Proheat M80 User Manual

G-I PCM SERVICE MANUAL

M50/M80

SE R I AL NUMBER S

VANE CO M P RESSOR : 50 0 000 - 69 9 9 99

DI A P HRAGM C O MPRESS O R : 700000 - 70 4999

Rev. H

CONTENTS

A. SAFETY .

SAFETY CONSIDERATIONS ..............................................................A-2

..................................................................................... A-1

B. INTRODUCTION ......................................................................... B-1

C. MODEL DESCRIPTIONS............................................................ C-1

D. COMPRESSOR TYPE ................................................................ D-1

1.0 TECHNICAL SPECIFICATIONS .................................................. 1-1

1.1 PHYSICAL .............................................................................. 1-2

1.2 ELECTRICAL........................................................................... 1-4

1.3 TORQUE SPECIFICATIONS ....................................................... 1-5

2.0 PRINCIPLES OF OPERATION ................................................... 2-1

2.1 COMPONENT DESCRIPTION .................................................... 2-1

2.2 MODES OF OPERATION .......................................................... 2-4

2.2.1 Standard Mode............................................................2-4

2.2.2 Preheat Mode............................................................. 2-5

2.2.3 Supplemental Mode.................................................... 2-6

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 ........... 4-2

4.1.2 START Diagnostic Code ............................................... 4-3

4.1.3 FLAME OUT Diagnostic Code ..................................... 4-26

4.1.4 COOLANT FLOW Diagnostic Code ............................... 4-27

4.1.5 OVERHEAT Diagnostic Code....................................... 4-29

4.1.6 VOLTAGE Diagnostic Code ......................................... 4-29

4.1.7 FLAME FAULT Diagnostic Code .................................. 4-31

4.1.8 TEMPERATURE SENSOR T1 Diagnostic Code .............. 4-31

4.1.9 FUEL SHUT-OFF VALVE Diagnostic Code...................... 4-34

4.1.10 TEMPERATURE SENSOR T2 Diagnostic Code .............. 4-35

4.1.11 IGNITION MODULE Diagnostic Code ........................... 4-35

4.1.12 COOLANT PUMP Diagnostic Code............................... 4-36

4.1.13 MOTOR Diagnostic Code ........................................... 4-37

4.1.14 AUXILIARY OUTPUT Diagnostic Code .......................... 4-38

4.1.15 SWITCH/TIMER POWER Diagnostic Code .................... 4-38

4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS.......... 4-39

4.2.1 Fuel Nozzle .............................................................. 4-39

4.2.2 Fuel Shut-off Valve .................................................... 4-39

4.2.3 Fuel Regulator .......................................................... 4-39

4.2.4 Air Compressor......................................................... 4-39

4.2.5 Fuel Supply Pump ..................................................... 4-39

4.2.6 Ignition Electrodes .................................................... 4-39

4.2.7 G-I PCM Fuse ........................................................... 4-39

4.3 OPERATIONAL PROBLEMS..................................................... 4-42

PROHEAT G-I PCM SERVICE MANUAL

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

.... 5-6

6.0 PROHEAT WARRANTY .............................................................. 6-1

PROHEAT G-I 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 G-I PCM SERVICE MANUAL

A-1

SAFETY CONSIDERATIONS

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

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 G-I PCM SERVICE MANUAL

INTRODUCTION

MODEL: M50/M80 G-I 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 G-I PCM SERVICE MANUAL

B-1

B-2

PROHEAT G-I PCM SERVICE MANUAL

G-II PCM G-I 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 (G-I 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. Please refer to the M-Series Parts Book at www.proheat.com for part numbers.

THIS MANUAL COVERS ONLY THE G-I PCM. Please see SL9157 for Service information on the G-II PCM.

sensor and advanced Data Link software. Both styles can be

Figure C-1. G-I PCM and G-II PCM.

PROHEAT G-I PCM SERVICE MANUAL

C-1

C-2

PROHEAT G-I 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 G-I PCM SERVICE MANUAL

D-1

D-2

PROHEAT G-I PCM SERVICE MANUAL

MODEL DESCRIPTIONSE.

