Proheat M80 Manual de Serviço

G-II PCM SERVICE MANUALM50, M80/90 & M105/125SERIAL NUMBERSG-II PCM MODEL HEATERS: 705000 – TO DATEAND ALL MODELS EQUIPPED WITH AG-II REPLACEMENT

NOTICEFor continuity, all figures shown in thismanual will use a diaphragm compressorunlesswhere special instructions orillustrationsare required.Figu

PROHEAT M-SERIES G-II PCM SERVICE MANUALD-2

Please refer to the M-Series Parts Book at www.proheat.com for detailed partdescriptions and part numbers. Included in the parts book are optional fea

PROHEAT M-SERIES G-II PCM SERVICE MANUALE-2Splash Guard, Straight and Right Angle Snorkel Attachments.The M-Series can be equipped with a splash guard

M50 12V M50 24V M80 12V M80 24V M90 24VM105 24V M125 24VRATING BTU/hr (kW) 50,000 50,000 80,000 80,000 90,000 105,000 125,000(15) (15) (23) (23) (26)

EXHAUST(SEE NOTE 2 AND 4)-4 JIC MALE FUEL INLET (INTERNALFUEL FILTER) (SEE NOTE 5)2.75 (70)12.60 (320)23.24 (590)4.45(113)8.14 (207)2.03 (52)FRONT VIE

PROHEAT M-SERIES G-II PCM SERVICE MANUAL1-3AIR INTAKE OPTION:3" OD SNORKEL SEE NOTE 7AIR INTAKE OPTION:2.25" OD ELBOW WITH 26° ADAPTER PLATE

EXHAUST(SEE NOTE 2 AND 4)-4 JIC MALE FUEL INLET (INTERNALFUEL FILTER) (SEE NOTE 5)2.75 (70)12.60 (320)25.74 (654)5.37(136)8.14 (207)2.03 (52)FRONT VIE

AIR INTAKE OPTION:3" OD SNORKEL SEE NOTE 7AIR INTAKE OPTION:2.25" OD ELBOW WITH 26° ADAPTER PLATESEE NOTE 7CAN BE INSTALLED AT: 26°, 116°, 2

EXHAUST(SEE NOTE 2 AND 4)-4 JIC MALE FUEL INLET (INTERNALFUEL FILTER) (SEE NOTE 5)2.75 (70)12.60 (320)27.24 (692)4.45(113)8.14 (207)2.03 (52)FRONT VIE

CONTENTSA. SAFETY ... A-1SAFETY CONSIDERATIONS ...

AIR INTAKE OPTION:3" OD SNORKEL SEE NOTE 7AIR INTAKE OPTION: 2.25" OD ELBOWWITH 26° ADAPTER PLATESEE NOTE 7CAN BE INSTALLED AT:26°, 116°, 20

G-II PCM ELECTRICAL1.2PROHEAT G-II PCMINDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX)POWER OUTPUT (CONSTANT POW

TORQUE SPECIFICATIONS1.3Solenoid Valve• Lubricate O-ring with diesel fuel.• Install solenoid valve by hand.• Ensure poppet and spring remain in place

Ignition Module• Torque screws (2) 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

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

PROHEAT M-SERIES G-II PCM SERVICE MANUAL1-12

PRINCIPLE OFOPERATIONCOMPONENT DESCRIPTIONSImpeller-style blower driven by the Motor provides the principle combustion air.Drives the Combustion Air B

Coolant is circulated through the heat exchanger via the inlet and outlet ports.Heat is transferred from the heat exchanger through the inner wall of

BLOWER HOUSINGFUELSUPPLYPUMPFUEL REGULATORFUELNOZZLEFUELSOLENOIDVALVEBURNER HEADFLANGE WITH BUILTIN AIR COMPRESSORIGNITION MODULEG-II PCM (PROHEAT CON

THEORY OF OPERATIONThere are four basic systems within the Proheat.The purpose of the Air compressor is to deliver a metered amount of cleancompressed

