Proheat M125 User Manual
G-II PCM SERVICE MANUAL
M50, M80/90 & M105/125
SE RIAL NUMBER S
G- II PCM MODEL HEATE RS: 705000 – TO DAT E
AN D ALL MODELS EQ UIPPED WITH A
G- II REPLACEMENT PCM
Rev. C
CONTENTS
A. SAFETY .
SAFETY CONSIDERATIONS ..............................................................A-2
..................................................................................... A-1
B. INTRODUCTION ......................................................................... B-1
C. PROHEAT CONTROL MODULE (PCM) TYPE ............................ C-1
D. COMPRESSOR TYPE ................................................................ D-1
E. MODEL DESCRIPTIONS ............................................................ E-1
1.0 TECHNICAL SPECIFICATIONS.................................................. 1-1
1.1 PHYSICAL .............................................................................. 1-2
1.2 G-II PCM ELECTRICAL ............................................................. 1-8
1.3 TORQUE SPECIFICATIONS ....................................................... 1-9
2.0 PRINCIPLES OF OPERATION ................................................... 2-1
2.1 COMPONENT DESCRIPTION .................................................... 2-1
2.2 THEORY OF OPERATION .......................................................... 2-4
2.3 MODES OF OPERATION .......................................................... 2-6
2.3.1 Standard Mode............................................................2-6
2.3.2 Preheat Mode............................................................. 2-7
2.3.3 Supplemental Mode.................................................... 2-8
3.0 MAINTENANCE TOOLS ............................................................. 3-1
4.0 TROUBLESHOOTING AND REPAIR........................................... 4-1
4.1 SYSTEM AND COMPONENT DIAGNOSTICS................................ 4-2
4.1.1 EXAMPLE PROHEAT BEHAVIOR ERROR – Code 1 ........... 4-4
4.1.2 START Diagnostic Code 1............................................ 4-5
4.1.3 FLAME OUT Diagnostic Code 2 .................................. 4-23
4.1.4 COOLANT FLOW Diagnostic Code3 ............................. 4-24
4.1.5 OVERHEAT Diagnostic Code 4.................................... 4-25
4.1.6 VOLTAGE Diagnostic Code 5...................................... 4-26
4.1.7 FLAME FAULT Diagnostic Code 6 ............................... 4-27
4.1.8 TEMP SENSOR/COOLANT FLOW
Diagnostic Code 7 .................................................... 4-27
4.1.9 FUEL SOLENOID VALVE Diagnostic Code 8 ................. 4-29
4.1.10 NOT USED Diagnostic Code 9.................................... 4-29
4.1.11 IGNITION MODULE Diagnostic Code 10 ...................... 4-30
4.1.12 COOLANT PUMP Diagnostic Code 11.......................... 4-31
4.1.13 MOTOR Diagnostic Code 12 ...................................... 4-32
4.1.14 AUXILIARY OUTPUT Diagnostic Code 13 ..................... 4-34
4.1.15 ACCESSORY/SWITCH OUTPUT Diagnostic Code 14 ..... 4-34
4.1.16 INDICATOR OUTPUT Diagnostic Code 15 .................... 4-35
4.1.17 SYSTEM CURRENT Diagnostic Code 16...................... 4-35
4.1.18 MOTOR SPEED SENSOR Diagnostic Code 17 .............. 4-35
4.1.19 CANbus ERROR Diagnostic Code 18 .......................... 4-35
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
i
4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS.......... 4-36
4.2.1 Fuel Nozzle .............................................................. 4-36
4.2.2 Fuel Solenoid Valve .................................................. 4-36
4.2.3 Fuel Regulator .......................................................... 4-36
4.2.4 Air Compressor......................................................... 4-36
4.2.5 Fuel Supply Pump ..................................................... 4-36
4.2.6 Ignition Electrodes .................................................... 4-36
4.2.7 G-II PCM Fuse........................................................... 4-36
4.3 OPERATIONAL PROBLEMS..................................................... 4-36
5.0 MAINTENANCE .......................................................................... 5-1
5.1 WEEKLY MAINTENANCE .......................................................... 5-1
5.2 ANNUAL MAINTENANCE .......................................................... 5-2
5.3
ROTARY VANE COMPRESSOR SERVICE & VANES INSTALLATION
.... 5-7
6.0 PROHEAT WARRANTY .............................................................. 6-1
ii
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
SAFETYA.