MODEL : M80- 24V S

/N : XXX XXX POWER : 95 WATTS FUEL TY PE: DIE SEL MAX PRE SS: 2 BAR OPER. VOLT:

20-30 VDC

HEAT OUTPUT: 24.0 KW

NSTALLATION DATE :

07 08 09 10 11 12

ade bt Teleflex Canad a

Richmond B C Canada

PID 200101

Please refer to the M-Series 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, 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-I PCM CANbus, Voltage, Fuel Fitting optional configurations, and Air Intake optional configurations.

Heat Output:

G-I PCM:

Voltage:

50,000 BTU/hr or 80,000 BTU/hr (15 kW or 23 kW).

The M-Series is available in either a 50,000 BTU/hr or 80,000 BTU/hr (15 kW or 23 kW) model.

CANbus SAE J1939.

The M-Series Proheat Control Module (G-I 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 G-I 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 G-I PCM SERVICE MANUAL

1.0

TECHNICAL SPECIFICATIONS

M50 12V M50 24V M80 12V M80 24V

RATING BTU/hr (kW) 50,000 (15) 50,000 (15) 80,000 (23) 80,000 (23)

SYSTEM VOLTAGE

Nominal DC Voltage (Range) 12 (10 – 15) 24 (20 – 30) 12 (10 – 15) 24 (20 – 30)

CURRENT DRAW (MAX) Amps 9.5 5.2 8.5 5.2

FUEL CONSUMPTION US gal/hr (L/hr) 0.48 (1.8) 0.48 (1.8) 0.78 (2.95) 0.78 (2.95)

IGNITION TYPE Electronic Spark Ignition

COOLANT OUTPUT TEMPERATURE MAX. 185°F (85°C)

AMBIENT OPERATING TEMPERATURE -40°F to +122°F (-40°C to +50°C)

WEIGHT lbs (kg) 53 (24)

HEAT EXCHANGER CAPACITY US gal (l) 0.5 (2)

COOLANT SYSTEM Minimum Capacity US gal (l) 2.64 (10) 2.64 (10) 2.64 (10) 2.64 (10) Recommended Flow Rate Through

Heater US gpm (lpm) 5 (19) 5 (19) 7 (26.5) 7 (26.5)

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

AUXILIARY OUTPUT Same as System Voltage

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

COOLANT PUMP Same as System Voltage

Maximum 10 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 – 30V

Standard Run Mode Preheat Run Mode Supplemental Run Mode

COOLANT PUMP 10 – 30V AUXILIARY Allows independent operation of Coolant Pump through

the Proheat Control Module

POWER 12 Volt or 24 Volt

PROHEAT G-I 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-I 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)

T1 PRIMA RY TEMPERATURE SENSOR SEE NOTE 8

.55 (243)

TOP VIEW

2 SECONDARY TEMPERATURE SENSOR LOCATION (SENSOR NOT SHOWN) SEE NOTE 8

INLE T SEE NOTE 8

OUTLET SEE NOTE 8

2 x 1.50 (38)

.97 (50)

PHYSICAL1.1

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 LENGTH AND BEND RESTRICTIONS

THE INLET AND OUTLET CAN BE REVERSED WITH THE ADDITION OF A T2 SECONDARY TEMPERATURE SENSOR.

FOR

1-2

PROHEAT G-I PCM SERVICE MANUAL

IR INTAKE OPTION:

3" OD SNORKEL SEE NOTE 7

AIR INTAKE OPTION:

2.25" OD ELBOW WITH

7° ADAPTER PLATE SEE NOTE 7

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°

4.31 (617

)

.77

(

147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.21 (234)

9.09 (637

)

.77

(

147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.99 (254)

24.00 (610)

5.77

(147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

8.90 (226)

24.80 (630)

5.77

(147)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.70 (246)

90°

0°

270°

180°

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.

PROHEAT G-I PCM SERVICE MANUAL

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

THE INLET AND OUTLET CAN BE REVERSED WITH THE ADDITION OF A T2 SECONDARY TEMPERATURE SENSOR.

1-3

ELECTRICAL1.2

GHF

ECD

INDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX)

ENGINE RUN (ALTERNATOR SIGNAL)

SPRING CENTRED

DOUBLE THROW

MOMENTARY SWITCH.

LOCATED ON THE

DRIVERS CONSOLE.

