- Manuals
- Brands
- Proheat Manuals
- Heater
- Teleflex X45
- Installation and service
-
Contents
-
Table of Contents
-
Troubleshooting
-
Bookmarks
Quick Links
INSTALLATION
AND SERVICE
MODEL X45
Related Manuals for Proheat x45
Summary of Contents for Proheat x45
-
Page 1
INSTALLATION AND SERVICE MODEL X45… -
Page 3: Table Of Contents
Power Connection to Batteries……….3-14 Timer Connections…………..3-15 On/Off Switch …………..3-16 Sleeper Heater Wiring Details ……….3-17 Option A – OEM Heater & PROHEAT Thermostat….3-17 Option B – OEM Heater & Thermostat ……..3-18 Option C – Auxiliary Sleeper Heater ……..3-19 Option D – Relay Sleeper Heater……….3-20 FUEL SYSTEM …………….3-21…
-
Page 4
Clean Heater Enclosure…………6-1 Heat Exchanger …………..6-2 Exhaust System …………..6-2 Electrical System…………..6-3 Clean Air intake …………..6-3 Fuel System ……………..6-4 Vehicle Batteries …………..6-4 Operation Test …………..6-5 PCM: Pin-out Details ………….6-5 Proheat Wiring Diagram…………6-6 7. WARRANTY …………….7-1 8. APPENDICES Service Bulletin #951528………8-3 #967329………8-5 SB0003………..8-7… -
Page 5: Introduction
(school, transit and coach), construction heat for the interior. equipment, off road equipment, military equipment (4) Cargo Heat – PROHEAT can be used to provide and cargo. heat to protect valuable cargo such as produce or beverages from damage due to freezing.
-
Page 7: Operating Your Proheat Heater
ELECTRICAL CONNECTIONS. (See Troubleshooting & Repair, Section 5) NOTE: The PROHEAT may be operated if the engine is running or not running. 2. When engine preheat is no longer required, switch the PROHEAT heater “OFF.”…
-
Page 9: Technical Specifications
L inches (318 x 280 x 521 mm) Weight, Heater only: X45…40 lbs. (18 kg) Weight, with Enclosure: X45…55 lbs. (25 kg) Operating Temperature Range:..-40˚ to 122˚F (- 40˚ to 50˚C) Heat Exchanger Capacity:….1 quart U.S. (0.97 litre) 10 1/8″…
-
Page 10: Heater Dimensions
Figure 2-2 Heater Dimensions X45 PROHEAT INSTALLATION & SERVICE…
-
Page 11: Installation
PROHEAT Dealer regarding your specific application. Prior to the installation of your PROHEAT, consult your engine owner’s manual or engine manufacturer for any restrictions or changes that may apply to plumbing into the engine coolant system.
-
Page 12: Locating The Heater
You Choose • On either side of the frame rails (2). • In an existing enclosure on the vehicle (step or toolbox) (3). Caution Do not weld PROHEAT heater mounting brackets to the vehicle frame. If repairs to the vehicle require welding, disconnect the PROHEAT power cable at the PCM.
-
Page 13
HIGHEST POINT PROHEAT ENGINE OR RADIATOR Figure 3-4 Height Requirement Mounting the PROHEAT heater in an enclosure Do not locate the heater in an airtight enclosure. If the heater is to be mounted in an enclosure other than the PROHEAT enclosure, adequate air flow must be provided to ensure proper combustion. -
Page 14: Mounting The Heater
CENTERLINE OF ENCLOSURE 12″ (306 mm) 5 3/4″ (146 mm) 8 13/16″ (223 mm) 3/4″ (20 mm) MOUNTING HOLES (4 REQUIRED) 5″ (127 mm) 16 11/16″ (427 mm) 1 5/8″ (45 mm) Figure 3-8 X45 Enclosure Base Dimensions PROHEAT INSTALLATION & SERVICE…
-
Page 15
4 X .38″ (10MM) 1.0″ (25 mm) MOUNTING HOLES 3″ (76 mm) Dia. 5″ (127 mm) 5.5″ (140 mm) 6.4″ (163mm) 5″ (127 mm) 2.02″ 7.5″ (191 mm) (51 mm) Figure 3-9 X45 Mounting Plate Dimensions & Exhaust Hole INSTALLATION… -
Page 16: Exhaust Pipe Connection
Exhaust gases must not enter the vehicle interior. Direct exhaust pipe away from vehicle. Use formed elbows. Do not use welded 90˚ elbows. EXHAUST CLAMP U BOLT (APPLY ANTI-SEIZE COMPOUND TO THREADS) Figure 3-10 Exhaust Pipe PROHEAT INSTALLATION & SERVICE…
-
Page 17: Plumbing The System
NOTE: When the engine block is preheated you will have nearly instant heat from the dash heat exchanger. OPTION B: Engine and sleeper heat. The PROHEAT heats the engine block and the sleeper. NOTE: Plumbing the PROHEAT through the dash fan is not recommended. INSTALLATION…
-
Page 18: Option A — Engine Heat Or Supplemental Heat
Figure 3-12 Engine Heat or Supplemental Heat NOTE: On coolant systems where the return from the PROHEAT is plumbed to the bottom of the main coolant supply line from the radiator to engine pump, the return line must be moved to avoid loss of heat through the radiator.
-
Page 19
(NORMALLY CLOSED) position. Western Star RETURN TO ENGINE NOTE: The PROHEAT PCM sleeper fan circuit has a one minute delay during ignition. Power to open a sleeper fan coolant valve must be taken from another source such SUPPLY TO PROHEAT ENGINE as the wire for the hour meter. -
Page 21
Engine Connection Details CATERPILLAR 3116 ………………3-i 3176 ………………3-i 3306 ………………3-ii 3406 ………………3-ii 3408 ………………3-iii CUMMINS “B” Series ……………..3-iv “C” Series ………………3-v KTA1150………………3-v L103-vi NT, BIG CAM II …………….3-vi NT, BIG CAM IV, N14 …………..3-vii DETROIT DIESEL SERIES 60 …………….3-viii 6V92, 8V92 …………….3-viii MACK E6 + E7………………3-ix ENGINE CONNECTION DETAILS… -
Page 23: Engine Connection Details
1/2″NPT 3/4″ – 16 UNF THREAD .44″ #8 SAE TUBE FITTING NOTE: The Caterpillar #3116 requires this fitting to connect the PROHEAT supply and return lines to the engine ports. RETURN FROM PROHEAT Caterpillar #3116 SUPPLY TO PROHEAT RETURN FROM…
-
Page 24: 3306
CATERPILLAR SUPPLY TO PROHEAT RETURN FROM PROHEAT Caterpillar #3306 RETURN FROM PROHEAT SUPPLY TO PROHEAT Caterpillar #3406 3-ii PROHEAT INSTALLATION & SERVICE…
-
Page 25: 3408
CATERPILLAR SUPPLY TO PROHEAT RETURN FROM PROHEAT Caterpillar #3408 ENGINE CONNECTION DETAILS 3-iii…
-
Page 26: Cummins #B Series
CUMMINS SUPPLY TO PROHEAT LEFT SIDE RETURN FROM PROHEAT RIGHT SIDE Cummins #B SERIES 3-iv PROHEAT INSTALLATION & SERVICE…
-
Page 27: C» Series
CUMMINS SUPPLY TO PROHEAT RETURN FROM PROHEAT Cummins #C SERIES SUPPLY TO PROHEAT RETURN FROM PROHEAT Cummins #KTA1150 ENGINE CONNECTION DETAILS…
-
Page 28
CUMMINS SUPPLY TO PROHEAT RETURN FROM PROHEAT Cummins #L10 RETURN FROM PROHEAT SUPPLY TO PROHEAT Cummins #NT, BIG CAM II 3-vi PROHEAT INSTALLATION & SERVICE… -
Page 29
CUMMINS RETURN FROM PROHEAT SUPPLY TO PROHEAT Cummins #NT, BIG CAM IV, N14 ENGINE CONNECTION DETAILS 3-vii… -
Page 30
DETROIT DIESEL RETURN FROM PROHEAT SUPPLY TO PROHEAT Detroit Diesel Series 60 RETURN FROM PROHEAT SUPPLY TO PROHEAT Detroit Diesel #6V92, 8V92 3-viii PROHEAT INSTALLATION & SERVICE… -
Page 31
SUPPLY TO PROHEAT (LOCATED BEHIND THE COOLANT CONTAINER) Mack #E6 & #E7 NOTE: It will be necessary to move the supply line for PROHEAT toward the back of the engine on the coolant manifold to ensure full engine heating. ENGINE CONNECTION DETAILS… -
Page 33: Wiring & Electrical Connections
Wiring & Electrical Connections GENERAL CONSIDERATIONS • Prior to installation of the PROHEAT Heater system, ensure that the vehicle batteries are in good condition. • Do not kink or abrade wires when routing them through the vehicle during installation. • Ensure wires are well supported and secured with tie-wraps.
-
Page 34: Power Connection To Batteries
Systems providing heat to both 3. Leave power harness disconnected. (See Figure 3-18) engine and sleeper require four (4) Do not install until PROHEAT coolant pump system has been purged of batteries. air. (See First Time Startup, page 3-25) NOTE: When power is connected to the PCM, the “ON” light on the PCM function display panel will light for one second and then go out.
-
Page 35: Timer Connections
Timer Connections TIMER Caution The switch input circuit should only be used to supply power to the ON/OFF Switch, the Timer, or as a signal to trip a relay. Failure to follow this installation practice will result in damage to the PCM. NOTE: The PCM must be reset (power disconnected and reconnected)
-
Page 36: On/Off Switch
NOTE: Many dash panels have switches which are not utilized. It may be The switch input circuit should only convenient to remove one and replace it with the PROHEAT switch. be used to supply power to the ON/OFF Switch, the Timer, or as a 2.
-
Page 37: Sleeper Heater Wiring Details
Sleeper Heater Wiring Details These installation options allow the operator to: 1. Run the PROHEAT with the ignition key in the “OFF” position. 2. Return full control to the OEM system in normal operation mode. You Choose Select one of the following wiring options…
-
Page 38
NOTE: The constant power supply wire must be of sufficient size to handle sleeper fan motor electrical current draw. 5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length. Connect white wire to terminal 1 of the thermostat. -
Page 39
2. Locate the auxiliary heater in a suitable area of the vehicle. Install plumbing and air duct connections as per the manufacturer’s recommendations. 3. Locate the PROHEAT thermostat in a central area of the sleeper, approximately 12″ above the bunk. Avoid direct air flow from sleeper fan ducts. (Figure 3-24) 4. -
Page 40
4. Remove the adjusting knob and face cover. Mark and drill mounting holes. Mount thermostat using the screws provided. (Figure 3-26) 5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length. Connect white wire to terminal 1 of the thermostat. Use fork terminal provided. -
Page 41: Fuel System
Fuel System GENERAL CONSIDERATIONS Caution •Use ⁄ » ID fuel line between the fuel tank and heater Do not use fuel lines and pick-up meeting SAE 30R7 (supplied with kit) tubes less than » ID or greater than » ID. Failure to use the •Ensure fuel lines are well secured and will not abrade.
-
Page 42: Option A
FUEL PICK-UP EXISTING PORT IN FUEL TANK 1/4″ NPT FUEL TANK Figure 3-30 ⁄ » NPT Port FUEL PICK-UP EXISTING PORT 1/2″ NPT IN FUEL TANK FUEL TANK Figure 3-31 ⁄ » NPT Port 3-22 PROHEAT INSTALLATION & SERVICE…
-
Page 43
OPTION B: Locate an existing, blank fuel sender port in the vehicle fuel tank. Remove the cover plate, drill a 1″ diameter hole and install the fuel pick-up as shown. WASHER GASKET COVER PLATE SUPPLIED WITH FUEL TANK (REQUIRES MODIFICATION) GASKET WASHER FUEL SENDER PORT IN TANK… -
Page 44: Installation
4. Attach the fuel line to the heater fuel pump fitting and the fuel pick-up with hose clamps. Lubricating the fittings with fuel may ease the installation effort. GROMMET HOSE CLAMP FUEL TANK FUEL LINE FUEL HOSE CLAMP FUEL PICK-UP FUEL LINE Figure 3-36 Fuel Line Connection Detail 3-24 PROHEAT INSTALLATION & SERVICE…
-
Page 45: First Time Startup
6. Connect the power harness. The “ON” light on the PCM function display will light for one second and then go out. 7. Start the PROHEAT heater using the ON/OFF switch. The indicator lamp should be lit with a solid red light. Go to the heater and observe its operation.
-
Page 46
(65˚C) at heater outlet, as long as the ON/OFF switch is left “ON.” 10. If the vehicle has been equipped with the sleeper heat option then: a) Adjust the PROHEAT sleeper thermostat to highest heat position. b) The sleeper heat exchanger fan will start blowing warm air. -
Page 47: Principles Of Operation
PRINCIPLE OF OPERATION GENERAL DESCRIPTION Figure 4-1 1. Fuel Pump A gear pump driven from the same motor as the compressor pulls fuel from the tank. The fuel is filtered at the fuel pump inlet. The gear pump will develop a maximum pressure of 10 PSI on the outlet side of the pump. 2.
-
Page 48
3 Amps. This is done to control the total current draw on the vehicles batteries. NOTE: The PROHEAT PCM “Sleeper Fan” circuit has a one minute delay during ignition. Power to open a sleeper fan coolant valve must be taken from another source such as the wire for the hour meter. -
Page 49
Figure 4-3 7. Nozzle An air/fuel aspirating type spray nozzle (located inside housing). The compressed air flows through the nozzle at high speed creating a venturi effect. This siphons fuel from the regulator and combines it with the air, creating an extremely fine mist which is sprayed out of the nozzle into the combustion chamber. -
Page 50
LEDs on the PCM diagnostic display will be lit. (See page 4-6 for details) Indicator Light Located in the Toggle Figure 4-4 ON/OFF Switch INDICATOR LIGHT (RED) MANUAL BUTTON TIMER SET BUTTON CLOCK TIMER ID LIGHT (GREEN) Figure 4-5 7 Day Timer PROHEAT INSTALLATION & SERVICE… -
Page 51: Normal Operating Sequence
“sees” a flame, the PROHEAT goes to “Full Output.” 4. Full Output The PROHEAT runs at Full Output until the coolant temperature reaches 185˚F (85˚C) at the heater outlet. At this time, the PROHEAT shuts the flame off and goes to “Purge.” 5. Purge The air compressor and fuel pump shut off immediately.
-
Page 52: Function Diagnostics
Function and The microprocessor in the PCM continually monitors all the PROHEAT systems. If the internal diagnostics discover a problem, a diagnostic code Component Diagnostics will be displayed on the PCM function display. The remote ON/OFF Switch or Timer red “ON” light will also flash the diagnostic code followed by a pause and then repeated, the number of flashes correspond to the numbered diagnostic code eg.
-
Page 53: Operational Problems
• 12 failure. Component problems can also cause Function diagnostic codes. • 13 NOTE: A SLEEPER FAN error (13) will not shut the PROHEAT down and heat to the engine will be maintained. Components: This section includes the electrode gap, fuse, nozzle and fuel regulator.
-
Page 54
Is a blower error displayed? (page 5-19) b) The blower operation – is it turning? – is it turning slowly? c) For restrictions at the fan inlet port and in the exhaust system. d) For carbon build up in the combustion chamber. PROHEAT INSTALLATION & SERVICE… -
Page 55: Flame Out
Check: Fuel System a) Is fuel level low? b) Air leaking into fuel system? Symptom: No visible flame No spark The heater shuts down after the 60 second ignition period. Check: Ignition System a) Check for a poor electrical connection between the ignition coil and the high tension lead.
-
Page 56: Coolant Flow
⁄ » NPT or larger. Avoid using 90˚ fittings where possible. d) Coolant Flow Direction: The PROHEAT must be plumbed so that the coolant pump is pumping the coolant in the same direction as the engine coolant pump. The PROHEAT can be used when the engine is running.
-
Page 57: Overheat
4 Overheat An OVERHEAT diagnostic code is displayed when the overheat breaker has • tripped, shutting the heater down. This occurs if the heater has been started with little or no coolant in the heat exchanger. Check: Coolant Flow a) Is there coolant in the system? b) Determine if there is a blockage or air in the plumbing.
-
Page 58: Voltage
3) Check current draw on the black NEGATIVE wire with the heater NOT running and the red POSITIVE wire disconnected. Should read 0 mA. This test is to confirm whether or not there is a power leakage from the vehicle through the heater. PROHEAT INSTALLATION & SERVICE…
-
Page 59
The negative lead of the multimeter should be attached to the heater chassis at the PROHEAT ground boss. (Figure 5-7) c) Read the voltage with the heater running or trying to run. -
Page 60: Component Diagnostics
START or a FLAME OUT diagnostic code to display. Check: Flame Sensor a) Inspect the flame sensor wiring for a short circuit. b) Inspect the flame sensor lens for cleanliness. c) Test the flame sensor. (See following page) PROHEAT INSTALLATION & SERVICE…
-
Page 61
Flame Sensor Test Procedure Start Unit Start Unit Is there a Flame Stop Unit Stop Unit Sensor Code? Disconnect Disconnect Sensor/Start Unit Sensor/Start Unit Is there Check Flame Quality Check Flame Quality a Flame? Is there Replace Replace a Flame Sensor Sensor Sensor Code? -
Page 62: Temperature Sensor
• in a freezer • in boiling water. c) Compare the measured values against the graph (Figure 5-5). If values do not approximately match, then the sensor is defective and must be replaced. Figure 5-4 Temperature Sensor Test 5-10 PROHEAT INSTALLATION & SERVICE…
-
Page 63
Temperature Temperature Centigrade Farenheit 150˚ 290˚ 140˚ 2023 130˚ C (266˚ F) OUT OF RANGE (UPPER LIMIT) 130˚ 260˚ 120˚ 110˚ 230˚ 100˚ 200˚ 90˚ 1541 85˚ C (185˚ F) UPPER SET POINT 80˚ 170˚ 70˚ 1354 65˚ C (150˚ F) LOWER SET POINT 60˚… -
Page 64: Fuel Pump
8 Fuel Pump The X45 fuel gear pump is driven by the same motor as the compressor. • Therefore, there is NO fuel pump electrical diagnostic code. A FUEL PUMP diagnostic code would indicate a fault in the PCM only.