4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS... 4-364.2.1 Fuel Nozzle ... 4-364.2

An increase in the compressor air pressure over the nozzle will add moreatomized fuel into the combustion tube; however the combustion air providedby

MODES OF OPERATION2.3The G-II Proheat Control Module (G-II PCM) has three modes of operation: Standard,Preheat and Supplemental. Depending on the inst

CAUTIONAlways ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3minutes.If the power is shut off without a proper Cool Down (Purge)

The Motor and Coolant Pump continue to operate for three minutes. After threeminutes, the Motor stops and the PROHEAT enters Standby. The PROHEATwill

CAUTIONAlways ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3minutes.If the power is shut off without a proper Cool Down (Purge)

2-10PROHEAT M-SERIES G-II PCM SERVICE MANUAL

MAINTENANCE TOOLS3.0The following list is the minimum recommended tools to properly service theM-Series. Please refer to the M-Series parts book at ww

3-2PROHEAT M-SERIES G-II PCM SERVICE MANUALMinimum Standard Hand Tools• Digital Multimeter• Ratchet – 3/8" drive• Extension, 12" – 3/8"

TROUBLESHOOTINGAND REPAIR4.0Problems with the PROHEAT and its operation will be indicated in two ways:1.PROHEAT Diagnostic Faults indicated by means o

4.1 SYSTEM AND COMPONENTDIAGNOSTICSThe G-II PCM continually monitors the PROHEAT operating conditions. If the G-IIPCM detects a problem, the indicator

SAFETYA.Throughout this manual, you will see notes labeled DANGER, WARNING,CAUTION, and NOTICE to alert you to special instructions or precautionsconc

LOCKOUT MODE (Requires power to the G-II PCM to be removed and reapplied.)Configuration error on the first occurrence (Status light on solid RED).10 c

4.1.1EXAMPLE PROHEAT BEHAVIOR ERROR – CODE 1The following is an example of M-Series PROHEAT behavior during an faultcondition. The following example s

START Diagnostic Code 1Indicates that the G-II PCM Flame Sensor did not detect a flame or the flamewas too weak to be detected during the FULL 30 seco

PROHEAT fuel filter – Check:a) For filter contamination and restrictions.b) For damaged inlet fitting.Test Procedure – Fuel filter inspection, cleanin

Fuel Nozzle and Fuel Nozzle cavity – Check:a) For Fuel Nozzle and O-ring damage and/or contamination.b)For correct Fuel Nozzle for the PROHEAT BTU rat

• Re-clamp the Fuel Nozzle stem lightly but firmly in a vise using softjaws, take care not to cause damage. Reinstall the distributor andFuel Nozzle h

Air Compressor – Check:a) Air Compressor pressure and operation.Before checking air pressure, remove, disassemble and clean FuelNozzle. Go to Fuel Noz

DIGITALMANOMETER(P/N PK0036)PRESSURE ADJUSTMENT SCREWDECREASEPRESSUREINCREASEPRESSUREFLAMESHIELDDIAPHRAGMCOMPRESSORIGNITIONELECTRODEASSEMBLYFigure 4-9

4-11PROHEAT M-SERIES G-II PCM SERVICE MANUALTest Procedure – Air Compressor pressure (Rotary Vane Compressor models):Ensure fuel nozzle is clean (see

Figure 4-11: Pressure Relief Valve adjustment.PRESSURE RELIEF CAPLOCK NUTPRESSURE RELIEFVALVE BODY4-12PROHEAT M-SERIES G-II PCM SERVICE MANUALm) Adjus

SAFETY CONSIDERATIONSExhaustInhalation of exhaust gas (containing carbon monoxide) may cause severe personalinjury and/or death. Anyone suspected of s

Fuel Solenoid Valve – Check:a) Valve plunger – mechanical fault. Test the PROHEAT operation; FuelSolenoid Valve plunger removed.Procedure – Fuel Solen

e) Using a flat head screwdriver hold the valve stem while loosening the coilnut. Remove the coil.r) Loosen and remove the valve stem. Remove the O-ri