RED

TIMER OPTION

GREEN

WHITE

BLACK

MECHANICS DISABLE

SWITCH MOUNTED IN A

PROTECTED LOCATION

LOCATED AS PER CUSTOMER

REQUEST OR OEM REQUIREMENT

OFF

SIGNAL FROM OEM HEATING SYSTEM TO

TURN ON COOLANT PUMP WHEN REQUIRED

FOR A REASON OTHER THAN WHEN THE

HEATER REQUIRES THE PUMP

POWER OUTPUT (CONSTANT POWER. TIMER/SWITCH REMOTE PANEL) (1 AMP MAX SHARED WITH P3-D)

MAIN SWITCH INPUT (STANDARD "ON" SIGNAL OR PREHEAT UNLATCH) (ACTIVE HIGH)

GROUND (INDICATOR GROUND) (1 AMP MAX)

GROUND (ACCESSORY OUTPUT GROUND) (1 AMP MAX)

PREHEAT SWITCH INPUT (ACTIVE HIGH)

SUPPLEMENTAL SWITCH INPUT (ACTIVE HIGH)

PUMP (COOLANT) SWITCH INPUT (ACTIVE HIGH)

O.E.M. SUPPLIED

BATTERY POSITIVE (FUSE/BREAKER 30 AMP)

BATTERY NEGATIVE (GROUND)

PROHEAT G-I PCM

30 AMP

FUSE

(-)

POWER

SUPPLY

(+)

VEHICLE

GROUND

INDICATOR

LIGHT

CDE

RS232 Rx

RS232 Tx

FACTORY USE (N/A)

GROUND (1 AMP MAX)

INDICATOR OUTPUT (1 AMP MAX)

CAN-H

CAN-L

SHIELD

ACCESSORY POWER OUTPUT (1 AMP MAX SHARED WITH P2-C)

COOLANT PUMP GROUND

COOLANT PUMP OUTPUT

GROUND (AUXILIARY OUTPUT) (1 AMP MAX)

AUXILIARY OUTPUT (HIGH SIDE SWITCHED) (1 AMP MAX)

GHF

ECD

CDE

PROHEAT G-I PCM

O.E.M. SUPPLIED

MAXIMUM

10 AMPS

COOLANT PUMP

OUTPUT

AUXILIARY

OUTPUT

DATALINK

CAN BUS

CONTROL

POWER

P2 - CONTROL (SWITCH)

METRI-PACK 150 SERIES, 8 PIN

NOTE 1

P1 - POWER

METRI-PACK 280 SERIES, 2 PIN

NOTE 2

P3 - DATALINK (DOWNLOAD)

METRI-PACK 150 SERIES, 6 PIN

NOTE 1

NOTE 3

P5 - AUX (OUTPUT)

METRI-PACK 150 SERIES, 2 PIN

NOTE 1

NOTE 3

PROHEAT G-I PCM

P4 - PUMP (COOLANT)

METRI-PACK 150 SERIES, 2 PIN

NOTE 1

NOTE 3

P8 - T1: TEMP SENSOR

P7 - T2: TEMP SENSOR

NOTE 3

P6 - CANBUS (OPTIONAL)

METRI-PACK 150 SERIES, 3 PIN

NOTE 1

NOTE 3

NOTES:

1/ 150 SERIES CONNECTOR ASSEMBLIES TO BE

USED WITH 18AWG WIRE WITH MAXIMUM

.1" INSULATION DIAMETER. WIRE MUST MEET

OR EXCEED SAE J1128 GPT SPECIFICATIONS.

2/ 280 SERIES CONNECTOR ASSEMBLIES TO BE

USED WITH 10AWG WIRE WITH MAXIMUM

.161" INSULATION DIAMETER. WIRE MUST

MEET OR EXCEED SAE J1128 GPT OR GXL.

3/ ALL UNUSED CONNECTIONS ON THE PCM ARE

SUPPLIED WITH SEAL PLUGS ON STANDARD

HEATERS.

LOCK

PART#

G-I PCM CONNECTOR WIRE SEAL

PART#

TERMINAL

PART#

CAVITY SEAL

PART#

----

12052850

P3-DATALINK (DOWNLOAD)

1204808612048074

12059168

12052848

12052634P4-PUMP (COOLANT) 120480861204807412052641

12052634P5-AUXILIARY 120480861204807412052641

12052845P6-CAN BUS 120480861204807412110293

15300014P1-POWER 120151931207741315300027

12066304

P2-CONTROL (SWITCH)

1204808612048074

12059168

12047937

CONNECTOR

PART#

1-4

PROHEAT G-I 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 (not shown).

