Smartgen Hwp120 Engine Heater User Manual

HWP120 Engine Heater

HWP Series Forced Circulation Heater

The HWP series forced circulation water engine heater is
designed to provide heating for various engines with a displacement
of 15~100 liters. It is composed of three parts: the control
section, water pump, and water heater. The heater features cast
stainless steel inner pipes and end closure, providing high
corrosion resistance. It also includes heating and overheat light
indicators, a user-defined thermostat set point, and dry heating
and overheat protection.

To select the appropriate heater for your engine, please visit
our company’s official website www.smartgen.cn.

Performance and Characteristics

• The circulating water pump adopts a special customized pump
  with a stainless steel pump head.
• The control section is designed with a microprocessor and PT100
  temperature sampling. The coolant temperature can be set via the
  control panel, and the current coolant temperature and set point
  temperature can be displayed on the four digital LED display.
• Dry heating and overheat protection are provided by an inner
  overheating temperature detect switch.
• The water pump and water heater can be separately controlled.
  When the set temperature is reached, the water heater will be
  powered off first, followed by the water pump after 60 seconds.
  This helps prevent heat concentration and prolongs the water pump’s
  lifetime.
• A manual test function allows you to check if the water heater
  and water pump are functioning normally via the panel button.
• The heater is enclosed in a fine cast aluminum enclosure, and
  the inner pipes and sealed end closure are made of stainless
  steel.
• A water drain valve with a seal ring is located at the bottom
  of the heater for easy drainage when needed.
• There is a one-way inlet valve on the water inlet.
• The product can work normally at temperatures as low as
  -25°C.

Specification

HWP SERIES (HWP40/ HWP60/ HWP90/ HWP120)
FORCED CIRCULATION HEATER
USER MANUAL

Chinese trademark
English trademark SmartGen — make your generator smart SmartGen Technology Co., Ltd.
No.28 Jinsuo Road, Zhengzhou, Henan Province, China Tel: +86-371-67988888/67981888/67992951
+86-371-67981000(overseas) Fax: +86-371-67992952 Email: [email protected] Web: www.smartgen.com.cn
www.smartgen.cn
All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Smartgen Technology at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. SmartGen Technology reserves the right to change the contents of this document without prior notice.

Date 2014-07-08 2015-04-10 2016-01-22 2016-07-12
2017-11-11
2018-03-22 2022-05-09

Version 1.0 1.1 1.2 1.3
1.4
1.5 1.6

Table 1 – Software Version
Note Original release. Add types HWP60, HWP90, HWP120, remove type HWP30. DC pump has been updated to AC pump. Modify relay expansion board type. Modify relay expansion board & wiring connection diagram, and add AC contactor. Modify wire connection diagram. Add the description of precautions for pipeline installation.

CONTENT
1. OVERVIEW………………………………………………………………………………………………………………………………….4 2. PERFORMANCE AND CHARACTERISTICS…………………………………………………………………………………….4 3. SPECIFICATION ………………………………………………………………………………………………………………………….5 4. HEATER INSTALLATION ……………………………………………………………………………………………………………..6 5. OPERATING INSTRUCTIONS ……………………………………………………………………………………………………….7 5.1. PANEL AND BUTTON……………………………………………………………………………………………………………7 5.2. DISPLAY DESCRIPTION ………………………………………………………………………………………………………..8 5.3. PANEL DESCRIPTION …………………………………………………………………………………………………………..8 5.4. OPERATION DESCRIPTION …………………………………………………………………………………………………..8 6. USE AND MAINTENANCE ……………………………………………………………………………………………………………9 7. CONNECTIONS ……………………………………………………………………………………………………………………….. 11 8. CASE AND DIMENSIONS………………………………………………………………………………………………………….. 12