-
Page 65: Compressor
Check: Air Compressor wiring & function a) That compressor is connected to harness correctly. (See PROHEAT Wiring Diagram page 6-6) b) The connector pins for damage or corrosion. c) Harness for pinched or abraded wires. d) Test compressor. If it tests OK replace PCM.
-
Page 66
Symptom: Air Compressor running (NO CODE indicated) No or low air flow Check: Air flow using the PROHEAT pressure gauge (PK0060) or equivalent. Ensure that the gauge is accurate (0-15 psi). Procedure: install the pressure gauge as shown in Figure 5-8 Pressure Reading for X45: 6.5 psi @ 12/24 Volts. -
Page 67: Ignition Coil
This component is ground side switched in the PCM. WARNING Symptom: No spark at the electrode (code indicated) The PROHEAT chassis is Check: Coil wiring grounded from the PCM as a) Inspect the wiring harness to ensure the ring terminals are shown in Figure 5-12.
-
Page 68
“open circuit” or 0 ohms (short circuit) then replace the ignition coil. NOTE: Remove positive and negative wires from the coil when testing. Figure 5-11 Ignition Coil Test GROUND WIRE FROM PCM CHASSIS GROUND BOSS Figure 5-12 PROHEAT Ground Boss 5-16 PROHEAT INSTALLATION & SERVICE… -
Page 69: Coolant Pump
Check: Coolant Pump wiring & function a) That coolant pump is connected to harness correctly. (See PROHEAT Wiring Diagram page 6-6) b) The connector pins for damage or corrosion. c) Harness for pinched or abraded wires. d) Test pump. If it tests OK replace PCM.
-
Page 70
Measure coolant pump current. Use test lead part #967921 as described on Service Bulletin #967329 in Appendix. Figure 5-13 Coolant Pump Test MODEL CURRENT DRAW (Amps) X45-12 1.50 — 4.00 @ 12 Volts X45-24 0.75 — 2.00 @ 24 Volts 5-18 PROHEAT INSTALLATION & SERVICE… -
Page 71: Blower
That blower is connected to harness correctly. checked for carbon build up and (See PROHEAT Wiring Diagram page 6-6) cleaned as necessary. b) The connector pins for damage or corrosion. c) Harness for pinched or abraded wires.
-
Page 72
Measure blower current. Use test lead part #967921 as described on Service Bulletin #967329 in Appendix. Figure 5-14 Blower Test MODEL CURRENT DRAW (Amps) X45-12 .75 — 1.5 @ 12 Volts X45-24 .5 — 1.0 @ 24 Volts 5-20 PROHEAT INSTALLATION & SERVICE… -
Page 73: Sleeper Fan
PROHEAT is supplying enough power to drive the sleeper fan. Test Procedure: a) Disconnect sleeper fan harness. b) Restart the PROHEAT, If there is still an error, replace the PCM. c) Check for correct voltage at the sleeper fan output on the PCM. (See Figure 6-7) d) Reconnect sleeper fan harness.
-
Page 74: Components
The electrode gap is factory set and should not require adjustment. ELECTRODE COMBUSTOR TUBE 1/4″ — 9/32″ Figure 5-15 Electrode Gap Detail NOTE: Ensure that the electrode is not bent during servicing. To readjust the electrode, bend it to the correct setting. 5-22 PROHEAT INSTALLATION & SERVICE…
-
Page 75: Fuse
HARNESS TO COMPONENTS COIL BLOWER COMPRESSOR 3 2 1 COOLANT PUMP Figure 5-16 Internal Wire Harness Test The following page describes the test procedure for a blown fuse with power connected and the PROHEAT switched “OFF.” TROUBLESHOOTING & REPAIR 5-23…
-
Page 76
Blow? Does Fuse Check Switch Harness Blow? and Connections for Short Circuit Replace Internal Harness OK Wire Harness Reconnect Components One at a time Does Fuse Blow? Component OK Check Component as per Troubleshooting Guide 5-24 PROHEAT INSTALLATION & SERVICE… -
Page 77: Nozzle
Nozzle The nozzle (and the compressor) regulate the fuel air mixture. A set orifice size allows a certain amount of fuel and air to flow through the distributor. (See Figure 5-17) Problems in the nozzle can cause poor burning. This will be indicated by a START or FLAME OUT diagnostic code on the PCM function display.
-
Page 78: Fuel Regulator
Should a fuel regulator fail, the combustion chamber must be checked for carbon build up and cleaned as necessary. FUEL REGULATOR VENT HOLE BLUNT PIN TO DEPRESS DIAPHRAGM UNDER VENT HOLE Figure 5-19 Fuel Regulator Test 5-26 PROHEAT INSTALLATION & SERVICE…
-
Page 79: Fuel System
Is there fuel in the tank? Step 2 Start the PROHEAT. The heater will try to start twice. Wait until it has gone through two cycles (approx. 10 minutes). The PROHEAT diagnostic system will tell you what it thinks is wrong.
-
Page 80
Eliminating Fuel Pump and Regulator from system. Step 7 Is the Fuel Nozzle contaminated? (See Nozzle page 5-25) • Clean the nozzle with a cleaner/degreaser, which will wash contamination out the back end of the nozzle. 5-28 PROHEAT INSTALLATION & SERVICE… -
Page 81: Operational Problems
These symptoms are usually an indication of an extremely rich air/fuel mixture. Smelly exhaust fumes Check: a) Is the PROHEAT connected to the correct voltage? (page 5-6) b) Is the blower functioning? Is the air inlet restricted? c) Is the compressor functioning? (page 5-13)
-
Page 82: Maintenance
Read this section of the manual carefully. Always return to your Authorized PROHEAT Dealer for major maintenance. Your PROHEAT Dealer has the specialized equipment necessary to keep your PROHEAT in new condition.
-
Page 83: Heat Exchanger
Check the exhaust system carefully. Make sure the exhaust pipe is vented safely away from the vehicle cab. Check the pipe for dents, restrictions or severely corroded areas. Replace the exhaust pipe and clamps if necessary. Ensure the exhaust pipe clamp is tight. PROHEAT INSTALLATION & SERVICE…
-
Page 84: Electrical System
Electrical System Check the internal and the external wire harnesses for damage. Replace if required. Figure 6-3 Wire Harnesses Clean Air Intake Check the combustion air inlet screen for restrictions. Clean as required. AIR INLET SCREEN Figure 6-4 Air Intake MAINTENANCE…
-
Page 85: Fuel System
The heater will not function properly with weak batteries or corroded connections. If you are unsure of their condition, load test each battery separately and replace as required. Clean terminals to remove all corrosion. Figure 6-6 Test Battery PROHEAT INSTALLATION & SERVICE…
-
Page 86: Operation Test
Operation Test Run the system for at least 15 minutes or until the heater cycles “OFF” and then “ON” again. Alternate the thermostat for the sleeper heater (if connected) between the lowest and highest settings to ensure that the sleeper heater fan cycles “ON” and “OFF.” SLEEPER FAN POWER +12V/+24V (3 AMP LIMIT) GROUND (-)
-
Page 87: Proheat Wiring Diagram
Figure 6-8 PROHEAT Wiring Diagram PROHEAT INSTALLATION & SERVICE…
-
Page 88: Warranty
Replacement parts are covered for the remainder of the heater’s warranty or ninety (90) days, which ever is greater. This warranty does not apply to damage or failure of the PROHEAT Heater or the vehicle into which it was installed due to improper installation, assembly, maintenance, abuse, neglect, accident, or the use of parts not supplied by Teleflex.
-
Page 90: Appendices
APPENDICES Contents COOLANT FLOW INDICATOR …………951528 TEST LEADS…………….967329 GROUND SIDE BATTERY DISCONNECT ……..SB0003…
-
Page 91
PROHEAT INSTALLATION & SERVICE… -
Page 92: Service Bulletin #951528
Tel: (604) 270-6899 © 1993 Reproduction in any form electronic, print, or otherwise is 3831 No.6 Road Fax: (604) 270-0137 ® ® encouraged providing the PROHEAT Richmond, B.C. Web: www.proheat.com logo (watermark) is visible on the energy solutions Canada Email: proheat@proheat.com ®…
-
Page 93
PROHEAT INSTALLATION & SERVICE… -
Page 94
Service Bulletin NO. 967329 May 1994 Description: The PROHEAT wiring system uses sealed connectors for resistance USE SPADE CONNECTORS TO TEST VOLTAGE, RESISTANCE to corrosion and greater reliability. OR CONTINUITY The following test leads are required for troubleshooting. BLACK Parts:… -
Page 95
PROHEAT INSTALLATION & SERVICE… -
Page 96
2. If the fuel pump does not operate, ground the body of the fuel pump directly to the battery negative post using a wire. Restart the Proheat. If the fuel pump runs and the Proheat starts then the problem is in the ground wire. -
Page 97: Sb0003
Tel: (604) 270-6899 © 1995 Reproduction in any form electronic, print, or otherwise is 3831 No.6 Road Fax: (604) 270-0137 ® ® encouraged providing the PROHEAT Richmond, B.C. Web: www.proheat.com logo (watermark) is visible on the energy solutions Canada Email: proheat@proheat.com ®…
-
Page 98
Proheat Serial Number: Installation Date: Dealer: ® ® energy solutions ® A Division of Teleflex Incorporated Teleflex (Canada) Ltd. 3831 No.6 Road Richmond, B.C. Canada V6V 1P6 Tel: (604) 270-6899 Fax: (604) 270-0137 Designed and Manufactured in North America Toll Free: 1-800-667-HEAT(4328) www.proheat.com…
INSTALLATION AND SE R V I C E M A N U A L
PROHEAT X45
Rev. H
CONTENTS
A. SAFETY .
B. INTRODUCTION .
…………………………………………………………………………. A-1
……………………………………………………………… B-1
C. MODEL DESCRIPTIONS…………………………………………………… C-1
1.0 TECHNICAL SPECIFICATIONS …………………………………………. 1-1
1.1 PHYSICAL – X45 …………………………………………………………… 1-2
1.2 ELECTRICAL – X45 ………………………………………………………… 1-4
1.3 TORQUE SPECIFICATIONS ……………………………………………….. 1-6
2.0 OPERATING YOUR PROHEAT HEATER………………………………. 2-1
3.0 INSTALLATION ……………………………………………………………….. 3-1
3.1 LOCATING THE HEATER ………………………………………………….. 3-2
3.1.1 Select Your Location ……………………………………………… 3-2
3.1.2 General considerations…………………………………………… 3-2
3.1.3 Mounting the Proheat Heater in an Enclosure………………. 3-3
3.2 MOUNTING THE HEATER …………………………………………………. 3-4
3.2.1 Option A – Heater With Enclosure ……………………………… 3-4
3.2.1 Option B – Heater Without Enclosure …………………………. 3-5
3.3 EXHAUST PIPE CONNECTION……………………………………………. 3-6
3.4 PLUMBING THE SYSTEM…………………………………………………. 3-7
3.4.1 General Considerations ………………………………………….. 3-7
3.4.2 Option A – Engine Heat or Supplemental Heat ……………… 3-8
3.4.3 Option B – Engine and Sleeper Heat ………………………….. 3-9
3.5 WIRING & ELECTRICAL CONNECTIONS……………………………… 3-10
3.5.1 General Considerations ………………………………………… 3-10
3.5.2 Power Connection to Batteries ……………………………….. 3-11
3.5.3 Timer Connections (Optional) …………………………………. 3-12
3.5.4 On/Off Switch Connections ……………………………………. 3-13
3.5.5 Sleeper Fan Model Heater Wiring Details ………………….. 3-14
3.5.6 Option A – OEM Heater & Proheat Thermostat ……………. 3-14
3.5.7 Option B – OEM Heater & Thermostat………………………. 3-15
3.5.8 Option C – Auxiliary Sleeper Heater………………………….. 3-16
3.5.9 Option D – Auxiliary Sleeper Heater Current Limited …….. 3-17
3.5.10 Auxiliary Input Model Heater Wiring Details………………. 3-18
3.5.11 Option A –
3.5.12 Option B –
3.5.13 Option C – Standard Mode & Supplemental Mode ………3-20
3.6 FUEL SYSTEM …………………………………………………………….. 3-22
3.6.1 General Considerations ………………………………………… 3-22
3.6.2 Option A – 1/4″ or 1/2″ NPT Port …………………………… 3-23
3.6.3 Option B – Existing Blank Fuel Sender Cover Plate ………. 3-24
3.6.4 Option C – Hole Drilled into Fuel Tank ………………………. 3-24
3.6.5 Installation ………………………………………………………… 3-25
3.7 FIRST TIME STARTUP……………………………………………………. 3-26
Preheat Mode Supplemental Mode Operation
Preheat and Supplemental Mode
………………. 3-20
… 3-19
4.0 PRINCIPLES OF OPERATION …………………………………………… 4-1
4-1 GENERAL DESCRIPTION ………………………………………………….. 4-1
4-2 MODES OF OPERATION …………………………………………………… 4-5
4.2.1 Standard Mode – All Models ……………………………………. 4-5
4.2.2 Preheat Mode – Aux Input Models Only ………………………. 4-6
4.2.3 Supplemental Mode – Aux Input Models Only ………………. 4-7
i
5.0 TROUBLESHOOTING & REPAIR .
5.0.1 Troubleshooting a Problem…………………………………. 5-1
.0.2 Example Proheat Behavior Error – Code 01…………….. 5-2
5
5-1 OPERATION INDICATORS, FUNCTION & COMPONENT
IAGNOSTICS …………………………………………………………. 5-3
D
5.1.1 Operation Indicators …………………………………………. 5-4
5.1.2 Function Diagnostics ………………………………………… 5-5
1 Start …………………………………………………………. 5-5
0
02 Flame Out ………………………………………………… 5-15
03 Coolant Flow …………………………………………….. 5-16
04 Overheat ………………………………………………….. 5-17
05 Voltage ……………………………………………………. 5-18
5.1.3 Component Diagnostics………………………………………… 5-19
06 Flame Sensor……………………………………………. 5-19
07 Temp Sensor ……………………………………………. 5-21
08 Fuel Pump………………………………………………… 5-23
09 Compressor ……………………………………………… 5-23
10 Ignition Coil………………………………………………. 5-25
11 Coolant Pump …………………………………………… 5-27
12 Blower …………………………………………………….. 5-30
13 Sleeper Fan ……………………………………………… 5-32
14 Hour Meter (Auxiliary Output)………………………… 5-33
5-2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS ……….. 5-34
5.2.1 Fuel Nozzle ………………………………………………………… 5-34
5.2.2 Fuel Regulator…………………………………………………….. 5-34
5.2.3 Air Compressor …………………………………………………… 5-34
5.2.4 Fuel Pump …………………………………………………………. 5-34
5.2.5 Ignition Electrode ………………………………………………… 5-34
5.2.6 Coolant Pump …………………………………………………….. 5-34
5.2.7 Blower ………………………………………………………………. 5-34
5.2.8 Fuse ………………………………………………………………… 5-35
5-3 OPERATIONAL PROBLEMS ……………………………………………… 5-37
5.3.1 Smoking exhaust ………………………………………………… 5-37
5.3.2 Low heat output ………………………………………………….. 5-37
5.3.3 Engine temperature gauge reads low ……………………….. 5-37
5.3.4 Backfiring ………………………………………………………….. 5-37
………………………………………. 5-1
6.0 MAINTENANCE……………………………………………………………….. 6-1
6-1 WEEKLY MAINTENANCE ………………………………………………….. 6-1
6-2 ANNUAL MAINTENANCE ………………………………………………….. 6-1
6.2.1 Clean Heater Enclosure and Air Intake ……………………….. 6-2
6.2.2 Check Exhaust System …………………………………………… 6-3
6.2.3 Check Heat Exchanger……………………………………………. 6-3
6.2.4 Clean Flame Sensor ………………………………………………. 6-4
6.2.5 Check Cooling System ……………………………………………. 6-4
6.2.6 Check Batteries ……………………………………………………. 6-4
6.2.7 Check Fuel System………………………………………………… 6-5
6.2.8 Check Fuel Filter …………………………………………………… 6-5
6.2.9 Clean Nozzle………………………………………………………… 6-6
6.2.10 Replace Compressor Air Filter ………………………………… 6-6
6.2.11 Check Electrical System ……………………………………….. 6-7
6.2.12 Check Air Pressure ………………………………………………. 6-8
6.2.13 Check
Modes of Operation – Switch, Timer or OEM Signals
.. 6-8
7.0 APPENDICES …………………………………………………………………. 7-1
Bulletins 951528, 967329, SB0003, PB0034, SB0062
8.0 WARRANTY ……………………………………………………………………. 8-1
ii
PROHEAT INSTALLATION & SERVICE
A.
SAFETY
Throughout this manual, you will see notes labeled DANGER, WARNING,
CAUTION and NOTICE to alert you to special instructions or precautions
concerning a particular procedure that would be hazardous if performed
incorrectly or carelessly.
Observe them carefully!
