PHP PHP-52W Manual Download

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PHP-52W ENGINE HEATER

Technical Description

Installation Instructions

Operating Instructions

Troubleshooting and Parts

PHP-06.18.20-TM52W-DR16

Summary of Contents for PHP-52W

Page 1: ... PHP 52W ENGINE HEATER Technical Description Installation Instructions Operating Instructions Troubleshooting and Parts PHP 06 18 20 TM52W DR16 ...

Page 2: ... 5 Heater Kit List 6 Main Components and Operating Concept 8 Heater Mounting 9 Heater Plumbing 11 Fuel System 13 Electrical Connections 16 Operating Switch 18 Exhaust Combustion Air Intake Connections 24 Heater Operation 26 Troubleshooting Parts 29 Heater Components 30 ...

Page 3: ...sing on board diesel fuel and battery systems Operation is simple and the heater provides a safe and reliable alternative to cold engine starting 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: ... of water and antifreeze to prevent coolant from Freezing Ensure that the coolant flow can never be blocked while heater is in operation Blocking coolant flow can result in extreme pressure bursting hoses and release of scalding coolant 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...

Page 5: ...ower Consumption WATT 135 Min Coolant Through put L hr US Gal hr 250 66 Fuel Type Diesel Nominal Voltage 12 Volt 24 Volt Lower Voltage Limit 10 5 21 0 Volts over 20 seconds Upper Voltage Limit 16 0 32 0 Volt over 20 seconds Overheat Protection 115º C 239º F Allowed Ambient Temperature 40º C to 80º C 40º F to 176º F Weight 2 5 kg 5 5 lbs Above Specifications 10 15cm 5 75 22cm 8 5 9cm 3 5 Principal ...

Page 6: ... on Universal Kit Version Description Operating Switch 2 Sided Mounting Tape Description Mounting Bracket Description Wiring Harness 5M 16 Power Harness 20A Fuse 5M 16 Fuel Pump Harness 7 5M 25 Switch Harness 5A Fuse 0 3M 12 Coolant Pump Harness Description Flexible Stainless Steel Exhaust 0 6M x 22mm Combustion Air Intake Tube 0 6M x 22mm P Clamp 24 26 mm Exhaust Clamp 24 26 mm Combustion Air Hos...

Page 7: ...Nut Brass Hex Nut Brass Securing Body Fuel Metering Pump Fuel Pump Holder Black Rubber Fuel Line 0 3M 12 7mm ID 5mm x 50mm Fuel Line Connectors Z Mounting Bracket Clear Plastic Fuel Line 5M 16 2mm ID Small Fuel Line Clamps 9 11 mm QTY 1 2 4 3 3 4 6 3 6 Part Number U65D X704 U65D X706 NPN NPN NPN NPN NPN NPN NPN NPN Description Z Mounting Bracket L Brackets M6 x 15 Screws M6 x 25 Screws M6 Hex Nuts...

Page 8: ...pump Combustion air is delivered to the heater via the heaters 12v combustion air blower Fuel is atomized and the fuel air mixture is ignited using a glow pin The flame is contained in a flame tube and exhaust gases expelled The heater s coolant pump takes cold coolant from the engine circulates it through the heater s water jacket then it pumps hot coolant back to the engine Figure O2 ...

Page 9: ...to maximize flow and minimize heat loss Keep power wiring short to minimize voltage drop Keep fuel lines short to ensure good combustion Suggested Locations Step box External storage compartments Not inside cab Inside frame rail Inside engine compartment Note PHP boxed version can be used to simplify your installation and protect your investment ...

Page 10: ...shielding as required to protect the heater from environmental conditions Orientate the heater within permissible mounting configurations shown in Figure M1 Do not mount the heater inside passenger compartments where poisonous exhaust fumes may be inhaled Guard the heater against excessive road spray to minimize corrosion and avoid ingestion of debris Warning Asphyxiation Hazard Caution ...

Page 11: ...ieve a safe and quality installation It is important to try to optimize the coolant flow to get the best heat distribution and heater operation Installation Procedure Plan the heater plumbing circuit Install the coolant pump in a protected location close to the heater Note Pump is pre installed in the boxed version Install fittings valves and run hoses as required Bleed the air out of the system R...

Page 12: ...n be incorporated into the system However ensure that the heater flow can never be completely blocked by a flow control valve Do not work on the plumbing system when it is hot or under pressure Do not work on the heater or plumbing system when the heater or engine are in operation Always wear safety gloves and appropriate eye protection Ensure system has pressure relief protection limiting maximum...

Page 13: ... s operation to stay within parameters outlined below and only use the components provided Figure F1 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 f...

Page 14: ...mounting angle is observed to avoid cavitation Figure F3 Fuel Source Connect directly into the fuel tank using our dedicated fuel pickup tube Teeing into the existing vehicle fuel lines is not recommended There are three common methods to install a fuel pickup tube Use NPT compression fittings if available Use spare fuel gauge plate if available Drill dedicated holes into the tank Fuel Pickup Pipe...

Page 15: ...pipe as shown Position pick up pipe 4 from bottom of tank 1 for flat tanks 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 plastic fuel lines to avoid fuel line pinching Fuel ...

Page 16: ...s using either an existing cable passage or drill holes as required Seal the hole around the cables and make sure they are protected from chaffing and pinching Cut each harness section to length and install terminals and connectors as required Below is a summary of the wiring connections required Figure E1 ...

Page 17: ...tion from heater to switch location Cut harness to length and attach wiring terminals Install terminals into connector so they match the wire colours from the operating switch Yellow is a spare wire Attached connector to operating switch This circuit is protected by a 5 amp fuse located near the main harness connection D Fuel Metering Pump Harness 2 Core 5M 16 Long Purple White Route fuel metering...

Page 18: ...ers and diagnostics Refer to the Operating Switch Instructions for operational details Operating Switch Mount Operating Switch in a suitable location using the keyed mounting holes or two sided tape provided Route the switch harness from the heater to the Operating Switch Cut the harness to length attached terminals and connector Connect harness to Operating Switch Figure E2 Figure E3 ...

Page 19: ...ure 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 1 Heating Mode Flashes in standby mode 2 Heater On 3 Heater Off 4 Degrees Celsius 5 Water Temp Mode 6 Automatic Climate Mode 7 Indicates Run Time 8 Ind...

Page 20: ...uirements to maintain the desired maximum temperature Automatic Climate A C mode allows you to control the maximum cabin temperature that the heater will maintain This is a less common operating mode and is only practical for use with cargo and cabin heating applications This mode allows you to set the maximum cabin temperature from 14 to 40 As measured at the Control Switch In this mode the heate...

Page 21: ...ed the controller will return to the home screen Operational information and corresponding icons will display order 1 Voltage 12 U 2 Glow Pin Status 83 UA 3 Fan Speed 5000 4 Fuel Pump Pulse Frequency H1 30 5 Timed Shut Down 2 00 6 Temperature 40 Coolant Temperature WaterTemp mode or Cabin Temperature A C Mode 7 Flame Sensor Temperature 086 Timed Shutdown To set the timed shutdown first select the ...

Page 22: ... Flashing Minutes two digits on right Colon appears Flashing Clock with Flashing Hours two digits on left Colon appears Flashing Set Automatic Start Time Once your Clock Time has been set and you have pressed You will be able to set the Automatic Start Time When the upper colon flashes you can set the start time 1 Rotate to set the minutes 2 Press to move to setting hours 3 Rotate to set the hours...

Page 23: ...g Minutes two digits on right Lower Dot in Colon ONLY appears Flashing Clock with Flashing Hours two digits on left Lower Dot in Colon ONLY appears Flashing Additional Features Heater in Off Mode Fuel Pump Priming Upon initial installation and before heater has be run it is possible to fill the fuel line bleed air out of the system using the controller Press 5 Times to activate fuel pump Run fuel ...

Page 24: ...aust fumes cannot be sucked into combustion air intake Install exhaust pipe with incline for moisture run off Drill a small drain hole at low 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 flexible water resistant paper a...

Page 25: ... from any heat sensitive material Route exhaust beyond the skirt of the cab and outside of the frame area Failure to comply with this warning could result in Carbon Monoxide Poisoning Combustion Air Intake Max 1M 3 Exhaust Min 0 2M 8 Max 2M 6 Figure A1 Warning Fire Hazard Warning Asphyxiation Hazard ...

Page 26: ... If unsuccessful the heater will shut down completely Note On initial start up the heater may require several start attempts to self prime the fuel system Tech Tip Heater has a Priming function See Operating Switch Instructions Upon ignition the heater will continue to operate as follows Temperature is monitored at the heat exchanger Once coolant reaches 75 C 167 F or set maximum heater will autom...

Page 27: ...on ECU conducts circuit check on start up Heater will shut down after two consecutive unsuccessful 90 second attempts Heater automatically attempts to restart upon flame out Heater will shut down in case of overheat ECU monitors voltage and will shut down heater if outside 10 5V to 16 0V for 20 seconds The heater must be switched off while any fuel tank on the vehicle is being filled The heater mu...

Page 28: ...Check for damage inside blower 9 Flame Extinguished Check fuel flow Check combustion air flow 10 Failed Ignition Check Voltage Supply Check fuel flow 11 Over Temperature Check coolant flow Check water pump operation 12 Inlet Sensor Open Circuit Check sensor connections Check resistance across sensor 13 Inlet Sensor Short Circuit Check sensor connections Check resistance across sensor 14 Not Applic...

Page 29: ...er The PHP 52W is equipped with self diagnostic capabilities In the event of failure an error code will be displayed on the operating switch Refer to the Fault Code Diagnostic Chart for direction In addition consider our basic troubleshooting steps Basic Troubleshooting Look for error code on timer and consult Fault Code Diagnostic Chart for direction Ensure sufficient fuel Check wiring connection...

Page 30: ...tional part listing Item Description Part Number 1 Heat Exchanger P52W X101 2 Burner Flame Tube P52W X102 3 Combustion Blower Integrated ECU P52W T101 4 Flame Sensor P52W X103 5 Glow Pin P52W T102 6 Temperature and Overheat Sensors P52W X104 7 Cover P52W X201 8 Coolant Fittings P52W X602 ...

Page 31: ...www parkingheaterproducts com help dksi com 877 508 3900 Unit B 1465 Kebet Way Port Coquitlam British Columbia Canada V3C 6L3 PHP 06 18 20 TM52W DR16 ...

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