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.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
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 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 M-SERIES G-II PCM SERVICE MANUAL
B.
INTRODUCTION
MODEL: M50, M80, M90,
M105, & M125 G-II PCM
Figure B-1.
This manual is provided to assist in troubleshooting and maintaining the
PROHEAT M-Series heater. They are designed for use 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 for the following applications:
(1) Engine Block Heat – The PROHEAT will preheat an engine block to ensure
reliable starting in cold weather. Its’ use throughout the year will reduce
engine wear caused by cold starts.
(2) Supplemental Heat (engine running) – The PROHEAT can be used while
the vehicle is operating to provide supplemental heat for the engine
and/or passenger compartment.
(3) Cargo Heat – The PROHEAT can supply heat to individual compartments
as a stand-alone heating system, or it can provide supplemental heat to
an existing heating system.
(4) Marine – Marine applications typically involve the
installation of a complete hot-water
is only one component. SeaStar Solutions recommends that only an
expert in marine hot-water heating systems install a PROHEAT for
marine applications. NOTE: It is the
that an installation
complies with all applicable codes and regulations.
heating system of which PROHEAT
installer’s responsibility to ensure
engineering and
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
B-1
B-2
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
C.
G-I PCM G-II PCM
MET RI-PACK
1205264 4 AUX
CONNECTOR
KEYING
7 PIN
DATA LINK
CONNECTOR
FOUR PIN
DUAL MODE
TEMPERATURE
SENSOR
CONNECTOR
MET RI-PACK
12052641 A UX
CONNECTOR
KEYING
2 X TWO P IN
ANA LOG
TEMPERATURE
SENSOR
CONNECTORS
6 PIN
DATA LINK
CONNECTOR
NO AIR F ILTER
RET ENT ION
TANGS
AIR FILTER
RET ENT ION
TANGS
STATUS
INDICATOR
LIGHT
PROHEAT CONTROL
MODULE (PCM) TYPE
The G-I Proheat Control Module (PCM) is no longer available has been replaced
with the G-II PCM. The new G-II PCM incorporates a new dual mode analog/digital
temperature
identified in the figures below.
THIS MANUAL COVERS ONLY THE G-II PCM.
Please see G-I PCM Service Manual (M50/M80) part number
SL9150. This can be found by visiting www.proheat.com
sensor and advanced Data Link software. Both styles can be
Figure C-1. G-I PCM and G-II PCM.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
C-1
DUAL MODE
TEMP SENSOR
S
TATUS
INDICATOR
LIGHT
DUAL MODE
HAS 4 PIN
CONNECTOR
G-II PCM
DUAL MODE
TEMP
SENSOR
ANALOG TEMP
SENSOR
NO STATUS
INDICATOR
LIGHT
ANALOG SENSOR
HAS 2 PIN
CONNECTOR
G-I PCM
ANALOG
TEMP
SENSOR
Figure C-2. G-II PCM can be identified on a heater by looking for the status indicator light.
Also the Dual Mode Temp Sensor has a 4 pin connector.
C-2
Figure C-3. G-I PCM can be identified on a heater by not having the status indicator light.
Also the Analog Temp Sensor has a 2 pin connector.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
COMPRESSOR TYPED.
NOTICE
For continuity, all figures shown in this
manual will use a diaphragm compressor
unless
where special instructions or
illustrations
are required
.
The rotary vane compressor is no longer available has been replaced with the
diaphragm type. Both styles can be identified in the Figures below. Please refer
to the M-Series Parts Book at www.proheat.com for part numbers. This manual
covers both styles of compressors and clearly identifies the differences
where applicable.
ROTARY VANE COMPRESSOR
Serial Numbers:
500000 – 699999
Figure D-1. Rotary Vane Compressor Type.
