ARMY A-A-59686-2001 PREHEATER ENGINE COOLANT DIESEL-FIRED 24-VOLT DC《24伏直流电柴油燃料发动机冷却预热器》.pdf

1、NOT MEASUREMENTSENSITIVEA-A-59686May 25, 2001COMMERCIAL ITEM DESCRIPTIONPREHEATER, ENGINE COOLANT, DIESEL-FIRED, 24-VOLT DCThe General Services Administration has authorized the use of this commercial itemdescription, for all federal agencies.1. SCOPE. This commercial item description (CID) covers r

2、equirements for diesel-fired enginecoolant preheaters, known hereinafter as preheaters. The purpose of a preheater is to preheatwater-cooled diesel engines that are at ambient temperatures from -18 degrees Celsius ( C)to -46 C (0 degrees Fahrenheit ( F) to -50 F) so they can be started without damag

3、ing theengine. Preheaters bought in accordance with (IAW) this CID should not be used on systemswith operational ether start. Type 1 and type 2 preheaters are recommended for enginedisplacements of up to 8 liters (L) (488 cubic inches (in 3 ); Type 3 preheaters are recommendedfor engine displacement

4、s of 9 to 12.5 L (549 to 763 in 3 ).2. CLASSIFICATION. Preheaters shall be of the following types:Type 1 - 2.2 to 5.0 kilowatts (kW) ( 7,5 00 to 17,000 British thermal units per hour(Btu/hr) capacity, with enclosed heater/water pump assembly.Type 2 - 2.2 to 5.0 kW capacity, with heater and water pum

5、p supplied separately, toaccommodate space limitations on host vehicles.Type 3 - 1.5 to 9.0 kW (5,000 to 31,000 Btu/hr) capacity, with enclosed heater/waterpump assembly.Beneficial comments, recommendations, additions, deletions, clarifications, etc. and any datathat may improve this document should

6、 be sent by letter to : U.S. Army Tank-automotive andArmaments Command, ATTN: AMSTA-TR-E/IE, Warren, MI 48397-5000.AMSC N/A FSC 2990DISTRIBUTION STATEMENT A . Approved for public release; distribution is unlimited.Provided by IHSNot for ResaleNo reproduction or networking permitted without license f

7、rom IHS-,-,-A-A-5968623. SALIENT CHARACTERISTICS.3.1 Materials . Unless specified herein, materials shall be IAW the manufacturers materialspecifications. The use of recovered material made in compliance with regulatory requirementsis acceptable providing that all requirements of this CID are met (s

8、ee 4).3.1.1 Dissimilar metals . Dissimilar metals shall electrically insulated from one another toprevent galvanic corrosion.3.1.2 Fuel resistance . Preheater components that are exposed to fuel shall be resistant to damagecaused by direct contact with the fuel (see 3.2.7.1).3.1.3 Corrosion resistan

9、ce . Preheater components shall be fabricated from compatible materials,inherently corrosion resistant or treated to provide against corrosion and deterioration duringstorage and operation.3.1.4 Hazardous materials . Asbestos and cadmium-plated components shall not be used in thepreheater or any of

10、its components.3.2 Design and construction .3.2.1 Type 1 preheaters . Type 1 preheaters shall have a minimum of two heat settings(high/low) and shall have a heat output capacity of 2.2 to 5.0 kW. Type 1 preheaters shall beprovided with a heater/water pump assembly enclosed in a weather resistant enc

11、losure or boxwith a quick release cover for easy access (see 3.2.6). Type 1 preheaters shall have all interfaceconnections within the enclosure or surface mounted on the exterior of the enclosure. Type 1preheaters shall be provided with the components specified in table I.3.2.2 Type 2 preheaters . T

12、ype 2 preheaters shall have a minimum of two heat settings(high/low) and shall have a heat output capacity of 2.2 to 5.0 kW. Type 2 preheaters shall beprovided as a “kit”, with individual components supplied for specialized installation within ahost vehicle, where space is limited. The kit shall con

13、tain all necessary components for acomplete installation into the host vehicle, including, but not limited to those specified in table I.3.2.3 Type 3 preheaters . Type 3 preheaters shall have a minimum of four heat settings(boost/high/medium/low) or variable heat output, and shall have a heat output

14、 capacity of 1.5 to9.0 kW (see 7.5). Type 3 preheaters shall be provided with a heater/water pump assemblyenclosed in a weather resistant enclosure or box with a quick release cover for easy access(see 3.2. 6). Type 3 preheaters shall have all interface connections within the enclosure or surfacemou

15、nted on the exterior of the enclosure. Type 3 preheaters shall be provided with thecomponents specified in table I.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-596863TABLE I Preheater component list .Component Type 1 Type 2 Type 3Heater/water

16、pump, enclosed X XHeater/water pump, separate XFuel metering pump X X XFuel hose, pressure, 6.1 meters (m) (20 feet (ft.), with clamps X X XFuel hose, suction, 1.8 m (6 ft.), with clamps X X XControl unit/timer and harness (see 3.2.8 and 3.2.9) X X XElectrical harnesses, electrical connectors and wi

