motor gasket 2 4 can be removed and discarded once the air motor is clear Refitting the Air Motor 1 Place a new air motor gasket 2 4 around the end of the heat exchanger 2 Refit the air motor 2 3 back into position 3 Fit the 8 x hex bolts around the base of the air motor and tighten to 4 0 0 4 Nm...

Page 13: ...rommet fully through toward the burner 3 Using the socket screwdriver remove the 3 x 5 5mm hex screws from the burner 2 5 and place to one side 4 Use the flat bladed screwdriver to gently push in the fuel inlet grommet toward the burner being careful not to split it 5 Slightly lift the burner from the top away from the combustion tube and pull slightly toward the top of the heat exchanger 6 Rotate...

Page 14: ...2 6 in place 2 Gently remove the glow pin from out of its housing the glow pin can be tight to remove 3 Once out of its housing feed the glow pin through the correct hole the largest elongated one located on the burner 4 The burner and glow pin can now be inspected cleaned and replaced as necessary Glow Pin Refit 1 Feed the glow pin back through the largest elongated hole on the burner and reinser...

Page 15: ...2 Rotate the burner 180 to the left so that it faces the correct way and gently push it toward the combustion chamber 3 Insert and tighten the 3 x 5 5mm hex screws back into the burner to 2 5 0 25 Nm to hold it in place 4 Using the flat bladed screwdriver carefully push the fuel inlet grommet fully into position using some lubricant like WD40 as necessary 5 Feed the glow pin back through the glow ...

Page 16: ...can be stiff as the rubber O ring can become bonded between the chamber and heat exchanger 4 Remove the rubber O ring 2 8 from its position inside the combustion chamber and discard Refitting the Combustion Chamber 1 Place a new rubber O ring 2 8 into the recess of the combustion chamber 2 Insert the combustion tube 2 7 back into the heat exchanger 2 9 3 Replace and tighten the 4 x hex bolts into ...

Page 17: ...ssembly A5Z 004 5 Gasket A5Z 005 6 Air Motor 12V 24V A5C 006 A5A 006 7 Insulation Bushes A25Z 007 8 E C U 12V 24V A5C 009 A5A 009 9 Glow Pin 12V 24V A5C 014 A5C 014 10 Overheat Sensor A25Z 016 11 Inlet Cap A5Z 027 12 Outlet Cap A5Z 028 13 E C U Cover A5Z 024 14 Top Cover A5Z 025 15 Bottom Cover A5Z 026 16 Grill A5Z 029 17 Fuel Pump 12V 24V AHC 023 AHA 023 ...

Page 18: ... 44 0 23 8052 2345 17 MV Heating UK Ltd Notes ...

Page 19: ... 44 0 23 8052 2345 18 MV Heating UK Ltd ...