Hunter Falconaire PH20-30A Operation manual

  


Propane Heater
20,000 BTU/HR Model PH20-30A
With Automatic Gas Ignition Control
Installation Operation Service
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
EXHAUST GASES
Donotoperateheaterinanenclosedareaunlesstheexhaust
gasesarepipedoutside. Exhaustgasesmaycontaincarbon
monoxide,acolorlessandpoisonousgas.

FUEL USE
This heater is designed for use with propane (LP gas) only. Do not
attempttousegasolineasfuelsincefireorexplosionsmayresult.
Usethisheateronlywithgasregulatorpartnumber88301-T
suppliedwiththeheater. Operationwithotherregulatorsvoidsall
warrantiesandmayresultinfire,explosion,ordamagetothe
heater.

ELECTRICAL
Heatermustbegroundedthroughgroundscrewsupplied. Donot
usethefuellineasanelectricalconductororgroundconnections.
Useofthefuellineaselectricalorgroundconductormayresultin
fireorexplosion.Beforeperformingmaintenanceorinspection
(exceptoperatingtests),disconnectthepowersource. Donot
operatetheheaterwiththecoversoff.Thetiltswitchisasafety
devicethatstopsheateroperationincasethevehicleoverturns.
Do not remove this switch or defeat its purpose.

Donotoperatetheheateratlessthan11volts. Propaneflowtothe
burnerheadisconstant,butblowermotorspeedandcombustion
airflowvarydirectlywithvoltage.Operationonlowvoltagewill
producepoorburning,smoke,andunburnedfuelmixtures.

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

Section One____________________________________________________________ 3
Introduction and Description __________________________________________________ 3
Description _______________________________________________________________________ 3
Section Two ___________________________________________________________ 4
INSTALLATION INSTRUCTIONS ____________________________________________ 4
Pre-Installation Inspection____________________________________________________________ 4
Location and Mounting ______________________________________________________________ 4
Electrical Requirements (FIG.1) _______________________________________________________ 6
Fuel Requirements (FIG.2) ___________________________________________________________ 6
Exhaust and Combustion Air Requirements (FIG.3)________________________________________ 7
Heater Mounting Dimensions (FIG.6)___________________________________________________ 8
Fuel Connections___________________________________________________________________ 9
Electrical Connections______________________________________________________________ 10
Section Three _________________________________________________________ 12
OPERATION ______________________________________________________________ 12
Controls and Indicators _____________________________________________________________ 12
Theory of Operation _______________________________________________________________ 13
Starting _________________________________________________________________________ 14
Section Four __________________________________________________________ 15
TROUBLESHOOTING and DIAGNOSTICS ___________________________________ 15
Fault Codes ______________________________________________________________________ 15
Troubleshooting___________________________________________________________________ 16
Burner Head Maintenance ___________________________________________________________ 16
Preseason Maintenance, Annual Service ________________________________________________ 17
Section Five __________________________________________________________ 18
PARTS LIST ______________________________________________________________ 18
Installation Hardware ______________________________________________________________ 18
Case and Heat Exchanger ___________________________________________________________ 19
Fuel, Ignition, and Electronic Control System____________________________________________ 20
Blower and Motor Assembly_________________________________________________________ 21
Comfort Control and Remote Harness__________________________________________________ 22
Section Six ___________________________________________________________ 23
OPTIONS and ACCESSORIES_______________________________________________ 23
Remote Calibrated Thermostat Installation ______________________________________________ 24
External Diagnostic Light Installation__________________________________________________ 25
HunterMfg.1999





Thismanualcontainsinstallation,operation,maintenance,andrepairinstructions
forModelPH-20-30AHeatersmanufacturedbyHunterManufacturingCompany,Solon,
Ohio.

TheFalconairePH20-30Aisa12VDCMicroprocessorBased,DirectSpark
Ignition,thermostaticallycontrolledheater. Thecontrolutilizesamicroprocessorto
continuallyandsafely,monitor,analyzeandcontroltheproperoperationofthegas
burner. Valueaddedfeaturessuchas,combustionblowercontrol,LEDdiagnostic
output,automaticonehourreset,andmultipleignitiontries,highlightthecontrols
benefits.
ModelPH-20-30Aisdesignedforusesolelywithpropane(LPgas)asfuel.
Combustionairissuppliedbyasingle-stagecombustionairblower,andfuelflowtothe
burnerheadiscontrolledbyasolenoidvalveandarestrictorinthefuelline.Because
thepropaneenterstheburnerheadasagas,nocarburetorisrequired. Ignitionofthe
propaneisaccomplishedwithasparkplug-likeigniter,whichissuppliedwithhigh
voltagecurrentfromtheElectronicControlModule(ECM).

Heatercasedimensions.....................16in.longx11in.widex63/4in.high
Weight ..........................................................…28lbs.
Shippingweight .....................................................30lbs.
Rating ........................................................20,000BTU
Heatedairoutletdiameter...............................................5in.
Exhaustoutlet.....................................11/4NPTstainlesssteelpipe
Combustionairinlet .............................................1in.ODtube
Fuelconnection ............................ 5/8-18UNFx45deg flaremalefitting
Electricalrequirements............................................12voltsDC
Currentdraw(average,startandrun)....................................8amps
Fuelrequirement............................................Propane(LPgas)
Fuelconsumption ..........................1hour/poundonhighthermostatsetting
Burner................................................... Lowpressuretype
Ignition ...............................................Electronicignitionpack
NOTE
Allspecificationsarebasedontheuseofavapor-withdrawalgas
bottleandgasregulatorpartnumber88301-T.Operationunder
otherfuelconditionsvoidsallwarranties.Thisregulatorprovidesthe
mandatorypressure(11inchesH2O)requiredbythecalibrated
burnerheadorifice.





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1. Inspecttheheaterfordamagethatmayhaveoccurred
duringshipment. Checkagainstthepackinglistor
invoiceforlostparts.
2. Inspectthecontrolsforlooseormissinghardware.
3. Inspectalllines,tubing,andfittingstoseethattheyare
secureandfreeofbreaks,kinks,orotherdamage.
!"
.
Theheaterisnormallyinstalledwithinthecompartmentbeingheated.Itcanbe
installedoutsidethecompartmentbeingheatedbyusingaflexibleheatducttodirectthe
heatedairintothecompartment.
The heater must be shielded against direct contact from rain and snow.

Read all warning
tags supplied
with the heater.
Perform all duties
indicated on the
tags.
NOTE
Awarrantycardispackedwitheachheaterleavingthefactory.Attached
isareturnpostalcard.Itisthedutyofthedealertoensurethatboththe
owner'scopyandtheregistrationcardarecompletedandtheregistration
cardreturnedtoHunterManufacturingCompany.Tobecertainthatyou
obtainthebenefitsoftheabovewarranty,thiscardshouldbereturned
within10daysfromthedateyoupurchasedthisequipment

Thetiltswitchisasafetydevicethatstopsheateroperationincasethe
vehicleoverturns.Donotremovethisswitchordefeatitspurpose.
CAUTION
Theheaterisdesignedforuseinthehorizontalpositionwiththeheatexchanger
exhaustoutletdown.Otherpermissiblepositionsarethosewhichretainthe
motorshaftinthehorizontalplane.Operationinanyotherattitudevoidsall
warrantiesandmayresultindamageorrapidheaterwearunlessmodifiedfor
suchusebyHunterManufacturingCo

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
LOCATION AND MOUNTING (cont.)
1. Mounttheheaterhorizontally,asshowninfigure4.Chooseamounting
locationthatwillenablemountingtheheateronalevelsurface,withadequateroom
aroundtheheaterforremovalandservice.Checkthatthetiltswitchisupright.Referto
figure6formountingdimensionsandclearances.
2. Afterselectingalocation,removeallcombustiblematerialfromarea,within
twoinchesofwheretheheaterwillbelocated. Thisincludescarpeting,rubbermats,
plywoodflooring,etc.
3. Cutholesasrequiredforairinletandexhaust.Removecrossbarandcovers.
Setheaterinplaceoverinletandexhaustholesandmarkmountingholes.Remove
heateranddrill5/16inchdiameterholesformountingstuds(page8)
4. Positionheatshield(page17)aroundtheholefortheexhaustconnection,as
showninfigure3.Theheatercasebecomeshotinthisareaduringoperation,andthe
heatshieldisrequiredtoprotectthevehiclefromexcessiveheat.Settheheateroverthe
mountingholesandsecurewithmountingstudsusingthenutsandlockwashers
suppliedwiththeheater.
.
5.Directtheexhaustawayfromthecompartmentusingelbowandnipple,and
additional11/4-inchnipplesasrequired.Iftheexhaustmustpassthroughanadditional
vehiclebodypanelorfloor,useexhaustcollar toprotectpaintand/ortrim.Cutaholein
thepanel2-7/8to3inchesindiametertoensureadequateclearancebetweenthehot
pipeandthepaintedpanelandtoprovideaccessforlaterservicing.Covertheopening
withexhaustcollar anddirecttheexhaustpipethroughit.
6.Iftheheaterismountedentirelywithinthecab,connecta1-inchrubberor
plastichosetotheairinletandrunitoutsidethecabtoprovidefreshairforcombustion.
CAUTION
Useheatshieldandexhaustcollarasdescribedbelowtopreventdamageto
paintandfurnishingsofvehiclefromexcessiveheat.

