Proheat A4 User Manual
INSTALLATION MANUAL
PROHEAT A 2 / A 4
Rev. B
CONTENTS
A. SAFETY .
SAFETY CONSIDERATIONS ............................................................. A-2
..................................................................................... A-1
B. INTRODUCTION ......................................................................... B-1
1.0 TECHNICAL SPECIFICATIONS.................................................. 1-1
1.1 PACKAGE CONTENTS.............................................................. 1-1
1.2 PHYSICAL A2 ......................................................................... 1-2
1.3 PHYSICAL A4 ......................................................................... 1-3
2.0 INSTALLATION .......................................................................... 2-1
2.1 TOOLS & PARTS REQUIRED .................................................... 2-1
2.2 GENERAL CONSIDERATIONS ................................................... 2-1
2.3 LOCATING THE HEATER .......................................................... 2-2
2.4 INSTALLING THE HEATER ........................................................ 2-4
2.5 COMBUSTION AIR INTAKE SILENCER ....................................... 2-5
2.6 EXHAUST PIPE INSTALLATION.................................................. 2-6
2.7 DCP INSTALLATION ................................................................ 2-7
2.8 WIRING & ELECTRICAL CONNECTIONS ..................................... 2-8
2.9 FUEL SYSTEM ...................................................................... 2-13
2.10 AIR DUCT INSTALLATION....................................................... 2-17
3.0 FIRST TIME START UP .............................................................. 3-1
3.1 SETTING UP THE DCP ............................................................ 3-1
4.0 NORMAL OPERATING SEQUENCE ........................................... 4-1
5.0 PROHEAT WARRANTY .............................................................. 5-1
6.0 APPENDIX ................................................................................. 6-1
6.1 HEATER FUNCTIONS .............................................................. 6-1
6.2 ERROR CODES ....................................................................... 6-2
6.3 A2 MOUNTING TEMPLATE ...................................................... 6-3
6.4 A4 MOUNTING TEMPLATE ....................................................... 6-5
6.5 DCP MOUNTING TEMPLATE ..................................................... 6-7
A.
SAFETY
Read these instructions carefully before operating the heater.
Safety alerts labeled DANGER, WARNING and CAUTION alert you to special
instructions or precautions concerning procedures that would be hazardous
if performed incorrectly or carelessly.
The safety alerts alone cannot eliminate all hazards. Strict compliance with
these special instructions and common sense are major accident
prevention measures.
DANGER
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.
Hazards or unsafe practices that
could result in minor injury or
product or property damage.
Information that is important to
proper installation or maintenance,
but is not hazard-related.
CAUTION
NOTICE
SAFETY CONSIDERATIONS
CALIFORNIA PROPOSITION 65
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, an element known
to the State of California to cause cancer, birth defects and other
reproductive harm.
WARNING
WARNING
PROHEAT AIR A2/A4 INSTALLATION MANUAL
FUEL
DO NOT breathe fuel vapors.
DO NOT smoke or handle open flame equipment, such as a blow torch,
around fuel.
Wear hand and eye protection when handling fuel.
EXPLOSION HAZARDS
The heater must be turned OFF during refuelling.
The heater must be turned OFF when combustible fumes or air born
particles, such as sawdust, are present.
A-1
WARNING
FIRE HAZARDS
DO NOT place any items of clothing, textiles or other flammable items over
he heater or in front of the air intake or hot air outlet.
t
DO NOT block or restrict air flow in ducting with rags or other materials.
WARNING
NOTICE
WARNING
WARNING
WARNING
CAUTION
EXHAUST
To prevent carbon monoxide poisoning DO NOT operate heater in garages or
in other closed or unventilated areas.
It is a recommended safe practice to have a carbon monoxide (CO) detector
installed in the vehicle to monitor for any CO leakage.
BATTERIES
Wear hand and eye protection when handling batteries.
Do not smoke or use open flames near batteries.
ELECTRICAL
Electric shock can cause severe personal injury or death.
Before working on any internal heater component or subsystem disconnect
the batteries.
HOT PARTS
DO NOT touch a heater or its parts until it has had sufficient time to cool down.
MARINE APPLICATIONS
Installation of the Proheat Air Heater is not approved for Marine applications.