DIAPHRAGM COMPRESSOR
Serial Numbers:
700000 – To Date
Figure D-2. Diaphragm Compressor Type.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
D-1
D-2
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
MODEL : M80- 24V
S/ N: XXX XXX
POWER : 95 WATT S
FUEL TY PE: D IESEL
MAX PRE SS: 2 BAR
OPER. VOLT:
20-30 VDC
HEAT OUTPUT: 24.0 K
W
INSTALLATION DATE :
07 08 09 10 11 12
Made by SeaStar S olutions
Richmond B C Canada
PID 200101
MODEL DESCRIPTIONSE.
Please refer to the M-Series Parts Book at www.proheat.com for detailed part
descriptions and part numbers
such as a timer, coolant pump and associated installation equipment and
maintenance tools. The following information describes the general characteristics
of M-Series models covered in this manual: Heat Output, G-II PCM CANbus,
Voltage, Fuel Fitting optional configurations, and Air Intake optional configurations.
. Included in the parts book are optional features
Heat Output
G-II PCM
Voltage
The M Series is available in:
50,000 BTU/H (15 kW/H)
80,000 BTU/H (23 kW/H)
90,000 BTU/H (26 kW/H)
105,000 BTU/H (31 kW/H)
125,000 BTU/H (37 kW/H)
CANbus SAE J1939.
The M-Series G-II Proheat Control Module (G-II PCM) is available with CANbus
SAE J1939.
12 V or 24 V.
The M-Series is available in either a 12 V (10 – 15 VDC) or 24 V (20 – 30
VDC) model.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
Figure E-1.
E-1
SPLASH GUARD STR AIGHT 3" OD
STR AIGHT SNORKEL
2.25" (55 mm) OD
SNORKEL ELBOW
26° SNORKEL ELBOW
Fuel Fitting – Optional
Configurations
-4 JIC, NPT 1/8” and -4 Hose Barb.
There are fuel fitting options including JIC, NPT, hose barb and tight access.
Refer to parts book at www.proheat.com.
Air Intake – Optional
Configurations
NOTICE
For continuity, all figures shown in this
manual
will use a splash guard intake.
Figure E-2.
Splash Guard, Straight and Right Angle Snorkel Attachments.
The M-Series can be equipped with a splash guard, straight and right angle
intake snorkels. Refer to parts book at www.proheat.com
E-2
Figure E-3. Air Intake Options.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
1.0
TECHNICAL
SPECIFICATIONS
M50 12V M50 24V M80 12V M80 24V M90 24V
RATING BTU/hr (kW) 50,000 50,000 80,000 80,000 90,000 105,000 125,000
SYSTEM VOLTAGE 12 24 12 24 24 24 24
Nominal DC Voltage (Range) (10–15) (20–30) (10–15) (20–30) (20–30) (20–30) (20–30)
CURRENT DRAW (MAX) Amps 9.5 5.2 8.5 5.2 5.2 9.5 9.5
FUEL CONSUMPTION US gal/hr (L/hr) 0.48 0.48 0.78 0.78 0.82 1.05 1.10
IGNITION TYPE Electronic Spark Ignition
COOLANT OUTPUT TEMPERATURE MAX.
AMBIENT OPERATING TEMPERATURE
WEIGHT lbs (kg) 53 (24) 57.5 (26.1)
HEAT EXCHANGER CAPACITY US gal (l) 0.5 (2) 0.6 (2.3)
COOLANT SYSTEM
Minimum Capacity/Recommended Flow
Rate Through Heater US gpm (lpm) 7.5 (28) 7.5 (28) 12 (45) 12 (45) 13.2 (50) 15.8 (60) 18 (68)
Maximum Coolant Pressure PSI (bar) 29 (2) 29 (2) 29 (2) 29 (2) 29 (2) 29 (2) 29 (2)
DANGER
Do not use gasoline.
