Pacbrake PowerHalt PH2 User manual

InstallationManual
www.powerhalt.com
AIR INTAKE EMERGENCY SHUT-OFF VALVE
AIR INTAKE EMERGENCY SHUT-OFF VALVE
PH2 AIR INTAKE EMERGENCY SHUT-OFF VALVE
AUTO / MANUAL / ELECTRIC WITH PULL CABLE
WITH POWERGUARD SMART OVERSPEED LIMITER*
*COMES WITH AUTOMATIC ACTUATION ONLY
L6372_REV6.17.04.2018
ECN 1-1859

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INSTALLATION REQUIREMENTS & RECOMMENDATIONS:
Prior to the installation, please read through the requirements and recommendations listed below so you have
a clear understanding of your system and the location you plan to install the shut-off valve.
If you cannot meet these requirements, or are unsure of your system, please contact your dealer or PowerHalt
representative and we can work with you to overcome your installation constraints and challenges.
PowerHalt Technical Representative can be reached Monday-Friday 6:00-4:30 (PST) at 800.663.0096
• A 1" clearance is required from the valve to any other components. The valve can be in any orientation.
• Maximum air temperature at the valve should not exceed 120°C. On a turbo-charged engine,
‘Option B’ (see diagram below) should be the last option due to high temperatures. (There are special
options available for higher temperatures, contact Pacbrake).
• Allhoses,adapters,andttingsmustbesuitableforthevibrationoftheengineapplication,
and of reinforced type. *If unsure of your vibration requirement, contact Pacbrake.
• Flexible hose gaps should be kept to a minimum and the overall pipe quality and integrity
 fromtheshut-offvalvetotheintakemanifoldshouldbeconrmed.
NOTE: - Failure to ensure this may result in hose collapse during valve activation and
possible system leaks, preventing engine shutdown
- For excessive vibration applications, and installations with long pipe runs,
additional support brackets may be required.
• Ifanairintakeametrapisused,thevalvemustbeinstalledupstreamofthetrap.
• Crankcase breather connections in the intake system between the valve and engine
(or in engine intake parts) must be sealed and replaced by an external breather.
• If you need to cut the existing intake piping to allow for the shut-off valve installation, please make sure to
cut the pipe off of the engine and that it is cleaned thoroughly to ensure no shavings are present.
NOTE: Failure to do so may result in engine damage caused by foreign debris ingesting into the engine.
• Itishighlyrecommendedthatthepipeisrolledwithabeadtoensurehosettingretentiononboththeinlet
and outlet sides of the shut-off valve.
• If more than one shut-off valve is installed on one engine it is imperative that the control method is
consistent with this requirement, ensuring valve activation is simultaneous for both valves.
In order of preferred location to least preferred
1
st POST INTERCOOLER
■Low Plumbing Leakage Risk
■Moderate Charge Air Temperature
■Fast Shutdown Response Time
2
nd POST TURBO
■Moderate Plumbing Leakage Risk
■High Charge Air Temperature
■Moderate Shutdown Response Time
3
rd PRE TURBO
■High Plumbing Leakage Risk
■Low Charge Air Temperature
■Slow Shutdown Response Time
1
st
2
nd
3
rd
ACCEPTABLE
(Not recommended)
OPTIMAL
(Recommended)
PERFORMANCE

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KIT LAYOUT
Please ensure that you have all the parts listed in this kit before you start the installation.*
This Manual L6372 supersedes L6336.
REQUIRED TOOLS
• Drill
• 1⁄2" Unibit
• Ratchet with 7⁄16"& 1⁄2" Sockets
(a 14″extension is ideal)
• Hack Saw
• Utility Knife
• Torque Wrench
KIT CONTENTS
A (1) PH2 Manual / Electric with Pull Cable Shut-off Valve.
B (8) Tie Straps
C (4) Pre-Tension Clamps
D (2) Silicone hose
E (1) Wiring Harness (Automatic Actuation Harness Shown)
F (1) PH2 PowerGuard Controller (Automatic Actuation Only)
G (1) Mag Pick-up (Automatic Actuation Only)
H (1) Override Switch
I (1) Pull Cable with T- Handle (2 Supplied with Dual Pull Cable Kits)
J (1) Pull Cable Nameplate (2 Supplied with Dual Pull Cable Kits)
A
B
C
D
E
FG
H
I
J
*NOTE: Complete kit contents shown above, contents may vary for custom applications
*Microswitch where applicable

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Thank you for your purchase of a PowerHalt Air Intake Emergency Shut-Off Valve by Pacbrake.
Please read the entire manual before beginning to ensure you can complete the installation once started.
Should you have any issues during the installation, please call technical support at 800.663.0096.
2A
CORRECT
INCORRECT
2B
1VALVE INSTALLATION
Disconnect the battery.
Remove the engine panels or covers to gain access to
the intake hose location where the shut-off valve will be
installed.
2Remove the stock clamps and hoses from the air cleaner
and intake manifold.
Take the provided silicone hoses, install them on the air
cleaner outlet and intake manifold.
NOTE: Ensure the hoses are fully sealed onto the valve
(see photo 2B).
3Install the provided pre-tension clamps on the hoses and
leave them loose.
4Install the PH2 valve into the hoses openings. After the
installation, rotate the valve accordingly; ensuring the pull
cable armature is in the upright position.
5Torque all 4 clamps to 70- 80 in-lbs (7.9 - 9 N•m).

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6A
6B
6C
6D
1
2
31 4
2
FIGURE 6A
1 T- Handle Bulk Head Fitting
2 M10 Nuts
3 M10 Flat Washers
4 M5 Nut
5 T- Handle
FIGURE 6B
1 Threadedendtting
2 M8 Pretention adjusting nuts
3 M8 Flat washers
4 Cable Ball End
FIGURE 6C
1 Coupling Sleeve
FIGURE 6D
1 Activation Pin
1334
225
1
6 PULL CABLE PARTS IDENTIFICATION
COUNTERBORE

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7B
7C
8B
INCORRECT
CORRECT
8A
7Insert the Cable ball end into the activation pin. (See photo 7A)
Install the Coupling sleeve over the activation pin, align the slot
to allow the cable to pass through the coupling sleeve.
NOTE: One end of the coupling sleeve has a counter bore, this
end must go towards the activation pin. (See photo 7B)
Rotatethecable90°,andinsertthethreadedendttingintothe
slot on the attaching bracket, with one M10 nut and washer on
either side of the bracket. (see photo 7C)
For valves with dual pull cables, repeat steps 7.
8 Cable pretension is achieved when the T-handle M5 jamb nut is
justbeingpulledagainstthreadedendofthebulkheadtting.
Adjustthethreadedendtting,M8adjustingnut,withatwoM14
wrenches to ensure the cable pretension is correct.
NOTE: The Coupling sleeve must be held from moving, this is
achieved with proper adjustment of the threaded end tting.
Torque adjusting nuts to 11 +/- 1 ft-lbs (15 +/- 1.3 N•m).
Torquethenutsofthethreadedendttingtothevalvebracketto
9 +/- 1 ft-lbs (12 +/- 1.3 N•m). Installed in step 7.
NOTE: Secure the pull cable with the provided tie straps, away
from any moving parts or high heat sources.
NOTE: A MINIMUM BEND RADIUS OF 4" MUST BE MAINTAINED.
7A

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MANUAL KIT INSTALLATION
9SWITCH INSTALLATION
Locate the desired location for the activation switch in your cab
or control panel.
NOTE:
• Activation switch should be as close to driver’s side door as
possible to allow for shutdown when standing outside of the
vehicle
• Consider the dash construction, as the switch requires a single
dash wall for install unless the double wall is modied
• DO NOT ACTIVATE THE MANUAL SWITCH FOR
MORE THAN 10 SECONDS.
Damage to the solenoid may occur
10 Drill a ½" hole in the desired location.
11 Install the toggle switch through the backside of the dash and
thenremovethenameplatecoverlmandinstallthenameplate,
toggle cover, and lock washer as shown in picture.
Tightenlockwasherrmly.
NOTE: If the dash cannot accept the switch nameplate, use the
toggle sticker and install onto the switch cover as shown.
12 ELECTRICAL WIRING (MANUAL ACTIVATION)
Connect the relay, toggle switch, power source and valve
solenoid as per schematic on page 11.
9A
9B
9C

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AUTOMATIC KIT INSTALLATION
13 POWERGUARD INSTALLATION
Locate a suitable location for the PowerGuard controller. It is
recommended that the controller be within a compartment and in
alocationthatisprotectedfrommechanicaldamage.Aat
(7" x 7") space is required to mount the controller.
Use 2 self-tapping screws or 2 cap screws (not provided) to
fastenthecontrollerrmlyinplace.
Connect the wiring harness’ grey and black connectors as per
the wiring schematic provided at the back of this manual to the
PowerGuard controller (see page 11).
NOTE: Ensure the PowerGuard controller is not mounted in
locations that are exposed to high pressure water or locations
which can exceed ambient temperatures of 80°C
14 SWITCH INSTALLATION
Locate a convenient location on the control panel (see photo
14A) to install the PowerHalt shutdown switch. Drill a ½” hole in
the control panel for the switch installation.
Install the toggle switch through the backside of the control
panelandthenremovethenameplatecoverlmandinstallthe
nameplate, the switch cover, the washer, and the nut (see photo
14Band14C).Torquethenutrmly.Connectthewiringharness
lead with the 2 blue spade connectors to the override switch.
15 POWER INSTALLATION
Route the harness leg with the 15 AMP fuse and Ground wire to
the Engine battery location as per the wiring schematic provided
(see page 11).
Connect to the Power and ground lugs.
NOTE: Secure the wiring harness with the provided tie straps
away from any moving parts or high heat sources.
14A
14B
14C
13A

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16 MAGNETIC PICK UP INSTALLATION
Inspect the engine for a suitable location on the Bell Housing
for a magnetic pick-up. Ensure this location is accessible and
centeredovertheywheelringgears.
NOTE: If a ywheel inspection chamber is present then use this
to determine the center position for drilling.
Drill and tap as required based on your magnetic pick-up
SuggestedTorquespecicationsbelow.
Suggested Torque:
Magnetic pick-up diameter 3⁄8 - 24 is 4 ft-lbs
Magnetic pick-up diameter 5⁄8 -18 is 20 ft-lbs
Magnetic pick-up diameter 3⁄4 - 16 is 62 ft-lbs
Install the provided magnetic pick-up (mag) into the new tapped
hole on the Bell Housing. Thread in all the way until the mag
contacts the ring gear. Once this happens back off a ½ turn. Use
hand tap to clean port threads if necessary. Tighten the jam nut
securely as per the suggested torque.
Route the mag pick-up wiring to the mag location on your engine
and connect the weather-pack connector.
NOTE: Secure the wiring harness with the provided tie straps.
Away from any moving parts or high heat sources.
17 VALVE WIRING INSTALLATION
Route the harness leg with 2 pin Metri-Pak to the PowerHalt
valve. Connect the connector to the mating connector on
the valve.
NOTE: Secure the wiring harness with the provided tie straps
away from any moving parts or high heat sources.

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VALVE CLOSED
(TRIPPED)
VALVE OPEN
(RUN POSITION)
POST INSTALLATION TESTING OF YOUR POWERHALT SHUT-OFF VALVE
Once the installation is complete, ensuring that all the steps, schematics and recommendations have been
followed, it is time to test your system.
1. Activate the manual switch (no engine running).
NOTE: DO NOT ACTIVATE THE MANUAL SWITCH FOR MORE THAN 10 SECONDS.
Damage to the solenoid may occur
2.Viewvalveandconrmvalvehastripped.Theresetknobshouldbeinthetrippedposition
Thiswillhavethelinedirectionontheresetknob,perpendicularfromtheairowdirection.
3. Reset the valve.
4. Activate both pull cable stations.
5. Reset valve.
6. Start the engine and run.
7. Activate the PowerHalt shut-off valve by pushing the test button on the PowerGuard Controller for
at least 3 seconds. The engine should stop within a few seconds.
•Iftheenginedoesnotshutdowninthespeciedtimepleasecheckallintakepipingandhoses
for leaks between the valve and intake system.
• If the system is leak-free and your valve still does not shutdown the engine, please consult a
PowerHalt Service Representative for support.
8. Once the engine stops, wait 30 seconds, then reset the valve by turning the red reset knob
clockwisetotheopen“Run”positionwithknoblineinlinewiththeairowdirection.

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VALVE OPERATION
Prior to running your system you must ensure that the valve is latched (clockwise) into its open position and
that the above installation procedure was completed as described. It is recommended that the engine be
shipped with the shut-off valve system in its active/open and ready-to-use state.
To carry out the emergency shutdown procedure, the pull cable handle must be pulled as this will shut the
valve and stop the engine.
CAUTION: No attempt to restart the engine should happen until the activation information/details are
understood and the valve is confi rmed to be returned back to the open “Run” position.
NOTE: Please reference your specifi c operation procedures defi ned by your organization for additional
operation specifi cs / details. If you require additional recommendations on the steps to operate your shut-off
valve, please reference PowerHalt’s operation manual based on your application.
VALVE MAINTENANCE
To ensure a trouble-free long life of your PowerHalt shut-off valve a scheduled maintenance procedure is
mandatory. It is recommended that you follow the requirements & procedures stated below:
MONTHLY REQUIREMENTS
● Inspect all clamps, pull cables and support brackets to ensure they are in good condition and to the
required torque.
● Inspect all wiring & cable runs to ensure there is no corrosion or wear.
● Inspect all hoses to ensure there are no cracks or damage.
● Activate the valve to ensure it is exercised.
See procedure below.
3 MONTH REQUIREMENT (or at oil change interval’s whichever comes fi rst)
● Lubricate the PH2, fl ap O-ring, with Parker® Super O-Lube, Part # SLUBE 884-2, or equivalent.
VALVE ACTIVATION PROCEDURE:
1Run engine at low RPM (preferably at idle).
2 Activate the PowerHalt shut-off valve by pulling the cable handle.
The engine should stop within a few seconds.
NOTE:
● If the engine does not shutdown in the specifi ed time, please check all intake piping and hoses
for leaks between the valve and the intake system.
● If the system is leak free and your valve still does not shut down the engine, please consult
PowerHalt’s service representative for support.
3 Once the engine stops, wait 30 seconds, then reset the valve by turning the red reset knob
clockwise to the open “Run” position with knob arrow in line with air fl ow direction.
CAUTION: The #1 failure mode of any valve in the market is seizing due to lack of use. As this is a safety
device, it is imperative that you employ safety activation testing at a minimum of once per month.

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SETUP PROCEDURE
The PowerHalt is a smart controller that detects diesel engine runaway and immediately stops the engine by triggering
the emergency air shut-off valve. The unit has the following states:
UNPROGRAMMED STATE: When you fi rst purchase your kit, the controller’s red and green lights will fl ash in an
alternating order to indicate there is no emergency engine shut-off speed programmed.
PROGRAMMED STATE: If an emergency engine shutdown speed has been programmed to the controller’s memory,
the controller unit will act in the following way:
■Engine off: no lights fl ashing.
■Engine running: green light fl ashes every 5 seconds indicating the system is working as intended.
■Valve actuated (manually or automatically): the emergency shut-off has occurred and the red light on the
controller turns on for 5 seconds.
SETTING THE EMERGENCY ENGINE SHUT-OFF SPEED
If the controller has no emergency engine shutoff speed programmed, setup is required for the emergency
shut-off system to function. The controller uses a setup engine speed and adds a user defi ned overspeed margin to
program the emergency engine shut-off speed.
IMPORTANT: Please consult your engine manufacturer and the relevant safety operating procedures to determine the
emergency engine shut-off speed prior to proceeding.
1. With the engine idling, hold down the SET and TEST buttons simultaneously until both lights begin to fl ash
(approximately 5 seconds), then release the buttons.
2. Press and release the SET button on the controller to begin monitoring engine speed – the red light will fl ash
rapidly to confi rm the engine speed is being monitored.
3. Bring the engine to your desired setup engine speed GRADUALLY, then return engine to idle.
WARNING: The controller is monitoring for the peak RPM while the engine is brought up to speed
– do not exceed your target RPM or you will need to restart this procedure.
4. Press the SET button: 1 time to add 10% to the setup engine speed for the emergency engine shut-off speed, 2
times for 20%, 3 times for 30% or 4 times for 100%.
5. When the data is saved successfully, the red light will confi rm your input by blinking the same number of times the
SET button was pressed. If no engine speed is detected, the controller will exit the setup and erase any saved
engine speed from the memory.
6. Check the controller to verify that programming was successful by confi rming that the green light blinks every
5 seconds while the engine is running .
7. Document your emergency shut-off speed for future reference.
CURRENT CONTROLLER
(AFTER SERIAL # CPG100339)
LEGACY CONTROLLER
(SERIAL # CPG100339 & BEFORE)
POWERGUARD LEGACY CONTROLLER
NOTE: The PowerGuard controller For PH2 kits
has been updated with new technology. If you
have a kit with our Legacy Controller (Serial #
CPG100339 & before) see the addendum for the
proper set-up procedure.
Pacbrake.com/Legacy

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TEST MODE
The test mode ensures that the system’s automatic function is working as intended.
1. Hold the SET and TEST buttons simultaneously until both lights begin to fl ash (approximately 5 seconds), then
release both buttons.
2. Press then release the TEST button on the controller, the green light will start fl ashing rapidly and the red light will
turn off.
3. Raise the engine speed to HALF of the emergency engine shut-off speed.
4. The emergency shut-off valve will actuate to shut down the engine.
5. The green light will continue fl ashing and the red light will illuminate for 5 seconds before returning to Programmed
State.
NOTE: If the valve activated but the engine failed to shut down, check for leaks in the piping and consult a
PowerHalt representative.
ERASING THE EXISTING EMERGENCY ENGINE SHUTOFF SPEED
1. Hold both SET and TEST buttons simultaneously until both lights begin to fl ash (approximately 5 seconds) before
releasing.
2. Press and hold the SET button until the red and green lights begin fl ashing in an alternating order, indicating that
memory has been cleared.
3. Repeat SETUP PROCEDURES to program a new emergency engine shut-off speed.
UNPROGRAMMED
STATE
SETTING EMERGENCY
ENGINE SHUT-OFF
SPEED
ERASING SAVED
EMERGENCY ENGINE
SHUT-OFF SPEED
PROGRAMMED STATE
TEST MODE
SYSTEM FUNCTION FLOW CHART
EXAMPLE:
SETUP RPM
PRESS "SET"
BUTTON
OVERSPEED MARGIN EMERGENCY ENGINE SHUTOFF SPEED
(SETUP RPM) + (OVERSPEED MARGIN)% RPM
1800 1 time 10 1800 x 0.10 = 180 1800 + 180 = 1980
1800 2 times 20 1800 x 0.20 = 360 1800 + 360 = 2160
1800 3 times 30 1800 x 0.30 = 540 1800 + 540 = 2340
1800 4 times 100 1800 x 1.00 = 1800 1800 + 1800 = 3600

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AUTOMATIC WIRING SCHEMATIC
To Valve
Solenoid
To PH2
Micro Switch*
POWERGUARD
WEATHER PACK
CONNECTOR
METRI PACK
CONNECTOR
To Customer
Connection
TOGGLE
SWITCH
To Mag Pickup
Sensor Connection
TO MICRO SWITCH
(To Customer Connection)
15A FUSE
5A FUSE
BATTERY
+
*Micro switch may or may not be included depending on application.
MANUAL WIRING SCHEMATIC
85 86
3087
RELAY
SWITCH
BATTERY
15 AMP
FUSE
PH2 POWERHALT
SHUT-OFF VALVE
+
electric manual
electric pneumatic
electric manual pull
Patents pending. Pacbrake is a registered trademark of Pacbrake Company. Other trademarks used herein are property of their respective holders. Printed in Canada