CONTENTS. 1. Planning The Installation Installation Trial Operation Final Check Wiring Diagrams...

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Amos Walton
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1 CONTENTS 1. Planning The Installation Installation Trial Operation Final Check Wiring Diagrams

2 Installation of the heater. The Mikuni MX series heaters are diesel fired water heaters running off either a 12 or 24 volt DC supply.to ensure good service from your heater it is important to install it correctly paying attention to al l the details laid out within this instruction manual. This manual details installation of models MX40 & MX60 as there are many c ommon installation parameters. When the parameters differ seperate details are given specific to each heater. Planning the Installation Take time to plan your installation! The heater should be sited in an area where: (i) It will not have items stored against it. (ii) It will not be exposed to weather. (iii) It is within the parameters set out in this m anual regarding fuel and power supply. (iv) It is within the parameters set out in this manual regarding heater mounting. (v) The exhaust outlet skin fitting is well clear of the water line. (vi) The exhaust pipe is not touching anything inside the boat which could be damaged by hea t - The exhaust pipe does get hot even though it is insulated! Types of installation. The 'MX' Heaters can be used to heat radiators, matrix heaters or a combination of both. The domestic hot water can be obtained by passing the hot water from the Mikuni throug h the coil of a calorifier. The system can be either gravity fed from a header tank or pressurised from the domestic pump with an accumulator tank to allow for expansion in the system. Tools for your Installation. 1. Electric drill with slow speed. 2. Crimping pliers. 3. Wire cutters. 4. Metric spanners 8mm to 13mm. 5. Flat blade & posidrive screwdrivers. 6. Sharp knife. 7. Pipe shears [for plastic & rubber water pipe]. Plumbing requirements. We recommend plastic plumbing for marine applications as it is easy to fit and modify i.e: If you wish to add an extra radiator/ matrix heater at a later date. The MX40 & MX60 should be plumbed with a 22mm main circuit with 15mm 'T' off to the radiators/ matrix heaters. It is very important to maintain good water flow through th e heat exchanger of the Mikuni heater due to their compact size

3 1. Mounting the heater. The heater should be monted in a well ventilated locker which should be dry and within 2 m etres of a suitable site for the exhaust skin fitting. It should also give consideration to servicing and acce ss for cleaning the glow plug. MX40: The MX40 is supplied mounted on a stainless steel 'plate' which incorporates the control box and fuel pump assy. The unit is prewired and factory tested for ease of installation. The Anti-Vibration mounts and mounting brackets should be fixed to the mounting plate as shown in Dia 2. The mounting plate should then be screwed to a vertical bulkhea d with the 4 x 3/4" No10 s/s self tapping screws provided. Try and keep the horizontal axis as close to 0 o as possible. It is very important to mount the heater as shown in Dia 2. b elow for correct operation. Note: The permissible inclination angles shown in Dia 2. Mounting Bracket A.V. Mount Control Box Mounting Plate Fuse Holders Heater Body Dia 1. Fuel Pump Permissible longitudinal inclination = 15 o either side of vertical TOP Permissible Vertical inclination. 16mm TOP Hot Water Outlet 20 o Horizontal Axis Combustion Air Inlet 16mm Mounting Plate Exhaust Pipe Water Inlet A.V. Mount Vertical Bulkhead END VIEW Dia 2. FRONT VIEW - 3 -

4 MX60: The MX60 is supplied on a mounting bracket which is best mounted on a horizontal surf ace as shown in Dia 3. If you want to mount the heater on a vertical bulkhead it is possible to rotate the mounting bracket by r eleasing the 2 x hose clips marked 'A'. The MX60 shown is Dia 3. is a 24 volt unit which has the water pump attached to the heat er body. The 12 volt MX60 has a seperate water pump. 'A'. Water pump [fixed to heater on 24v model only]. SIDE VIEW Exhaust pipe Combustion air inlet END VIEW Dia 3. If you mount the MX60 on a horizontal surface, mark the mounting screws and exhau st position with the template provided. Drill a 40mm clearance hole for the exhaust pipe and 4 x 7mm holes for the mounting bracket. Now fix heater in place with the 4 x M6x25mm s/s set screws provided. 2. Exhaust system: There are 2 types of exhaust fitting supplied with the MX40/MX60 heater units. The i nland waterways kits have a brass screw in skin fitting whilst the 'offshore' kits have a polished stainless steel skin fitting. The exhaus t skin fitting needs to be fitted as far above the water line as possible to prevent any ingress of water into the heater. An ideal place for the skin fitting is on the transom. Brass Skin Fitting: Once you have planned the siting, drill a 4mm pilot hole as guidance for the pilot drill o n the hole saw arbour. Now drill the correct size hole: MX40=28mm MX60=35mm. When you have completed this apply silicon to the rear of the face and tighten the brass nut to secure. Silicon sealant Transom Exhaust Outlet Spigot for s/s exhaust Securing Nut Brass Exhaust Terminal - 4 -