(15) (15) (23) (23) (26) (31) (37)
(1.8) (1.8) (2.95) (2.95) (3.10) (3.97) (4.16)
185°F (85°C)
-40°F to +122°F (-40°C to +50°C)
FUEL TYPES
COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1
Bio Fuels - Contact Proheat www.proheat.com
M105 24V M125 24V
60 (27.2)
0.7 (2.6)
SYSTEM OUTPUTS
AUXILIARY OUTPUT Same as Power Supply Voltage
SWITCH/TIMER Same as Power Supply Voltage
POWER Maximum 1 Amp draw (over-load shut-off protection)
COOLANT PUMP Same as Power Supply Voltage
INDICATOR LIGHT Same as Power Supply Voltage
SWITCH Same as Power Supply Voltage
COOLANT PUMP Same as Power Supply Voltage
AUXILIARY Allows independent operation of Coolant Pump through
POWER 12 Volt or 24 Volt
Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
High-side switched
Maximum 10 Amp draw (over-load shut-off protection)
High-side switched
Maximum 1 Amp draw (over-load shut-off protection)
High-side switched
SYSTEM INPUTS
Standard Run Mode
Preheat Run Mode
Supplemental Run Mode
the G-II Proheat Control Module
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
1-1
EXHAUST
(SEE NOTE 2 AND 4)
-4 JIC MALE FUEL INLET (INTERNAL
FUEL FILTER) (SEE NOTE 5)
2.75 (70)
12.60 (320)
23.24 (590)
4.45
(113)
8.14 (207)
2.03 (52)
FRONT VIEW
6 x .41 (10)
BOTTOM VIEW
AIR INTAKE
ALTERNATE
SNORKELS
AVAILABLE
(SEE PAGE 1-3 )
3.23 (82)
3.98
(101)
SIDE VIEW
SERVICE SPACE REQUIREMENT
(
MAY VARY SEE NOTE 3 & PAGE 1-3)
G-II
PCM
5.39
(137)
8.58
(218)
7.63
(194)
REAR VIEW
4.33
(110)
5.90
(150)
4 x M8 x 1.25 MOUNTING PEM NUTS
HEAT EXCHANGER
(SEE NOTE 6)
.75 (19)
10.13 (257)
9.00 (229)
5.77
(147)
DUAL MODE TEMPERATURE
SENSOR
9
.55 (243)
TOP VIEW
COOL AN T INLET
COOL AN T OUTLET
2 x 1.50 (38)
1
.97 (50)
PHYSICAL – M50/M801.1
NOTES:
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
1-2
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
A
IR INTAKE OPTION:
3" OD SNORKEL SEE NOTE 7
AIR INTAKE OPTION:
2
.25" OD ELBOW WITH 26° ADAPTER PLATE
S
EE NOTE 7
CAN BE INSTALLED AT: 26°, 116°, 206°, 296°
AIR INTAKE OPTION:
2.25" OD SNORKEL SEE NOTE 7
AIR INTAKE OPTION: 2.25" OD ELBOW SEE NOTE 7
CAN BE INSTALLED AT 0°, 90°, 180°, 270°
2
4.31 (617
)
4
.71
(
120
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.21 (234)
2
9.09 (637
)
3
.93
(
100
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.99 (254)
24.00 (610)
5.20
(132
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
8.90 (226)
24.80 (630)
4.22
(107)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.70 (246)
90°
0°
270°
180°
1
16°
26°
296°
206°
NOTES:
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
1-3
EXHAUST
(SEE NOTE 2 AND 4)
-4 JIC MALE FUEL INLET (INTERNAL
FUEL FILTER) (SEE NOTE 5)
2.75 (70)
12.60 (320)
25.74 (654)
5.37
(136)
8.14 (207)
2.03 (52)
FRONT VIEW
2 x .394 (10)
BOTTOM VIEW
AIR INTAKE
ALTERNATE
SNORKELS
AVAILABLE
(SEE PAGE 1-3 )
3.22 (82)
5.00 (27)
3.98
(101)
SIDE VIEW
SERVICE SPACE REQUIREMENT
(
MAY VARY SEE NOTE 3 & PAGE 1-3)
G-II
PCM
5.39
(137)
9.5
(241)
8.55
(217)
REAR VIEW
4.33
(110)
4.33
(110)
5.91
(150)
.394
(10)
3 x M8 x 1.25
HEAT EXCHANGER
(SEE NOTE 6)
10.13 (257)
