Proheat Teleflex X45 Manuale
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
i
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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