These safety alerts alone cannot eliminate all hazards. Strict compliance
with these special instructions and common sense are major accident
prevention measures.
DANGER
Immediate hazards that will result
in severe injury or death.
WARNING
Hazards or unsafe practices that
could result in severe personal
injury or death.
CAUTION
Hazards or unsafe practices that
could result in minor injury or
product or property damage.
NOTICE
Information that is important to
proper installation or maintenance,
but is not hazard-related.
SECTION A. SAFETY
A-1
SAFETY CONSIDERATIONS
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
Exhaust
Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal
injury and/or death. Anyone suspected of suffering from CO inhalation should be
removed from the hazardous area and given medical assistance immediately.
Explosion Hazard
Do not operate heater where combustible fumes or airborne particles, such as sawdust, are present.
Fuel
Exercise extreme caution when working near fuel or fuel-filled equipment. Do not
operate heater during fueling operations. In addition, do not smoke or handle open
flame equipment, such as a blowtorch, around fuel.
Fire Hazard
Do not place any flammable items around the heater and exhaust pipe.
Batteries
Wear hand and eye protection when working near batteries. Do not smoke or use open
flames near batteries.
Electrical
Electric shock can cause severe personal injury, burns, and death. Before working on
any unit, disconnect the batteries. Use only approved materials and methods when
working on the electrical system and follow local electrical codes. Never work with
electricity in wet conditions or when you are feeling fatigued.
WARNING
WARNING
WARNING
DANGER
Poisons/Toxins
Fuel and coolant are toxic and in some cases, carcinogenic. Wear eye and hand
protection at all times. Remove contaminated clothing immediately and wash
contaminated skin. Do not breathe in vapors.
Moving/Hot Parts
Moving/hot parts can cause severe injury and or death. Before working on any unit,
shut it off. Do not operate any unit until protective covers have been replaced. Always
ensure bolts and clamps are correctly torqued and secured. Inspect mechanical components periodically for damage and corrosion.
Coolant
Never remove the filler cap when the engine is hot – escaping steam or scalding water
could cause serious personal injury. The coolant level in the expansion tank should be
checked at least weekly (more frequently in high mileage or arduous conditions). Always
check the level when the system is cold. Unscrew the filler cap slowly, allowing the
pressure to escape before removing completely. Never run the engine without coolant.
Prevent anti-freeze coming in contact with the skin or eyes. If this occurs, rinse
immediately with plenty of water. Anti-freeze will damage painted surfaces.
Never top-up with salt water. Even when travelling in territories where the water supply
contains salt, always ensure you carry a supply of fresh (rain or distilled) water.
California Proposition 65 Warning
Do not operate heater in garages or in other closed or unventilated areas.
Diesel exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
Electrical components in this product may contain lead, a chemical known to the
State of California to cause cancer and birth defects and other reproductive harm.
A-2
PROHEAT INSTALLATION & SERVICE
INTRODUCTIONB.
PROHEAT Model X45
This manual is provided to assist an authorized PROHEAT
dealer to install and service a PROHEAT heater. Although
trucks have been used in the examples, applications for
PROHEAT are by no means limited to trucks. PROHEAT
heaters are designed to be used on any diesel equipped
vehicle including: trucks, buses (school, transit and coach),
construction equipment, off road equipment, military
equipment and cargo.
PROHEAT heaters are used in the following applications:
(1) Engine Block Heat – PROHEAT will preheat an engine
block to ensure reliable starting in cold weather. At
the same time it may be used throughout the year to
reduce the wear associated with cold starts.
(2)
Cab or Sleeper Heat (engine off) – PROHEAT will supply
heat to the cab or sleeper. Drivers can sleep in comfort
not only in the cold of winter but also in the spring
and fall when the weather is miserable. Substantial
savings through reduced fuel consumption and engine
wear can be obtained by not idling the engine.
(3)
Supplemental Heat (engine running) – as the efficiency
of modern diesel engines are improved there is no
longer adequate reject heat available to heat the
vehicle’s interior. This is particularly true for buses.
PROHEAT can be used while the vehicle is operating
to provide supplemental heat for the interior.
(4) Cargo Heat – PROHEAT can be used to provide heat to
protect valuable cargo such as produce or beverages
from damage due to freezing.
(5) Marine – Marine applications typically involve the
engineering and installation of a complete hot-water
heating system of which PROHEAT is only one
component. Proheat recommends that only an
expert in marine hot-water heating systems install a
PROHEAT on a boat. It is the installer’s responsibility
to ensure that the installation complies with all
applicable regulations.
SECTION B. INTRODUCTION
B-1
B-2
PROHEAT INSTALLATION & SERVICE
C.
Sleeper Fan Output or Auxiliary Input
Identification.
MODEL DESCRIPTIONS
This manual covers all models of PROHEAT X45. Please refer to the X45 Parts
Book at www.proheat.com for detailed part descriptions and part numbers.
Included in the parts book are optional features such as a timer, sleeper fan
ontrol kit, impact switch (for school bus applications) and associated
c
installation and maintenance tools.
The following information describes the three general characteristics of X45
models covered in this manual: voltage, enclosure and Proheat Control Module
(PCM) options.
PROHEAT CONTROL MODULE (PCM): SLEEPER FAN
OUTPUT OR AUXILIARY INPUT
The PCM comes in either a sleeper fan output or auxiliary input model. The
sleeper fan model is limited to a 3 amp output and is generally installed on
trucks that require sleeper fan power (it is only available on 12 V models).
The
Auxiliary
Mode and Supplemental Mode. This operation is typically used for transit and
coach installation. Refer to page 4-2 for more information.
Input model uses two special input pins that allow for a Preheat
Voltage Identification.
VOLTAGE CONFIGURATION: 12 V OR 24 V
The X45 is available in either a 12 V or 24 V models.
ENCLOSURE
An optional enclosure provides environmental protection.
SECTION C. MODEL DESCRIPTIONS
C-1
C-2
PROHEAT INSTALLATION & SERVICE
1.0
TECHNICAL
SPECIFICATIONS
X45 12V X45 24V
RATING 45,000 BTU (13 kW)
YSTEM VOLTAGE 10 –15 VDC 20 – 30 VDC
S
ominal Voltage Range
N
CURRENT DRAW 7.5 Amps 3.75 Amps
FUEL CONSUMPTION
(Average to Maximum) 0.1 – 0.45 gal/hr. (0.4 – 1.7 L/hr.)
COOLANT FLOW 8.0 gal/min. (30 L/min.)
COOLANT TEMPERATURE (at Heater) 150°F to 185°F (65°C to 85°C)
OPERATING TEMPERATURE RANGE -40°F to +122°F (-40°C to +50°C)
IGNITION TYPE Electronic Spark Ignition
HEAT EXCHANGER CAPACITY 1 quart (0.95 L)
WEIGHT Heater ONLY 40 lbs (18 Kg)
WEIGHT Heater with Enclosure 55 lbs (25 Kg)
DIMENSIONS – HEATER (L x W x H) 18.9 x 11.2 x 10.6 inches
DIMENSIONS – ENCLOSURE (L x W x H) 20.2 x 12.3 x 10.5 inches
WARRANTY Two years parts and labor
(520 x 320 x 280 mm)
(513 x 313 x 267 mm)
DANGER
DO NOT use gasoline.
FUEL TYPES
COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1
Bio Fuels – Contact Proheat www.proheat.com
SYSTEM OUTPUTS
HOUR METER Same as System Voltage
(AUXILIARY OUTPUT) Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SWITCH/TIMER Same as System Voltage
POWER Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SLEEPER FAN Same as System Voltage
(Certain Models Only) Maximum 3 Amp draw (over-load shut-off protection)
High-side switched
INDICATOR LIGHT Same as System Voltage
Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SYSTEM INPUTS
SWITCH 10 – 15 VDC (12V X45) | 20 – 30 VDC (24V X45)
Standard Run Mode
Preheat Run Mode (Certain Models Only)
Supplemental (Certain Models Only)
POWER 12 VDC or 24 VDC
SECTION 1. TECHNICAL SPECIFICATIONS
1-1
O
A
L
I
T
T
R
L
L
D
N
A
L
E
I
,
E
R
E
S
O
T
N
R
HEATERMODELNo:……….
SERIALNo:
MadeinCanadabyTeleexCanada Ltd Richmond B.C.
OPERATINGVOLTAGE:…10-16VOLTS
HEATOUTPUT:………….
PRESSURE:…………..
MAX.OPERATING
FUELTYPE:……………….
******
915822
9.0kW(KBTU)
2BAR(29PSI)
DIESELFUEL
X-4512V
POWER
G-IIISOFT START
PROHEATCONTROL MODULE
FUSE15A
SWITCHINPUT
SLEEPERFAN
ThisProductMeets
FHWABusHeater
Requirements
DieselFueledVechicle
CoolentHeater
ApprovedforUsein
BusApplications
12VOLT
999100
COMMINICATION
RS232&
CANBus
DONOT
POWER
WASH
ProtectedbyUSPatents
5,878,950and6,082,625
1.5 I.D.
C EXHAUST
PORT
L
Ø1.5″ [38]
4.9″ [125]
1.9″ [49]
8.7″ [222]
1.3″ [33]
1.6″ [41]
10.6″ [270]
4.0″ [101]
1.3″ [34]
10.1″ [258]
11.2″ [285]
4.4″ [112]
4X 0.38″ [10]
MOUNTING HOLES
STANDARD EXHAUST PIPE
SEE NOTE 1
5.5″ [140]
9.4″ [239]
COOLANT OUTLET
TOP VIEW
COOLANT INLET
C EXHAUST
PORT
L
NOTES:
1/ REFER TO X45 PARTS BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
AND SUBJECT TO CHANGE WITHOUT NOTICE
AUXILIARY MOUNTING PLATE
SEE NOTE 1
18.9″ [479]
C EXHAUST
PORT
L
5.1″ [129]
C EXHAUST
PORT
L
COOLANT OUTLET
CONNECTION3/4″ [19]
ID HOSE1/2″ NPT
HOSE FITTINGSEE
NOTE 1
FUEL SUPPLY
CONNECTION
3/16″ [48] ID HOSE
SEE NOTE 1
COOLANT INLET
CONNECTION
3/4″ [19] ID HOSE
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
AUXILIARY MOUNTING PLATE — SEE NOTE 1
TOP VIEW
MOUNT HOLE DIMENSIONS
2X 5.5″ [140]
2X 7.5″ [191]8.50″ [216]
6.40″ [163]
THIS SPACE
IS REQUIRED FOR
COMBUSTION TUBE REMOVAL
11.2″ [284]
10.2″ [259]
5.5″ [140]
THIS SPACE
IS REQUIRED FOR
COMBUSTION TUBE REMOVAL
2.0″ [50]
1.1
PHYSICAL – X45
X45 HEATER1.1.1
Figure 1-1 Heater Dimensions – X45
1-2
PROHEAT INSTALLATION & SERVICE
POWER
G-IIISOFT START
PROHEATCONTROL MODULE
FUSE15A
SWITCHINPUT
SLEEPERFAN
ThisProductMeets
FHWABusHeater
Requirements
DieselFueledVechicle
CoolentHeater
ApprovedforUsein
BusApplications
12VOLT
999100
COMMINICATION
RS232&
CANBus
DONOT
POWER
WASH
ProtectedbyUSPatents
5,878,950and6,082,625
O
A
L
I
T
T
R
L
L
D
N
A
L
E
I
E
R
E
S
O
T
N
R
HEATERMODELNo:……….
SERIALNo:
MadeinCanadabyTeleexCanadaLtd Richmond B.C.
OPERATINGVOLTAGE:…XX-XXVOLTS
HEATOUTPUT:………….
PRESSURE:…………..
MAX.OPERATING
FUELTYPE:……………….
******
XXXXXX
9.0kW(KBTU)
2BAR(29PSI)
DIESELFUEL
X-45XXV
COOLANT INLET
CONNECTION
3/4″ [19] ID HOSE
COOLANT OUTLET CONNECTION
3/4″ [19] ID HOSE
1/2″ NPT HOSE FITTING
SEE NOTE 1
TOP VIEW
ENCLOSURE LID REMOVED
FUEL SUPPLY
CONNECTION
1/4″ [48] ID HOSE
SEE NOTE 1
9.9″ [252]
2X 1.4″ [36]
FRONT VIEW
ENCLOSURE LID REMOVED
LEFT SIDE VIEW
ENCLOSURE LID REMOVED
RIGHT SIDE VIEW
ENCLOSURE LID REMOVED
ENCLOSURE COVER
FRONT VIEW
ENCLOSURE COVER
LEFT SIDE VIEW
20.2″ [513]
10.5″ [267]
20.0″ [508]
10.5″ [267]
12.0″ [305]
8.5″ [216]
ENCLOSURE COVER
RIGHT SIDE VIEW
12.3″ [313]
3.8″ [97]
2X 1.20″ [30]
7.1″ [181]
12.0″ [305]
10.5″ [267]
3.6″ [92]
3.6″ [92]
THIS SPACE
IS REQUIRED FOR
COMBUSTION
TUBE REMOVAL
ASSEMBLED
ENCLOSURE
NOTES:
1/ REFER TO X45 PARTS BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
AND SUBJECT TO CHANGE WITHOUT NOTICE
X45 WITH ENCLOSURE1.1.2
Figure 1-2 Heater Dimensions including Enclosure – X45
SECTION 1. TECHNICAL SPECIFICATIONS
1-3
FUEL PUMP
COMPRESSOR
ELECTRODE
IGNITION
BLOWER
PUMP
FLAME
TEMPERATURE
SENSOR
SENSOR
COOLANT
B (-)BLACK/BLUE
HOUR METER (AUXILIARY OUTPUT)
12V/24V 1A MAX.