9.00 (229)
8.25
(210)
DUAL MODE TEMPERATURE
SENSOR
1
2.05 (306)
TOP VIEW
COOL AN T INLET
COOL AN T OUTLET
2 x 1.50 (38)
1
.97 (50)
PHYSICAL – M90/105
NOTES:
1-4
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
A
IR INTAKE OPTION:
3" OD SNORKEL SEE NOTE 7
AIR INTAKE OPTION:
2
.25" OD ELBOW WITH 26° ADAPTER PLATE
S
EE NOTE 7
CAN BE INSTALLED AT: 26°, 116°, 206°, 296°
AIR INTAKE OPTION:
2.25" OD SNORKEL SEE NOTE 7
AIR INTAKE OPTION: 2.25" OD ELBOW
SEE NOTE 7
CAN BE INSTALLED AT 0°, 90°, 180°, 270°
2
6.81 (681
)
7
.21
(
183
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.21 (234)
3
1.59 (802
)
6
.43
(
163
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.99 (254)
26.50 (673)
7.70
(196
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
8.90 (226)
27.30 (693)
6.72
(171)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.70 (246)
90°
0°
270°
180°
1
16°
26°
296°
206°
NOTES:
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
1-5
EXHAUST
(SEE NOTE 2 AND 4)
-4 JIC MALE FUEL INLET (INTERNAL
FUEL FILTER) (SEE NOTE 5)
2.75 (70)
12.60 (320)
27.24 (692)
4.45
(113)
8.14 (207)
2.03 (52)
FRONT VIEW
6 x .41 (10)
BOTTOM VIEW
AIR INTAKE
ALTERNATE
SNORKELS
AVAILABLE
(SEE PAGE 1-3 )
3.23 (82)
3.98
(101)
SIDE VIEW
SERVICE SPACE REQUIREMENT
(
MAY VARY SEE NOTE 3 & PAGE 1-3)
G-II
PCM
5.39
(137)
8.58
(218)
7.63
(194)
REAR VIEW
4.33
(110)
5.90
(150)
4 x M8 x 1.25 MOUNTING PEM NUTS
HEAT EXCHANGER
(SEE NOTE 6)
.75 (19)
10.13 (257)
9.00 (229)
9.78
(248)
DUAL MODE TEMPERATURE
SENSOR
1
3.55 (3 44)
TOP VIEW
COOL AN T INLET
COOL AN T OUTLET
2 x 1.50 (38)
1
.97 (50)
PHYSICAL – M125
NOTES:
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
1-6
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
A
IR INTAKE OPTION:
3" OD SNORKEL SEE NOTE 7
A
IR INTAKE OPTION: 2.25" OD ELBOW
WITH 26° ADAPTER PLATE
SEE NOTE 7
C
AN BE INSTALLED AT:
26°, 116°, 206°, 296°
AIR INTAKE OPTION:
2.25" OD SNORKEL SEE NOTE 7
AIR INTAKE OPTION: 2.25" OD
ELBOW SEE NOTE 7
CAN BE INSTALLED AT:
0°, 90°, 180°, 270°
2
8.31 (719
)
8
.71
(
221
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.21 (234)
3
3.09 (840
)
7
.93
(
201
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.99 (254)
28.00 (711)
9.02
(22.9
)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
8.90 (226)
28.80 (732)
8.22
(209)
SERVICE
SPACE
REQUIREMENT
(SEE NOTE 3)
9.70 (246)
90°
0°
270°
180°
1
16°
26°
296°
206°
NOTES:
1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).
2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.
3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND
COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.
4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF
2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN
180° OF BENDS.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE
PARTS BOOK FOR FURTHER INFORMATION.
6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK
FOR FURTHER INFORMATION.
7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION.
CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR
LENGTH AND BEND RESTRICTIONS.
