GENESIS Diesel fired combination air/hot water system

Installation guidelines

Index Introduction……………………………………………………..1 Component location………………………………………….2 Plumbing the coolant hoses………………………………3 Controlling the coolant flow………………………………5 Plumbing tempering valve (if supplied)……………..6 Electrical Wiring for diesel furnace…………………….7 Electrical wiring for cabin heater (if supplied)……8 Commissioning…………………….…………………………..9 Operation………………………………………………..……..10

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DHA is providing installation advice only and takes no responsibility for poor installation practises or failing to following recommended guidelines that may result in performance loss, product damage or failure.

INTRODUCTION HOW IT WORKS Genesis operates by transferring the energy from coolant heated by the diesel furnace to heat

exchangers. One heat exchanger is the Genesis water service and the other is one or more

cabin fan heaters similar to what is under the dashboard of a motor vehicle to warm the interior.

The system consists of the SS4 coolant furnace and Genesis hot water service to produce hot

water or three components if you wish to include the cabin fan heater.

SS4 DIESEL COOLANT FURNACE This is the heart of the system, the component that atomizes the diesel/air mixture to generate

heat that is transferred to the coolant passing through the water jacket surrounding the furnace.

GENESIS HOT WATER SERVICE This is where the energy in the coolant is transferred to you domestic water. Hot coolant is sent

by a circulating pump to the Genesis water service by rubber heater hose. After the coolant has

travelled through the system and given up its energy to the domestic water it is returned to the

SS4diesel furnace to be reheated to again be sent to the Genesis water service. At this point

you have two components linked together by rubber heater hose. One hose supplying coolant

to the Genesis water service and one returning the coolant to the diesel furnace.

CABIN FAN HEATER These are available in different energy output as well as different types of axial or radial fans.

DHA supply the French KALORI SILENCIO heater units because of its efficiency and use of

computer fans that reduce noise and DC power consumption significantly plus the quality is

excellent. DHA also supply the ECONO unit based on the same principal but with lower heat

output and cost. These units have an inlet and outlet connector the same as the Genesis water

service. It is plumbed in parallel off the two hoses connecting the furnace and water heater.

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COMPONENT LOCATION One of the many benefits of the system is the components don’t have to live in close proximity to each other and in many situations it is ideal to have them some distance apart to increase the coolant volume in the system.

SS4 DIESEL COOLANT FURNACE The furnace is weather proof and can be mounted externally in a box or even under the chassis on a vehicle that will not be used off road. This is a good option because there are no fuel line or exhaust connections in the vehicle plus noise is reduced in the vehicle. In most situations it would be mounted in the same compartment a typical LPG hot water service would be fitted. The furnace would generally be mounted in the engine compartment or below floor level in a marine situation. Please refer to the installation manual accompanying the SS4 furnace for installation details.

NOTE: The coolant circulating pump is mounted on top of the SS4 coolant heater and must not be higher than the middle of the Genesis hot water service.

GENESIS HOT WATER SERVICE As with the SS4 furnace the Genesis water service can be mounted externally and can be up to 4mt’s away from the SS4 furnace. At floor level in marine or vehicle application is ideal and the compartment of a LPG water system is generally a good location.

Hints 1. Must be mounted vertically with filler cap on top. 2. Mount the Genesis water service at least 20mm off the floor 3. Filler cap should be accessible to fill the system and periodically check coolant level. 4. If the genesis water service is mounted inside the vehicle it can be covered in 10mm closed cell Insulation foam to reduce radiated heat. 5. Run overflow tube on filler neck through the floor

NOTE: The middle of the Genesis water service should not be lower than the inlet/outlet pipes on the SS4 diesel coolant heater