HWP Series Forced Circulation Heater

Page 3 of 12

1. OVERVIEW HWP series forced circulation water engine heater is composed of 3 parts (control section, water
pump and water heater). If during cranking the outside temperature is lower than 4ºC, engine coolant and lubricant may
condense into solid state and lose their lubricating and cooling properties, which can damage the engine. Thus engine heater should be installed to ensure normal starting and running of the engine when the outside temperature is lower than 4 ºC.
HWP series forced circulation water engine heater combines the following features: cast stainless steel inner pipes and end closure with high corrosion resistance; heating and overheat light indicators; user-defined thermostat set point; dry heating and overheat protection.
This product is suitable for various engine with (15~100) L displacement. Please login our company’s official website (www.smartgen.cn) to select heaters.
2. PERFORMANCE AND CHARACTERISTICS
— The circulating water pump adopts special customized pump with stainless steel pump head. — Control section: microprocessor design; PT100 temperature sampling. Coolant temperature can be
set via the control panel. Four digital LED display, current coolant temperature and all kinds of set point temperature can be displayed clearly.
— Dry heating and overheat protection due to the inner overheating temperature detect switch. — Separately control of water pump and water heater: power on the water pump and water heater
synchronously, once the set temperature has reached, water heater will be powered off firstly, after 60s, following is water pump. The goal is to prevent heat concentration and significantly prolong water pump lifetime.
— Manual test: test the water heater and water pump are normal or not via panel button. — Fine cast aluminum enclosure; — Stainless steel inner pipes and sealed end closure; — There is a water drain valve with seal ring on the bottom of the heater so as to be used when
needed;
— There is one-way inlet valve on the water inlet. — This product can work normally at -25 temperature.

HWP Series Forced Circulation Heater

Page 4 of 12

3. SPECIFICATION

Table 2 ­ Parameters Specification

Type Rated Power Rated Voltage Rated Current Phase Engine Displacement (L) Thermostat Range Default Thermostat Range Overheating Thermostat Range Insulating Resistance Electrical Strength Inlet/Outlet Size Max. Water Pressure Pump Flow Velocity Protection Level
Vibration Resistance
Shock Resistance Working Conditions Storage Conditions Case Dimensions Weight

HWP40 4000W AC 240V 16.7A Single phase 15~30 Off: (5~99)ºC Off: (40±2)ºC

HWP60 6000W AC 420V 8.3A Three phase 25~50 On: (0~94)ºC On: (25±2)ºC

HWP90 9000W
12.5A
50~75

Off: (95±3)ºC On: (80±6)ºC

50M AC 1.5kV 1min 3/4″(19.5mm) 0.5MPa 40L/min (1.5m of lift) IP44 (5~8)Hz Amplitude±7.5mm Triaxial (8~500)Hz a=2g Triaxial Half-sine Wave; apeak=50g; Triaxial -25 ºC~+70 ºC -30 ºC~+70 ºC 444 mm×270 mm×380 mm 14kg

HWP120 12000W
16.7A
75~100

HWP Series Forced Circulation Heater

Page 5 of 12

4. HEATER INSTALLATION Please install the heater vertically according to the diagram before use. Pay attention to the
direction of heater inlet and outlet, and ensure that the heater position is below the lowest water lever of the engine and that all the air is exhausted out of the heater and it is topped off with coolant.
Fig.1 – Installation Plane Schematic

Fig.2 ­ Installation Side Schematic HWP Series Forced Circulation Heater

Page 6 of 12

Fig. 3 ­ Incorrect Pipe Connection Methods
NOTE: If there is a W-shaped bend or reverse U-shaped bend during pipe connection, the air accumulated in the pipe cannot be discharged normally, resulting in the liquid cannot be circulated properly. The air dissolved in the liquid will be precipitated during heating and retained in the bend, so on the condition of unsmoothed pipeline, even if by the manual exhaust, it will repeat in the next heating process of air collection. To ensure that the smooth liquid circulation, the hosepipe with an inner diameter of more than 20mm and pipe joints with an inner diameter of more than 15mm should be selected.

Fig. 4 ­ Assembly Structure 5. OPERATING INSTRUCTIONS 5.1. PANEL AND BUTTON
Table 3 ­ Panel Display and Buttons

Button

Definition

Description

Test

Pressing this button will test-run the machine.

Lamp Test

All indicators will be illuminated when the button is pressed.