Fuel Regulator and Inlet Screen Plate – Check:a) Check Regulator for damage and/or contamination.b) Check Regulator Screen Plate for contamination.Pro

NOTICEAll plugs/harnesses must be rein-stalled into the G-II Proheat ControlModule (G-II PCM) before heatergoes back into service.m) Using new O-rings

4-17PROHEAT M-SERIES G-II PCM SERVICE MANUALFuel Supply Pump – Check:a) Fuel Supply Pump pressure and operation.Test Procedure – Fuel Supply Pump pres

4-18PROHEAT M-SERIES G-II PCM SERVICE MANUALFuel Supply Pump cleaning:a) Disconnect all harnesses at the G-II PCM.b) Disconnect the fuel supply line.c

4-19PROHEAT M-SERIES G-II PCM SERVICE MANUALFigure 4-21: Fuel Supply Pump Gear Removal.k) Re-install the Fuel Delivery Block using the three original

4-20PROHEAT M-SERIES G-II PCM SERVICE MANUALIgnition Module – Check:a) Ignition Operation using Ignition mode.b) Ignition Electrode check.Test Procedu

4-21PROHEAT M-SERIES G-II PCM SERVICE MANUALf) Switch the PROHEAT on and observe for a spark. Spark will continue forfive seconds.If the spark is OK,

Figure 4-25: Combustion Tube Orientation.ORIENTATION BOSSHEAT EXCHANGER FLANGE NOTCHMOUNTING BOLTSTORQUE = SEE SECTION 1.3G-II PCMSTATUSLIGHTFigure 4-

INTRODUCTIONMODEL: M50, M80, M90,M105, & M125 G-II PCMThis manual is provided to assist in troubleshooting and maintaining thePROHEAT M-Series hea

4-23PROHEAT M-SERIES G-II PCM SERVICE MANUALFLAME OUT Diagnostic Code 2Indicates that a flame was detected but it could not be maintained or afterbein

COOLANT FLOW Diagnostic Code 3Indicates that the coolant temperature in the PROHEAT reached 185°F (85°C)within 90 seconds in Preheat mode or 60 second

4-25PROHEAT M-SERIES G-II PCM SERVICE MANUAL4.1.5(4 Flashes)CAUTIONRepeatedly resetting the PROHEATwithout resolving the Overheatdiagnostic code will

VOLTAGE: Step 2(5 Flashes)VOLTAGE Diagnostic Code 5Indicates that the supply voltage to the G-II PCM is outside the operatingrange for more then 10 se

4-27PROHEAT M-SERIES G-II PCM SERVICE MANUAL4.1.8(7 Flashes)4.1.7(6 Flashes)ci) G-II PCM—Locate and measure across pins C and E in the G-II PCM DataLi

3. Analog temperature sensor open.4. Digital temperature sensor not communicating with the G-II PCM.Troubleshoot the Dual Mode Temperature Sensor Diag

4-29PROHEAT M-SERIES G-II PCM SERVICE MANUAL4.1.10(9 Flashes)4.1.9(8 Flashes)Figure 4-31: Burner Head Removal and Fuel Solenoid Valve Connection.FUEL

IGNITION MODULE Diagnostic Code 10Indicates an open circuit or an over-load fault is detected.Troubleshoot the Ignition Module diagnostic code based o

4-31PROHEAT M-SERIES G-II PCM SERVICE MANUALCOOLANT PUMP Diagnostic Code 11Indicates an over-load fault is detected. (Pump is drawing more than 10 amp

MOTOR Diagnostic Code 12Indicates that a short circuit, over-load or an open circuit fault is detected inprecheck (motor is not running in pre-check).