1-7
G-II PCM ELECTRICAL1.2
PROHEAT G-II PCM
INDIC ATOR OUTP UT (HIGH SI DE SWITCH ED. DASH OR PR OHEAT TOGG LE SWITC H LIGHT) (1 A MP MAX)
POWE R OUTPUT (C ONSTANT P OWER. TIM ER/SWI TCH REMO TE PANEL) (1 A MP MAX SH ARED WIT H P3-E)
MAI N SWITCH IN PUT (STAND ARD "ON" S IGNAL OR PR EHEAT UNL ATCH) – AC TIVE HIGH
BB
GROUN D (INDICAT OR GROUND) (1 AM P MAX)
UNUSE D
ACCE SSORY POW ER OUTPU T (1 AMP MA X)
USBD + (I /O) – SEE NOT E 6
USBD - (I /O) – SEE NOT E 6
COOL ANT PUMP O UTPUT GR OUND (10 AMP MA X)
COOL ANT PUMP O UTPUT (10 A MP MAX)
USB GRO UND – SEE NOT E 6
GROUN D (ACCESS ORY OUTPU T GROUND) (1 AM P MAX)
PREH EAT SWITC H INPUT – AC TIVE HIGH
SUPP LEMENTA L SWITCH IN PUT – ACTI VE HIGH
PUMP (C OOLANT ) SWITCH I NPUT – ACT IVE HIGH
P4
COOLANT
PUMP
OUTPUT
PROHEAT PCM
B
A
B
A
P3
DATALINK
F FCE
B
A
CEB
A
P2
CONTROL
GG
H H
F
ECD
F
ECD
O.E.M. SUPPLIED
BATT ERY POSI TIVE (FUS E/BRE AKER 30 A MP)
BATT ERY NEGAT IVE (GROUN D)
P1
POWER
A A
B
A
B
A
PROHEAT PCM
FUSE
30 AMP
P5 - AUX (OUTPUT)
METRI-PACK
150 SERIES, 2 PIN
ENGINE RUN (ALTERNATOR SIGNAL)
SIGNAL FROM OEM HEATING SYSTEM
TO TURN ON COOLANT PUMP WHEN
REQUIRED FOR A REASON OTHER
THAN WHEN THE HEATER REQUIRES
THE PUMP.
MECHANICS DISABLE
SWITCH MOUNTED IN A
PROTECTED LOCATION
O.E.M. SUPPLIED
OFF
ON
SPRING CENTERED
DOUBLE THROW
MOMENTARY SWITCH.
LOCATED ON THE
DRIVERS CONSOLE.
NOTES:
1/ WIRE MUST MEET OR EXCEED SAE J1128 GLX SPECIFICATIONS.
2/ ALL WIRE AND INSULATION THICKNESSES TO MATCH THOSE
SPECIFIED BY DELPHI FOR THE GIVEN PART NUMBERS IN TABLE 1
3/ ALL UNUSED CONNECTIONS ON THE PCM ARE SUPPLIED
WITH CONNECTOR PLUGS ON STANDARD HEATERS.
4/ ALL CONTROL SIGNAL INPUT VOLTAGES MUST MATCH
HEATER SUPPLY VOLTAGE.
5/ ALL HEATER OUTPUT SIGNALS WILL MATCH HEATER
SUPPLY VOLTAGE.
6/ WIRE USED ON DATALINK CONNECTOR USB CONNECTIONS
(P3) MUST MEET UNIVERSAL SERIAL BUS CABLES AND
CONNECTION STANDARDS REV 2.0. USB WIRES MAXIMUM
LENGTH IS 13.1FT (4M).
