Proheat Teleflex X45 Manuel

INSTALLATION

AND SERVICE

MODEL X45

CONTENTS

INTRODUCTION...........................................................................i

1. OPERATING YOUR PROHEAT HEATER ..................................1-1

2. TECHNICAL SPECIFICATIONS

ENCLOSURE DIMENSIONS ..........................................................2-1

HEATER DIMENSIONS .................................................................2-2

3. INSTALLATION

LOCATING THE HEATER...............................................................3-2

MOUNTING THE HEATER .............................................................3-4

EXHAUST PIPE CONNECTION .......................................................3-6

PLUMBING THE SYSTEM .............................................................3-7

General Considerations.........................................................3-7

Option A – Engine Heat or Supplemental Heat ........................3-8

Option B – Engine & Sleeper Heat..........................................3-9

Engine Connection Details...................................................3-11

WIRING & ELECTRICAL CONNECTIONS .......................................3-13

General Considerations.......................................................3-13

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

General Considerations.......................................................3-21

Option A – 1⁄4" OR 1⁄2" NPT Port...........................................3-22

Option B – Existing Blank Fuel Sender Cover Plate ................3-23

Option C – Hole Drilled into Fuel Tank ..................................3-23

Installation.........................................................................3-24

FIRST TIME STARTUP ................................................................3-25

4. PRINCIPLES OF OPERATION

GENERAL DESCRIPTION ..............................................................4-1

NORMAL OPERATING SEQUENCE .................................................4-5

5. TROUBLESHOOTING & REPAIR

“ON” Indicator Light..............................................................5-1

FUNCTION DIAGNOSTICS.............................................................5-2

Start....................................................................................5-2

Flame Out ............................................................................5-3

Coolant Flow ........................................................................5-4

Overheat..............................................................................5-5

Voltage ................................................................................5-6

COMPONENT DIAGNOSTICS.........................................................5-8

Flame Sensor.......................................................................5-8

Temperature Sensor ...........................................................5-10

Fuel Pump..........................................................................5-12

Compressor .......................................................................5-13

Ignition Coil........................................................................5-15

Coolant Pump ....................................................................5-17

Blower ...............................................................................5-19

Sleeper Fan .......................................................................5-21

COMPONENTS..........................................................................5-22

Electrode Gap ....................................................................5-22

Fuse ..................................................................................5-23

Nozzle ...............................................................................5-25

Fuel Regulator ....................................................................5-26

FUEL SYSTEM ..........................................................................5-27

General..............................................................................5-27

OPERATIONAL PROBLEMS .........................................................5-29

Smoking Exhaust................................................................5-29

Low Heat Output.................................................................5-29

Engine Temperature Gauge .................................................5-29

Backfiring...........................................................................5-29

6. MAINTENANCE

Weekly Maintenance.............................................................6-1

Annual Maintenance .............................................................6-1

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

INTRODUCTION

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.

PROHEAT Model X45

(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. Teleflex 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

Coast Guard regulations.

OPERATING YOUR PROHEAT HEATER 1-1

OPERATING YOUR

PROHEAT HEATER

Engine Heat Only

1. Switch the ON/OFF switch located in the vehicle dash to “ON.”

The switch will light and the heater will fire. It will continue to fire

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 fire. It will continue to fire

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. 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.”

1.0

NOTE:

Regular use of your PROHEAT

throughout the year will improve

its reliability. Weekly operation is

recommended.

NOTE:

The PROHEAT heater can be

operated by either using a toggle

switch or a 7 day timer.

Refer to Page 3-13 for WIRING &

ELECTRICAL CONNECTIONS.

TECHNICAL SPECIFICATIONS

Model Heat Rating Volts Current Fuel Rate Coolant Flow

BTU/hr. (kw) Nominal Amps Gal/hr (l/hr) Gal/min (l/min.)

(range)

X45-12 45,000 12 7.5 .32 (1.2) 8.0 (30)

(13.0) (10.0 – 15)

X45-24 45,000 24 3.75 .32 (1.2) 8.0 (30)

(13.0) (20 – 30)

2-1

TECHNICAL

SPECIFICATIONS

Ignition Type: .................................Electronic spark ignition

Fuel Types:.....................................Diesel #1, #2, Kerosene

Coolant Temperature: .....................150˚ to 185˚F (65˚ to 85˚C) @ heater

Enclosure Dimensions: X45...........12 1⁄2 W x 11 H x 20 1⁄2 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)

WARNING

DO NOT use gasoline

2.0

Figure 2-1 Enclosure Dimensions

10 1/8"

(241 mm)

1 1/4"

(31 mm)

8 1/2"

(216 mm)

3 7/8"

(92 mm)

1 7/16"

(36 mm)

7 5/16"

(186 mm) 12 1/2" (318 mm)

20 1/2" (521 mm)

11"

(280 mm)

Figure 2-2 Heater Dimensions X45

PROHEAT INSTALLATION & SERVICE

2-2

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