Manual for the Autonomous Air Heater Air Heater HEATCOOL
Introduction
This manual describes the basic functions, operating principle, and technical specifications of the HEATCOOL air heater. Before installing, using, or servicing the HEATCOOL heater, carefully read this manual in full.
The HEATCOOL air heater is intended for preheating and maintaining a comfortable temperature in the interior space of a vehicle (vehicle cabin, passenger areas, luggage compartments).
The heater features a compact structure, convenient installation, energy efficiency, safety and reliability, and simple maintenance.
Technical specifications
Supply voltage: 12 V / 24 V
Heat output: 1.5–5 kW
Fuel: diesel
Heat carrier: air
Volume of heated air: 160–285 m3
Fuel consumption: 0.19–0.55 l/h
Power consumption: 19–48 W
Operating range: 9–16 V / 18–32 V
Heater weight: 4.8 kg
(!) To ensure safe operation of the heater, all installation requirements specified in this manual must be observed.
Scope of delivery
User manual
Autonomous heater Air Heater HEATCOOL
Exhaust pipe
Air intake duct
Muffler
Remote control
Air duct and outlet grille
Fuel tank
Mounting plate
Wiring harnesses
Installation hardware kit
Fuel pump
Wiring diagram
Operating principle and installation location of Air Heater HEATCOOL
The air heater is a compact device for heating air in a vehicle cabin that operates independently of the vehicle’s engine. Electrical power is supplied by the vehicle’s battery. Fuel is drawn from the fuel tank included with the heater kit.
Areas of application:
1. Light, medium, and heavy diesel commercial vehicles (various types of trucks).
2. Construction machinery (loaders, excavators, cranes, etc.).
3. Vessels.
4. Agricultural machinery.
5. Small premises requiring heating.
The heater should be installed:
• in a free location within the passenger compartment (vehicle cabin);
• under a seat, between seats;
• in a free space under a toolbox or under a bunk;
• in the cargo compartment;
(!)
Attention:
The heater should be periodically switched off if operating continuously for an extended period (more than 8 hours).
When using the heater in enclosed spaces, such as a garage, pay attention to ventilation and do not allow exhaust gases to enter the heated area in order to prevent carbon monoxide poisoning or oxygen deficiency.
Permissible mounting position
The mounting position of the Air Heater HEATCOOL air heater must correspond to the illustration.
The inlet stub of the air intake and the outlet stub of the exhaust pipe must be directed downward (installation of the heater into the floor, suspended bracket, etc.) or at 90° relative to the heater axis (installation of the heater on a wall, bracket, etc.). When mounting the heater at 90°, the fuel line must be located above the axis of the heater. The exhaust pipe and air intake must be oriented below the horizontal to allow unobstructed condensate drainage.
Installation in a horizontal position is recommended. Operation is permissible with a deviation of up to 15° downward at the hot air outlet from the recommended position when the vehicle is parked on an uneven surface.
The mounting surface must be flat to prevent any gap between the heater and the mounting surface, thereby preventing exhaust gases from entering the heated space.
(!) The above installation rules must be followed to ensure safe operation of the vehicle, and the above key points must be strictly observed during installation.
.Heater installation
1. There must be free space between the heater and the underside of the mounting surface. Also check that the blower fan rotates freely.
2. The heater surface on which the sealing gasket is installed must be flat and free of burrs.
3. The rubber seal must be intact and fit tightly to the heater.
4. The vehicle mounting surface must be flat and free of burrs.
5. If necessary, an adapter mounting plate may be used.
To install the Air Heater HEATCOOL air heater, create the mounting holes at the installation location. Deburr the edges of the openings. The rubber seal is installed on the heater to ensure airtightness between the heater and the mounting surface, preventing exhaust gases from entering the heated space.
(!) Safety, stable operation, and long-term use of the product can be ensured by installation and operation in accordance with this manual.
.Air intake installation
The minimum air intake length must be at least 20 cm; the maximum length must not exceed 150 cm. The air intake and exhaust pipe must be directed in opposite directions.
An air filter may be installed at the inlet (depending on the configuration).
(!) Bending the air intake hose is prohibited.
(!) It is prohibited to orient the air intake in the direction of vehicle motion.
.Exhaust pipe installation
The minimum exhaust pipe length must be at least 20 cm; the maximum length must not exceed 150 cm.
The exhaust pipe must be directed opposite to the direction of vehicle movement to avoid potential impediments to exhaust gas removal.
During heater operation the exhaust pipe heats up due to the discharge of hot gases from the combustion chamber. The following instructions must be observed:
The exhaust outlet must be installed outside the vehicle.
The exhaust pipe must not protrude beyond the side of the vehicle.
The exhaust pipe must be inclined downward to drain condensate.
The distance between the exhaust pipe and vehicle components must be at least 50 cm.
When installing the exhaust pipe, avoid contact with any vehicle components, especially fuel lines, brake lines, and pneumatic circuits.
To prevent noise and vibration, the exhaust pipe must be rigidly secured using the fasteners supplied with the heater.