RED
GREEN
WHITE
BLACK
TIMER OPTION TI* OR TII
INDICATOR
LIGHT
LOCATED AS PER
CUSTOMER REQUEST OR
OEM REQUIREMENT
SHIEL D
CAN- L
CAN- H
P6
CAN BUS
C
B
C
B
A A
AUX ILIARY OU TPUT (HIG H SIDE SWIT CHED) (1 AMP M AX)
AUX ILIARY OU TPUT GROU ND (AUXIL IARY OUT PUT) (1 AM P MAX)
P5
AUXILIARY
OUTPUT
B
A
B
A
H
G
UNUSE D
USB PO WER – SEE NOT E 6
H
G
VEHICLE BATTERY
OPTIONALLY, PUMP CAN BE CONNECTED DIRECTTLY
TO PCM (10 AMP MAX CURRENT DRAW)
FUSE
*TI TIMER REQUIRES HARNESS PID: 200100
VEHICLE BATTERY
LOCK
PART#
12052634
12066304
12066304
15300014
PCM
CONNECTOR
P4-PUMP (COOLANT)
P3-DATALINK(DOWNLOAD)
P2-CONTROL (SWITCH)
P1-POWER
12047937
12052641
12047938
CONNECTOR
PART#
15300027
CAVITY PLUG
PART#
1205916812048074 12048086
12048086
12048086
12048074
12048074
----
12059168
WIRE SEAL
PART#
12015193
TERMINAL
PART#
12077413
----
P5-AUXILIARY
P6-CAN BUS
12052644
12110293
12052634
12052845
12048074
12048074
12048086
12048086
----
----
TABLE 1: CONNECTOR ASSEMBLY PART NUMBERS
+
–
+
–
COOLANT PUMP
86 30
85
87a 87
COOLANT
PUMP
RELAY
+ –
CLOCK
TIME
DAY
TIMER
THERMALSYSTEMS
MANUAL
P6 - CANBUS (OPTIONAL)
METRI-PACK 150 SERIES,
3-PIN
P7 - DUAL MODE TEMP
SENSOR
P4 - PUMP (COOLANT)
METRI-PACK 150 SERIES,
2 PIN
P3 - DATALINK
(DOWNLOAD)
METRI-PACK
150 SERIES, 7 PIN
P2 - CONTROL (SWITCH)
METRI-PACK
150 SERIES, 8 PIN
P1 - POWER
METRI-PACK
280 SERIES, 2 PIN
1-8
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
TORQUE SPECIFICATIONS1.3
Solenoid Valve
• Lubricate O-ring with diesel fuel.
• Install solenoid valve by hand.
• Ensure poppet and spring remain in place during assembly.
• Torque solenoid valve to fuel block to 25 in. lbs. ± 3 in. lbs.
(2.8 Nm ± 0.3 Nm).
Regulator
• Install 2 o-rings on back side of regulator.
• Torque screws (2) to 75 in. lbs. ± 3 in. lbs. (8.5 Nm ± 0.3 Nm).
Fuel Delivery Block
• Ensure all three O-rings are in place.
• Torque screws (3) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).
Nozzle
• Lubricate O-ring on nozzle with diesel fuel.
• Torque nozzle to fuel block to 150 in. lbs. ± 10 in. lbs.
(16.9 Nm ± 1.1 Nm).
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
Nozzle Assembly
• Torque nozzle to nozzle stem to 30 in. lbs. ± 3 in. lbs. (3.4Nm ± .3 Nm).
1-9
Motor
• Rotate motor shaft until motor drops into fuel pump gear.
• Ensure correct alignment (refer to ‘Motor Replacement’ on page 4-33)
Torque bolts (4) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).
•
Blower Housing
• Torque bolts (2) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).
Ignition Module
• Torque screws (2) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).
Dual Mode Temperature Sensor
• Install O-ring onto sensor.
• Torque sensor to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).
Burner Head/Heat Exchanger
• Torque bolts (2) to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).
1-10
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
Enclosure Lid (Optional)
• Torque screws (4) to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).
Fuel Filter Fitting
• Install O-ring onto fitting.
• Torque fitting to 100 ± 10 in. lbs. (11.3 ± 1.1 Nm).
Diaphragm Compressor ONLY
Serial Numbers 70000 and above
• Install O-rings in to cylinder head and valve cover (not shown).
• Ensure connecting rod is at BDC and ensure the diaphragm is concentric
to the diaphragm opening (not shown).
• Torque to 27 in. lbs +/- 3 in. lbs using a crisscross pattern.