5 Stainless Steel Skin Fitting: Once you have planned the siting, drill a 4mm pilot hole as guidance for the pilot drill o n the hole saw arbour. Now drill the correct size hole: MX40=40mm MX60=55mm. When you have completed this re-drill the hole at an angle at a slow speed (see dia 2 ) to allow the skin fitting to fit in a snug hole. Now drill 4 x 5mm holes for the fixing bolts, appl y silicon to the rear of the face and secure in place with the 4 x M5 x 40 c/s screws provided. Transom 4 x fixing screws Drill with hole saw at angle after you have drilled the perpendicular hole. BE CAREFUL! Dia 5. Silicon sealant Fix the s/s exhaust to the skin fitting and secure with the heavy duty clamp. Cut the exhaust at a convenient place and slide over the first section of insulating sleeve, turn the ends back inside themselves and clamp in place with 2 x 38mm hose clips provided. Now put a heavy duty clamp on the remaining end and insert the silencer. Take the remaining insulation sleeve and 2 x 38mm clamps, slide onto the exhaust, form into a swan neck to prevent any ingress of water, cut to length and fit to the silencer with the heavy duty clamp. Now fix the insulation sleeve as before. NOTE: THE EXHAUST DOES GET HOT- DO NOT CLAMP IT TO ANY COMBUSTIBLE MATERIALS. 3. Combustion Air Inlet. The combustion air is normally drawn from the area/locker that the heater is situat ed in. Ensure that there is adequate ventilation for the burner MX40 = 1,020mm 2. MX60 = 1,960mm 2. The MX40 has an integral combustion air silencer and filter whilst the MX60 is a seperate unit which has to be fitted. Mount the silencer in a convienient place near the heater with the cable ties provided. Now cut the 28mm enduraflex ducting to length and fix using 2 x 28mm hose clips. 4. Fuel System. The heater is supplied with a fuel standpipe to be fitted into the top of the fuel tank. Use this whe never possible-it is the preferred method because it does not interfere with the engine fuel supply. Find a suitable location in the fuel tank that has no obstructions inside, put some g rease around the chosen location and drill a 22mm hole - the grease should help prevent any debris falling into the fuel tank. Now cut the standpipe so that it is about 30mm off the bottom of the fuel tank, slide into place and tighten the fixing nut. (see dia 6.) The fuel pump should be fitted near the fuel standpipe - 5 -

6 Installation of copper fuel line. 1. Fit the 1/4" to 3/16" reducer onto the standpipe. 2. Cut the required length of copper pipe from the amount supplied and fit to the fuel cock. 3. Fit the straight connectors to the fuel pump. NOTE: 3 connectors are fitted with 1 rubber olive and 1 copper olive and 1 straight connector is fitted with 2 rubber olives.the connector with 2 rubber olives is to be mounted between the fuel pump outlet and the fuel damper. Item 'A'. 4. Mount the fuel pump near the fuel cock at a 45 o angle as shown. The MX60 has a solenoid valve instead of the manual fuel cock which will turn the fuel on automatically when the heater is operated. 5. Fix the remaining connector to the fu el inlet on the heater with the rubber olive on the heater stub. 6. Cut the copper pipe to length, fit to the pump and the heater. These olives are neoprene rubber. The fitting on the heater uses a neoprene rubber olive Heater. 'A'. Fuel pump. 1/4" x 3/16" Reducer 3/16" Fuel cock Fuel standpipe Solenoid Valve MX60 Only 30mm Diesel tank Length of pipe (max) Standpipe to fuel pump: Fuel pump to heater: Head (max) Bottom of fuel tank to pump centre: Pump centre to heater centre: (mm) <2000 Dia 6. NOTE: The fuel pump is a solenoid which is pulsed by the control box - be careful not to mount it on a board that may resonate. If after installation the pump is n oisy re-locate it! 5. Electrical. The Mikuni heaters are supplied with simple plug together wiring looms. MX40. The MX40 is prewired on the s/s mounting plate. The only connections required are for the bat tery supply, the on/off switch and the timer/thermostat. Plug the 2 core power loom into the heater loom and run it directly to the battery. Fit the i nline 30 amp fuseholder and connect up to the battery leaving the fuse out at the moment. Now mount the timer/thermostat and on /off switch and run the 3 core cable. Plug the on/off switch in and connect the 2 x blue/yellow wires to the 'com' and 'n.o.' terminals on the timer/thermostat. NOTE: Do not connect the live feed to the main power switch. If the power is turned off at the supply whilst the heater is running, it will not be able to perform its cool down purge cycle, which could cause damage to the internal components