CAUTION
CAUTION
BIO-DIESEL FUEL
Proheat Air Heaters are not certified for use with all bio-diesel fuels. Biodiesel fuel of up to 5% (B5) is allowed.
HIGH ALTITUDE
Proheat Air Heaters are not certified for continuous use at more than 5,000
feet (1,500 meters) above sea level. Operation at more than 5,000 feet
(1,500 meters) above sea level is in principle possible for short periods of
time, such as when crossing mountain passes.
A-2
PROHEAT AIR A2/A4 INSTALLATION MANUAL
B.
INTRODUCTION
OVERVIEW
Proheat Air is a diesel-powered air heater that supplies heat for in-cab driver
comfort during cold weather. Available in either 2 or 4 kW models, the heater
consumes 95% less fuel than engine idling while supplying heat more quietly
and efficiently. Proheat Air includes a digital control panel for easy set-up and
control of the heater from inside the truck cab.
Easy to Use
The included Driver Control Panel (DCP) makes set-up and operation of the
heater quick and easy. The DCP features a large, backlit display that provides
at-a-glance display of heater status. Programmable start times mean drivers
can start the heater when away from the truck or automatically turn it on
when they are asleep.
PROHEAT AIR A2/A4 INSTALLATION MANUAL
Figure 1
This manual is provided to assist an Authorized Proheat Dealer in the installation
of a Proheat Air heater. Although trucks have been used in the examples,
applications are by no means limited to trucks.
B-1
HEATED AIR
ELECTRICAL
CONNECTION
DUCTING
DRIVER CONTROL
PANEL (DCP)
HEATER
EXHAUST
FUEL PUMP
FUEL PICK-UP
AIR INTAKE
COMBUSTION
AIR INTAKE
Proheat Air heaters will help provide a comfortable cab or cargo temperature
without having to idle the vehicle’s main engine.
1. Cab or sleeper heat (engine off) – Proheat Air heaters will supply heat to
the cab or sleeper. Substantial savings through reduced fuel consumption
nd engine wear can be obtained by not idling the engine.
a
. Supplemental heat (engine running) – As the efficiency of modern diesel
2
engines have improved, there is less reject heat available to heat the
vehicle’s interior. Proheat Air heaters can be used while the vehicle is
operating to provide supplemental heat for the interior.
Proheat Air heaters are designed to be used in most classes of trucks, cabs of
heavy machinery, and cargo areas. Proheat Air heaters are not approved for
Marine applications.
Components and Basic Operation
An electric pump delivers diesel fuel to the Proheat Air heater
diesel fuel in a combustion chamber. An electric fan blows air over the heated
combustion chamber transferring heat to the air as it passes. The heated air
is then delivered through ducting to the area to be heated. Pre-combustion air
comes from an external air intake. Combustion exhaust is externally vented
from the vehicle. The Proheat Air heater is controlled by a Driver Control Panel
(DCP). The DCP is used to turn the heater on/off and it can be programmed
to start the heater at predetermined times.
The Proheat Air heater should be installed by an Authorized Proheat Dealer or
trained professional installer.
which burns the
B-2
Figure 2. Component Layout
PROHEAT AIR A2/A4 INSTALLATION MANUAL
1.0
TECHNICAL
SPECIFICATIONS
MODEL A2 (12V/24V) A4 (12V/24V)
RATING 2 kW (6,800 BTU) 4 kW (13,600 BTU)
OPERATING VOLTAGE
tand-By 0.4 W 0.4 W
S
Ignition 130 W 145 W
Maximum Heat 25 W 60 W
FUEL CONSUMPTION 0.03–0.06 US gal/hr (0.1–0.22 l/hr) 0.06–0.012 US gal/hr (0.21–0.46 l/hr)
FUEL TYPE ULSD, Diesel # 1, Diesel # 2, Arctic, B5 Bio-diesel
OPERATING Ventilation mode: -40°F to 149°F (-40°C to 65°C)
TEMPERATURE
RANGE
AIR FLOW 41 CFM (70 m³/hr) 65 CFM (110 m³/hr)
WEIGHT (Maximum) 7.7 lb (3.5 kg) 11.2 lb (5.1 kg)
DIMENSIONS (L x W x H) 14 x 4.75 x 6.14 inches (355 x 120 x 156 mm) 16.4 x 6.1 x 7.4 inches (417 x 154 x 189 mm)
WARRANTY Two years parts and labor
Heating Mode: -40°F to 104°F (-40°C to 40°C)
PACKAGE CONTENTS1.1
Check box carefully and report any missing parts to your dealer or supplier.
