PF Jones PFJ-2D-12 User manual

AIR NIGHT HEATER
TECHNICAL SPECIFICATIONS
installation, operation and maintenance instructions

USER MANUAL
A RELIABLE ENERGY SAVING AIR NIGHT HEATER !
This manual contains the products structure and installation instructions.
Please read the instructions carefully before installing and using, to ensure
the correct usage.
Please keep safe for future reference.
Attention!
➢The manual contents may incur some changes without being notified, but will still comply in
accordance with the product.
➢Please contact us directly if you have any queries.
➢After opening the product, please check the main equipment and spare parts according to the
packing list.
➢Please contact the distributor if there are any problems as soon as possible
➢Please keep the warranty card safe, as this is the only valid credential of after-sale service.
Thank you for purchasing our air night heater

CONTENTS
PACKING LIST 01 - 02
OVERVIEW 03
TECHNICAL PARAMETERS 04
STRUCTURE 05 - 06
INSTALLATION 07 - 17
SOLUTIONS TO COMMON MALFUNCTION 18
PRECAUTIONS 18 - 19
FUNCTION AND DESCRIPTION OF THE CONTROL SWITCH 20 - 27
WARRANTY CARD FOR REPAIR AND MAINTENANCE AND WARRANTY CARD FORM 28 - 29

PAGE 1 TABLE 1
Packing List (PFJ-2D-12/ PFJ-2D-24 )
No.
Name
Specification
Unit
Quantity
No.
Name
Specification
Unit
Quantity
1
Main equipment
12V/24V diesel
Set
1
13
Intake (exhaust) pipe clip
German hose clamp (t)28mm
Piece
2
2
Main wire harness
Fuse (20A)
Set
1
14
Fixing clip for
intake (exhaust) pipe
Piece
4
3
Fuel pump
12V/24V (22mL)
Piece
1
15
Fuel tank
IOL/5L
Piece
1
4
Diverter
12V/24V (22mL)
Piece
2
16
Gasket
(018mm x (06.5mmx 1.5mm
Piece
9
5
Control switch
and wire harness
60mm
Piece
1
17
Nut
Piece
4
6
Fuel filter
Piece
1
18
Self-drilling tapping screw
ST5.5 x 25mm
Piece
8
7
Oil-conveying pipe
Nylon pipe (i)
7mm
Piece
1
19
3M Double-sided
back foam
45mm x 35mm x 2mm
Piece
1
8
Air inlet pipe
(025mm x 600mm
Piece
1
20
Nylon cable ties
200mm
Piece
5
9
Exhaust pipe
(025mm x 600mm
Piece
1
21
Air inlet hood
Piece
1
10
Air duct
(t)60mm x 600mm
Piece
2
22
(060 air duct clip
(t)80mm - (0100mm
Piece
2
11
Gasket
Piece
1
23
Tee
Ø90/75mm
Piece
1
12
Dead plate
Piece
1
24
Fuel pipe clip
(t)32mm
Piece
1

PAGE 2 TABLE 2
Packing List (PFJ-4D-12/PFJ-4D-24)
No.
Name
Specification
Unit
Quantity
No.
Name
Specification
Unit
Quantity
1
Main equipment
12V/24V diesel
Set
1
13
Intake (exhaust) pipe clip
German hose clamp (t)28mm
Piece
2
2
Main wire harness
Fuse (20A)
Set
1
14
Fixing clip for
intake (exhaust) pipe
Piece
4
3
Fuel pump
12V/24V 28mm
Piece
1
15
Fuel tank
IOL 5L
Piece
1
4
Diverter
(090/75mm
Piece
1
16
Gasket
(018mm x (t)6.5mmx 1.5mm
Piece
9
5
Control switch
and wire harness
Piece
1
17
Nut
Piece
4
6
Fuel filter
Piece
1
18
Self-drilling tapping screw
ST5.5 x 25mm
Piece
8
7
Oil-conveying pipe
Nylon pipe (i)
7mm
Piece
1
19
3M Double-sided
back foam
45mm x 35mm x 2mm
Piece
1
8
Air inlet pipe
(025mm x 600mm
Piece
1
20
Nylon cable ties
200mm
Piece
5
9
Exhaust pipe
(025mm x 600mm
Piece
1
21
Air inlet hood
Piece
1
10
Air duct
(090/75mmx 600mm
Piece
1
22
(090 air duct clip
(080mm - (0100mm
Piece
2
11
Gasket
Piece
1
23
Tee
Ø90/75mm
Piece
1
12
Dead plate
Piece
1
24
Fuel pipe clip
(t)32mm
Piece
1