7 MX60 The MX60 wiring loom as shown in Dia 7 is a plug together assy. It is important to make sure that all the plugs are connected correctly and that the 'No 2' neutral wires are all con nected to a common negative. 17 way housing to control box. Red No.24 To fuel solenoid valve Black No.2 To fuel solenoid valve 2 x Black No.2 To Neutral Heater to control box glow plug regulator & resistor heater plug glow plug connectors MX60 main harness. Switch panel to control box 2 core cable to fuel pump Yellow/red No.12 black/white No.10 3A 25A Plug in fuse holders 2 core cable to water pump main power feed Black No.2 Red No.19 red/blue 30A Dia Plumbing. The MX40 and MX60 heaters are both plumbed in the same way using a 2 pipe syste m with a 22mm 'spine' and 15mm 'T' off's to the radiators or matrix heaters [ see Dia 8 ]. This allows for maximum water flow through the system and takes into account the resriction in internal diameter of elbows, 'T' pieces etc when using plastic plumbing

8 Plumbing Circuit Guide. Pressurised System. Calorifier Heater Heater Heater Heater Heater Mikuni MX Heater Hot out Water Pump 'A' Heater Air Separat or = 15mm pipe = 22mm pipe Cold water feed. Cold water feed from domestic pump. Accumulator Tank Gravity System Header Tank 2-3 Litres. Calorifier Heater Heater Heater Heater Heater Mikuni MX Heater Hot out Water Pump 'A' Heater Air Separa tor = 15mm pipe = 22mm pipe NOTE: 'A' is an optional gate valve for shutting off the heating circuit in the summer

9 MP OR SENSOR ME FLA M M L RB WATER PU B RY BW MOTOR R COMBUSTION GB GW THERMIST ACK 3A FUSE EDR V=5A 12V=7.5A. 24 SEFU RED/BL G HEATER CONTROL BOX ON/OFF SWITCH TIMER/THERMOSTAT W G B BW GB RY RB R L L W W BW GW L YR LY B B WR R R TEMPERATUR E AT IC CH 1. MPLA LED DANFOSS WR OVERHEAT ST RESISTOR OWGL L1. PLUG OWGL Q6 Q4 Q5 TE WHI 2R Q3 BLUE SELF DIAGNOST ON/OFF SWIT WHITE GREEN BLUE/YELLOW BLUE/YELLOW Cable Colour White Green Black Black/White Green/Black Red/Yellow Red/Black Black/White Green/White Blue Yellow/Red Blue/Yellow White/Red Symbol W G B BW GB RY R/B BW GW L YR LY WR BLACK RED FUEL SOLENOID VALVE NOTE: The Optional fuel solenoid valve is directional. There is an arrow engraved on the back to show the flow direction FUSE 30A BATTERY D.C. 12V, 24V. SOLENOID FUEL PUMP NOTES: 1. L1=THE 12V VERSION HAS NO GLOW RESISTOR SO THE CIRCUIT WILL INCLUDE L1 IN THE LOOM. MX40 Wiring Diagram incl Optional Fuel solenoid valve

Installation of the heater. Planning the Installation. Tools for your installation:

Installation of the heater. Planning the Installation. Tools for your installation: Installation of the heater. The Mikuni MY series heaters are blown air diesel fired heaters running off either a or volt DC supply.to ensure good service from your heater it is important to install it