DESCRIPTION QTY
Air Heater A2 or A4
12 or 24 V 1
Heater to Battery Harness 2
Driver Control Panel (DCP) 1
DCP to Heater Harness 1
DCP to Ignition Harness 1
Fuses 7.5 or 15A 2
Fuel Pump 12 or 24 V 1
Fuel Pump to Heater Harness 1
Fuel Pump Bracket 1
Fuel Pickup Pipe 1
DESCRIPTION QTY
Fuel Lines Rubber 4
Fuel Lines Plastic 2
Fuel Line Clamps 8
Air Intake Silencer 1
Exhaust Pipe 1
Exhaust Pipe P Clamp 1
Installation Hardware
Package 1
Hot Air Duct (optional) 1
Owner's Manual 1
PROHEAT AIR A2/A4 INSTALLATION MANUAL
1-1
1.46"
(37 mm)
4.13" (105 mm)
1.73"
(44 mm)
1.88"
(74 mm)
4 x 0.26" DIA.
(7 mm DIA.)
1" (25 mm)
0.30" DIA.
(8 mm DIA.)
CABIN AIR
COMBUSTION AIR
14.0" (3 55 mm) 4.9" (124 mm)
3.0" (75 mm)
3.0" (75 mm)
.157"
(4 mm)
4.75"
(120 mm)
1.42"
(36 mm)
10.8" (275 mm)
PHYSICAL A21.2
1-2
PROHEAT AIR A2/A4 INSTALLATION MANUAL
PHYSICAL A41.3
2.13"
(54 mm)
2.09"
(53 mm)
0.51" (13 mm)
0.12" (3 mm)
2.95"
(116 mm)
1.22"
(31 mm)
2.31"
(91 mm)
2.20"
(56 mm)
4 x 0.26" DIA.
(7 mm DIA.)
0.30" DIA.
(8 mm DIA.)
2 x 1.06" DI A.
(27 mm DI A.)
CABIN AIR
COMBUSTION AIR
5.87"
(149 mm)
1.57"
(40 mm)
16.4" (417 mm) 5.95" (151 mm)
3.54" (90 mm)
3.54" (90 mm)
12.6" (320 mm)
.55" (14 mm)
PROHEAT AIR A2/A4 INSTALLATION MANUAL
1-3
1-4
PROHEAT AIR A2/A4 INSTALLATION MANUAL
2.0
INSTALLATION
2.1
2.2
TOOLS & PARTS REQUIRED
• Protective wire loom where required
• Grommets
• Cable ties
• Electrical tape
• P clamps (metal or plastic)
• Multimeter
• Hacksaw
• Drill
• 1" (25 mm) Unibit or Step Bit
• 1" (25 mm), 3" (75 mm), or 3.5" (90 mm) hole saw
• Reciprocating saw
• Metric Wrenches 7mm, 8mm, 12mm, 17mm
• Metric Allen Keys 3mm
• Mounting templates (located at back of manual)
• Hot Air Duct
• Hot Air Vents
GENERAL CONSIDERATIONS
2.2.1
2.2.2
NOTICE
Other considerations will present
themselves depending on different
applications. For answers to questions
specific to your applications, please
contact your dealer or Proheat
technical assistance.
PROHEAT AIR A2/A4 INSTALLATION MANUAL
Environmental
•Proheat Air heaters are designed for mounting inside a vehicle or cargo area only.
• Although Proheat Air heaters are designed to operate over a very wide range
of environmental conditions, extreme temperature, humidity and altitude may
affect optimum performance.
Access for regular servicing
•Ensure the mounting location provides sufficient access for regular servicing
including access to the glow plug, cable harnesses, fuse and housing.
• It may be necessary to alter or relocate vehicle hardware that may interfere
with the heater installation or ease of service. Always check with the vehicle
owner before making any modifications.
• Fuel, power and air ducts should be located and secured in a manner that
allows easy removal of the heater or access to replacement parts.
• SeaStar Solutions is not responsible for additional time taken during warranty
or repair arising from awkward or difficult mounting locations. The Owner is
responsible for any extra time incurred due to access issues.
2-1
2.2.3
SERIAL NUMBER LOCATION
Fuel
efer to figure 17 for information on fuel line lengths and maximum lift of
•
R
fuel pump.
• Use the supplied fuel pick-up pipe, do not tap into the vehicle’s fuel lines.
• Fuel lines must not be run through the vehicle cab, ensure all lines are well
secured and protected from sharp edges and chaffing and are .
CAUTION
2.3
Combustion air must be drawn from outside the vehicle only, risk of
suffocation may occur otherwise.
Exhaust must be vented directly outside the vehicle and clear of the cab
outline. Always use the supplied exhaust pipe to ensure harmful exhaust
gases are vented clear of the vehicle.
Maintain a tight seal between the heater and the vehicle floor to prevent
ingress of exhaust gases into the vehicle.
LOCATING THE HEATER
The most suitable location for mounting the heater will vary depending on the
type of vehicle.
Recommended locations are under the bunk in sleeper applications or
behind/under the passenger seat in day-cab applications.
Using the supplied A2 or A4 mounting template as a guide, choose a location that:
• won’t interfere with normal operation and storage of gear
• allows easy access for regular servicing
• has a smooth, level surface and mounts the heater within 5 degrees of level
NOTICE
Prior to installation, record the heater
model and serial number on the
warranty card. You will need to send
this in for warranty registration
Note: If the floor surface is uneven, use an optional mounting plate to
ensure there is a tight seal between the heater and the vehicle floor.
• is within allowable distance of the battery compartment and fuel tanks
(refer to 2.8.2 and 2.9.1)
• is free of any obstruction under the cab such as brake or air lines, electrical
wiring, cross members or anything else that may interfere with the installation
and connection of fuel lines, exhaust pipe and air intake silencer
• meets the requirements for location of ducts and air vents, refer to figure 4,
23 and 24 for information on air duct options
Figure 3. Serial Number Location
2-2
PROHEAT AIR A2/A4 INSTALLATION MANUAL
Figure 4. Recommended Mounting Locations for a Sleeper Cab.
1
3
2
Figure 5. Recommended Mounting Locations for a Day Cab.
CAUTION
PROHEAT AIR A2/A4 INSTALLATION MANUAL
Protect the heater from outside damage (DO NOT cover or lean anything
over the heater).
2-3
2.4
NUT (4)
SILICON GASKET
FLANGE
SPRING WASHER (4)
CAB FLOOR
INSTALLING THE HEATER
2.4.1
Direct Mount
1. Move or remove any hardware to gain access to mounting location.
. Using the appropriate mounting template (supplied at rear of installation
2
manual) mark the location of the mounting, exhaust, air intake and fuel holes.
3. Using a drill bit and hole saw, drill 6 holes in the floor paying particular
attention to the underside of the vehicle.
4. File down any sharp edges and test fit the heater. Trim any excess as
required to ensure the heater fits without binding and the heater gasket
sits flat on the floor to create a tight seal.
5. Install the heater and secure with the supplied hardware (refer to figure 6).
2.4.2
Figure 6. Heater Mounted Directly to Cab Floor.
Optional Mounting Plate
This option is recommended for applications where direct mounting of the
heater is not possible such as:
• Uneven floors
• Composite or other heat sensitive
flooring material
1. Move or remove any hardware to gain access to mounting location.
2. Using the mounting plate as a guide, mark the location of the areas to
be drilled.
3. Using a 3” hole saw for A2 or a 3.5” hole saw for A4, cut a hole in the
floor paying particular attention to the underside of the vehicle to ensure
you are not cutting through anything but the floor.
4.
Drill four holes for the plate mounting hardware if not using self tapping screws.
5. Secure the heater to the mounting plate using the supplied hardware
(refer to figure 7).
6. File down any sharp edges and test fit the heater. Trim any excess
material as required to ensure the heater fits without binding and the
mounting plate gasket creates a tight seal.
7. Apply sealant to any exposed metal edges to prevent corrosion.
8. Fasten the mounting plate to the floor using #12 self tapping screws x
1.5" (40 mm) (minimum) or 1/4" (6 mm) machine screw and nut.
• Extra thick flooring material
• Additional insulation under
the vehicle
2-4
PROHEAT AIR A2/A4 INSTALLATION MANUAL
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