P5
COMMUNICATION
CANBUS AND
RS232
E
F
E
F
(+)RED/WHITE
(-)GREEN/WHITE
A
B
BCA
D
BCA
D
E1
F1
(-)BROWN
(-)BLACK/WHITE
(+)GRAYA
A
B
B
(+)WHITE
B
A
B
A
F3
E3
F2
E2
P1
POWER
C
C
A
B
B
A
HEATER CHASIS GROUND LUG
(GROUND VIA
COMBUSTION TUBE)
IGNITION
COIL
OVERHEAT SENSOR
D1
(-)BLACK
(+)PURPLE
(-)BLACK/PURPLE
B
(+)BLUE
B
A
A
A
B
A
B2
A2
B3
A3
(+)RED
D2
C3
P5
HEATER
INTERNAL
HARNESS
P2
SWITCH
C
C
D
D
B
A
A
B
(-)BLACK/ORANGE
(+)ORANGE
A
B
B
A
(-)PINK
(+)PINK
B
A
A
B
PLUGGED
C1
A1
B1
C2
D3
P3
SLEEPER
FAN
A
A
B
B
CONNECTOR TERMINAL
DESIGNATORS
NOTE ORIENTATION
OF CONNECTOR LUGS
(+) RED — BATTERY POSITIVE 12V/24V
(-) BLACK — BATTERY NEGATIVE
PLUGGED — NOT USED
(+) RED — POWER 12V/24V OUTPUT
(-) BLACK — GROUND
GREEN — ON SIGNAL STANDARD MODE 12V/24V INPUT
(+) WHITE — INDICATOR LAMP 12V/24V OUTPUT
(+) RED — POWER 12V/24V (3 AMP LIMIT) OUTPUT
(-) BLACK — GROUND
CAN — H
RS232 — GROUND
CAN — SHIELD
RS232 — TRANSMIT
CAN — L
RS232 — RECEIVE
E1
F1
F3
E3
F2
E2
A2
B3
D1
B2
A3
D2
C2
D3
A1
B1
C1
C3
NOTES:
1/ REFER TO X45 PART BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
(+)PINK
A
B
(-)PINK
(+)ORANGE
A
(-)BLACK/ORANGE
B
(+)
(-)
(+)PURPLEA
(-)BLACK/PURPLE
B
(+)BLUEA
(-)BLACK/BLUEB
(+)BROWNA
(-)BROWNB
(+)WHITEA
(-)BLACK/WHITEB
P3
AUXILIARY
INPUT
A
B
ON SIGNAL PREHEAT MODE 12V/24V INPUT
ON SIGNAL SUPPLEMENTAL MODE 12V/24V INPUT
A
B
SEE DETAIL A FOR
AUXILIARY INPUT OPTION
DETAIL A
AUXILIARY INPUT OPTION
SEE NOTE 1
OPTIONAL IMPACT SWITCH
SEE NOTE 1
A
B
A
B
C
SEE NOTE 1
FOR HARNESS
PART NUMBERS
SEE NOTE 1
FOR HARNESS
PART NUMBERS
OPTIONAL GROUND FUSE
SEE NOTE 1
(-)BLACK/GREEN
SLEEPER FAN PCM SHOWN
SEE NOTE 1
HEATER INTERNAL HARNESS
SEE NOTE 1
10 A
1 2 3
A
BCD
E
F
A
B
C
D
E
F
HEATER INTERNAL HARNESS
18 PIN CONNECTOR PIN OUT DETAIL
1.2
ELECTRICAL – X45
Figure 1-3 Wiring Diagram – X45
1-4
PROHEAT INSTALLATION & SERVICE
PROHEAT CONTROL MODULE
G-III SOFT START
5,878,950and 6,082,625
Protectedby US Patents
WASH
POWER
DO NOT
COMMINICATION
BusApplications
ApprovedforUse in
CoolentHeater
DieselFueledVechicle
Requirements
FHWABus Heater
ThisProduct Meets
CANBus
RS232&
FUSE 15A
999100
SLEEPER FAN
12 VOLT
SWITCHINPUT
POWER
P1 — POWER
3 PIN
P2 — SWITCH
4 PIN
P3 — SLEEPER FAN OUTPUT
OR AUXILIARY INPUT
2 PIN
SEE NOTE 1
P4 — COMMUNICATION
CANBUS AND
RS232 6 PIN
FUSE 15 A
SEE NOTE 1
P5 — HEATER
INTERNAL
HARNESS
18 PIN
PROHEAT CONTROL MODULE (PCM)
SEE NOTE 1 FOR PART NUMBER OPTIONS
1A
1B
1C
2A
2B2C
2D
3A3B
DETAIL B
DETAIL B
P1 — P3 CONNECTOR PIN OUT DETAIL
DETAIL C
2
3
1
CONNECTOR TERMINAL
DESIGNATORS
NOTE ORIENTATION
OF CONNECTOR LUGS
DETAIL C
P5 CONNECTOR PIN OUT DETAIL
ABC
DFE
CONTROLLER VOLTAGE AND
PART NUMBER IDENTIFICATION
SEE NOTE 1
SLEEPER FAN OR AUX INPUT MODEL
IDENTIFICATION — SEE NOTE 1
4A
4B
4C
4D
4E
4F
DETAIL D
DETAIL D
P4 CONNECTOR PIN OUT DETAIL
NOTES:
1/ REFER TO X45 PART BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
Figure 1-4 PCM Electrical Connections – X45
SECTION 1. TECHNICAL SPECIFICATIONS
1-5
TORQUE SPECIFICATIONS1.3
FAN END CASTING
Apply anti-seize to bolts (3)
•
• Torque bolts (3) to 75±5 in/lbs (8.5±0.5 Nm)
REGULATOR
• Apply anti-seize to cap screw
• Torque cap screw to 94±6 in/lbs (10.6±0.7 Nm)
FLAME SENSOR
• Torque sensor to 25±3 in/lbs (2.8±0.3 Nm)
IGNITER
• Apply anti-seize to igniter threads
• Ensure gasket is present before installing
• Torque igniter to 50±5 in/lbs (5.6±0.6 Nm)
COMBUSTION TUBE
• Apply anti-seize to cap screws
• Torque cap screws (4) to 25±3 in/lbs (2.8±0.3 Nm)
1-6
PROHEAT INSTALLATION & SERVICE
OVERHEAT SENSOR
• Lubricate o-ring with o-ring lubricant
• Torque senor to 500±50 in/lbs (56±5.6 Nm)
TEMPERATURE SENSOR
• Lubricate o-ring with o-ring lubricant
• Torque senor to 25±3 in/lbs (2.8±0.3 Nm)
AIR FILTER
• Torque cap screw to 50±5 in/lbs (5.6±0.6 Nm)
SECTION 1. TECHNICAL SPECIFICATIONS
BLOWER ASSEMBLY
• Apply anti-seize to bolts (4)
• Torque bolts (4) to 25±3 in/lbs (2.8±0.3 Nm)
PROHEAT CONTROL MODULE (PCM)
• Apply anti-seize to bolts (3)
• Torque bolts (3) to 75±7 in/lbs (8.5±0.8 Nm)
1-7
MAIN INTERNAL HARNESS
• Torque bolt (1) to 10±2 in/lbs (1.1 +/- 0.2)
NOZZLE TO FAN END
• Lubricate o-ring on nozzle with diesel
• Torque nozzle to 150±10 in/lbs (17±1.1 Nm)
NOZZLE REASSEMBLY
• Torque nozzle (1) to 30±3 in/lbs (3.4±0.3 Nm)
BAND CLAMPS
• Torque clamps (4) to 25±3 in/lbs (2.8±0.3 Nm)
ENCLOSURE LID (Optional)
• Anti-seize recommended on bolts
• Torque clamps (2) to 30±3 in/lbs (3.4±3.4 Nm)
1-8
PROHEAT INSTALLATION & SERVICE
HARNESS GROUND LUG
• Apply anti-seize to bolt
• Torque bolt (1) to 75±5 in/lbs (8.5±0.5 Nm)
FUEL PUMP ASSEMBLY
A
• Apply Loctite 242 to threads
• Torque bolts (2) to 25±3 in/lbs (2.8±0.3 Nm).
B
• Lubricate o-ring with diesel fuel
• Torque relief valve to 22±2 in/lbs (2.5±0.2 Nm).
C
• Apply Loctite 59241 sealant to threads
• Torque elbow (1) to 55±5 in/lbs (6.2±0.5 Nm) minimum or until
elbow is at correct orientation
FUEL FILTER
• Lubricate o-ring with diesel fuel
• Torque nut (1) to 150±10 in/lbs (17±1.1 Nm)
SECTION 1. TECHNICAL SPECIFICATIONS
1-9
1-10
PROHEAT INSTALLATION & SERVICE
2.0
OPERATING YOUR
PROHEAT HEATER
NOTICE
These instructions cover Standard
Mode operation that are normally
installed on trucks. To operate your
heater in Preheat or Supplemental,
refer to page 3-18 to page 3-20 and
page 4-6 to page 4-7.
NOTICE
Regular use of your PROHEAT
throughout the year will improve
its reliability. Weekly operation is
recommended.
NOTICE
The PROHEAT heater can be
operated by either using a toggle
switch or a 7 day timer.
Refer to page 3-10 for WIRING &
ELECTRICAL CONNECTIONS.
ENGINE HEAT ONLY
1. Switch the ON/OFF switch located in the vehicle dash to “ON.”
The switch will light and the heater will cycle on. It will continue to operate until
the coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”
When the coolant temperature falls below 150˚F (65˚C) at the heater
outlet, it will refire and repeat the cycle.
It will continue to cycle until:
a) the heater is switched “OFF,”
b) the heater runs out of fuel,
c) the vehicle battery voltage drops below 10.0 Volts, or
d) an error occurs and the switch light flashes
(See Troubleshooting & Repair, Section 5)
NOTE: The PROHEAT may be operated if the engine is running or not running.
2. When engine preheat is no longer required, switch the PROHEAT heater
“OFF.”
ENGINE AND SLEEPER HEAT
1. Switch the ON/OFF switch located in the vehicle dash to “ON.”
The switch will light and the heater will cycle on. It will continue to operate until
the coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”
When the coolant temperature falls below 150˚F (65˚C) at the heater
outlet, it will refire and repeat the cycle.
It will continue to cycle until:
a) the heater is switched “OFF,”
b) the heater runs out of fuel,
c) the vehicle battery voltage drops below 10.0 Volts, or
d) an error occurs and the switch light flashes
(See Troubleshooting & Repair, Section 5)
SECTION 2. OPERATING YOUR PROHEAT HEATER
NOTE: The PROHEAT may be operated if the engine is running or not running.
2. For sleeper heat – set the thermostat in the sleeper to the desired
temperature. If the set temperature is higher than the temperature in the
sleeper the fan will cycle “ON.” When the air reaches the set temperature
the fan will cycle “OFF.” The fan will cycle “ON” and “OFF” to maintain the
set temperature.
3. When engine and/or sleeper preheat is no longer required, switch the
PROHEAT heater “OFF.”
2-1
2-2
PROHEAT INSTALLATION & SERVICE
3.0
INSTALLATION
NOTICE
If additional installation information is
required
Dealer regarding your specific
application.
For more technical information,
please contact PROHEAT Product
Support at www.proheat.com
please contact your PROHEAT
The installation details described in this manual focuses on truck applications
and does not cover all of the possible installations. As seen in the figures
below, the PROHEAT X45 is installed on a variety of equipment including
trucks, school buses, coaches, drill rigs, mine dump trucks and excavators.
In these cases the manual should be used as a guideline only.
There are seven major steps that must be completed to successfully install
the PROHEAT heater.
3.1 LOCATING THE HEATER………………………………………………… page 3-2
3.2 MOUNTING THE HEATER ………………………………………………. page 3-4
3.3 EXHAUST PIPE CONNECTION …………………………………………. page 3-6
3.4 PLUMBING THE SYSTEM………………………………………………. page 3-7
3.5 WIRING & ELECTRICAL CONNECTIONS …………………………… page 3-10
3.6 FUEL SYSTEM ………………………………………………………….. page 3-22
3.7 FIRST TIME STARTUP…………………………………………………. page 3-26
Prior to the installation of your PROHEAT, consult your engine owner’s manual
or engine manufacturer for any restrictions or changes that may apply to
plumbing into the engine coolant system.
Figure 3-1 Other Applications.
SECTION 3. INSTALLATION
3-1
3.1
LOCATING THE HEATER
3.1.1
You Choose
CAUTION
Do not weld PROHEAT heater
mounting brackets to the
vehicle frame.
If repairs to the vehicle require
welding, disconnect the PROHEAT
power cable at the PCM. This will
prevent damage to the PROHEAT
electronics.
SELECT YOUR LOCATION
The most suitable location for mounting the heater will vary depending
on the type of vehicle. Recommended mounting locations are:
• Behind the cab across the frame rails (1).
• On either side of the frame rails (2).
• In an existing enclosure on the vehicle (step or toolbox) (3).
1
2
3
2
Figure 3-2 Recommended Mounting Positions
3.1.2
WARNING
Never locate the heater inside
the vehicle cab. (See Figure 3-3)
GENERAL CONSIDERATIONS
• Never mount the heater to two separate parts of the vehicle.
• Avoid mounting the heater in areas of excessive vibration.
• Do not mount the heater directly to the engine.
• Do not mount the heater beneath a wood floor without a proper fire wall
above the heater.
• Avoid mounting the heater in areas of excessive dust, dirt and moisture
accumulation.
• The heater must be easily accessed for service.
COOLANT OUT
FUEL IN
Figure 3-3
MINIMUM
CLEARANCE 6″
Figure 3-4 Allow minimum 6″ clearance
for hose connections.
COOLANT IN
3-2
PROHEAT INSTALLATION & SERVICE
Heater must be mounted below the highest point in the cooling system. An
expansion tank may be added to the coolant system above the heater if this
is not possible.
HIGHEST POINT IN
COOLING SYSTEM
HEATER MUST
BE MOUNTED
BELOW
HIGHEST POINT
PROHEAT ENGINE OR RADIATOR
Figure 3-5 Height Requirement
3.1.3
MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE
Do not locate the heater in an
airtight enclosure. If the heater is to
be mounted in an enclosure other
than the PROHEAT enclosure,
adequate air flow must be provided
to ensure proper combustion. The
enclosure must also be adequately
ventilated so that the ambient
temperature inside the enclosure
does not exceed 185 °F (85 °C).
The openings must be positioned to prevent moisture dirt and snow from
accumulating in the enclosure. The heater enclosure must be easily
accessed for servicing of the heater.
Heater must be mounted within 5˚ of horizontal, as shown.
Figure 3-6 Adequate Air Flow
SECTION 3. INSTALLATION
5˚
5˚
Figure 3-7 Mounting Angle
5˚
5˚
3-3
3.2
MOUNTING THE HEATER
Select Your Mounting Option
Figure 3-8 Mounting Tray
3.2.1
OPTION A
1. Remove the enclosure cover.
2. Drill the (4) mounting holes and exhaust pipe clearance hole.
3. Using the bolts supplied, fasten the enclosure to the mounting
tray or brackets.
4. Ensure that the combustion tube can be removed for service.
See Figure 1-2 on page 1-3 for service space requirements.
– Heater With Enclosure
20″ (508 mm)
1 5/8″
(45 mm)
3″ (76 mm) Dia.
5″ (127 mm)
12″
(306 mm)
5 3/4″ (146 mm)
3/4″ (20 mm) MOUNTING HOLES
(4 REQUIRED)
Figure 3-9 X45 Enclosure Base Dimensions
5″ (127 mm)
CENTERLINE OF ENCLOSURE
8 13/16″
(223 mm)
5″ (127 mm)
16 11/16″ (427 mm)
1 5/8″ (45 mm)
3-4
PROHEAT INSTALLATION & SERVICE
NOTICE
3.2.2
OPTION B
– Heater Without Enclosure
Heater supplied without an enclosure (mount in an existing enclosure on the
vehicle ie. tool box). Heater supplied with an auxiliary mounting plate.
Use anti-seize compound on fasteners
to prevent galling and corrosion.
3″ (76 mm) Dia.
. Ensure that the proposed enclosure is big enough for the heater.
1
2
1
⁄2W x 11H x 201⁄2L inches (318 x 280 x 521 mm)
12
. Using the indicated dimensions, drill the (4) mounting holes
and exhaust pipe clearance hole.
3. Ensure that the combustion tube can be removed for service.
See Figure 1-2 on page 1-3 for service space requirements.
8.5″ (216 mm)
1.0″ (25 mm)
4 X .38″ (10MM)
MOUNTING HOLES
5″
(127 mm)
2.02″
(51 mm)
Figure 3-10 X45 Mounting Plate Dimensions & Exhaust Hole
5.5″
(140 mm)
6.4″
(163mm)
5″ (127 mm)
7.5″ (191 mm)
SECTION 3. INSTALLATION
3-5
3.3
NOTICE
If additional information is required,
please contact your PROHEAT Dealer
regarding your specific application.
Alternatively, please contact PROHEAT
Product Support at www.proheat.com.
EXHAUST PIPE CONNECTION
1. Push the exhaust pipe through the hole in the enclosure and onto the
exhaust outlet port of the heater. Ensure that the pipe is pushed onto
the spigot at least 11⁄2» (38 mm).
2. Route the exhaust pipe such that:
• exhaust gasses do not enter the passenger compartment.
• exhaust gasses do not enter the heater’s combustion air inlet
• exhaust system does not rest against or be directed toward any parts
of the vehicle that may be damaged by heat (i.e. brake lines, seals, wires
rubber hoses or bumpers). The exhaust pipe may be have to be insulated
if it’s within 6″ of combustible materials or composite body parts
• the exhaust outlet does not face the same direction as vehicle travel
• debris and snow will not plug the outlet
• the exhaust pipe is protected from curb damage
• the exhaust system should have a downwards slope for condensation
to drain. If needed a 3/8″ hole should be drilled into the exhaust pipe
at the lowest point so that the condensation will drain.
3. Disassemble the exhaust pipe clamp and apply anti-seize compound to
the threads.
4. Assemble the exhaust clamp over the exhaust pipe (clamp goes inside
the enclosure) and tighten the nuts.
,
WARNING
Exhaust gases must not enter
the vehicle interior. Direct
exhaust pipe away from vehicle.
NOTICE
Use of muffler or other restrictions in the
exhaust system is not recommended.
NOTE: 11⁄2» exhaust pipe should not exceed 5 ft and have no more than
180 degrees of bends. The bends must be formed for best results.
Do not use 90 degree welded pipe to turn corners.
Use formed elbows.
Do not use welded
90˚ elbows.
DIRECTION
OF VEHICLE
TRAVEL
EXHAUST CLAMP
U BOLT (APPLY
ANTI-SEIZE
COMPOUND
TO THREADS)
3-6
ENSURE THERE ARE
NO AIR LEAKS AROUND
THE CONNECTION
Figure 3-11 Exhaust Pipe
PROHEAT INSTALLATION & SERVICE
3.4
PLUMBING THE SYSTEM
MA
X
I
MUM
C
ROS
S
—
F
Figure 3-12 Maximum cross-flow
3.4.1
L
OW
GENERAL CONSIDERATIONS
Coolant flow must be maintained throughout the coolant system
nder all conditions.
u
• Keep the engine inlet and outlet ports as far apart as possible to maximize
cross-flow through engine.
• Coolant pump and engine water pump must flow in the same direction.
• Ensure that no sharp kinks or bends exist in the hoses which may restrict
coolant flow.
• Avoid high points in the hose routing to prevent air traps.
• For systems requiring more than 50 feet of coolant line, contact Proheat
Product Support at www.proheat.com for coolant pump recommendations.
For plumbing the system use:
1
⁄2» NPT pipe fittings or bigger.
3
⁄4» ID heater hose.
NOTE: Use of silicone hose requires special hose clamps.
Shut-off valves are not required at the engine inlet and outlet connections but
may be used if desired. They should be left open at all times so that the heater
can be operated throughout the year.
You Choose
Select Your Plumbing Option
Option A:
Engine heat or supplemental heat.
The PROHEAT heats the engine block only.
NOTE: When the engine block is preheated you will have nearly
instant heat from the dash heat exchanger.
Option B: Engine and sleeper heat.
The PROHEAT heats the engine block and the sleeper.
NOTE: Plumbing the PROHEAT through the dash fan is not
recommended.
SECTION 3. INSTALLATION
3-7
Instructions for Options A and B
WARNING
Opening the radiator cap when
the engine is hot may cause
serious injury.
3.4.2
1. Remove the radiator cap to release the system pressure.
2. Drain the coolant system.
3. Plumb the system as per Figure 3-13 or Figure 3-15
. Add engine coolant to the system as per the specific engine
4
manufacturer’s recommendations and re-install the radiator cap.
NOTE: Plumbing the PROHEAT through the dash fan is not recommended.
OPTION A – Engine Heat or Supplemental Heat
DASH HEATER
RETURN TO ENGINE
RETURN TO ENGINE
SUPPLY TO PROHEAT
SUPPLY TO PROHEAT
Figure 3-13 Engine Heat or Supplemental Heat
ENGINE
NOTE: On coolant systems where the return from the PROHEAT is plumbed to
the bottom of the main coolant supply line from the radiator to engine
pump, the return line must be moved to avoid loss of heat through the
radiator.
ENGINE
RETURN TO ENGINE
SUPPLY TO PROHEAT
ENGINE
Figure 3-14 Correct Return Line Plumbing
3-8
PROHEAT INSTALLATION & SERVICE
3.4.3
or best results these vehicles
F
should use an auxiliary heater.