Set

Using this button you can set the temperature value.

Turn Page

Using this button you can scroll pages of the LED Nixie Tube; and adjust the value.

HWP Series Forced Circulation Heater

Page 7 of 12

5.2. DISPLAY DESCRIPTION

The heater is heating on when the “Heating” indicator is illuminated while the Thermostat is open and the heater stops heating when the “Overheat” indicator is flashing.

Temp. Display: OFF

Temp. Display: ON

Temp. Display: Current Temp. Alarm: Sensor Abnormal 5.3. PANEL DESCRIPTION

5.4. OPERATION DESCRIPTION

Fig.5­ Operation Panel Drawing

Turn Page( ) Using this button you can scroll pages of the LED Nixie Tube and adjust the value. Test( ) If the water temperature has exceeded the preset “ON” temperature, pressing this button will test-run the heater, after 3s, it turns into Auto mode automatically. Lamp Test( ) All indicators will be illuminated when the button is pressed. Set( )

Pressing this button will enter into setting interface, as shown:

(Letter “H” means

that it is the preset “OFF” temperature, here we take 40 as example)the first digital is flashing and

you can adjust it by pressing

button. Then press

button, the second digital will flash and the

HWP Series Forced Circulation Heater

Page 8 of 12

adjust way is same as the first digital. Press , as shown:

(Letter “L” means that it

is the preset “ON” temperature, here we take 25 as example)the first digital is flashing and you

can adjust it by pressing

button. Then press

button, the second digital will flash and the

adjusting way is same as the first digital. After doing these, press

button, the LED will back the

current temperature. All the adjustment should be saved and not lost even when power is off.

6. USE AND MAINTENANCE

Before starting the machine, ensure that all the air is exhausted out of the heater and it is topped off

with coolant, and make sure that the pump is full of water by using vent valve.

Fig.6 ­ Vent Valve Indicating Diagram If water is used, please drain it off when generator is stopped to avoid internal corrosion. Otherwise, the remaining water freezes when temperature is lower than 0°C, which can damage the enclosure.
Corresponding antifreeze is strongly recommended. Using tap water or river water will scale the surface of heating pipe and shorten the using life of the heater.
Earth line must be soundly connected to earth.
Drain valve: Can be opened or closed using hexagonal tools.

HWP Series Forced Circulation Heater

Page 9 of 12

Fig.7- Water Drain Valve
Common Faults and Solutions: 1. Overheat protection: a. Check the valve to assure whether it is opened and whether the heater is full of water; b. Check whether the hosepipe has an obvious W-shaped or reverse U-shaped trend, and whether there is an obvious hot and cold alternating area; Solutions: Shorten the hosepipe length and optimize the hosepipe trend; 2. High water outlet temperature: under normal circumstances, the outlet temperature is about 70. It occurs when the hosepipe is too long, both the inner diameter of the hosepipe and the inner diameter of the fitting joints are too small, as well as the water flow is not smooth so that the heat cannot be transferred properly. Solutions: Shorten the hosepipe length, using the hose with an inner diameter of more than 20mm, and the connectors with an inner diameter of more than 15mm. 3. Unable to reach the preheating temperature: a. The heater power is not enough; b. The cable of the power supply is too long and result in dividing resistance of the cable; Solutions: 1. Replace the heater whose power matches the engine; 2. Shorten the power cable as possible and increase the cable diameter.

HWP Series Forced Circulation Heater

Page 10 of 12

7. CONNECTIONS Fig.8 – HWP40 Diagram

Fig.9 – HWP60HWP90HWP120 Diagram Use 4mm2 power line for tie-in. Earth line must be soundly connected to earth.
HWP Series Forced Circulation Heater

Page 11 of 12

8. CASE AND DIMENSIONS

unit: mm

Fig.10 ­ Overall Dimensions Note: all the inlets/outlets connectors are Pagoda-shape.
_________________________________

HWP Series Forced Circulation Heater

Page 12 of 12

References

• 众智科技
• 众智科技
• 众智科技
• 众智科技