CABIN FAN HEATER A cabin heater is always mounted at floor level in a vertical surface in a kick board, bed end or along the hallway. Make sure the compartment it is mounted in is vented to the living area so the heater can breath (return air). The return air vent should be equal in size to the cabin heater outlet surface area. To mount the cabin heater 1. Remove the front facia of the heater and measure the outlet surface area cut the appropriate

hole in the kickboard. 2. Sandwich the kickboard between the facial and the main heater housing. 3. If the kickboard is thicker than 10mm longer screws may be required 4. The cabin heater can be mounted vertically or horizontally 5. The coolant ports must be at the bottom if the cabin heater is mounted vertically

NOTE: The top of the cabin fan heater should not be higher that the top of the Genesis water heater. Do not mount the cabin heater so it blows air onto peoples legs (unless you want then to go home)

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PLUMBING THE COOLANT HOSES SS4 DIESEL FURNACE TO GENESIS WATER SERVICE The Genesis water service is also a coolant buffer tank that feeds the SS4 furnace with coolant. We have stressed the particular component levels in relation to each other in COMPONENT LOCATION. The reasons for this is it: 1. Guarantee's the coolant pump in the SS4 heater will always have coolant. 2. Increases the working volume of coolant in the system. 3. Makes bleeding the air out of the system much simpler (this is covered in COMMISSIONING) Once the Genesis water service and SS4 furnace are mounted screw the supplied hose barbs to the coolant inlet and outlet of the Genesis water service and connected to the SS4 furnace with the 19mm rubber heater hose supplied in the SS4 heater kit. If the components are located in separate compartments or the SS4 is mounted under floor, drill two suitable sized holes through the flooring or walls to let the heater hose through. Take appropriate precautions to stop external hose damage where hoses pass through walls or bulkheads If the hoses need to be routed around corners or bends and there is a possibility of kinking, use a spring coil (refer image below) or fit elbows into the hose. The hoses can be covered in insulation tube if the vehicle is in an ultra cold climate but is not really necessary in most Australian conditions.

The image to the left shows the four ports in the Genesis hot water service. As you look at the image Bottom right: coolant from SS4 furnace Bottom middle: cold domestic water in Bottom left: coolant to SS4 furnace Top centre: hot domestic water out Clear tubing on top of tank connects to the overflow barb on the coolant filler neck and exits through the floor of the compartment

In this installation the Genesis water service is mounted above the SS4 furnace because of space restrictions. Exhaust is exiting through the floor of the storage compartment and the fuel pump can be seen at the bottom right. If the system was living in a compartment in a caravan or motorhome the fuel pump should be mounted outside. Fuel tank is mounted on the side of the compartment. Note the spring guards on the heater hoses to stop kinking

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PLUMBING THE COOLANT HOSES CABIN FAN HEATER TO SS4/GENESIS PLUMBING The cabin fan heater operates on the same principal as the Genesis water service i.e. it requires hot coolant to transfer the heat energy to the cold domestic water . In the case of the cabin fan heater it is transferring the heat energy to the living environment. The cabin fan heater has a coolant inlet and outlet to receive and return the coolant to the SS4 furnace. The hoses connecting the cabin fan heater are teed of the main hoses connecting the Genesis water service to the SS4 furnace. If the components are located in separate compartments drill two suitable sized holes through the flooring or walls to let the heater hose through. Take appropriate precautions to stop external hose damage when hoses pass through walls or bulkheads If the hoses need to be routed around corners or bends and there is a possibility of kinking, use a spring coil or fit elbows into the hose. The hoses can be covered in insulation tube if the vehicle is in an ultra cold climate but is not really necessary in most Australian conditions.

NOTE: Hose diameter for the Cabin fan heater may vary to the main 19mm hoses.

Main inlet and outlet hoses can be seen going from the Genesis water service to the SS4 furnace at bottom of image. Tee’s are fitted anywhere inline on the main system hoses to connect the cabin fan heater. 19mm s/s 3 way barbed tee’s are supplied in the SS4 kit. 16mm hose that is normally used with cabin fan heaters will push over a 19mm barb.