17、ring XExhaust pipe X X XFuel tank pick-up pipe and connections X X XMounting brackets/fasteners X X XCoolant hoses and connectors XData plates X X XOperator/maintenance/installation manuals X X X3.2.4 Power requirements . Preheaters shall start and operate at applied voltages between20 - 28.5 volts

18、(V) direct current (dc). Preheaters shall cycle for up to two hours after eachstart -up unles s the operator manually turns it off or a fault occurs. Preheaters shall shut offwhenever low voltage (20 V or less) is detected. Maximum electrical power consumption withwater pump at 24 V shall be as spec

19、ified in table II.TABLE II. Power consumption .Power, watts (W)Preheater typeBoost setting High setting Low setting1 and 2 - 55 353 125 85 373.2.5 Weight and size . Preheater and weather-resistant enclosure shall not exceed the weightsand sizes specified in table III.TABLE III. Weight and size restr

20、ictions .Preheater type Weight, kilograms (kg) (pounds ( lb) Size, millimeter (mm) (inch (in.)1 10.0 (22) 150 x 320 x 240 (6.0 x 12.5 x 9.5)2 1 / 5.0 (11) 250 x 110 x 200 (10.0 x 4.5 x 8.0)3 21.0 (46) 430 x 300 x 230 (17.0 x 12.0 x 9.0)1 / As type 2 preheaters have no enclosure, the restrictions are

21、 for the heater (see 3.2.2).3.2.6 Preheater enclosure . Type 1 and type 3 preheaters (see 3.2.1 and 3.2.3) shall come with anenclosure that can be secured (bolted shut or locked with a padlock). The enclosure shall protectpreheater from outside environment (rain, humidity, dust, snow, salt, engine f

22、luids).Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5968643.2.7 Interfaces and compatibility .3.2.7.1 Fuel compatibility . Preheaters shall operate on and be compatible with diesel fuels IAWA-A-52557, MIL-DTL-83133 (JP-8), ASTM-D1655 (Jet A-1)

23、 and MIL-DTL-5624 (JP-4).3.2.7.2 Coolant compatibility . Preheaters shall be compatible with ethylene glycol (Type IP)and propylene glycol (Type II) based antifreezes IAW A-A-52624. Preheaters shall also becompatible with antifreeze having corrosion inhibitors IAW MIL-A-53009.3.2.7.3 Electrical inte

24、rface . Preheaters shall come with all required wiring harnesses, fuses,relays and mounting hardware, and shall have quick-disconnect waterproof connectors. Allwires shall be distinguishable from each other and match those in the schematic and electricaldiagram provided in the preheater manual and i

25、nstallation instructions.3.2.7.3.1 Type 1 and type 3 . The electrical power harness and preheater control unit (on/off)harness shall terminate at MS connector MS3102 E 20-16P (see table IV), surface mounted onthe exterior of the enclosure for connection with the vehicle harness (power, control, diag

26、nostic).TABLE IV. MS3102 insert arraignment .Pin designation Gage CircuitA 16 Fuel pump positive (+)B 16 Fuel pump negative ( -)C 16 Control (+)D 16 Control ( -)E 16 Heater enableF 16 Heater diagnosticsG 16 Free terminalH 12 Battery (+)I 12 Battery ( -)3.2.7.3.2 Type 2 . The electrical power harness

27、 and preheater control unit (on/off) harness shallbe 3.0 m (10 ft.) in length, shall terminate with MS3102 E 20-16P, and shall be capable of beingshortened during installation. Pins on all connectors shall be clearly labeled and coded forinterchangeability between manufacturers.3.2.7.4 Water/coolant

28、 interface .3.2.7.4.1 Type 1 and type 3 . The preheater coolant inlet/outlet ports shall be 3/4 in. outsidediameter ( O.D.), labeled and extended through the enclosure.3.2.7.4.2 Type 2 . The preheater coolant inlet/outlet ports shall be 3/4 in. O.D, and shall beprovided with all the required clamps

29、for connections at the inlet, outlet and water pump.3.2.7.5 Air intake/exhaust interface . Preheater intake and exhaust ports shall accept combustionair intake and exhaust pipes. Preheaters shall come with a flexible 1 .8 m long exhaust pipe,which can be shortened. All required clamps shall be inclu

30、ded.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5968653.2.7.6 Fuel interface . A self-priming fuel pump for pumping fuel from the host engine fueltank to the preheater shall be included with the preheater. Fuel pump installation instructionss

31、hall clearly identify the method of mounting the fuel pump relative to the heater, fuel tank andvertical and horizontal planes. Fuel pump electrical harness shall be 152 mm (6 in.) in length,and terminate in MS3100E10SL-4P, for connection with the vehicle harness. A fuel tankstandpipe or pickup pipe

32、 shall be provided for withdrawing fuel from the host vehicle fuel tank.Preheaters shall come with all connecting hardware, including but not limited to, hose clampsand 6.1 m of fuel pressure line. Preheaters shall be provided with 1.8 m of suction line.3.2.8 Preheater control unit . Preheaters shal