Rotary Vane Compressor ONLY
Serial Numbers 500000 – 699999
• Install O-rings into burner flange.
• Install compressor into burner flange. (Ensure correct alignment—refer to
Compressor Replacement’ on page 5-7.)
• Torque screws (2) to 75 in. lbs. ± 3 in. lbs. (8.5 Nm ± 0.3 Nm).
Relief Valve
– for Use with Rotary Vane Compressor ONLY
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
Serial Numbers 600000 – 699999
• Torque to 25 in. lbs. ± 3 in. lbs. (2.8 Nm ± 0.3 Nm).
1-11
1-12
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
2.0
PRINCIPLE OF
OPERATION
2.1
Combustion Air Blower:
Motor:
Fuel Supply Pump:
Fuel Regulator:
Fuel Nozzle:
COMPONENT DESCRIPTIONS
Impeller-style blower driven by the Motor provides the principle combustion air.
Drives the Combustion Air Blower, Air Compressor and Fuel Supply Pump.
A positive displacement, gear-type pump that draws fuel from the vehicle fuel
tank and supplies it to the Fuel Regulator. Pressure is regulated between
5 – 10 PSI by means of an internal relief valve. Fuel is re-circulated within the
pump, therefore a fuel return line to the tank is not required.
Diaphragm-type pressure reducing valve. The Fuel Regulator drops the fuel
supply pressure to atmospheric pressure (0 PSI).
Air-aspirating type burner nozzle. Compressed air flows through the air
passages, exiting the nozzle in front of the fuel orifice creating a vacuum in
the fuel supply. This draws fuel from the Fuel Regulator and the combined
fuel/air mixture is atomized into the combustion chamber.
Fuel Solenoid Valve:
Air Compressor:
Ignition Module:
G-II PCM:
(PROHEAT Control Module)
Combustion Tube:
Electrically operated solenoid valve which controls fuel flow to the Fuel Nozzle.
Diaphragm compressor that supplies air pressure to the Fuel Nozzle.
Note that older versions of M-Series use a rotary vane compressor. Refer to
page D-1 for more information.
Electronic Ignition Module with plug-in electrode.
Electronic control module that monitors inputs from the sensors and controls
outputs to PROHEAT components. It has an integrated Flame Sensor that photoelectrically measures the intensity of the flame to determine if a flame is present.
Also built-in to the G-II PCM is a Status Indicator Light that shows operation,
function/component problems and CANbus connectivity to assist with troubleshooting. Operation and fault history can be downloaded and viewed on a
computer using PROHEAT Data Link software.
Note that the older G-I PCM version does not have a built-in Status Indicator Light.
Refer to page C-1 for more information.
Directs the air supplied by the combustion air blower through a swirler into the
combustion zone, mixing it with the atomized fuel/air mixture from the Fuel Nozzle.
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
2-1
Heat Exchanger:
Coolant is circulated through the heat exchanger via the inlet and outlet ports.
eat is transferred from the heat exchanger through the inner wall of the
H
exchanger into the coolant. The exhaust gases are directed out through the
exhaust port.
Dual Mode Temperature
Sensor G-II PCM:
Coolant Pump:
Air Relief:
(Rotary Vane Compressor ONLY)
Measures the coolant temperature near the outlet port of the heat exchanger
and sends this information to the G-II PCM. The dual mode sensor contains
both digital and analog sensing elements for more accurate and reliable measurements. The sensor also touches the inner heat exchanger surface to measure the heat exchanger temperature for an overheat condition.
WARNING
The Dual Mode Temperature Sensor must be properly installed in the heat
exchanger at all times for overheat protection.
Circulates coolant through the PROHEAT and vehicle heating system.
Depending on the PROHEAT installation, it may be operated by the G-II PCM.
Regulates air pressure to the fuel nozzle.
For use with Rotary Vane Compressor ONLY Serial Numbers 600000 – 699999.
Refer to page D-1 for more information.
2-2
PROHEAT M-SERIES G-II PCM SERVICE MANUAL
Loading...