Connections into the Cabin fan heater may vary in size but they are generally 16mm. The hose barb on the bottom of the cabin fan heater is always coolant in from the SS4 furnace.

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CONTROLLING THE COOLANT FLOW The system is now plumbed with the SS4 furnace and the Genesis water heater connected together in series and the cabin fan heater running off in parallel between the SS4 furnace and Genesis water heater. Fluid like gas will travel the path of least resistance so the Genesis water service will be given more coolant than the cabin fan heater. This is fine and you will still have plenty of heat from the cabin fan heater. As an example there will be situations when you do not require cabin heating and times when you want all the energy the SS4 diesel furnace produces going to your cabin fan heater Below is the plumbing schematic fitted with ball valves in the system. A. The ball valve is fitted to the return line of the air cabin fan heater: 1. Close the valve completely stops coolant travelling to the Cabin heater. This stops the cabin fan heater acting like a static radiator in a warm climate. Genesis now receives all the coolant. 2. Partially closing the valve restricts the coolant flow to the cabin fan heater improving the performance of the Genesis water heater B. The ball valve is fitted on the main return line between the Genesis water heater and the Tee . 1. Close the valve completely stops coolant travelling to the Genesis. All coolant now goes to the cabin heater for maximum cabin fan heating performance. 2. Partially closing the valve will allow you to better control and balance the system. Sending a little more coolant to the cabin fan heater but still getting good performance from the Genesis water service.

X

X

5

A

B

PLUMBING TEMPERING VALVE WHY YOU NEED A TEMPERING VALVE When the system has been turned on and has cycled down the water coming straight from the Genesis hot water service will be approximately 70-75deg C. You can adjust the temperature with the mixer at the shower and galley but it is dangerous. This is the reason your home hot water service is set at approximately 55deg C The tempering valve not only controls the outlet temperature but will increase the usable hot water capacity. The volume of coolant at 80deg C is directly related to how much hot water is available at 45-50deg C .

Tempering valve s can be set at any temperature. The main advantage is you don’t get scalding water at the shower and galley

Hot water in one side from the Genesis hot water service. Cold water in the opposite side. Tempered water out the bottom port to shower and galley

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ELECTRICAL WIRING FOR SS4 DIESEL FURNACE Wiring harness is a plug and play with no two plug connections the same. The rheostat control interface has been replaced by a illuminated rocker switch. The harness is designed for a worst possible scenario as far as component location goes. Reduce the main harness length to the house battery as well as to the controller and fuel pump if it is not required. A simplified wiring schematic is below that also shows the correct wiring sequence to the control switch. Refer to the manual supplies in the SS4 for detailed information.

NOTE: SS4 heater must be connected directly to the house battery. Do not connect to any other wiring or circuit board

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ELECTRICAL WIRING FOR CABIN FAN HEATER Wiring diagram below is for the Kalori Silencio II air cabin heater. The heater has two speed fans, red wires are maximum speed orange is half speed. The fans use minimum DC power and can be connected to any DC power supply close by. A Room thermostat can be wired in series to the positive or negative wire to control cabin temperature if required. NOTE: Air cabin heaters are electronically independent of the SS4 coolant heater

SILENCIO II cabin fan

heater

3 position rocker switch

II O I

NEGATIVE -

POSITIVE +

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COMMISSIONING COMMISSIONING It is a time consuming and messy operation to rectify any bad joints or leaks after the system is filled with coolant. The coolant system operates at approximately 5psi so check that all hose connections are secure and all hoses are kink free.