33、l have a control unit to enable the operator tomanually turn the preheater on and off. A light next to or part of the control unit shall clearlyidentify to the operator whether or not the preheater is working when the switch is set to the onposition. The control unit shall have provisions for instru

34、ment panel mounting and shall be fittedwith MS3100E14S-2P, for connection with vehicle harness. For type 3 preheaters, the controlunit shall also function as a fault code retrieval device for the preheater diagnostics specifiedin 3.2.10.3.2.9 Timer . When specified (see 7.3), preheaters shall be equ

35、ipped with a programmable7 -day, 24 -hour timer in place of the control unit (see 3.2.8). The timer shall function as thecontrol unit and allow the user to preset up to 3 different preheater start and stop times per day.The preset times shall require activation of the preset timer after each use of

36、preheater. Thetimer shall also function as a fault code retrieval device for the preheater diagnostics specifiedin 3.2.10. The time r shall have provisions for instrument panel mounting and shall be fitted withMS3100E14S-2P, for connection with vehicle harness.3.2.10 Preheater diagnostics . When equ

37、ipped with the optional timer (see 3.2.9), preheatersshall have diagnostic capability to diagnose operational faults. When not equipped with theoptional timer, only type 3 preheaters shall have diagnostic capability. At a minimum, thediagnostic capabilities provided shall include low battery, no coo

38、lant, low coolant, no fuel,overheat, open circuit, short circuit, defective fuel pump, defective coolant pump, bad flame andbad glowplug. If the preheater fails to start after three attempts, it shall automatically exit thestart mode, diagnose the fault and indicate the reason for the failed start w

39、ithin five minutes ofinitial start attempt. Diagnostic fault codes shall be in the form of distinguishable audio or visualsignals. A decal or data plate with fault code definitions shall be mounted in a visible locationinside of the heater enclosure on type 1 and type 3 preheaters. Type 2 preheaters

40、 shall come witha fault code definition decal for users to mount.3.2.11 Overheat protection . Preheaters shall have an overheat switch that stops operation of thepreheater in cases of low coolant, no coolant and overheating (coolant temperature in excess of93 C (200 F).3.3 Performance . After each s

41、tart the preheater shall bring the coolant temperature at the heaterwater pump inlet up to 72 C (162 F) and maintain it between 72 C and 85 C (185 F) duringoperation.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5968663.3.1 Engine cold start .

42、Preheaters shall be able to preheat a cast iron diesel engine, cold-soakedto -46 C , to a temperature of 32 6 C ( 90 10F) at the water pump inlet, within one hour afterthe preheater is turned on.3.3.2 Fuel consumption . Preheater fuel consumption shall not be greater than as specified intable V.TABL

43、E V. Fuel consumption .Fuel consumption, liters per hour (L/hr)(gallons per hour (gal/hr)Preheater typeBoost setting High setting Low setting1 and 2 - 0.62 (0.14) 0.30 (0.07)3 1.20 (0.26) 0.91 (0.20) 0.24 (0.05)3.3.3 Environmental conditions . Preheaters and all components, including optional timer,

44、 shallreliably start and operate at ambient temperatures from -46 to 21 C ( -50 to 70 F) within fourminutes after activation by operator or by timer. Preheater and control unit shall be able towithstand extended storage at temperatures ranging from -46 to 49 C ( -50 to 120 F).3.3.4 Noise . Preheater

45、 steady state noise shall not exceed 85 decibels ( dB(A) at a radius of2.44 m (8 ft.).3.3.5 Vibration . Preheaters shall be able to withstand shock and vibrations of at least3 gravitational units (g) without breakage, loosening of parts, leakage, abrasion, or other physicaldamage.3.3.6 Electromagnet

46、ic compatibility . Electromagnetic energy from wiring harnesses/electricalsystem shall not interface with operation of electrical systems on board or near vehicles. Whenspecified (see 7.3), preheaters shall be IAW MIL-STD-461.3.3.7 Slope and grade . Preheaters shall function and shall not leak or su

47、stain damaged when thehost vehicle is operating on grades of up to 60% up hill or down hill and side slopes of up to40%. Preheaters shall be able to operate without malfunctioning when mounted on a vehicleparked on 15% slope in any direction.3.3.8 Smoke density . Within 7 minutes after preheater has

48、 started, its exhaust gases shall notexceed a smoke spot number of three IAW ASTM-D2156.3.4 Color . The color of the preheater enclosure shall be Green 383, IAW Drawing 12369003.3.5 Safety . All preheater components subject to high operating temperatures or energizedelectrically shall be insulated,

49、enclosed or guarded. All preheaters shall comply with Departmentof Transportation (DOT) standards in effect on date of manufacture.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-A-A-5968673.6 Manuals and installation instructions . Preheaters shall come with an operator manual and amaintenance manual. Operator manual shall include instruction for operating a basic preheaterpl