To prevent exhaust gases from entering the heater’s air intake, the directions of the exhaust pipe and the air intake must not coincide.
Accessories or items not specified by the manufacturer must not be installed on the exhaust pipe.
The exhaust outlet must not be exposed to mechanical impact and must be protected against ingress of foreign objects such as dirt, ice, snow, etc. The exhaust pipe must be directed opposite to the direction of vehicle movement.
(!) • High temperature and toxic exhaust gases are generated during heater operation; therefore the exhaust system must be installed in accordance with the installation instructions.
(!) • The heater must be switched off during mechanical work near the exhaust system. Protective gloves must be worn.
.Hot air duct installation
The air heated by the heater must be drawn from a clean location and must not be accompanied by dust, splashes, etc. Discharge of hot air may only be routed using a high-temperature air duct with a continuous heat resistance of at least 130°C.
The temperature of the heated air at a distance of approximately 30 cm from the air duct outlet must not exceed 110°C after approximately 10 minutes of operation with an intake air temperature of about 20°C. Reducing the cross-sectional area of the air ducts is prohibited.
(!) • When routing the hot air duct, it is prohibited to arrange it so that heated air is discharged directly onto people, animals, temperature-sensitive materials, or plastic vehicle parts, in order to avoid personal injury and damage to vehicle components.
(!) • The heater must be switched off during mechanical work near the heated air ducts. Protective gloves must be worn.
.Fuel pump installation
The fuel pump is designed to deliver metered portions of fuel to the heater’s combustion chamber. The fuel pump must be installed as shown in the illustration.
1. Fuel pump
2. High fuel level
3. Low fuel level
4. Heater fuel pickup
Optimal angle: 15°–35°
Permissible angle: 35°–90°
When the fuel pump is below the fuel tank, the height difference between the highest liquid level in the fuel tank and the fuel pump must not exceed 1.5 meters.
When the fuel pump is above the fuel tank, the height difference between the minimum fuel level and the fuel pump must not exceed 1 meter.
When the fuel pump is below the heater, the height difference between the fuel pump and the heater must not exceed 1.5 meters.
The length of the fuel line between the fuel tank and the fuel pump must not exceed 1.5 meters, and the distance between the fuel pump and the heater must not exceed 6 meters.
.Fuel line installation
The fuel tee for supply must be connected between the vehicle’s fuel tank and the vehicle’s fuel pump.
(!) It is prohibited to install the tee into a high-pressure fuel line. In such a case, use the fuel pickup included in the kit.
The fuel line must be securely fastened.
When routing the fuel line, exercise caution to avoid stretching, compression, abrasion, or vibration of the fuel line.
The fuel line must not be routed in high-temperature zones and must be kept away from heat sources. The fuel line must not be routed or secured near the vehicle’s exhaust system.
After connecting the heater to the fuel line, all joints of each component must be checked for fuel leakage.
It is prohibited to use the vehicle’s fuel pump to supply fuel to the heater.
Wiring harness and circuit installation
To connect the fuel pump to the heater or the heater to the vehicle, wiring harnesses are used; they must be routed and secured in appropriate positions. The distance between fixed points must not exceed 30 cm. A wiring harness installed outside the vehicle must be protected.
Electrical connection of the heater must be performed in accordance with the instructions.
The insulation of the wiring harness must not be damaged; avoid abrasion, folding, pinching, heating, etc.
For unsealed connectors, plugs shall be used to seal unused connector cavities to prevent ingress of water and dirt.
The main wiring harness, the control panel harness, and the fuel pump harness must be installed at a distance from heated parts of the vehicle to avoid damage.
.Air Heater HEATCOOL control panel
The control panel is intended for switching the heater on/off and for selecting the heater operating mode.
To start the heater, press and hold 
for 3 seconds. Switching between the “by temperature” mode and the “by power” mode is performed by briefly pressing while the heater is running.
In the “by temperature” mode, the knob can be used to set a temperature from 18°C to 45°C. The temperature sensor is located in the control panel. The heater will heat the air in the space to the set temperature.
In the “by power” mode, 9 steps are available, where step 9 corresponds to the heater operating at maximum output.
If a fault occurs, a fault code will be displayed on the control panel screen.
| Code | Description | Remedy |
| E-01 | No fuel | Check fuel level in the tank. Check the fuel line |
| E-02 | Flame interruption | Check fuel availability. Clean combustion chamber of soot. Replace mesh for the glow plug |
| E-03 | High/low supply voltage | Check the battery and voltage regulator |
| E-05 | Temperature sensor fault | Replace control unit |
| E-06 | Fuel pump fault | Check the fuel pump electrical circuit. Replace the fuel pump if necessary |
| E-07 | Blower fault | Check the blower for clogging. Check the electrical circuit |
| E-08 | Glow plug fault | Check the glow plug. Replace if necessary |
| E-09 | Heat exchanger casing overheating | Check the heater inlet and outlet grilles for foreign objects |
| E-10 | Flame sensor fault | Check the flame sensor. Replace if necessary |
Electrical schematic
Automotive electronics manuals |