International with single heater
OPTION B – Engine and Sleeper Heat
OEM OR AUXILIARY
SLEEPER HEATER
DASH HEATER
For vehicles with solenoid valves
in the normally closed position.
Western Star
SOLENOID VALVE
OEM COMBO HEATERS
ONLY (NORMALLY OPEN)
SUPPLY TO PROHEAT
Figure 3-15 Engine and Sleeper Heat
RETURN TO ENGINE
ENGINE
NOTE: Vehicles equipped with a combination heater/air-conditioner will have
a solenoid operated shut-off valve in the heater unit. Typically this valve
is normally open with the truck engine turned off and the key removed.
(See Figure 3-16 for plumbing)
Due to the many options available in vehicle heating and air
conditioning systems, the installer should be looking for any
restrictions that may affect coolant flow, with vehicle ignition in the
“OFF” position.
SLEEPER HEATER
SOLENOID VALVE
(NORMALLY CLOSED)
DASH HEATER
NOTICE
The PROHEAT PCM sleeper fan circuit
has a one minute delay during ignition.
Power to open a sleeper fan coolant
valve must be taken from another
source such as the wire for the hour
meter (auxiliary output). (See PROHEAT
Wiring Diagram on page 1-4.)
SECTION 3. INSTALLATION
SUPPLY TO PROHEAT
Figure 3-16 Engine and Sleeper Heat
RETURN TO ENGINE
ENGINE
3-9
3.5
WIRING & ELECTRICAL
CONNECTIONS
3.5.1
Figure 3-17 Test Battery
WARNING
Do not use on positive ground
vehicles.
GENERAL CONSIDERATIONS
• Prior to installation of the PROHEAT Heater system, ensure that the
vehicle batteries are in good condition.
• Do not kink or abrade wires when routing them through the vehicle during
installation.
• Ensure wires are well supported and secured with tie-wraps.
• Do not use acid core solder when making solder connections.
Major Electrical Connections Required
a) Power connection to batteries …………………………………………. page 3-11
b) Timer or ON/OFF switch connections…………………………………. page 3-12
c) Sleeper fan model heater connections (optional)………………….. page 3-14
d) Auxiliary Input model heater connections (optional)……………….. page 3-18
TO SLEEPER FAN OR AUX INPUT
DEPENDING ON MODEL
CAUTION
If repairs to the vehicle require
welding, disconnect the PROHEAT
power cable at the PCM. This will
prevent damage to the PROHEAT
electronics.
CAUTION
Vehicles using ground side battery
disconnect switches must install an
in-line 10 Amp fuse on the internal
harness (Proheat part # PK0310).
This will prevent damage to the
harness and PCM, (refer to Service
Bulletin SB0003 in Appendix).
TO BATTERIES
TO ON/OFF SWITCH
AND/OR TIMER
Figure 3-18 Major Electrical Connections
3-10
PROHEAT INSTALLATION & SERVICE
3.5.2
CAUTION
2 Volt products should not use
1
power split from a 24 Volt system.
This will cause uneven charging of
the batteries.
POWER CONNECTION TO BATTERIES
1. Route wire harness from PCM to the battery. Cut the harness to length
as required.
2. Strip outer wire jacket of harness back to expose the positive (red) and
negative (black) leads. Strip the leads as shown and crimp the ring
tongue terminals supplied to the wires. Connect the leads to the battery
erminals. (See Figure 3-19.)
t
NOTICE
Systems providing heat to both engine
and sleeper require four (4) batteries.
3. Leave power harness disconnected. (See Figure 3-19.) Do not install until
PROHEAT coolant pump system has been purged of air. (See First Time
Startup, page 3-26)
NOTE:
When power is connected to the PCM, all segments of the LED will flash
on the PCM. This indicates that power has been supplied. See page 5-4
for more information.
NOTE: Ensure the battery terminals are clean and free of corrosion. Remove
and clean. Prior to re-connecting grease terminals with electrically
conductive grease.
STRIP WIRE AS SHOWN AND
CRIMP TO TERMINAL
3/16″
POWER SUPPLY
HARNESS
BLACK (-) NEGATIVE
RED (+) POSITIVE
Figure 3-19 Power Connection to Battery
SECTION 3. INSTALLATION
3-11
TIM ER
1
ON
2 3
BLACK
RED
W
HITE
G
REEN
BLACK
TIMER
SWITCH INPUT
HARNESS
RED
W
HITE
G
REEN
GREY
TO KEYSWITCH (OPTIONAL)
3.5.3
CAUTION
The switch input circuit should only
be used to supply power to the
ON/OFF Switch, the Timer, or as a
signal to trip a relay. Failure to
follow this installation practice will
result in damage to the PCM.
NOTICE
The PCM must be reset (power
disconnected and reconnected)
when changing from a Timer to an
ON/OFF Switch or from an ON/OFF
Switch to a Timer.
Do not connect an ON/OFF Switch
and a Timer in the same circuit.
TIMER CONNECTIONS (OPTIONAL)
Black wire Ground
Red wire Power
White wire Operational signal from heater
Green wire “ON” Signal to heater
Grey wire Keyswitch backlighting (optional)
Figure 3-20 Timer Connections
3-12
PROHEAT INSTALLATION & SERVICE
BLACK
RED
WHITE
GREEN
GROUND
ON SIGNAL
ON
OFF
POWER
INDICATOR
2″ (51 mm)
3.5.4
ON/OFF SWITCH CONNECTIONS
1. Select a suitable location in the vehicle dash for the ON/OFF Switch.
CAUTION
The switch input circuit should only
be used to supply power to the
ON/OFF Switch, the Timer, or as a
signal to trip a relay. Failure to
follow this installation practice will
result in damage to the PCM.
NOTICE
The PCM must be reset (power
disconnected and reconnected)
when changing from a Timer to an
ON/OFF Switch or from an ON/OFF
Switch to a Timer.
Do not connect an ON/OFF Switch
and a Timer in the same circuit.
DASH
1/2″ DIA.
HOLE
SWITCH
LABEL
NOTE: Many dash panels have switches which are not utilized. It may be
convenient to remove one and replace it with the PROHEAT switch.
2. Drill a1⁄2» diameter hole through the dash for the switch. Make sure you
have clearance behind the dash for the switch wires and connections.
Install the switch as per the diagram. (Figure 3-21)
3. Route the switch wire harness from the PCM to the dash panel. You will
have to pass the wire harness through the vehicle firewall. If possible use
an existing hole. Use a grommet to prevent the wire from being damaged
when it is passed through the hole.
4. Cut the harness to length.
5. Strip outer wire jacket of harness back to expose the 4 wires. Strip the
wires as shown and crimp the supplied1⁄4» spade terminals.
NOTE: Use fully insulated disconnects when connecting Switch.
ON/OFF
SWITCH
NUT
Figure 3-21 ON/OFF Switch Assembly
Figure 3-22 ON/OFF Switch Connections
6. Connect the terminals to the switch as shown. (Figure 3-22)
NOTE: The PCM must be reset (power disconnected and reconnected) when
changing from a Timer to an ON/OFF Switch or from an ON/OFF Switch
to a Timer. Connecting an ON/OFF Switch and a Timer in the same
circuit will cause the indicator light to flash incorrectly.
SECTION 3. INSTALLATION
3-13
3.5.5
SLEEPER FAN MODEL HEATER WIRING DETAILS
NOTICE
These instructions require a Sleeper
Fan model. For more information see
age 4-2.
p
You Choose
NOTICE
Sleeper Fan output does not supply
power during ignition (1 minute after
switch ON). DO NOT use for controlling
coolant valves. See page 4-5 for
operational sequence information.
The Hour Meter (Auxiliary) Output may
be used to control supplemental relays
to turn on coolant valves.
If additional installation information is
required, please contact your PROHEAT
Dealer or Product Support at
www.proheat.com
These installation options allow the operator to:
1. Run the PROHEAT with the ignition key in the “OFF” position.
2. Return full control to the OEM system in normal operation mode.
Select one of the following wiring options
NOTE: PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN SLEEPER
FAN SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING
COMPANIES.
Due to the wide variety of wiring schematics that exist, we emphasize that
if you are in any doubt you should contact your dealer or PROHEAT Product
Support at www.proheat.com
Option A: Used when climate control systems in sleepers require one or
more of the following features to be controlled.
1. Normal OEM fan speed selection.
2. A separate thermostat is required to turn the sleeper fan
motor “ON” and “OFF” because the OEM system uses a
constant running fan.
3.
A valve in the sleeper heater coolant line regulates the flow
must be fully opened when the PROHEAT is running.
4. Prevent possible back-feeding on ground side switched
systems.
and
3.5.6
Option B: Used in larger sleepers requiring greater fan speed to provide
sufficient air movement to the sleeper. This allows the driver to
select the fan speed.
Option C: Used when a dedicated auxiliary heater is required.
Option D: Limits the power provided to the sleeper fan motor to
3 Amps. With this system the total electrical draw is controlled
by PROHEAT.
NOTE: For larger systems in the latest model trucks this may not provide
enough fan speed and therefore Option A, B or C should be used.
OPTION A – OEM Heater & Proheat Thermostat
Please go to www.proheat.com for equipment specific installation instructions.
3-14
PROHEAT INSTALLATION & SERVICE
3.5.7
OPTION B – OEM Heater & Thermostat
1. Make sure the vehicle ignition is switched “OFF.”
2. Locate the PROHEAT thermostat in a central area of the sleeper,
approximately 12″ above the bunk. Avoid direct air flow from sleeper fan
ducts. (Figure 3-25)
3. Remove the adjusting knob and face cover. Mark and drill mounting
holes. Mount thermostat using the screws provided. (Figure 3-27)
4. Install relay 1, always between OEM sleeper fan control and OEM
thermostat.
NOTE: The constant power supply wire must be of sufficient size to handle
sleeper fan motor electrical current draw.
5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length.
Connect white wire to terminal 1 of the thermostat.
6. Route a wire from terminal 2 of the thermostat to relay 1 (can be cut from left
over wire harness). Ground the relay using PROHEAT sleeper fan ground
wire (black).
VEHICLE
FUSE
PANEL
PROHEAT
THERMOSTAT
WHITE
SLEEPER FAN
HARNESS
PCM
WHITE
BLACK
OEM THERMOSTAT
15 AMP
RELAY 1 STANDARD
12 OR 24/30 AMP
RESISTOR ASSEMBLY
NOTE: MAY OR MAY NOT BE LOCATED
INSIDE SLEEPER HEATER ASSEMBLY
OEM
SLEEPER
HEATER
ASSEMBLY
(SINGLE WINDING TYPE)
CONSTANT POWER
SOURCE
(i.e. CIGARETTE LIGHTER)
OEM FAN
MOTOR
CONTROL
(2 OR 3 SPEED)
FAN MOTOR
SECTION 3. INSTALLATION
Figure 3-23 Option B
3-15
3.5.8
OPTION C – Auxiliary Sleeper Heater
1. Make sure the vehicle ignition is switched “OFF.”
2. Locate the auxiliary heater in a suitable area of the vehicle. Install plumbing
and air duct connections as per the manufacturer’s recommendations.
3. Locate the PROHEAT thermostat in a central area of the sleeper,
approximately 12″ above the bunk. Avoid direct air flow from sleeper fan
ducts. (Figure 3-25)
4. Remove the adjusting knob and face cover. Mark and drill mounting
holes. Mount thermostat using the screws provided. (Figure 3-27)
5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to
length. Connect white wire to terminal 1 of the thermostat using the fork
terminal provided. Black wire is not used.
6. Route a wire from terminal 2 of the thermostat to an appropriate wire on
the sleeper fan motor. Make a splice connection and seal the splice with
tape or heat shrink.
NOTE: The electrical power and operation in this option is controlled by the
PROHEAT. See Option B should a relay be required to provide more
electrical power.
WARNING
Systems using a ground side
battery disconnect must install
a 10 Amp fuse to protect the
sleeper fan harness.
Thermostat Wire Connection Detail
Screw # Wire Colour
1 White (from PCM)
2 White (to sleeper heater)
3 Not used
4 Not used
PCM
SLEEPER FAN
HARNESS
SPLICE WIRES
FAN MOTOR
(MULTIPLE WINDING TYPE)
ORANGE
RED
(NOT USED)
B
H
W
K
C
A
L
TE
HI
W
ITE
THERMOSTAT
1
1
2
2
3
4
AUXILIARY
SLEEPER HEATER
10 AMP
FUSE
GROUND
3-16
Figure 3-24 Option C
PROHEAT INSTALLATION & SERVICE
INSTALLATION AND SE R V I C E M A N U A L
PROHEAT X45
Rev. H
CONTENTS
A. SAFETY .
B. INTRODUCTION .
…………………………………………………………………………. A-1
……………………………………………………………… B-1
C. MODEL DESCRIPTIONS…………………………………………………… C-1
1.0 TECHNICAL SPECIFICATIONS …………………………………………. 1-1
1.1 PHYSICAL – X45 …………………………………………………………… 1-2
1.2 ELECTRICAL – X45 ………………………………………………………… 1-4
1.3 TORQUE SPECIFICATIONS ……………………………………………….. 1-6
2.0 OPERATING YOUR PROHEAT HEATER………………………………. 2-1
3.0 INSTALLATION ……………………………………………………………….. 3-1
3.1 LOCATING THE HEATER ………………………………………………….. 3-2
3.1.1 Select Your Location ……………………………………………… 3-2
3.1.2 General considerations…………………………………………… 3-2
3.1.3 Mounting the Proheat Heater in an Enclosure………………. 3-3
3.2 MOUNTING THE HEATER …………………………………………………. 3-4
3.2.1 Option A – Heater With Enclosure ……………………………… 3-4
3.2.1 Option B – Heater Without Enclosure …………………………. 3-5
3.3 EXHAUST PIPE CONNECTION……………………………………………. 3-6
3.4 PLUMBING THE SYSTEM…………………………………………………. 3-7
3.4.1 General Considerations ………………………………………….. 3-7
3.4.2 Option A – Engine Heat or Supplemental Heat ……………… 3-8
3.4.3 Option B – Engine and Sleeper Heat ………………………….. 3-9
3.5 WIRING & ELECTRICAL CONNECTIONS……………………………… 3-10
3.5.1 General Considerations ………………………………………… 3-10
3.5.2 Power Connection to Batteries ……………………………….. 3-11
3.5.3 Timer Connections (Optional) …………………………………. 3-12
3.5.4 On/Off Switch Connections ……………………………………. 3-13
3.5.5 Sleeper Fan Model Heater Wiring Details ………………….. 3-14
3.5.6 Option A – OEM Heater & Proheat Thermostat ……………. 3-14
3.5.7 Option B – OEM Heater & Thermostat………………………. 3-15
3.5.8 Option C – Auxiliary Sleeper Heater………………………….. 3-16
3.5.9 Option D – Auxiliary Sleeper Heater Current Limited …….. 3-17
3.5.10 Auxiliary Input Model Heater Wiring Details………………. 3-18
3.5.11 Option A –
3.5.12 Option B –
3.5.13 Option C – Standard Mode & Supplemental Mode ………3-20
3.6 FUEL SYSTEM …………………………………………………………….. 3-22
3.6.1 General Considerations ………………………………………… 3-22
3.6.2 Option A – 1/4″ or 1/2″ NPT Port …………………………… 3-23
3.6.3 Option B – Existing Blank Fuel Sender Cover Plate ………. 3-24
3.6.4 Option C – Hole Drilled into Fuel Tank ………………………. 3-24
3.6.5 Installation ………………………………………………………… 3-25
3.7 FIRST TIME STARTUP……………………………………………………. 3-26
Preheat Mode Supplemental Mode Operation
Preheat and Supplemental Mode
………………. 3-20
… 3-19
4.0 PRINCIPLES OF OPERATION …………………………………………… 4-1
4-1 GENERAL DESCRIPTION ………………………………………………….. 4-1
4-2 MODES OF OPERATION …………………………………………………… 4-5
4.2.1 Standard Mode – All Models ……………………………………. 4-5
4.2.2 Preheat Mode – Aux Input Models Only ………………………. 4-6
4.2.3 Supplemental Mode – Aux Input Models Only ………………. 4-7
i
5.0 TROUBLESHOOTING & REPAIR .
5.0.1 Troubleshooting a Problem…………………………………. 5-1
.0.2 Example Proheat Behavior Error – Code 01…………….. 5-2
5
5-1 OPERATION INDICATORS, FUNCTION & COMPONENT
IAGNOSTICS …………………………………………………………. 5-3
D
5.1.1 Operation Indicators …………………………………………. 5-4
5.1.2 Function Diagnostics ………………………………………… 5-5
1 Start …………………………………………………………. 5-5
0
02 Flame Out ………………………………………………… 5-15
03 Coolant Flow …………………………………………….. 5-16
04 Overheat ………………………………………………….. 5-17
05 Voltage ……………………………………………………. 5-18
5.1.3 Component Diagnostics………………………………………… 5-19
06 Flame Sensor……………………………………………. 5-19
07 Temp Sensor ……………………………………………. 5-21
08 Fuel Pump………………………………………………… 5-23
09 Compressor ……………………………………………… 5-23
10 Ignition Coil………………………………………………. 5-25
11 Coolant Pump …………………………………………… 5-27
12 Blower …………………………………………………….. 5-30
13 Sleeper Fan ……………………………………………… 5-32
14 Hour Meter (Auxiliary Output)………………………… 5-33
5-2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS ……….. 5-34
5.2.1 Fuel Nozzle ………………………………………………………… 5-34
5.2.2 Fuel Regulator…………………………………………………….. 5-34
5.2.3 Air Compressor …………………………………………………… 5-34
5.2.4 Fuel Pump …………………………………………………………. 5-34
5.2.5 Ignition Electrode ………………………………………………… 5-34
5.2.6 Coolant Pump …………………………………………………….. 5-34
5.2.7 Blower ………………………………………………………………. 5-34
5.2.8 Fuse ………………………………………………………………… 5-35
5-3 OPERATIONAL PROBLEMS ……………………………………………… 5-37
5.3.1 Smoking exhaust ………………………………………………… 5-37
5.3.2 Low heat output ………………………………………………….. 5-37
5.3.3 Engine temperature gauge reads low ……………………….. 5-37
5.3.4 Backfiring ………………………………………………………….. 5-37
………………………………………. 5-1
6.0 MAINTENANCE……………………………………………………………….. 6-1
6-1 WEEKLY MAINTENANCE ………………………………………………….. 6-1
6-2 ANNUAL MAINTENANCE ………………………………………………….. 6-1
6.2.1 Clean Heater Enclosure and Air Intake ……………………….. 6-2
6.2.2 Check Exhaust System …………………………………………… 6-3
6.2.3 Check Heat Exchanger……………………………………………. 6-3
6.2.4 Clean Flame Sensor ………………………………………………. 6-4
6.2.5 Check Cooling System ……………………………………………. 6-4
6.2.6 Check Batteries ……………………………………………………. 6-4
6.2.7 Check Fuel System………………………………………………… 6-5
6.2.8 Check Fuel Filter …………………………………………………… 6-5
6.2.9 Clean Nozzle………………………………………………………… 6-6
6.2.10 Replace Compressor Air Filter ………………………………… 6-6
6.2.11 Check Electrical System ……………………………………….. 6-7
6.2.12 Check Air Pressure ………………………………………………. 6-8
6.2.13 Check
Modes of Operation – Switch, Timer or OEM Signals
.. 6-8
7.0 APPENDICES …………………………………………………………………. 7-1
Bulletins 951528, 967329, SB0003, PB0034, SB0062
8.0 WARRANTY ……………………………………………………………………. 8-1
ii
PROHEAT INSTALLATION & SERVICE
A.