• 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 G-I PCM SERVICE MANUAL

Nozzle Assembly

• Torque nozzle to nozzle stem to 30 in. lbs. ± 3 in. lbs. (3.4Nm ± .3 Nm).

1-5

Motor

• Rotate motor shaft until motor drops into fuel pump gear..

• Ensure correct alignment (refer to ‘Motor Replacement’ on page 4-25)

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).

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).

1-6

PROHEAT G-I 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).

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 4-15)

• Torque screws (2) to 75 in. lbs. ± 3 in. lbs. (8.5 Nm ± 0.3 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.

Relief Valve

Serial Numbers 600000 – 699999

– for Use with Rotary Vane Compressor ONLY

PROHEAT G-I PCM SERVICE MANUAL

• Torque to 25 in. lbs. ± 3 in. lbs. (2.8 Nm ± 0.3 Nm).

1-7

1-8

PROHEAT G-I 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 7 – 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 Shut-off Valve:

Air Compressor:

Air Relief:

Ignition Module:

G-I 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.

Regulates air pressure to the fuel nozzle.

For use with Rotary Vane Compressor ONLY Serial Numbers 600000 – 699999.

Electronic Ignition Module with plug-in electrode.

Electronic control module monitors the PROHEAT sensors, operating conditions, and controls the Motor and other devices. Diagnostics are utilized for both safety in operations and detection of component faults to aid in service and troubleshooting. The G-I PCM contains the flame sensor which senses the flame intensity. This information can be retrieved by a personal computer using PROHEAT Datalink software.

Directs the air supplied by the blower through a swirler into the combustion zone, mixing it with the atomized fuel/air mixture from the Fuel Nozzle.

PROHEAT G-I PCM SERVICE MANUAL

2-1

Heat Exchanger:

Coolant is circulated through the heat exchanger via the inlet and outlet

orts. Heat is transferred from the heat exchanger through the inner wall of

p the exchanger into the coolant. The exhaust gases are directed out through the exhaust port.

Temperature Sensor 1:

Temperature Sensor 2:

Coolant Pump:

Measures the coolant temperature near the outlet port of the heat exchanger and sends this information to the G-I PCM. This sensor also measures the inner heat exchanger surface temperature for an overheat condition. It must

be connected at all times for overheat protection.

For installations where the coolant flow through the heat exchanger is opposite of what is specified on page 1-2 and page 2-3.

Circulates coolant through the PROHEAT and vehicle heating system. Depending on the PROHEAT installation, it may be operated by the G-I PCM.

2-2

PROHEAT G-I PCM SERVICE MANUAL

OUTLET

600000 – 699999

SERIAL NUMBERS

SENSOR 1

TEMPERATURE

ROTARY VANE COMPRESSOR

AIR RELIEF

HEAT EXCHANGER

AIR COMPRESSOR

INLET

TUBE

COMBUSTION

COMPRESSOR

BUILT IN AIR

FLANGE WITH

BURNER HEAD

REQUIRED

FOR REVERSE

COOLANT FLOW

(IF EQUIPPED)

SENSOR 2

TEMPERATURE

MOTOR

FUEL

NOZZLE

IGNITION

ELECTRODES

AIR FILTER

IGNITION MODULE

FUEL

VALVE

SHUT-OFF

FUEL REGULATOR

FUEL

PUMP

SUPPLY

COMBUSTION AIR BLOWER

G-I PCM (PROHEAT CONTROL MODULE)

PROHEAT G-I PCM SERVICE MANUAL

IN AIR COMPRESSOR

FLANGE WITH BUILT

BURNER HEAD

BLOWER HOUSING

2-3

MODES OF OPERATION2.2

The Proheat Control Module (G-I PCM) has three modes of operation: Standard, Preheat and Supplemental. Depending on the installation, more than one mode may be wired for operation. The wired modes may be identified by referring to the installation wiring diagram to determine the G-I PCM pins on P2 Control that have been connected. This wiring diagram may be compared with the drawing in Section 1.2 Electrical. The following is a summary of the operation modes:

2.2.1

1. Switch “ON” Standard

Mode Signal

2. Precheck

Standard Heat Mode

• normal operation of the Proheat

• over-rides and drops out

preheat mode

• overrides supplemental mode

Preheat Mode

• similar to standard mode

Except: 90 minute

time out.