NOTE: DO NOT START THE SS4 FURNACE WITHOUT COOLANT IN THE SYSTEM

1. Remove the radiator cap on the Genesis hot water service. 2. Fill the system with AS 2108-2004 "TYPE B“ premixed coolant to the top of the Genesis hot water service 3. With the filler cap still removed, start the SS4 diesel furnace (red light comes on, coolant circulating pump will start after approximately 30 seconds) 4. The pump has coolant fed to it by gravity and will now push air out of the hoses into the Genesis water service. 5. After approximately another 30 seconds the fuel pump and glow pin come on, if the fuel line is primed and diesel has reached the furnace combustion will start. 6. At this point the best tools you have are your hands. As the SS4 furnace begins to heat the coolant the hoses will start to get warm. Move your hands over all the hoses, they all should be a similar temperature. 7. After a few minuted the Genesis water heater should be warm to touch. The hoses to and from the cabin fan heater should be a similar temperature to the main hoses. 8. If these hoses are still at ambient temperature there is an air lock in the loop. If there is a ball valve (B) in the main line as described on page 5 (controlling coolant flow) closing it will force coolant into the cabin fan heater loop pushing the air into the Genesis water heater. If a ball valve is not fitted, massaging the hoses by squeezing and releasing them will generally push the air through. 8. Depending on ambient temperature the furnace will cycle down after 8-10 minutes. All hoses should be at a similar temperature. 9. Top the coolant level up in the Genesis hot water service until it is approximately 30mm from the top of the tank and replace the filler cap. 10. Leave the system on and wait until the furnace reignites. Wait until it cycles down again and check and rectify any leaks.

Congratulations you have now successfully installed your Genesis air/hot water system

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OPERATION SS4 COOLANT FURNACE 1. Turn on the SS4 furnace 2. After approximately 30 seconds the coolant circulating pump comes on. The temperature

sensor indicates ambient temperature . The glow pin and fuel pump will then come on and the furnace will start combustion cycle.

3. Once the SS4 furnace obtains full combustion the glow pin will fall away and the furnace will continue to produce heat until the coolant temperature reaches 80deg C. This will take approximately 7-10 minutes depending on the ambient temperature.

4. At this temperature the SS4 furnace will cycle down but the circulating pump will continue to circulate coolant around the system and over the temperature sensor.

5. The SS4 furnace will not restart until the coolant temperature drops to approximately 68deg C. This will happen either by heat dissipation over time or if the Genesis hot water service or cabin fan heater demands heat.

NOTE: TURN THE SS4 FURNACE OFF ONLY BY ITS OWN SWITCH. DO NOT CUT POWER TO THE FURACE DURING ANY STAGE OF ITS OPERATION.

GENESIS HOT WATER SERVICE The SS4 has been turned on, the system has reached operating temperature and cycled down, it is now in standby. There is now approximately 14litres of coolant at 80deg ready to transfer its energy to the fresh water that will be sent through the Genesis hot water system by the 12v fresh water pump from the on board fresh water tank or mains supply if you are connected to a Caravan park water supply. When a hot water tap is turned on fresh water and coolant will travel through the genesis hot water service but in separate channels. This is when the coolant gives up its energy to the fresh water resulting in fresh water exiting the system to the tempering valve at approximately 70-75deg. At the same time the temperature sensor in the SS4 furnace is registering a temperature drop in the coolant and will restart at approx 68deg. It will continue to produce heat while the Genesis water service asks for heat. Once the hot water tap is turned off the coolant temperature will rise to 80deg and the SS4 will cycle down until there is another demand for heat.

CABIN FAN HEATER The relationship the cabin fan heater has with the SS4 coolant furnace is the same as the Genesis hot water service. When the fan is turned on for cabin heating it is taking energy from the coolant being circulated around the system and sending in into the cabin area. The SS4 will continue to produce heat while there is a demand for cabin heating. When the cabin fan heater is turned off the SS4 furnace will continue operating to get the coolant back up to 80deg and then cycle down until there is another demand for heat.

If you have noticed the excessive use of the word approximate it is intentional. The variation in Ambient air, liquid temperatures as well as the distance between components that affect coolant volume, flow rates of coolant and fresh water make it impossible to accurately determine times, temperatures and flow rates.

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