SAFETY
Throughout this manual, you will see notes labeled DANGER, WARNING,
CAUTION and NOTICE to alert you to special instructions or precautions
concerning a particular procedure that would be hazardous if performed
incorrectly or carelessly.
Observe them carefully!
These safety alerts alone cannot eliminate all hazards. Strict compliance
with these special instructions and common sense are major accident
prevention measures.
DANGER
Immediate hazards that will result
in severe injury or death.
WARNING
Hazards or unsafe practices that
could result in severe personal
injury or death.
CAUTION
Hazards or unsafe practices that
could result in minor injury or
product or property damage.
NOTICE
Information that is important to
proper installation or maintenance,
but is not hazard-related.
SECTION A. SAFETY
A-1
SAFETY CONSIDERATIONS
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
Exhaust
Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal
injury and/or death. Anyone suspected of suffering from CO inhalation should be
removed from the hazardous area and given medical assistance immediately.
Explosion Hazard
Do not operate heater where combustible fumes or airborne particles, such as sawdust, are present.
Fuel
Exercise extreme caution when working near fuel or fuel-filled equipment. Do not
operate heater during fueling operations. In addition, do not smoke or handle open
flame equipment, such as a blowtorch, around fuel.
Fire Hazard
Do not place any flammable items around the heater and exhaust pipe.
Batteries
Wear hand and eye protection when working near batteries. Do not smoke or use open
flames near batteries.
Electrical
Electric shock can cause severe personal injury, burns, and death. Before working on
any unit, disconnect the batteries. Use only approved materials and methods when
working on the electrical system and follow local electrical codes. Never work with
electricity in wet conditions or when you are feeling fatigued.
WARNING
WARNING
WARNING
DANGER
Poisons/Toxins
Fuel and coolant are toxic and in some cases, carcinogenic. Wear eye and hand
protection at all times. Remove contaminated clothing immediately and wash
contaminated skin. Do not breathe in vapors.
Moving/Hot Parts
Moving/hot parts can cause severe injury and or death. Before working on any unit,
shut it off. Do not operate any unit until protective covers have been replaced. Always
ensure bolts and clamps are correctly torqued and secured. Inspect mechanical components periodically for damage and corrosion.
Coolant
Never remove the filler cap when the engine is hot – escaping steam or scalding water
could cause serious personal injury. The coolant level in the expansion tank should be
checked at least weekly (more frequently in high mileage or arduous conditions). Always
check the level when the system is cold. Unscrew the filler cap slowly, allowing the
pressure to escape before removing completely. Never run the engine without coolant.
Prevent anti-freeze coming in contact with the skin or eyes. If this occurs, rinse
immediately with plenty of water. Anti-freeze will damage painted surfaces.
Never top-up with salt water. Even when travelling in territories where the water supply
contains salt, always ensure you carry a supply of fresh (rain or distilled) water.
California Proposition 65 Warning
Do not operate heater in garages or in other closed or unventilated areas.
Diesel exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
Electrical components in this product may contain lead, a chemical known to the
State of California to cause cancer and birth defects and other reproductive harm.
A-2
PROHEAT INSTALLATION & SERVICE
INTRODUCTIONB.
PROHEAT Model X45
This manual is provided to assist an authorized PROHEAT
dealer to install and service a PROHEAT heater. Although
trucks have been used in the examples, applications for
PROHEAT are by no means limited to trucks. PROHEAT
heaters are designed to be used on any diesel equipped
vehicle including: trucks, buses (school, transit and coach),
construction equipment, off road equipment, military
equipment and cargo.
PROHEAT heaters are used in the following applications:
(1) Engine Block Heat – PROHEAT will preheat an engine
block to ensure reliable starting in cold weather. At
the same time it may be used throughout the year to
reduce the wear associated with cold starts.
(2)
Cab or Sleeper Heat (engine off) – PROHEAT will supply
heat to the cab or sleeper. Drivers can sleep in comfort
not only in the cold of winter but also in the spring
and fall when the weather is miserable. Substantial
savings through reduced fuel consumption and engine
wear can be obtained by not idling the engine.
(3)
Supplemental Heat (engine running) – as the efficiency
of modern diesel engines are improved there is no
longer adequate reject heat available to heat the
vehicle’s interior. This is particularly true for buses.
PROHEAT can be used while the vehicle is operating
to provide supplemental heat for the interior.
(4) Cargo Heat – PROHEAT can be used to provide heat to
protect valuable cargo such as produce or beverages
from damage due to freezing.
(5) Marine – Marine applications typically involve the
engineering and installation of a complete hot-water
heating system of which PROHEAT is only one
component. Proheat recommends that only an
expert in marine hot-water heating systems install a
PROHEAT on a boat. It is the installer’s responsibility
to ensure that the installation complies with all
applicable regulations.
SECTION B. INTRODUCTION
B-1
B-2
PROHEAT INSTALLATION & SERVICE
C.
Sleeper Fan Output or Auxiliary Input
Identification.
MODEL DESCRIPTIONS
This manual covers all models of PROHEAT X45. Please refer to the X45 Parts
Book at www.proheat.com for detailed part descriptions and part numbers.
Included in the parts book are optional features such as a timer, sleeper fan
ontrol kit, impact switch (for school bus applications) and associated
c
installation and maintenance tools.
The following information describes the three general characteristics of X45
models covered in this manual: voltage, enclosure and Proheat Control Module
(PCM) options.
PROHEAT CONTROL MODULE (PCM): SLEEPER FAN
OUTPUT OR AUXILIARY INPUT
The PCM comes in either a sleeper fan output or auxiliary input model. The
sleeper fan model is limited to a 3 amp output and is generally installed on
trucks that require sleeper fan power (it is only available on 12 V models).
The
Auxiliary
Mode and Supplemental Mode. This operation is typically used for transit and
coach installation. Refer to page 4-2 for more information.
Input model uses two special input pins that allow for a Preheat
Voltage Identification.
VOLTAGE CONFIGURATION: 12 V OR 24 V
The X45 is available in either a 12 V or 24 V models.
ENCLOSURE
An optional enclosure provides environmental protection.
SECTION C. MODEL DESCRIPTIONS
C-1
C-2
PROHEAT INSTALLATION & SERVICE
1.0
TECHNICAL
SPECIFICATIONS
X45 12V X45 24V
RATING 45,000 BTU (13 kW)
YSTEM VOLTAGE 10 –15 VDC 20 – 30 VDC
S
ominal Voltage Range
N
CURRENT DRAW 7.5 Amps 3.75 Amps
FUEL CONSUMPTION
(Average to Maximum) 0.1 – 0.45 gal/hr. (0.4 – 1.7 L/hr.)
COOLANT FLOW 8.0 gal/min. (30 L/min.)
COOLANT TEMPERATURE (at Heater) 150°F to 185°F (65°C to 85°C)
OPERATING TEMPERATURE RANGE -40°F to +122°F (-40°C to +50°C)
IGNITION TYPE Electronic Spark Ignition
HEAT EXCHANGER CAPACITY 1 quart (0.95 L)
WEIGHT Heater ONLY 40 lbs (18 Kg)
WEIGHT Heater with Enclosure 55 lbs (25 Kg)
DIMENSIONS – HEATER (L x W x H) 18.9 x 11.2 x 10.6 inches
DIMENSIONS – ENCLOSURE (L x W x H) 20.2 x 12.3 x 10.5 inches
WARRANTY Two years parts and labor
(520 x 320 x 280 mm)
(513 x 313 x 267 mm)
DANGER
DO NOT use gasoline.
FUEL TYPES
COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1
Bio Fuels – Contact Proheat www.proheat.com
SYSTEM OUTPUTS
HOUR METER Same as System Voltage
(AUXILIARY OUTPUT) Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SWITCH/TIMER Same as System Voltage
POWER Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SLEEPER FAN Same as System Voltage
(Certain Models Only) Maximum 3 Amp draw (over-load shut-off protection)
High-side switched
INDICATOR LIGHT Same as System Voltage
Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SYSTEM INPUTS
SWITCH 10 – 15 VDC (12V X45) | 20 – 30 VDC (24V X45)
Standard Run Mode
Preheat Run Mode (Certain Models Only)
Supplemental (Certain Models Only)
POWER 12 VDC or 24 VDC
SECTION 1. TECHNICAL SPECIFICATIONS
1-1
O
A
L
I
T
T
R
L
L
D
N
A
L
E
I
,
E
R
E
S
O
T
N
R
HEATERMODELNo:……….
SERIALNo:
MadeinCanadabyTeleexCanada Ltd Richmond B.C.
OPERATINGVOLTAGE:…10-16VOLTS
HEATOUTPUT:………….
PRESSURE:…………..
MAX.OPERATING
FUELTYPE:……………….
******
915822
9.0kW(KBTU)
2BAR(29PSI)
DIESELFUEL
X-4512V
POWER
G-IIISOFT START
PROHEATCONTROL MODULE
FUSE15A
SWITCHINPUT
SLEEPERFAN
ThisProductMeets
FHWABusHeater
Requirements
DieselFueledVechicle
CoolentHeater
ApprovedforUsein
BusApplications
12VOLT
999100
COMMINICATION
RS232&
CANBus
DONOT
POWER
WASH
ProtectedbyUSPatents
5,878,950and6,082,625
1.5 I.D.
C EXHAUST
PORT
L
Ø1.5″ [38]
4.9″ [125]
1.9″ [49]
8.7″ [222]
1.3″ [33]
1.6″ [41]
10.6″ [270]
4.0″ [101]
1.3″ [34]
10.1″ [258]
11.2″ [285]
4.4″ [112]
4X 0.38″ [10]
MOUNTING HOLES
STANDARD EXHAUST PIPE
SEE NOTE 1
5.5″ [140]
9.4″ [239]
COOLANT OUTLET
TOP VIEW
COOLANT INLET
C EXHAUST
PORT
L
NOTES:
1/ REFER TO X45 PARTS BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
AND SUBJECT TO CHANGE WITHOUT NOTICE
AUXILIARY MOUNTING PLATE
SEE NOTE 1
18.9″ [479]
C EXHAUST
PORT
L
5.1″ [129]
C EXHAUST
PORT
L
COOLANT OUTLET
CONNECTION3/4″ [19]
ID HOSE1/2″ NPT
HOSE FITTINGSEE
NOTE 1
FUEL SUPPLY
CONNECTION
3/16″ [48] ID HOSE
SEE NOTE 1
COOLANT INLET
CONNECTION
3/4″ [19] ID HOSE
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
AUXILIARY MOUNTING PLATE — SEE NOTE 1
TOP VIEW
MOUNT HOLE DIMENSIONS
2X 5.5″ [140]
2X 7.5″ [191]8.50″ [216]
6.40″ [163]
THIS SPACE
IS REQUIRED FOR
COMBUSTION TUBE REMOVAL
11.2″ [284]
10.2″ [259]
5.5″ [140]
THIS SPACE
IS REQUIRED FOR
COMBUSTION TUBE REMOVAL
2.0″ [50]
1.1
PHYSICAL – X45
X45 HEATER1.1.1
Figure 1-1 Heater Dimensions – X45
1-2
PROHEAT INSTALLATION & SERVICE
POWER
G-IIISOFT START
PROHEATCONTROL MODULE
FUSE15A
SWITCHINPUT
SLEEPERFAN
ThisProductMeets
FHWABusHeater
Requirements
DieselFueledVechicle
CoolentHeater
ApprovedforUsein
BusApplications
12VOLT
999100
COMMINICATION
RS232&
CANBus
DONOT
POWER
WASH
ProtectedbyUSPatents
5,878,950and6,082,625
O
A
L
I
T
T
R
L
L
D
N
A
L
E
I
E
R
E
S
O
T
N
R
HEATERMODELNo:……….
SERIALNo:
MadeinCanadabyTeleexCanadaLtd Richmond B.C.
OPERATINGVOLTAGE:…XX-XXVOLTS
HEATOUTPUT:………….
PRESSURE:…………..
MAX.OPERATING
FUELTYPE:……………….
******
XXXXXX
9.0kW(KBTU)
2BAR(29PSI)
DIESELFUEL
X-45XXV
COOLANT INLET
CONNECTION
3/4″ [19] ID HOSE
COOLANT OUTLET CONNECTION
3/4″ [19] ID HOSE
1/2″ NPT HOSE FITTING
SEE NOTE 1
TOP VIEW
ENCLOSURE LID REMOVED
FUEL SUPPLY
CONNECTION
1/4″ [48] ID HOSE
SEE NOTE 1
9.9″ [252]
2X 1.4″ [36]
FRONT VIEW
ENCLOSURE LID REMOVED
LEFT SIDE VIEW
ENCLOSURE LID REMOVED
RIGHT SIDE VIEW
ENCLOSURE LID REMOVED
ENCLOSURE COVER
FRONT VIEW
ENCLOSURE COVER
LEFT SIDE VIEW
20.2″ [513]
10.5″ [267]
20.0″ [508]
10.5″ [267]
12.0″ [305]
8.5″ [216]
ENCLOSURE COVER
RIGHT SIDE VIEW
12.3″ [313]
3.8″ [97]
2X 1.20″ [30]
7.1″ [181]
12.0″ [305]
10.5″ [267]
3.6″ [92]
3.6″ [92]
THIS SPACE
IS REQUIRED FOR
COMBUSTION
TUBE REMOVAL
ASSEMBLED
ENCLOSURE
NOTES:
1/ REFER TO X45 PARTS BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
AND SUBJECT TO CHANGE WITHOUT NOTICE
X45 WITH ENCLOSURE1.1.2
Figure 1-2 Heater Dimensions including Enclosure – X45
SECTION 1. TECHNICAL SPECIFICATIONS
1-3
FUEL PUMP
COMPRESSOR
ELECTRODE
IGNITION
BLOWER
PUMP
FLAME
TEMPERATURE
SENSOR
SENSOR
COOLANT
B (-)BLACK/BLUE
HOUR METER (AUXILIARY OUTPUT)
12V/24V 1A MAX.