Exhaustgasmustbepipedtotheoutsideoftheheatedcompartment.Donot
allowtheexhaustgastoexitdirectlybeneaththevehicle

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 . 
  )&%
/1- 8)  & )&
&))-)  +  )
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&-& && + 
0  '- %
 &-& 
2
 (76D
,1 '1 &&
# 7
 # --
 E 7
)*")+

 
(+, %
)//0
# /- 
(,
@) )//-A
#




1. Locateandmountthepropanetank(gasbottle)awayfromtheengineand
heaterexhaustports.Thelocationshouldalsoprotectthetankfromaccidental
mechanicaldamage.
2. Thepropanetankmustbeagasbottledesignedormodifiedforvaportakeoff
only.InstallPOL(putonleft)connector(fig.2)attheINporton regulator,andinstall
theseassembledpartsintothepropanetankshutoffvalve,asshowninfigure2.
3. Fuellinefromtheregulatortotheheatershouldbe3/8-inchdiametertube.If
available,ashortpieceofflexiblefuellinemaybeusedattheregulatortomakebottle
changingmoreconvenient.Flexiblelinemustbeapproved300-psitestneoprenehose,
whichcannormallybeobtainedfromthepropanesupplier.
:Thisheaterisdesignedforusewithpropane(LPgas)only.Donot
attempttousegasolineasfuelsincefireorexplosionmayresult.Usethisheater
onlywithgasregulatorpartnumber88301-TandPOLconnectorpartnumber
88014suppliedwiththeheater.Operationwithotherregulators,ortampering
withtheregulatoradjustment,voidsallwarranties,andmayresultinfire,
explosionordamagetotheheater.
CAUTION
Useonlypropanetankswhicharedesignedormodifiedforvaporwithdrawal.
ConnecttheheatertotheVAPORportonthetank.Damagetotheheaterand
regulatorwillresultifconnectionsarenotmadeproperly.
NOTE: POLconnector,partnumber88014,incorporatesan
excessflowvalve.Useofanexcessflowvalveisasafety
requirementoftheDepartmentofTransportation(DOT).
CAUTION
Useofflexiblefuellineisrecommended.Ifrigidlineisused,it
mustwithstandvehiclevibration,whichmaycauserigidlinetocrack.




1. Refertothewiringdiagraminfigure7,locatethepowerandground
connectionsonyourheater.Thegroundterminalislocatedoneinchtotheleftof thefuel
inlet. Connectthisterminaltoagood,cleanchassisground,usingthewiresizelistedin
Table1.
2. Refertothewiringdiagramandconnecttheredpowerleadfromtheheater
fusetothevehicleelectricalsystem,usingthewiresizespecifiedinTable1.Thisline
shouldbehotatalltimes,sotheheatercanpurgeevenifthevehicleignitionisoff.
Protectthevehiclewithacircuitbreakeror10ampfuseinthefeedline.
     
LessThan10
10to30
Over30
10gauge
8gauge
6gauge
Table1.WireSizes
Groundtheheaterelectricallythroughthegroundscrewprovided
ontheheatercase,andconnecttoaclean,securechassisground.Donotuse
thefuellineasagroundorelectricalconductor.Useofthefuellineasan
electricalorgroundconductorcanresultinfireorexplosion.Donotrelyon
heatermountingstudstoprovideelectricalground.



   ! " (figure7)
Symbol Description
B1 BlowerMotor
ECM ElectronicControlModule
E1 Igniter
L1 SolenoidValve
LED1 L.E.D.Assembly
PS1 PressureSwitch
S1 TiltSwitch
S2 OverheatThermostat
S3 RoomThermostat(optional)
S4 ComfortControlThermo.
SW1 MainSwitch
TB TerminalBlock
LT1 ExternalDiagnosticLight(optional)



'


Comfort Control Assembly
Controls and Indicators (figure5)
Table 2. Control and Indicator Functions
Name Function
MainSwitch Simpleon/offswitch.MovetoONforheatertorun.
Note:Greenlightwillcomeonbutheaterwillnotstartuntil
heatiscalledforbythetemperaturecontrolorremoteroom
thermostat.
TemperatureControl
Knob Controlsthetemperatureintheheatedareabywayofan internalthermostat.Temperaturerangeis45-95degreesF.Turn
clockwisetoincrease.Thecontrolhasadetentwhenturned
counterclockwise,whichlocksoutthisthermostat.Thiswillnot
shutofftheheater(seemainswitch)
GreenLED Indicateswhentheheaterisonandreadytooperate.
RedLED Indicateswhenafaulthasoccurredbyflashingacode.
RemoteRoom
Thermostat
(notpictured) AnoptionalcalibratedroomthermostatkitP/N51643canbe
attachedforbeveragebodyorcargoheating.
2'/ , 5*
. 46+?  
 46+? +-)-&)
- %-&
Note:WhenaremoteroomthermostatandtheComfort Control areused
together,eitheronewillstarttheheater,afterthemainswitchisON.



'+
TheFalconairePH20-30AisaMicroprocessorBasedDirectSpark
Ignition,thermostaticallycontrolledheater. Thecontrolutilizesamicroprocessor
tocontinuallyandsafelymonitor,analyzeandcontroltheproperoperationofthe
gasburner. Valueaddedfeaturessuchascombustionblowercontrol,LED
diagnosticoutput,automaticonehourreset,andmultipleignitiontrieshighlight
thecontrolsbenefits.
OPERATION
POWER UP/STANDBY
Whenthemainpowerswitchisturnedon,thecontrolwillreset,performa
selfcheckroutine,initiatefulltimeflamesensing,andenterthethermostatscan
state.
HEAT MODE
Whenacallforheatisreceivedfromthethermostat,thecontrolwillcheck
thecombustionpressureswitchfornormallyopencontacts. Thebloweristhen
energizedandoncethecombustionpressureswitchcontactsclose,a3-second
prepurgedelaybegins. Followingtheprepurgeperiod,thegasvalveis
energizedandsparkscommenceforthetrialforignition(TFI)period.
WhenflameisdetectedduringTFI,sparksareshutoffimmediatelyand
thegasvalveandcombustionblowerremainsenergized. Thethermostat,
combustionpressureswitch,andmainburnerflameareconstantlymonitoredto
assurethesystemcontinuestooperateproperly. Whenthethermostatis
satisfiedandthedemandforheatends,themainvalveisde-energized
immediately,thecontrolsensesthelossofflamesignalandinitiatesa60-second
postpurgeperiodbeforede-energizingthecombustionblower.
FAILURE TO LIGHT - LOCKOUT
Shouldthemainburnerfailtolight,orflameisnotdetectedduringthefirst
TFIperiod,thegasvalveisde-energizedandthecontrolgoesthroughan
interpurgedelaybeforeanotherignitionattempt. Thecontrolwillattempttwo
additionalignitionsequencesbeforegoingintolockout. Thevalverelaywillbe
de-energizedimmediately,andthecombustionblowerwillbeturnedofffollowing
thepostpurgeperiod.
Recoveryfromlockoutrequiresamanualresetbyresettingthethermostat,
turningoffthemainpowerswitchorremoving12-voltpowerforaperiodof5
seconds.
Ifthethermostatisstillcallingforheatafteronehourthecontrolwillautomatically
resetandattempttoignitetheburneragain.



"
Cab or Crew Area
1. FlipMainswitchtoON
2. Rotate
Comfort Control knobapproximately75%offull travelclockwise.
3. When temperature in the heated area is satisfactory rotate Comfort Control knob
counterclockwiseuntil a"click"isfeltintheknob.Nowthecabin temperatureisset.
The Comfort Control will maintain the current temperature. Some adjusting will be
necessaryuntilthe"perfect"settingisreached.
Cargo or Beverage
1. FlipMainswitchtoON
2. Rotate
Comfort Control knobapproximately50%offull travelclockwise.
3. If using calibrated room thermostat, set it to the desired setting. If this thermostat is
tocontroltheheaterthensettheComfort Control tothelowestsetting.
4. Adjust,asnecessarytomaintaindesiredtemperature.
Heating
The heater will run as long as fuel and power are supplied to it. If the supply
voltage is below 9.0VDC when the heater is started then it will go into fault mode. (See
faultcodes)
As long as the green light is on and the red light is not blinking, the heater is
readytorun.
Shutdown
1. FlipMainswitchtoOFF.Thegreenindicatorlightshouldgooutimmediately.
2. Theheaterwillgointoa60secondpostpurge,thenshutoff.
3. The
Comfort Control does not have to be turned down. It is recommended for ease
ofoperationthatyousetitandforgetit.




)(##

The PH20-30A has built in diagnostic capabilities. When the microprocessor-based
control detects a fault, it displays an error code by flashing the red LED. To clear an
errorcode,turnoffthemainswitch.(Exceptforlowvoltage)
Table 3 Error Codes
Number
of
Flashes
Problem Remedy
1
*Combustionpressurefault.
Pressureswitchdidnot
closeduringTFI Checkvoltageatheaterwhilerunning.
Checkcombustionpressuretubebetweenburner
headandpressureswitch.
Checkcombustionairinletforblockages.
Checkmotor
2 Flameisdetectedinthe
combustionchamberata
timeitshouldnotbe. Checksolenoidvalveforopencondition.
3 Burnerhasfailedtoignite
afterTFIsequence Checkfuelsupply.
* Theblowerwillrunforapproximately5minutesbeforethiscodeisflashed.Duringthis
time,theunitwillnotheat.



'"
The diagnostic features of the ECS will cover most problems that you may have with
your heater. Table 5 Troubleshooting chart addresses some other problems that may
arise
TABLE 5. TROUBLESHOOTING CHART
Trouble Causeand/orRemedy
Heater fails to start -
motor does not run,
green light is not
on.
1. Checkfuse.
2. Checkallelectricalconnectionsincludingground.
3. Checkmotor.Replaceifnecessary.
4. Isitturnedon?
Heater fails to start -
motor does not run,
green light is on.
1. ChecktoseeifComfortControl isturnedup
)(!
The PH20-30A is designed so that the igniter should
never have to be replaced. If for some reason the
igniterisbrokenortheburnerheadrequirescleaning
and the igniter is removed, the igniter gap should be
checked.Setthegapto.125”+.03-00.Itisimportant
that the gap be set correctly for flame ignition and
flamesensing.
To set the spark gap:
1. bend the center electrode
slightly
2. check with feeler gage
between igniter tip and
centerelectrode
NOTE: igniter should not need
to be bent. Adjust center
electrodeonly



!,*
Thefollowingserviceprocedures,ifperformedasindicated,willhelpensureproperoperation
andextendthelifeofyourheater.
Description Daily Weekly Monthly Pre-
season
Inspectpropanetank,regulator,andexcessflow
valve **
Inspectcombustionairinletforobstructions **
Inspectexhaustpipeforblockages **
Cleancombustionblower *
Oilmotorbearings *
Inspectfuellinesforleaksusingleakdetector **
Inspectandifnecessarytightenmounting
hardware *
Havepropanetanksinspectedforexcessoil,
desiccant,wateretc. *
Checkelectricalconnectionsincludingground **
Operateheaterduringnon-heatingseason **
Service Tip:Usehightempanti-seizecompoundonburnerheadscrews.



*

General
This section lists and illustrates the major parts of your model PH20-30A Hunter
heater.Ingeneral, attachingpartssuchasscrews,nutsandlockwashershavenot been
listed or illustrated since their application is obvious. If a part has not been assigned a
part number, or the abbreviation COML appears, the part can be replaced with a
commerciallyavailableequivalent.
All available service kits are listed. Parts shown with an asterisk ( * ) are available only
aspartofakit.
(
1
2
3
5 4
6 7
Index Number Part Number Description
*1 88301-T Regulator
*2 88014 POLConn.
**3 49084 ¼-20Stud
**4 51718 ExhaustCollarAssy.
**5 49091 HeatShield
**6 47006 1¼“PipeElbow
**7 47008 1¼”PipeX8"
*88301RegulatorKit
**50930ExhaustKit



(&'"
1
2
3
4 5
6
7
8 9
10 11 12
13
Index # Part # Description
1 49131 Crossbar
2 49196 Covers
3 493151 TopCover
4 49828 Terminal
5 52712 Panel
6 4347 OverHeat
Thermostat
7 52618 CaseAssembly
8 49420 HeatExchanger
Index # Part # Description
9 50734 Deflector
10 4952201 Brkt.Exch.
11 49355 ExhaustConn.
12 52745 Panel
13 52632 FuseAssembly
Note:Togetcompletesetordertwo
49196covers.