PAGE 3
Overview
The main equipment of an air night heater is a small burner tube controlled
by a single-chip microprocessor. It’s furnace body (heat exchanger) is
located in the hood-shape case, which serves as an independent air
passage. Cold air is sucked into the air passage by the heat fan and blown
out when it becomes hot, therefore forming another heating system that is
independent to that of the vehicle. Heat can then be supplied by the heater
to the driver 's cab and passengers' compartment, no matter if the engine is
working or not. The schematic diagram is shown in IMAGE 1. The heater is
fully automatically controlled, and it has many advantages such as compact
structure, easy installation, energy saving, environmental protection, safety,
reliability, and simple maintenance.
IMAGE 1

PAGE 4
Main Technical Parameters
Please refer to TABLE 3 and Table 4 for the main technical specifications.
TABLE 3 TABLE 4
Structure and Work Principle
The structure of the main heater is as shown in IMAGE 2.
1. Heat exchanger
2. Casing / hood cover
3. Control unit IMAGE 2
Item No.
PFJ-2D-12/PFJ-2D-24
Thermal Power
2000W
Fuel
Diesel
Rated voltage
12YT/24v
Fuel consumption
0.12—0.21 L/h
Rated power
40W
Operating (ambient) temperature
-400C+400C
Weight of the main equipment
4.45 kg
Dimension
310xl 16x122 mm
Item No.
PFJ-4D-12/PFJ-4D-24
Thermal Power
4000W
Fuel
Diesel
Rated voltage
12YT/24v
Fuel consumption
0.15—0.55 L/h
Rated power
40W
Operating (ambient) temperature
-400C+400C
Weight of the main equipment
4.45 kg
Dimension
372x141x150 mm

PAGE 5
Case IMAGE 3
The case structure of an air night heater is as shown in IMAGE 3. The Blade wheel on the
heating fan and on the fan motor (the same motor for the combustion-supporting fan) sucks in
cold air from the air inlet and delivers the air after being heated by the heat exchanger and then
out through the hot air outlet.
Controller (circuit board)
The controller is mounted on the rear side of the heating fan. After start-up it will automatically
control and monitor the entire working procedure of the heater and the implementation of fault
protection functions according to the pre-programmed procedures.
1-Top hood cover 2-Bottom hood cover 3-Hot air outlet 4-airinlet hood
Fault Lock
The heater will automatically shut down and go into the locking state for protection, if the following conditions happen: 1) The heater cannot be
ignited or will not work naturally after being ignited 2) An open circuit or short circuit happens to the glow plug, fan motor, fuel pump or sensors
etc. 3) Overheat of the heat exchanger, flame out, unsuccessful ignition, abnormal voltage. To override the fault lock, turn the control switch off
for more than 3 seconds and then restart it.
4

PAGE 6
Circuit Interfaces IMAGE 4
The following circuit interfaces can be found on the controller outer case: X1 for glow plug/flame sensor socket,
X2 for overheating sensor socket, X3 for fan motor socket. Please refer to IMAGE 4 for their locations
Sensors and safety protection
Flame sensor / glow plug
This component has dual functions, when it works as the flame sensor it can monitor the temperature of the furnace cavity.
It is also used to judge whether the furnace is ignited or not in the ignition stage. In normal working conditions it helps to
judge whether the flame is burning continuously or not.
Overheating Sensor
The overheating sensor is installed on the outer wall of the middle of the heat exchanger. When the exchanger's temperature is over 210 oC for a long
time the controller cuts off the fuel pump circuit, stops the fuel supply, and then shuts down the heater to protect the system from overheating.
Temperature Sensor
The temperature sensor is plugged into the corresponding socket on the controller. It measures the air temperature at the air inlet and according to this
temperature the controller changes the working status of combustion furnace to adjust the output power.
Power Supply
The heater shares the power supply with the car's engine, or secondary battery but with a separate fuse. When the power supply voltage is lower than the
specified lower limit value or higher than the specified upper limit value, the heater will automatically report the fault.
Fuel Supply
The fuel used by the heater can be supplied by a special fuel tank. Fuel delivery and fuel supply adjustment is via a fuel pump from vehicle tank or separate
tank.

PAGE 7
Installation
Only approved heating parts can be used for installation of the heater. IMAGE 5 is the diagram for installation. The positions and fixing
ways of various parts may vary for different types of vehicles, but the general principles must be followed to conform with the requirements
of this chapter. Otherwise the heater may not work normally and safety problems may occur.
Requirements for installation and places of application of the air night heater
The air night heater must NOT be near or in direct contact with inflammable or explosive substances (such as flammable gas or flammable
dust).
Do NOT use the air night heater in any closed spaces (such as garages or maintenance workshops) without proper air ventilation. As you
run the risk of carbon monoxide poisoning.
Do NOT install or use the air night heater indoors.
If the heater is installed in a special –purpose vehicle (such as a vehicle to deliver dangerous goods) pet - reg rules must be followed when
installing.
Do NOT place the air night heater near any of the following: fuel tank, compression tank, fire extinguisher, paper or clothing.
Also avoid placing near hot air vents.

PAGE 8
Installation Diagram
Image 5
Connected with the
connector of control switch
20
1- Heater
2- Main harness
3- Fuse holder
4- Fuse box cover
5- Insert disk fusing
6- Control switch
7- Connector for control switch X9
8- Fuel pipe
9- Fuel filter
10-Fuel pump
11-Fuel pump connector
12-Pump leading wire
13-Fuel pump clamp
14-Air inlet pipe clamp
15-Air inlet pipe
16-Air inlet pipe fixing clamp
17-M6 nut
18-Gasket
19-Exhaust pipe fixing clamp
20-Exhaust pipe
21-Exhaust pipe fixing clamp
22-Fuel tank

PAGE 9
Installation of the main equipment
The main equipment can be installed inside or outside of the vehicle, but when it
is installed outside of the vehicle a shield can prevent the damage from external
forces (such as stones and debris).
The heater should not be immersed in water or soaked by rain. If the heater is
corroded by rain and water, please stop using the heater immediately and let a
qualified technician inspect all components.
To ensure heating airflow and easy access of the main equipment, enough space
must be provided on installation. Please refer to the scope of double dot line for
the space of installation, as shown in IMAGES 6 and 7.
Make sure that there is no interference of objects in the gap between the bottom
surface of the main equipment and the mounting surface of the vehicle. As this
can damage the blower motor.
( IMAGE 6 and 7 )
A –Inset of air to be heated
B –Outlet of heated air
C –Inlet of combustion supporting air
D –Discharge of exhaust
E –Fuel inlet
F –None interference area
PFJ-4D-12/PFJ-4D-24
PFJ-2D-12/PFJ-2D-24
123
IMAGE 7
IMAGE 6

PAGE 10
Good sealing is necessary between the main equipment and the installation face on the vehicle. A special gasket (as shown in IMAGE 8 AND
9) supplied by the manufacturer must be padded for installation. The installation surface must be even. The parts at the installation bases of the
main equipment must not have unevenness more than 1mm. After drilling installation holes, evenness must be improved according to the
requirements when installing. Please rotate the four M6 nuts provided by the manufacturer tightly. The torque for tightening should be
6Nm+1Nm. The position of installation holes is shown in IMAGE 8.
If the thickness of the installation panel is < 1.5mm, a mounting plate is needed. The gap between the mounting plate and the car body must
also be sealed (IMAGE 9). Please confirm the actual size with the real product.
NOTE: A new gasket must be replaced when the main unit is reinstalled.
IMAGE 8 IMAGE 9

PAGE 11
The installation direction of the main heater is as shown in IMAGE 10. It must be noted that the tilt angle has to be exactly 90
degrees on both sides, otherwise it will affect the normal operation.
After the installation, it must be checked to ensure that there is no contact or friction between the fan wheel and the surrounding
components, to prevent malfunction during operation.
IMAGE 10

PAGE 12
Installation of Air Heating System
It's recommended to select an independent air duct system for heater
installation. If the air heating system of the heater must to be connected with
the air duct of the vehicle the air flow should be decided by a professional to
ensure the flow is unobstructed.
When an external heating air pipe is attached to the heater, its material shall
be capable to resist the temperature of 1500C.
The maximum pressure drop between the air inlet side and air outlet side of
the air heating system must not be higher than 0.3kPa.
The hot air from the heating system must not flow onto such parts that are
unable to resist heat. In the case of passenger vehicles, measures must be
taken to avoid the blockage of the air vent.
For a heater working in internal circulation, measures must be taken to avoid
re-entering of the supplied hot air into the air inlet port (as shown in
IMAGE 11). The inlet air shall be drawn from the cold area of the compartment,
such as under the seats or berths. If no air inlet pipe is attached in this mode,
an air inlet hood with grids (IMAGES 3 AND 4) must be installed at the air inlet
port of the main equipment.
IMAGE 11

PAGE 13
Installation of Fuel Supply System
The fuel supply system for the heater is as shown in IMAGE 12.
The fuel pump must be fixed in a protective rubber clamp to eliminate the transfer of
vibrations. The outlet of the fuel pump is required to tilt upwards. The tilt angle can be
selected from the range of 45 0 C -95 0 C (as shown in IMAGE 13). When conditions
permit, the fuel pipe between the fuel pump and the heater shall go up gradually.
The elevation difference between the level of fuel and the fuel pump as well as the
elevation difference between the fuel pump and the fuel inlet of the heater,can produce
pressure (or suction) in the fuel pipeline (See IMAGE 13). Therefore, these dimensions
conform to the requirements as follows
3
Connected
with
the
IMAGE 12
1- Fuel tank
2- Filter
3- Fuel connecting pipe
4- Fuel pump
IMAGE 13
1-Fuel pump
2-The highest level of fuel
3-The lowest level of fuel
4-Fuel inlet level for the main
equipment
(1) -The prior installation angle
NOTE: PLEASE CHECK THE VENT
HOLE ON THE FUEL TANK CAP
INSTALLATION.

PAGE 14
Installation of Fuel Filter
➢A fuel filter should be installed before the fuel inlet port of the fuel pump. Make sure that the fuel flow
is correctly followed. Its position must be at exactly 90 degrees - in conformity with IMAGE 14.
The fuel filter should be replaced every 6 months.
Installation of Electrical Components
➢Connection diagram of the main wire harness and the heater is as shown in IMAGE 15.(PAGE
15)The wires of the main equipment for connection to outside circuits have been made into wire
bundles. They can be laid according to the positions of various components and must be fixed in
the proper locations. The distance between two fixing points must not exceed 300mm. Please note
that any exposed wire bundle out of the vehicle body or out of the wiring groove must be protected
by the convoluted pipe.
➢Connect the red wire on the fuse box to the "+" terminals of the vehicle's battery; and connect the IMAGE14
black wire on the main harness to the "-" terminals of the vehicle's battery.
➢Connect the fuel pump leads with the fuel pump.
➢Install the control switch in a position forconvenient operation. Theterminals of the leads ofthe control switch should be plugged
in the socket according to the order as shown in IMAGE 16(PAGE 16), and then connected with the self-locking mechanism to
the connector X9 on the main wire harness.
➢Each wire end must be wrapped with electrician's insulating tape to avoid short-circuit.

PAGE 15
Installation of Combustion Supporting the Air Intake Pipe and
Exhaust Discharge Pipe
➢The combustion supporting air must be sucked in from the external fresh air
outside the vehicle. The fumes from combustion must be discharged externally
through the exhaust pipe. Measures must be taken to avoid the fumes from re-
entering the vehicle.
➢The pipes go through the outer wall or holes on the bottom of the vehicle.
Measures have to be taken to prevent splashes of water entering into the pipes.
The pipes must be protected and can resist shock permanently.
➢Only the air inlet pipe and exhaust pipe provided with the heater can be used.
The air inlet pipe is an aluminium bellow; the exhaust pipe is a stainless steel
bellow. They cannot be installed incorrectly or swapped during operation. To
connect them with the heater, please use the supplied clamps to fix them tightly
on the combustion supporting air inlet and exhaust pipe vent. The protective
hood on the vents of the air inlet
pipe and exhaust pipe must be
kept intact and must not be
damaged or removed.
IMAGE 16
IMAGE 15

PAGE 16
IMAGE 19
IMAGE 20
➢Both the air inlet pipe and
exhaust pipe must come
outwards and downwards from
the heater
(IMAGE 17 AND 18)
➢Or a ɸ5mm hole should be
prepared at the bottom of the pipe
for discharge of condensed water.
If the pipe has to be bent, the
bending radius of the pipe cannot
be less than 50mm.Also the sum
off all the curved angles for each
pipe must exceed 270 °.
➢The openings of the pipe must
not be opposite to the direction of
the running vehicle.
(IMAGE 19 AND 20)
IMAGE 17
IMAGE 18

PAGE 17
Arrangement of the pipes must be protected
from blocking by slurry, snow or other dirt.
( AS SEEN IN IMAGE 21 BELOW )
IMAGE 22
When the heater is running, the exhaust pipe is at a high temperature. During installation, make
sure to install the pipe away from any plastic parts or other objects with poor thermal resistance.
The exhaust pipe must be properly fixed.
The exhaust vent must be downwards, perpendicular to road surface with an angle of
900 C ± 100 C . To ensure an such an angle, the fixing clamp for the exhaust pipe must be within
150mm from the pipe end. (IMAGE 22)
WARNING : VIOLATION AGAINST THE ABOVE REQUIREMENTS MAY CAUSE A FIRE.WE
WILL NOT ACCEPT ANY RESPONSIBILITY FOR ANY PROBLEMS THAT MAY OCCUR
DURING INSTALLATION,IF YOU HAVE NOT FOLLOWED OUR GUIDELINES.
If the exhaust pipe inside the vehicle is in reach of a passenger, a protective cover has to be
installed to prevent human contact and scalding.
HIGH TEMPERATRE
The inflammables should be away from here because there
might be flames out.
WARNING !!!
HIGH TEMPERATURE
Inflammables should be kept away from
here at all times as there may be
exposed flames.