P5
COMMUNICATION
CANBUS AND
RS232
E
F
E
F
(+)RED/WHITE
(-)GREEN/WHITE
A
B
BCA
D
BCA
D
E1
F1
(-)BROWN
(-)BLACK/WHITE
(+)GRAYA
A
B
B
(+)WHITE
B
A
B
A
F3
E3
F2
E2
P1
POWER
C
C
A
B
B
A
HEATER CHASIS GROUND LUG
(GROUND VIA
COMBUSTION TUBE)
IGNITION
COIL
OVERHEAT SENSOR
D1
(-)BLACK
(+)PURPLE
(-)BLACK/PURPLE
B
(+)BLUE
B
A
A
A
B
A
B2
A2
B3
A3
(+)RED
D2
C3
P5
HEATER
INTERNAL
HARNESS
P2
SWITCH
C
C
D
D
B
A
A
B
(-)BLACK/ORANGE
(+)ORANGE
A
B
B
A
(-)PINK
(+)PINK
B
A
A
B
PLUGGED
C1
A1
B1
C2
D3
P3
SLEEPER
FAN
A
A
B
B
CONNECTOR TERMINAL
DESIGNATORS
NOTE ORIENTATION
OF CONNECTOR LUGS
(+) RED — BATTERY POSITIVE 12V/24V
(-) BLACK — BATTERY NEGATIVE
PLUGGED — NOT USED
(+) RED — POWER 12V/24V OUTPUT
(-) BLACK — GROUND
GREEN — ON SIGNAL STANDARD MODE 12V/24V INPUT
(+) WHITE — INDICATOR LAMP 12V/24V OUTPUT
(+) RED — POWER 12V/24V (3 AMP LIMIT) OUTPUT
(-) BLACK — GROUND
CAN — H
RS232 — GROUND
CAN — SHIELD
RS232 — TRANSMIT
CAN — L
RS232 — RECEIVE
E1
F1
F3
E3
F2
E2
A2
B3
D1
B2
A3
D2
C2
D3
A1
B1
C1
C3
NOTES:
1/ REFER TO X45 PART BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
(+)PINK
A
B
(-)PINK
(+)ORANGE
A
(-)BLACK/ORANGE
B
(+)
(-)
(+)PURPLEA
(-)BLACK/PURPLE
B
(+)BLUEA
(-)BLACK/BLUEB
(+)BROWNA
(-)BROWNB
(+)WHITEA
(-)BLACK/WHITEB
P3
AUXILIARY
INPUT
A
B
ON SIGNAL PREHEAT MODE 12V/24V INPUT
ON SIGNAL SUPPLEMENTAL MODE 12V/24V INPUT
A
B
SEE DETAIL A FOR
AUXILIARY INPUT OPTION
DETAIL A
AUXILIARY INPUT OPTION
SEE NOTE 1
OPTIONAL IMPACT SWITCH
SEE NOTE 1
A
B
A
B
C
SEE NOTE 1
FOR HARNESS
PART NUMBERS
SEE NOTE 1
FOR HARNESS
PART NUMBERS
OPTIONAL GROUND FUSE
SEE NOTE 1
(-)BLACK/GREEN
SLEEPER FAN PCM SHOWN
SEE NOTE 1
HEATER INTERNAL HARNESS
SEE NOTE 1
10 A
1 2 3
A
BCD
E
F
A
B
C
D
E
F
HEATER INTERNAL HARNESS
18 PIN CONNECTOR PIN OUT DETAIL
1.2
ELECTRICAL – X45
Figure 1-3 Wiring Diagram – X45
1-4
PROHEAT INSTALLATION & SERVICE
PROHEAT CONTROL MODULE
G-III SOFT START
5,878,950and 6,082,625
Protectedby US Patents
WASH
POWER
DO NOT
COMMINICATION
BusApplications
ApprovedforUse in
CoolentHeater
DieselFueledVechicle
Requirements
FHWABus Heater
ThisProduct Meets
CANBus
RS232&
FUSE 15A
999100
SLEEPER FAN
12 VOLT
SWITCHINPUT
POWER
P1 — POWER
3 PIN
P2 — SWITCH
4 PIN
P3 — SLEEPER FAN OUTPUT
OR AUXILIARY INPUT
2 PIN
SEE NOTE 1
P4 — COMMUNICATION
CANBUS AND
RS232 6 PIN
FUSE 15 A
SEE NOTE 1
P5 — HEATER
INTERNAL
HARNESS
18 PIN
PROHEAT CONTROL MODULE (PCM)
SEE NOTE 1 FOR PART NUMBER OPTIONS
1A
1B
1C
2A
2B2C
2D
3A3B
DETAIL B
DETAIL B
P1 — P3 CONNECTOR PIN OUT DETAIL
DETAIL C
2
3
1
CONNECTOR TERMINAL
DESIGNATORS
NOTE ORIENTATION
OF CONNECTOR LUGS
DETAIL C
P5 CONNECTOR PIN OUT DETAIL
ABC
DFE
CONTROLLER VOLTAGE AND
PART NUMBER IDENTIFICATION
SEE NOTE 1
SLEEPER FAN OR AUX INPUT MODEL
IDENTIFICATION — SEE NOTE 1
4A
4B
4C
4D
4E
4F
DETAIL D
DETAIL D
P4 CONNECTOR PIN OUT DETAIL
NOTES:
1/ REFER TO X45 PART BOOK SL9070 FOR PART
NUMBER IDENTIFICATION
Figure 1-4 PCM Electrical Connections – X45
SECTION 1. TECHNICAL SPECIFICATIONS
1-5
TORQUE SPECIFICATIONS1.3
FAN END CASTING
Apply anti-seize to bolts (3)
•
• Torque bolts (3) to 75±5 in/lbs (8.5±0.5 Nm)
REGULATOR
• Apply anti-seize to cap screw
• Torque cap screw to 94±6 in/lbs (10.6±0.7 Nm)
FLAME SENSOR
• Torque sensor to 25±3 in/lbs (2.8±0.3 Nm)
IGNITER
• Apply anti-seize to igniter threads
• Ensure gasket is present before installing
• Torque igniter to 50±5 in/lbs (5.6±0.6 Nm)
COMBUSTION TUBE
• Apply anti-seize to cap screws
• Torque cap screws (4) to 25±3 in/lbs (2.8±0.3 Nm)
1-6
PROHEAT INSTALLATION & SERVICE
OVERHEAT SENSOR
• Lubricate o-ring with o-ring lubricant
• Torque senor to 500±50 in/lbs (56±5.6 Nm)
TEMPERATURE SENSOR
• Lubricate o-ring with o-ring lubricant
• Torque senor to 25±3 in/lbs (2.8±0.3 Nm)
AIR FILTER
• Torque cap screw to 50±5 in/lbs (5.6±0.6 Nm)
SECTION 1. TECHNICAL SPECIFICATIONS
BLOWER ASSEMBLY
• Apply anti-seize to bolts (4)
• Torque bolts (4) to 25±3 in/lbs (2.8±0.3 Nm)
PROHEAT CONTROL MODULE (PCM)
• Apply anti-seize to bolts (3)
• Torque bolts (3) to 75±7 in/lbs (8.5±0.8 Nm)
1-7
MAIN INTERNAL HARNESS
• Torque bolt (1) to 10±2 in/lbs (1.1 +/- 0.2)
NOZZLE TO FAN END
• Lubricate o-ring on nozzle with diesel
• Torque nozzle to 150±10 in/lbs (17±1.1 Nm)
NOZZLE REASSEMBLY
• Torque nozzle (1) to 30±3 in/lbs (3.4±0.3 Nm)
BAND CLAMPS
• Torque clamps (4) to 25±3 in/lbs (2.8±0.3 Nm)
ENCLOSURE LID (Optional)
• Anti-seize recommended on bolts
• Torque clamps (2) to 30±3 in/lbs (3.4±3.4 Nm)
1-8
PROHEAT INSTALLATION & SERVICE
HARNESS GROUND LUG
• Apply anti-seize to bolt
• Torque bolt (1) to 75±5 in/lbs (8.5±0.5 Nm)
FUEL PUMP ASSEMBLY
A
• Apply Loctite 242 to threads
• Torque bolts (2) to 25±3 in/lbs (2.8±0.3 Nm).
B
• Lubricate o-ring with diesel fuel
• Torque relief valve to 22±2 in/lbs (2.5±0.2 Nm).
C
• Apply Loctite 59241 sealant to threads
• Torque elbow (1) to 55±5 in/lbs (6.2±0.5 Nm) minimum or until
elbow is at correct orientation
FUEL FILTER
• Lubricate o-ring with diesel fuel
• Torque nut (1) to 150±10 in/lbs (17±1.1 Nm)
SECTION 1. TECHNICAL SPECIFICATIONS
1-9
1-10
PROHEAT INSTALLATION & SERVICE
2.0
OPERATING YOUR
PROHEAT HEATER
NOTICE
These instructions cover Standard
Mode operation that are normally
installed on trucks. To operate your
heater in Preheat or Supplemental,
refer to page 3-18 to page 3-20 and
page 4-6 to page 4-7.
NOTICE
Regular use of your PROHEAT
throughout the year will improve
its reliability. Weekly operation is
recommended.
NOTICE
The PROHEAT heater can be
operated by either using a toggle
switch or a 7 day timer.
Refer to page 3-10 for WIRING &
ELECTRICAL CONNECTIONS.
ENGINE HEAT ONLY
1. Switch the ON/OFF switch located in the vehicle dash to “ON.”
The switch will light and the heater will cycle on. It will continue to operate until
the coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”
When the coolant temperature falls below 150˚F (65˚C) at the heater
outlet, it will refire and repeat the cycle.
It will continue to cycle until:
a) the heater is switched “OFF,”
b) the heater runs out of fuel,
c) the vehicle battery voltage drops below 10.0 Volts, or
d) an error occurs and the switch light flashes
(See Troubleshooting & Repair, Section 5)
NOTE: The PROHEAT may be operated if the engine is running or not running.
2. When engine preheat is no longer required, switch the PROHEAT heater
“OFF.”
ENGINE AND SLEEPER HEAT
1. Switch the ON/OFF switch located in the vehicle dash to “ON.”
The switch will light and the heater will cycle on. It will continue to operate until
the coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”
When the coolant temperature falls below 150˚F (65˚C) at the heater
outlet, it will refire and repeat the cycle.
It will continue to cycle until:
a) the heater is switched “OFF,”
b) the heater runs out of fuel,
c) the vehicle battery voltage drops below 10.0 Volts, or
d) an error occurs and the switch light flashes
(See Troubleshooting & Repair, Section 5)
SECTION 2. OPERATING YOUR PROHEAT HEATER
NOTE: The PROHEAT may be operated if the engine is running or not running.
2. For sleeper heat – set the thermostat in the sleeper to the desired
temperature. If the set temperature is higher than the temperature in the
sleeper the fan will cycle “ON.” When the air reaches the set temperature
the fan will cycle “OFF.” The fan will cycle “ON” and “OFF” to maintain the
set temperature.
3. When engine and/or sleeper preheat is no longer required, switch the
PROHEAT heater “OFF.”
2-1
2-2
PROHEAT INSTALLATION & SERVICE
3.0
INSTALLATION
NOTICE
If additional installation information is
required
Dealer regarding your specific
application.
For more technical information,
please contact PROHEAT Product
Support at www.proheat.com
please contact your PROHEAT
The installation details described in this manual focuses on truck applications
and does not cover all of the possible installations. As seen in the figures
below, the PROHEAT X45 is installed on a variety of equipment including
trucks, school buses, coaches, drill rigs, mine dump trucks and excavators.
In these cases the manual should be used as a guideline only.
There are seven major steps that must be completed to successfully install
the PROHEAT heater.
3.1 LOCATING THE HEATER………………………………………………… page 3-2
3.2 MOUNTING THE HEATER ………………………………………………. page 3-4
3.3 EXHAUST PIPE CONNECTION …………………………………………. page 3-6
3.4 PLUMBING THE SYSTEM………………………………………………. page 3-7
3.5 WIRING & ELECTRICAL CONNECTIONS …………………………… page 3-10
3.6 FUEL SYSTEM ………………………………………………………….. page 3-22
3.7 FIRST TIME STARTUP…………………………………………………. page 3-26
Prior to the installation of your PROHEAT, consult your engine owner’s manual
or engine manufacturer for any restrictions or changes that may apply to
plumbing into the engine coolant system.
Figure 3-1 Other Applications.
SECTION 3. INSTALLATION
3-1
3.1
LOCATING THE HEATER
3.1.1
You Choose
CAUTION
Do not weld PROHEAT heater
mounting brackets to the
vehicle frame.
If repairs to the vehicle require
welding, disconnect the PROHEAT
power cable at the PCM. This will
prevent damage to the PROHEAT
electronics.
SELECT YOUR LOCATION
The most suitable location for mounting the heater will vary depending
on the type of vehicle. Recommended mounting locations are:
• Behind the cab across the frame rails (1).
• On either side of the frame rails (2).
• In an existing enclosure on the vehicle (step or toolbox) (3).
1
2
3
2
Figure 3-2 Recommended Mounting Positions
3.1.2
WARNING
Never locate the heater inside
the vehicle cab. (See Figure 3-3)
GENERAL CONSIDERATIONS
• Never mount the heater to two separate parts of the vehicle.
• Avoid mounting the heater in areas of excessive vibration.
• Do not mount the heater directly to the engine.
• Do not mount the heater beneath a wood floor without a proper fire wall
above the heater.
• Avoid mounting the heater in areas of excessive dust, dirt and moisture
accumulation.
• The heater must be easily accessed for service.
COOLANT OUT
FUEL IN
Figure 3-3
MINIMUM
CLEARANCE 6″
Figure 3-4 Allow minimum 6″ clearance
for hose connections.
COOLANT IN
3-2
PROHEAT INSTALLATION & SERVICE
Heater must be mounted below the highest point in the cooling system. An
expansion tank may be added to the coolant system above the heater if this
is not possible.
HIGHEST POINT IN
COOLING SYSTEM
HEATER MUST
BE MOUNTED
BELOW
HIGHEST POINT
PROHEAT ENGINE OR RADIATOR
Figure 3-5 Height Requirement
3.1.3
MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE
Do not locate the heater in an
airtight enclosure. If the heater is to
be mounted in an enclosure other
than the PROHEAT enclosure,
adequate air flow must be provided
to ensure proper combustion. The
enclosure must also be adequately
ventilated so that the ambient
temperature inside the enclosure
does not exceed 185 °F (85 °C).
The openings must be positioned to prevent moisture dirt and snow from
accumulating in the enclosure. The heater enclosure must be easily
accessed for servicing of the heater.
Heater must be mounted within 5˚ of horizontal, as shown.
Figure 3-6 Adequate Air Flow
SECTION 3. INSTALLATION
5˚
5˚
Figure 3-7 Mounting Angle
5˚
5˚
3-3
3.2
MOUNTING THE HEATER
Select Your Mounting Option
Figure 3-8 Mounting Tray
3.2.1
OPTION A
1. Remove the enclosure cover.
2. Drill the (4) mounting holes and exhaust pipe clearance hole.
3. Using the bolts supplied, fasten the enclosure to the mounting
tray or brackets.
4. Ensure that the combustion tube can be removed for service.
See Figure 1-2 on page 1-3 for service space requirements.
– Heater With Enclosure
20″ (508 mm)
1 5/8″
(45 mm)
3″ (76 mm) Dia.
5″ (127 mm)
12″
(306 mm)
5 3/4″ (146 mm)
3/4″ (20 mm) MOUNTING HOLES
(4 REQUIRED)
Figure 3-9 X45 Enclosure Base Dimensions
5″ (127 mm)
CENTERLINE OF ENCLOSURE
8 13/16″
(223 mm)
5″ (127 mm)
16 11/16″ (427 mm)
1 5/8″ (45 mm)
3-4
PROHEAT INSTALLATION & SERVICE
NOTICE
3.2.2
OPTION B
– Heater Without Enclosure
Heater supplied without an enclosure (mount in an existing enclosure on the
vehicle ie. tool box). Heater supplied with an auxiliary mounting plate.
Use anti-seize compound on fasteners
to prevent galling and corrosion.
3″ (76 mm) Dia.
. Ensure that the proposed enclosure is big enough for the heater.
1
2
1
⁄2W x 11H x 201⁄2L inches (318 x 280 x 521 mm)
12
. Using the indicated dimensions, drill the (4) mounting holes
and exhaust pipe clearance hole.
3. Ensure that the combustion tube can be removed for service.
See Figure 1-2 on page 1-3 for service space requirements.
8.5″ (216 mm)
1.0″ (25 mm)
4 X .38″ (10MM)
MOUNTING HOLES
5″
(127 mm)
2.02″
(51 mm)
Figure 3-10 X45 Mounting Plate Dimensions & Exhaust Hole
5.5″
(140 mm)
6.4″
(163mm)
5″ (127 mm)
7.5″ (191 mm)
SECTION 3. INSTALLATION
3-5
3.3
NOTICE
If additional information is required,
please contact your PROHEAT Dealer
regarding your specific application.
Alternatively, please contact PROHEAT
Product Support at www.proheat.com.
EXHAUST PIPE CONNECTION
1. Push the exhaust pipe through the hole in the enclosure and onto the
exhaust outlet port of the heater. Ensure that the pipe is pushed onto
the spigot at least 11⁄2» (38 mm).
2. Route the exhaust pipe such that:
• exhaust gasses do not enter the passenger compartment.
• exhaust gasses do not enter the heater’s combustion air inlet
• exhaust system does not rest against or be directed toward any parts
of the vehicle that may be damaged by heat (i.e. brake lines, seals, wires
rubber hoses or bumpers). The exhaust pipe may be have to be insulated
if it’s within 6″ of combustible materials or composite body parts
• the exhaust outlet does not face the same direction as vehicle travel
• debris and snow will not plug the outlet
• the exhaust pipe is protected from curb damage
• the exhaust system should have a downwards slope for condensation
to drain. If needed a 3/8″ hole should be drilled into the exhaust pipe
at the lowest point so that the condensation will drain.
3. Disassemble the exhaust pipe clamp and apply anti-seize compound to
the threads.
4. Assemble the exhaust clamp over the exhaust pipe (clamp goes inside
the enclosure) and tighten the nuts.
,
WARNING
Exhaust gases must not enter
the vehicle interior. Direct
exhaust pipe away from vehicle.
NOTICE
Use of muffler or other restrictions in the
exhaust system is not recommended.
NOTE: 11⁄2» exhaust pipe should not exceed 5 ft and have no more than
180 degrees of bends. The bends must be formed for best results.
Do not use 90 degree welded pipe to turn corners.
Use formed elbows.
Do not use welded
90˚ elbows.
DIRECTION
OF VEHICLE
TRAVEL
EXHAUST CLAMP
U BOLT (APPLY
ANTI-SEIZE
COMPOUND
TO THREADS)
3-6
ENSURE THERE ARE
NO AIR LEAKS AROUND
THE CONNECTION
Figure 3-11 Exhaust Pipe
PROHEAT INSTALLATION & SERVICE
3.4
PLUMBING THE SYSTEM
MA
X
I
MUM
C
ROS
S
—
F
Figure 3-12 Maximum cross-flow
3.4.1
L
OW
GENERAL CONSIDERATIONS
Coolant flow must be maintained throughout the coolant system
nder all conditions.
u
• Keep the engine inlet and outlet ports as far apart as possible to maximize
cross-flow through engine.