• activated via momentary contact push button switch with latching internal to the G-I PCM

Supplemental Heat Mode

• similar to standard mode except: coolant pump does not run when Proheat is not firing

• overrides and drops out

preheat mode

• 30 second signal required before mode enabled

• No delay required for mode switch off

STANDARD MODE

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will light. If the coolant temperature is below 160°F (71°C) the PROHEAT enters Pre-check. If the coolant temperature is above 160°F (71°C) the PROHEAT enters Standby.

The G-I PCM performs self diagnosis checking sensors for correct range, electrical components for over-load and for a flame presence. Also during the first Pre-check, the Ignition Module sparks for five seconds to allow a service technician to visually check for a spark. If there are no errors indicated, the PROHEAT goes to Ignition.

2-4

3. Ignition

4. Full Output

5. Cool Down (Purge)

The Motor and Coolant Pump start first, followed by the ignition spark, and then Fuel Shut-off Valve opens. The Ignition Module sparks for 30 seconds during which time the flame sensor must detect a correct flame. At the end of the Ignition cycle the Flame Sensor checks the flame:

•

If the PROHEAT

•

If the PROHEAT does not detect proper flame, the PROHEAT enters Cool Down

(Purge). The PROHEAT will attempt to start again moving into Pre-check after Cool Down (Purge) Fault Shut Down.

The PROHEAT will continue in Full Output until the coolant temperature reaches 185°F (85°C) at the PROHEAT outlet Temperature Sensor. The PROHEAT closes the Fuel Shut-off Valve and goes into Cool Down (Purge).

The Motor and Coolant Pump continue to operate for three minutes. After three minutes, the Motor stops and the PROHEAT enters Standby. The PROHEAT will Cool Down (Purge) for three reasons:

• Coolant reaches 185°F (85°C).

• A fault is detected. Go to Section 4.0 Troubleshooting and Repair, page 4-1.

• The PROHEAT is operating in Ignition or Full Output when it is switched off.

detects proper flame, it enters Full Output.

. If the second start cycle fails, the PROHEAT will enter

PROHEAT G-I PCM SERVICE MANUAL

CAUTION

Always ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3 minutes. Full Output, DAMAGE TO THE HEATER MAY OCCUR.

If the power is shut off without a proper Cool Down (Purge) during

6. Standby

7. Switch “OFF”

8. Fault Shut Down

2.2.2

1. Momentary Switch “ON” Preheat

Mode Signal

The Coolant Pump continues to circulate coolant throughout the system. When the coolant temperature drops below 160°F (71°C), the G-I PCM will enter the cycle starting at Pre-check. The PROHEAT will continue to repeat Steps 2 to 6 until it is switched “OFF.”

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will turn off.

If the PROHEAT is in Full Output, it will Purge first and then shut “OFF”.

If the PROHEAT is in Standby, it will shut “OFF” immediately.

If the PROHEAT diagnostics sense a system or component fault, the PROHEAT will shut down all components and flash a fault code(s) which best represents the conditions. To reset the PROHEAT, it must be switched off and then on again.

NOTE: Damage may occur it the fault codes are ignored and the PROHEAT is

repeatedly switched off and on without addressing the problem.

PREHEAT MODE (ENGINE OFF)

2. Precheck

3. Ignition

4. Full Output

5. Cool Down (Purge)

•

If the PROHEAT

•

If the PROHEAT does not detect proper flame, the PROHEAT enters Cool Down (Purge). after Cool Down (Purge) enter Fault Shut Down.

The Motor and Coolant Pump continue to operate for three minutes. After three minutes, the Motor stops and the PROHEAT enters Standby. The PROHEAT will Cool Down (Purge) for three reasons:

• Coolant reaches 185°F (85°C).

• A fault is detected. Go to Section 4.0 Troubleshooting and Repair, page 4-1.

• The PROHEAT is operating in Ignition or Full Output when it is switched off.

detects proper flame, it enters Full Output.

The PROHEAT will attempt to start again moving into Pre-check

. If the second start cycle fails, the PROHEAT will

PROHEAT G-I PCM SERVICE MANUAL

2-5

+ 60 hidden pages

Proheat M80 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual