PHP PHP-40A, Technical Description, Installation Instructions, Operating Instructions, Maintenance & Troubleshoot

Page 1: ... Technical Description Installation Instructions Operating Instructions Maintenance Troubleshooting PHP 40A AIR HEATER ...

Page 2: ...eater Kit List 6 Main Components and Operating Concept 8 Heater Mounting 9 Fuel System 13 Electrical Connections 16 Operating Switch 18 Exhaust Combustion Air Intake Connections 25 Heater Ducting 27 Heater Operation 28 Maintenance 31 Troubleshooting 32 Fault Code Chart 34 ...

Page 3: ...highway equipment RVs and boats by using on board diesel fuel and battery systems Operation is simple and the heater provides a safe and reliable alternative to engine idling or need for electrical plug ins Please take a moment to familiarize yourself with this manual safety warnings and heater requirements before installing or operating your heater ...

Page 4: ...eration Avoid touching exhaust pipe during operation Route exhaust pipe in a manner to shield it from anyone making contact with it This heater is not designed for use with straight bio diesel Blends of bio diesel up to 10 are acceptable Operating outside of these conditions may plug the heater with soot and result in combustion failure This heater is not designed to operate continuously at altitu...

Page 5: ...0 5 0 13 0 4 0 10 0 3 0 08 0 11 0 03 Air Flow CFM 80 70 50 30 Power Consumption watts 40 30 16 12 Power Consumption at Start watts 120 Fuel Type Diesel Nominal Voltage 12 Volt Lower Voltage Limit 10 5 Volts over 20 seconds Upper Voltage Limit 16 0 Volt over 20 seconds Overheat Protection 115º C 239º F Allowed Ambient Temperature 40º C to 76º C 40º F to 168º F Weight 4 5 kg 10 lbs Above Specificati...

Page 6: ...perating Switch 2 Sided Mounting Tape Description Mounting Plate Mounting Plate Seal Description Wiring Harness 3 2M 10 5 Power Harness 30A Fuse 2 5M 8 Fuel Pump Harness 2M 6 Switch Harness Description 24mm Flexible Stainless Steel Exhaust 25mm Combustion Air Intake Tube P Clamp 24 26 mm Exhaust Clamp 16 25 mm Hose Clamp Description 75mm Hot Air Ducting 1M 3 Length 75mm Air Outlet Adjustable Vent ...

Page 7: ...rge Hex Nut Brass Hex Nut Brass Securing Body Fuel Metering Pump Fuel Pump Holder Black Rubber Fuel Line 0 5M 18 5mm ID Z Mounting Bracket Fuel Line 8m ID 1 5mm OD 5mm Small Fuel Line Clamps 9 11 mm QTY 2 10 8 5 5 2 5 4 4 2 Part Number NPN NPN NPN NPN NPN NPN NPN NPN NPN NPN Description Large Tie Straps Small Tie Straps Tek Mount Screws Self Tapping Screws Small Flat Washers Large Flat Washers M6 ...

Page 8: ... delivers fuel to the combustion chamber the blower motor delivers outside combustion air to the burner chamber and a glow pin is used to ignite the fuel air mixture to create heat The heat from the burner is transferred into the heat exchanger while the exhaust gases are expelled to the exterior of the vehicle The process air from the area to be heated is circulated through the heater over the ou...

Page 9: ...e exhaust to avoid any damage to heat sensitive materials or vehicle components The heater must not be exposed to the outside elements and in cases where it is mounted outside the vehicle cabin it must be properly enclosed and protected The mounting surface must be such that it is possible to get a complete seal between the heater and the floor or the heater mounting plate and the floor The heater...

Page 10: ...dual components openings should be made For ease of installation fasten the mounting plate to the heater and make exhaust combustion air intake and fuel connections at the base of the heater before mounting the assembly to the vehicle Cut a two 3 holes or a 4 x 5 rectangular opening on the cabin floor to accommodate mounting plate and seal Refer to Figure M4 Secure mounting plate to vehicle with s...

Page 11: ...11 Heater Mounting Figure M3 Combustion air Seal Exhaust Fuel Line Wiring Harness Heater Flange 22 ...

Page 12: ...12 Heater Mounting Figure M4 2 1 8 Ø3 x 2 4 x 5 Rectangle ...

Page 13: ...omponents provided System Layout Considerations Keep the length of the fuel system short as possible Mount the fuel pump as close to the fuel pickup as possible pump pushes better than it sucks Minimize vertical rise Mount the fuel pump in a protected location away from road spray Choose a mounting location for the fuel pickup pipe that is close to the heater and offer installation access Design y...

Page 14: ...o the tank in the order shown below Please Note To avoid dropping the compression fitting and base into the fuel tank make sure it is tightened onto the pipe before putting pipe into tank Be careful not to let go of the fuel pipe and drop it into the fuel tank while assembling components onto fuel pipe Electrical System Installation The heater harness that comes with the heater has all the electri...

Page 15: ...e as shown in Figure F4 Position fuel pick up 4 from bottom of tank for round tanks and 1 for flat tanks cut tube as necessary Fuel Line Connections Route fuel lines from the fuel pick up pipe to the heater Use only fuel lines provided Other sizes or types of fuel lines may inhibit proper fuel flow Make proper butt joints using clamps and connector pieces as shown Use a sharp utility knife to cut ...

Page 16: ...ss Connects switch and power harness to the heater harness Refer to Main Harness Connections Legend for details B Power Harness 2 Core 3 2M 10 5 Long Red White Black White Route power harness section from heater to vehicle batteries Connect red white wire to battery Connect black white wire to battery Install 30 amp main fuse Last step of installation C Switch Harness 4 Core 2M 6 Long Red White Gr...

Page 17: ...Terminal Wire Color Function 1 White Switch 2 Blue Switch 3 Yellow Fuel Pump 4 Red White Main Power 5 Red Switch 6 Green Switch 7 Yellow Fuel Pump 8 Black Main Power Open end view of main heater harness connector Figure E4 Green Red Blower Motor Glow Pin Flame Overheat Sensor Main Harness Access Black Yellow Black Black Open 1 5 2 6 3 7 4 8 ...

Page 18: ...e able to sense the temperature of the cabin area being heated Route the harness from the heater to the switch location Remove the 4 screws and backing plate and connect harness as shown in Figure F3 Re attach backing plate then mount the operating switch using either two mounting screws or two sided tape Notes All exposed electrical connections should be coated with protective grease To avoid acc...

Page 19: ...te temperature set operating mode timed shutdown and timed startup functions It also facilitates troubleshooting by providing diagnostic codes Operation Buttons and Display Icons Programming Keys 1 On Off Select 2 Operation Status 3 Switch Modes Display Icons and Terms 1 Heating Mode 2 Degrees Celsius 3 Manual Mode 4 Automatic Climate Mode 5 Indicates Time 6 Indicates Error On Off Control Press an...

Page 20: ...ng applications This mode allows you to set the target cabin temperature from 8ºC to 36ºC As measured at the Control Switch Note The heater will initially start in Gear Mode Switching Operating Modes To switch heater between Gear Mode and Automatic Temperature Control Mode the heater must first be started Switch between modes by pressing Heater will alternate between two operating modes For A C Mo...

Page 21: ...ll be displayed Heater will continue to operate until the countdown reaches 0 Heater will then commence a 5 minute cool down process Operating Status Heater Turn On or Off To access the heater operating status information Press To change between operating parameters Press Operational information will display in this order 1 Voltage 2 Glow Pin Status 3 Fan Speed 4 Fuel Pump Level 5 Heat Exchanger T...

Page 22: ...t Clock Time Press and Hold for 3 seconds Set the clock time When the double colon flashes you can set the clock time 1 Rotate to set the 10s of hours 2 Press to move to 1s of hours 3 Rotate to set the 1s of hours 4 Press to move to 10s of minutes 5 Rotate to set 10s of minutes 6 Press to set 1s of minutes 7 Rotate to set 1s of minutes Press to proceed to setting Automatic Start Time Colon appears...

Page 23: ... to set the clock time Press to proceed to setting Automatic Stop Time Upper Dot in Colon ONLY appears Flashing Set Automatic Stop Time Once your Clock Time and Automatic Start Time have been set and you have pressed You will be able to set the Automatic Stop Time When the Lower colon flashes you can set the Stop Time Use the same method used above to set the clock time Press to move back to Clock...

Page 24: ...eed air out of the system using the controller Press 5 Times to activate fuel pump Run fuel pump until fuel reaches the heater Press to Shut the Fuel Pump Off Running Blower Only Press and Hold 3 Seconds To Activate Blower Press To switch Blower off Self Diagnostics If the heater s ECU detects a fault during operation the display will flash and an error code Refer to the diagnostic fault code lege...

Page 25: ...ow point if proper incline cannot be maintained Route the exhaust pipe from the heater using p clamps provided Route away from the vehicle slip stream Combustion Air Intake Considerations The combustion air intake is made from a 25mm flexible water resistant paper aluminum compound Secure the combustion air intake tube to the heater using the clamp provided Draw air from a clean air source away fr...

Page 26: ...26 Exhaust Combustion Air Intake Connections 25mm Combustion Air Intake Min 0 4M 8 Max 1 0M 39 24mm Exhaust Min 0 4M 8 Max 2 0M 78 Figure A1 ...

Page 27: ...ris Hot Air Ducting Distribute heat efficiently throughout the cabin by using the high temperature 60mm flex ducting and rotatable outlet components provided in the installation kit Route ducting with smooth bends to avoid crushing Ensure ducting components will not come in contact with combustible materials Install protective covers or shields as required Position hot air outlet so that it cannot...

Page 28: ...conds 4 Stabilization Phase To further establish combustion the glow pin remains on and the fuel air mixture is slowly increased The flame sensor monitors the increasing temperature at the heat exchanger Typically 2 minutes 5 Running Phase Once the flame is established the glow pin will switch off Incoming fuel air will be ignited by the established flame inside the combustion chamber Running Mode...

Page 29: ...chamber and cool down the heat exchanger The cool down cycle will last approximately 4 minutes Safety Systems The heater is equipped with several control features to protect itself and the operator Systems Check The heater will not attempt to start if one of the components is detected by the control unit to be defective If the heater detects a problem during operation it will shut down and dependi...

Page 30: ...ed is continuously monitored If the fan motor does not start or if the speed deviates by more than 40 the heater will turn OFF after 60 seconds Emergency Shut Down In event of an emergency shut down the heater as follows 1 Turn the heater OFF with the control switch 2 Pull the fuse out 3 Disconnect battery power Heater Operation ...

Page 31: ...ctions and scratches or buildup on the heating element Wipe the glow pin clean with a soft cloth only do not use anything abrasive to clean the glow pin If the glow pin shows any signs of wear or damage it must be replaced Remove the atomizer screen with a hook pick or pick and needle nose pliers The atomizer screen cannot be reused and must be replaced annually Inspect the atomizer screen chamber...

Page 32: ...manual for further direction No Error Codes Detected If the heater does not attempt start and there is not an error code on the operating switch follow these procedures in order shown 1 Ensure that the ambient temperature does not exceed the settings on the operating switch 2 Reconfirm that you have checked the power supply to the heater as noted in Basic Inspection 3 Reboot the ECU by removing th...

Page 33: ...exhaust Source of Ignition The heater uses a glow pin as a source of ignition Normally when this fails it will create an open or short circuit and yield error code 5 or 6 However in some cases the glow pin may have a partial failure and will just not get hot enough Glow pins can be bench tested by applying 12 volts and observing how they heat up They should exhibit a consistent red throughout the ...

Page 34: ...in as required 6 Glow Pin Short Circuit Check glow pin connectors and resistance across glow pin Should be 0 8 Ω Replace glow pin as required 7 Blower Motor Open Circuit Check blower motor wiring blower motor for free rotation Repair wiring or replace blower as required 8 Blower Motor Short Circuit Check blower motor wiring Repair wiring or replace blower as required 9 Flame Extinguished Refer to ...

Page 35: ...www parkingheaterproducts com help dksi com 877 508 3900 Unit B 1465 Kebet Way Port Coquitlam British Columbia Canada V3C 6L3 ...