• Coolant pump and engine water pump must flow in the same direction.
• Ensure that no sharp kinks or bends exist in the hoses which may restrict
coolant flow.
• Avoid high points in the hose routing to prevent air traps.
• For systems requiring more than 50 feet of coolant line, contact Proheat
Product Support at www.proheat.com for coolant pump recommendations.
For plumbing the system use:
1
⁄2» NPT pipe fittings or bigger.
3
⁄4» ID heater hose.
NOTE: Use of silicone hose requires special hose clamps.
Shut-off valves are not required at the engine inlet and outlet connections but
may be used if desired. They should be left open at all times so that the heater
can be operated throughout the year.
You Choose
Select Your Plumbing Option
Option A:
Engine heat or supplemental heat.
The PROHEAT heats the engine block only.
NOTE: When the engine block is preheated you will have nearly
instant heat from the dash heat exchanger.
Option B: Engine and sleeper heat.
The PROHEAT heats the engine block and the sleeper.
NOTE: Plumbing the PROHEAT through the dash fan is not
recommended.
SECTION 3. INSTALLATION
3-7
Instructions for Options A and B
WARNING
Opening the radiator cap when
the engine is hot may cause
serious injury.
3.4.2
1. Remove the radiator cap to release the system pressure.
2. Drain the coolant system.
3. Plumb the system as per Figure 3-13 or Figure 3-15
. Add engine coolant to the system as per the specific engine
4
manufacturer’s recommendations and re-install the radiator cap.
NOTE: Plumbing the PROHEAT through the dash fan is not recommended.
OPTION A – Engine Heat or Supplemental Heat
DASH HEATER
RETURN TO ENGINE
RETURN TO ENGINE
SUPPLY TO PROHEAT
SUPPLY TO PROHEAT
Figure 3-13 Engine Heat or Supplemental Heat
ENGINE
NOTE: On coolant systems where the return from the PROHEAT is plumbed to
the bottom of the main coolant supply line from the radiator to engine
pump, the return line must be moved to avoid loss of heat through the
radiator.
ENGINE
RETURN TO ENGINE
SUPPLY TO PROHEAT
ENGINE
Figure 3-14 Correct Return Line Plumbing
3-8
PROHEAT INSTALLATION & SERVICE
3.4.3
or best results these vehicles
F
should use an auxiliary heater.
International with single heater
OPTION B – Engine and Sleeper Heat
OEM OR AUXILIARY
SLEEPER HEATER
DASH HEATER
For vehicles with solenoid valves
in the normally closed position.
Western Star
SOLENOID VALVE
OEM COMBO HEATERS
ONLY (NORMALLY OPEN)
SUPPLY TO PROHEAT
Figure 3-15 Engine and Sleeper Heat
RETURN TO ENGINE
ENGINE
NOTE: Vehicles equipped with a combination heater/air-conditioner will have
a solenoid operated shut-off valve in the heater unit. Typically this valve
is normally open with the truck engine turned off and the key removed.
(See Figure 3-16 for plumbing)
Due to the many options available in vehicle heating and air
conditioning systems, the installer should be looking for any
restrictions that may affect coolant flow, with vehicle ignition in the
“OFF” position.
SLEEPER HEATER
SOLENOID VALVE
(NORMALLY CLOSED)
DASH HEATER
NOTICE
The PROHEAT PCM sleeper fan circuit
has a one minute delay during ignition.
Power to open a sleeper fan coolant
valve must be taken from another
source such as the wire for the hour
meter (auxiliary output). (See PROHEAT
Wiring Diagram on page 1-4.)
SECTION 3. INSTALLATION
SUPPLY TO PROHEAT
Figure 3-16 Engine and Sleeper Heat
RETURN TO ENGINE
ENGINE
3-9
3.5
WIRING & ELECTRICAL
CONNECTIONS
3.5.1
Figure 3-17 Test Battery
WARNING
Do not use on positive ground
vehicles.
GENERAL CONSIDERATIONS
• Prior to installation of the PROHEAT Heater system, ensure that the
vehicle batteries are in good condition.
• Do not kink or abrade wires when routing them through the vehicle during
installation.
• Ensure wires are well supported and secured with tie-wraps.
• Do not use acid core solder when making solder connections.
Major Electrical Connections Required
a) Power connection to batteries …………………………………………. page 3-11
b) Timer or ON/OFF switch connections…………………………………. page 3-12
c) Sleeper fan model heater connections (optional)………………….. page 3-14
d) Auxiliary Input model heater connections (optional)……………….. page 3-18
TO SLEEPER FAN OR AUX INPUT
DEPENDING ON MODEL
CAUTION
If repairs to the vehicle require
welding, disconnect the PROHEAT
power cable at the PCM. This will
prevent damage to the PROHEAT
electronics.
CAUTION
Vehicles using ground side battery
disconnect switches must install an
in-line 10 Amp fuse on the internal
harness (Proheat part # PK0310).
This will prevent damage to the
harness and PCM, (refer to Service
Bulletin SB0003 in Appendix).
TO BATTERIES
TO ON/OFF SWITCH
AND/OR TIMER
Figure 3-18 Major Electrical Connections
3-10
PROHEAT INSTALLATION & SERVICE
3.5.2
CAUTION
2 Volt products should not use
1
power split from a 24 Volt system.
This will cause uneven charging of
the batteries.
POWER CONNECTION TO BATTERIES
1. Route wire harness from PCM to the battery. Cut the harness to length
as required.
2. Strip outer wire jacket of harness back to expose the positive (red) and
negative (black) leads. Strip the leads as shown and crimp the ring
tongue terminals supplied to the wires. Connect the leads to the battery
erminals. (See Figure 3-19.)
t
NOTICE
Systems providing heat to both engine
and sleeper require four (4) batteries.
3. Leave power harness disconnected. (See Figure 3-19.) Do not install until
PROHEAT coolant pump system has been purged of air. (See First Time
Startup, page 3-26)
NOTE:
When power is connected to the PCM, all segments of the LED will flash
on the PCM. This indicates that power has been supplied. See page 5-4
for more information.
NOTE: Ensure the battery terminals are clean and free of corrosion. Remove
and clean. Prior to re-connecting grease terminals with electrically
conductive grease.
STRIP WIRE AS SHOWN AND
CRIMP TO TERMINAL
3/16″
POWER SUPPLY
HARNESS
BLACK (-) NEGATIVE
RED (+) POSITIVE
Figure 3-19 Power Connection to Battery
SECTION 3. INSTALLATION
3-11
TIM ER
1
ON
2 3
BLACK
RED
W
HITE
G
REEN
BLACK
TIMER
SWITCH INPUT
HARNESS
RED
W
HITE
G
REEN
GREY
TO KEYSWITCH (OPTIONAL)
3.5.3
CAUTION
The switch input circuit should only
be used to supply power to the
ON/OFF Switch, the Timer, or as a
signal to trip a relay. Failure to
follow this installation practice will
result in damage to the PCM.
NOTICE
The PCM must be reset (power
disconnected and reconnected)
when changing from a Timer to an
ON/OFF Switch or from an ON/OFF
Switch to a Timer.
Do not connect an ON/OFF Switch
and a Timer in the same circuit.
TIMER CONNECTIONS (OPTIONAL)
Black wire Ground
Red wire Power
White wire Operational signal from heater
Green wire “ON” Signal to heater
Grey wire Keyswitch backlighting (optional)
Figure 3-20 Timer Connections
3-12
PROHEAT INSTALLATION & SERVICE
BLACK
RED
WHITE
GREEN
GROUND
ON SIGNAL
ON
OFF
POWER
INDICATOR
2″ (51 mm)
3.5.4
ON/OFF SWITCH CONNECTIONS
1. Select a suitable location in the vehicle dash for the ON/OFF Switch.
CAUTION
The switch input circuit should only
be used to supply power to the
ON/OFF Switch, the Timer, or as a
signal to trip a relay. Failure to
follow this installation practice will
result in damage to the PCM.
NOTICE
The PCM must be reset (power
disconnected and reconnected)
when changing from a Timer to an
ON/OFF Switch or from an ON/OFF
Switch to a Timer.
Do not connect an ON/OFF Switch
and a Timer in the same circuit.
DASH
1/2″ DIA.
HOLE
SWITCH
LABEL
NOTE: Many dash panels have switches which are not utilized. It may be
convenient to remove one and replace it with the PROHEAT switch.
2. Drill a1⁄2» diameter hole through the dash for the switch. Make sure you
have clearance behind the dash for the switch wires and connections.
Install the switch as per the diagram. (Figure 3-21)
3. Route the switch wire harness from the PCM to the dash panel. You will
have to pass the wire harness through the vehicle firewall. If possible use
an existing hole. Use a grommet to prevent the wire from being damaged
when it is passed through the hole.
4. Cut the harness to length.
5. Strip outer wire jacket of harness back to expose the 4 wires. Strip the
wires as shown and crimp the supplied1⁄4» spade terminals.
NOTE: Use fully insulated disconnects when connecting Switch.
ON/OFF
SWITCH
NUT
Figure 3-21 ON/OFF Switch Assembly
Figure 3-22 ON/OFF Switch Connections
6. Connect the terminals to the switch as shown. (Figure 3-22)
NOTE: The PCM must be reset (power disconnected and reconnected) when
changing from a Timer to an ON/OFF Switch or from an ON/OFF Switch
to a Timer. Connecting an ON/OFF Switch and a Timer in the same
circuit will cause the indicator light to flash incorrectly.
SECTION 3. INSTALLATION
3-13
3.5.5
SLEEPER FAN MODEL HEATER WIRING DETAILS
NOTICE
These instructions require a Sleeper
Fan model. For more information see
age 4-2.
p
You Choose
NOTICE
Sleeper Fan output does not supply
power during ignition (1 minute after
switch ON). DO NOT use for controlling
coolant valves. See page 4-5 for
operational sequence information.
The Hour Meter (Auxiliary) Output may
be used to control supplemental relays
to turn on coolant valves.
If additional installation information is
required, please contact your PROHEAT
Dealer or Product Support at
www.proheat.com
These installation options allow the operator to:
1. Run the PROHEAT with the ignition key in the “OFF” position.
2. Return full control to the OEM system in normal operation mode.
Select one of the following wiring options
NOTE: PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN SLEEPER
FAN SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING
COMPANIES.
Due to the wide variety of wiring schematics that exist, we emphasize that
if you are in any doubt you should contact your dealer or PROHEAT Product
Support at www.proheat.com
Option A: Used when climate control systems in sleepers require one or
more of the following features to be controlled.
1. Normal OEM fan speed selection.
2. A separate thermostat is required to turn the sleeper fan
motor “ON” and “OFF” because the OEM system uses a
constant running fan.
3.
A valve in the sleeper heater coolant line regulates the flow
must be fully opened when the PROHEAT is running.
4. Prevent possible back-feeding on ground side switched
systems.
and
3.5.6
Option B: Used in larger sleepers requiring greater fan speed to provide
sufficient air movement to the sleeper. This allows the driver to
select the fan speed.
Option C: Used when a dedicated auxiliary heater is required.
Option D: Limits the power provided to the sleeper fan motor to
3 Amps. With this system the total electrical draw is controlled
by PROHEAT.
NOTE: For larger systems in the latest model trucks this may not provide
enough fan speed and therefore Option A, B or C should be used.
OPTION A – OEM Heater & Proheat Thermostat
Please go to www.proheat.com for equipment specific installation instructions.
3-14
PROHEAT INSTALLATION & SERVICE
3.5.7
OPTION B – OEM Heater & Thermostat
1. Make sure the vehicle ignition is switched “OFF.”
2. Locate the PROHEAT thermostat in a central area of the sleeper,
approximately 12″ above the bunk. Avoid direct air flow from sleeper fan
ducts. (Figure 3-25)
3. Remove the adjusting knob and face cover. Mark and drill mounting
holes. Mount thermostat using the screws provided. (Figure 3-27)
4. Install relay 1, always between OEM sleeper fan control and OEM
thermostat.
NOTE: The constant power supply wire must be of sufficient size to handle
sleeper fan motor electrical current draw.
5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length.
Connect white wire to terminal 1 of the thermostat.
6. Route a wire from terminal 2 of the thermostat to relay 1 (can be cut from left
over wire harness). Ground the relay using PROHEAT sleeper fan ground
wire (black).
VEHICLE
FUSE
PANEL
PROHEAT
THERMOSTAT
WHITE
SLEEPER FAN
HARNESS
PCM
WHITE
BLACK
OEM THERMOSTAT
15 AMP
RELAY 1 STANDARD
12 OR 24/30 AMP
RESISTOR ASSEMBLY
NOTE: MAY OR MAY NOT BE LOCATED
INSIDE SLEEPER HEATER ASSEMBLY
OEM
SLEEPER
HEATER
ASSEMBLY
(SINGLE WINDING TYPE)
CONSTANT POWER
SOURCE
(i.e. CIGARETTE LIGHTER)
OEM FAN
MOTOR
CONTROL
(2 OR 3 SPEED)
FAN MOTOR
SECTION 3. INSTALLATION
Figure 3-23 Option B
3-15
3.5.8
OPTION C – Auxiliary Sleeper Heater
1. Make sure the vehicle ignition is switched “OFF.”
2. Locate the auxiliary heater in a suitable area of the vehicle. Install plumbing
and air duct connections as per the manufacturer’s recommendations.
3. Locate the PROHEAT thermostat in a central area of the sleeper,
approximately 12″ above the bunk. Avoid direct air flow from sleeper fan
ducts. (Figure 3-25)
4. Remove the adjusting knob and face cover. Mark and drill mounting
holes. Mount thermostat using the screws provided. (Figure 3-27)
5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to
length. Connect white wire to terminal 1 of the thermostat using the fork
terminal provided. Black wire is not used.
6. Route a wire from terminal 2 of the thermostat to an appropriate wire on
the sleeper fan motor. Make a splice connection and seal the splice with
tape or heat shrink.
NOTE: The electrical power and operation in this option is controlled by the
PROHEAT. See Option B should a relay be required to provide more
electrical power.
WARNING
Systems using a ground side
battery disconnect must install
a 10 Amp fuse to protect the
sleeper fan harness.
Thermostat Wire Connection Detail
Screw # Wire Colour
1 White (from PCM)
2 White (to sleeper heater)
3 Not used
4 Not used
PCM
SLEEPER FAN
HARNESS
SPLICE WIRES
FAN MOTOR
(MULTIPLE WINDING TYPE)
ORANGE
RED
(NOT USED)
B
H
W
K
C
A
L
TE
HI
W
ITE
THERMOSTAT
1
1
2
2
3
4
AUXILIARY
SLEEPER HEATER
10 AMP
FUSE
GROUND
3-16
Figure 3-24 Option C
PROHEAT INSTALLATION & SERVICE
Loading…
“Eliminate Idling for Engine Start-up & Sleeper Comfort”
The Proheat coolant heater provides ample power (up to 45,000 BTU/hr) to heat both the sleeper and the engine for comfort and reliable cold starts.
Also a must need for any piece of heavy equipment. Effectively heats and circulates the coolant on the coldest days of winter.
Quick and Easy Equipment Start-up: Eliminates the need to idle your engine overnight to keep the engine warm
Optional programmable 7-day timer for advanced engine start-up
Thermostatically controlled fan in the sleeper provides ultimate personal comfort
Save Time and Money: Less idling results in lower fuel & maintenance costs
Low fuel and electrical power consumption – draws only 4 amps of electrical power for greater battery life
Helps drivers comply with local idling restrictions
Safe and Reliable Performance: Safety of a low flow, low pressure fuel system
Multiple safety shut-off features
Large, efficient sealed motors
On-board diagnostics & memory for easy downloading to a PC
2-Year parts and labor warranty (5 years on select components)
The X45 12V Truck Heater Kit (p/n PH0401) includes the heater, aluminum enclosure box, the installation kit and sleeper control kit with thermostat.
PH0404: Same as PH0401 excluding sleeper control kit – 24 Volt
PK0001 – 7-Day Timer
Air Pressure Checks
Compressor Adjustment
NOTICE
NOTICE
If the air compressor pressure cannot
be adjusted back into normal range,
repair or replace air compressor.
Refer to parts manual.
© 2011 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6
SERVICE BULLETIN
Copy Part# SB0060, Rev. B, 08/2014
If air pressure is outside the recommended setting for your location
please perform the following checks before adjusting the compressor:
Low Pressure Reading – Check:
Ensure the coil voltage is nominally 12 ±1V for 12V models and 24 ±1V
for 24V models. If voltage is low, charge batteries and check compressor
reading again.
i) Inspect air line from compressor outlet to fan end inlet for leaks,
kinks or other restrictions.
ii) Check condition of air compressor filter. Retest with the filter
removed.
High Pressure Reading – Check:
Ensure the coil voltage is nominally 12 ±1V for 12V models and 24 ±1V
for 24V models. If voltage is high, stop charging batteries (turn engine
off) and check compressor reading again.
i) Nozzle and cavity for blockage. Refer to Step 5 on page 5-10 of
the X45 service manual.
If after performing the above checks and the air pressure is still
outside the recommended setting for your location, adjust the air
pressure by turning the screw as shown in figure D.
Altitude correction is needed above 7,000 feet (2134 m) (see figure C
on page 2).
COMPRESSOR
ELECTRICAL
MOTOR
Figure D. Compressor/Fuel Pump Assembly
Page 3 of 3
END VIEW OF
ADJUSTMENT SCREW:
INCREASE
PRESSURE
ADJUSTING
SCREW
FUEL PUMP
Tel: 604.270.6899
Web: www.proheat.com
DECREASE
PRESSURE