PROHEAT M-SERIES G-II PCM SERVICE MANUALB-2

4-33PROHEAT M-SERIES G-II PCM SERVICE MANUALMotor replacement:a) Disconnect all harnesses at the G-II PCM.b) Disconnect the fuel supply line.c) Loosen

4.1.15(14 Flashes)ACCESSORY/SWITCH OUTPUT Diagnostic Code 14Indicates a short circuit fault in the harness or the device being operated bythe Switch O

4-35PROHEAT M-SERIES G-II PCM SERVICE MANUAL4.1.16(15 Flashes)INDICATOR OUTPUT Diagnostic Code 15Indicates a short circuit fault (current draw greater

Fuel Nozzle Go to page 4-7, Step 3.Fuel Solenoid Valve Go to page 4-13, Step 4.Fuel Regulator Go to page 4-15, Step 5.Air Compressor Go to page 4-9, S

4-37PROHEAT M-SERIES G-II PCM SERVICE MANUALMOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3COOLANT PUMPSWITCH INPUTDUAL MODE TEMPSENSORPOWERFUEL INLETFigu

c) Loosen and back out the burner head mounting (2) bolts five to six turnsallowing enough room to rotate the burner head 15° counter-clockwiseand rem

4-39PROHEAT M-SERIES G-II PCM SERVICE MANUALProblems with the PROHEAT and/or vehicle application that are notspecifically defined but are observed dur

PROHEAT M-SERIES G-II PCM SERVICE MANUAL4-40

PROHEAT M-SERIES G-II PCM SERVICE MANUAL5-1MAINTENANCE5.0Your PROHEAT has been designed to operate with a minimum of maintenance.To ensure the efficie

PROHEAT M-SERIES G-II PCM SERVICE MANUAL5-21. Clean Heater Enclosure• Clean any accumulated debris or dust from the components.• Make sure the opening

PROHEAT CONTROLMODULE (PCM) TYPEC.The G-I Proheat Control Module (PCM) is no longer available has been replacedwith the G-II PCM. The new G-II PCM inc

BLOW THIS DIRECTIONWHEN USINGCOMPRESSED AIR.PROHEAT M-SERIES G-II PCM SERVICE MANUAL5-36. Check Fuel System• Check the fuel system for damage, cracks

DIGITALMANOMETER(P/N PK0036)PRESSURE ADJUSTMENT SCREWPRESSUREADJUSTMENTSCREWDECREASEPRESSUREINCREASEPRESSUREFLAMESHIELDDIAPHRAGMCOMPRESSORIGNITIONELEC

NOTICEInspect Proheat Control Module (PCM)to ensure that all connectors haveplugs or have an electrical connection.5-5PROHEAT M-SERIES G-II PCM SERVIC

5-6PROHEAT M-SERIES G-II PCM SERVICE MANUALPART # QTY DESCRIPTION200610K 1 Filter, Air, Element880035K 1 Fuel FilterPK0036 1 Digital ManometerPK0067 1

The rotary vane compressor may need service to clean and/or to replace thevanes. This can be indicated by a lack of compressor pressure (page 4-11) or

2. Clean the Rotary Vane Compressora) Remove the nozzle and air relief (see Figure 5-7). If the nozzle stemlooks black, clean as shown on page 4-7 or

g) Disconnect the power cable to remove power and stop motor.h) Disconnect the remote on/off switch.i) Reconnect ignition module connector.j) Reinstal

NOTICEDO NOT loosen the three screwsholding the compressor body (Figure5-9), as it requires special tools toinstall the compressor body back inproper

PROHEAT WARRANTY6.0SeaStar Solutions warrants the PROHEAT Heater to be free of defects in material and workmanshipunder design usage and service condi

6-2PROHEAT M-SERIES G-II PCM SERVICE MANUAL

C-2PROHEAT M-SERIES G-II PCM SERVICE MANUALDUAL MODETEMP SENSORSTATUSINDICATORLIGHTDUAL MODEHAS 4 PINCONNECTORG-II PCMDUAL MODETEMPSENSORANALOG TEMPSE

Proheat Serial Number:Installation Date:Dealer:Printed in Canada 04/14 PID# SL9157CDesigned and Manufacturedin North AmericaSeaStar Solutions3831 No.6