PHP PH21A User manual

®
Technical Description
Installation Instructions
Operating Instructions
Troubleshooting
PH21A AIR HEATER

2
Table of Contents
Introduction 3
Heater Warnings 4
Specications 5
Heater Kit List 6
Main Components and Operating Concept 8
Heater Mounting 9
Fuel System 13
Electrical Connections 16
Operating Switch 19
Exhaust & Combustion Air Intake Connections 23
Heater Ducting 25
Heater Operation 26
Maintenance 29
Troubleshooting 30
Fault Code Chart 32
Heater Components 33

3
Introduction
Thank you for purchasing our PH21A heater kit.
The PH21A heater is designed to provide cabin heating for trucks, o-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.

4
Heater Warnings
Special Notes
Warning
Caution
Caution - Operational Considerations
Indicates that personal injury or damage to equipment may occur unless specic guidelines
are followed.
Indicates that serious or fatal injury may result if specic guidelines are not followed.
• The installation of this kit requires trained decision making
concerning locating and integrating components, tying
components together, rerouting, or relocating OEM
components, etc. It is impossible to describe all of the
safety and operational considerations in the installation
instructions, therefore, the technician must exercise
professional judgment to achieve a safe and quality
installation.
• Read and understand this manual before attempting to
install the heater.
• Failure to follow all these instructions could cause serious
or fatal injury. • Exhaust pipe will become very hot during heater
operation.
• 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
altitudes above 1500 meters (4920’).
Operating in these conditions may plug the heater with soot
and result in combustion failure.
• Heater must be turned o while re-fueling.
• Do not install heater in enclosed areas where combustible
fumes may be present.
• Exhaust pipe must maintain a minimum a distance of
50mm (2”) from any ammable or heat sensitive material.
• Ensure there are no leaks in the fuel system.
• Ensure that exhaust fumes cannot enter passenger
compartments.
• The heat exchanger should not be used for more than 5
years. After expiration, it must be replaced with genuine
parts and replaced by the heater manufacturer.
Warning - Installation Hazards
Warning - Burn Hazards
Bio-Diesel
High Altitudes
Warning - Explosion Hazards
Warning - Fire Hazards
Warning - Asphyxiation Hazards
Note: Highlight areas requiring special attention or clarication.

5
Specications
Principal Dimensions
Performance Specifications
Heating Mode Super High Medium Low
Heating Capacity kW/hr (BTUs/hr) 2.0 (6,850) 1.5 (5,800) 1.1 (4,437) 0.9 (3,072)
Fuel Consumption L/hr (US Gal/hr) 0.21 (0.07) 0.16 (0.06) 0.12 (0.04) 0.10 (0.02)
Air Flow M^3/min (CFM) 1.65 (58) 1.19 (42) 0.72 (26) 0.47 (16)
Power Consumption - watts 34 23 13 9
Power Consumption at Start - watts ≤ 100
Fuel Type Diesel
Nominal Voltage 12 Volt
Lower Voltage Limit 9 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 2.6 kg (5.7 lbs)
Above Specications (± 10%)
335 mm
(13.19”)
116 mm
(4.57”)
123 mm
(4.84”)
Ø60 mm
(2.36”)
Ø60 mm
(2.36”)
Ø25 mm
(0.98”)
Ø24 mm
(0.95”)

6
Heater Kit List
QTY
1
1
QTY
1
QTY
1
QTY
1
1
1
QTY
1
1
4
1
QTY
1
Part Number
P65A-X310
NPN
Part Number
U65A-X702
Part Number
P65A-X303
Part Number
U65D-X518
U65D-X507
U65D-X509
Part Number
U20A-X603
U20A-X602
U20A-X604
U20A-X601
Part Number
P21A-T801
Description
Operating Switch
Mount Bracket
Description
Heater Mounting Plate & Seal
Description
Wiring Harness
4.5M (15’) Power Harness, 20A Fuse
4.5M (15’) Fuel Pump Harness
6M (20’) Switch Harness
Description
24mm Flexible Stainless Steel Exhaust
25mm Combustion Air Intake Tube,1M
Combustion air intake cap
Description
60mm Hot Air Ducting 1M (3’) Length
60mm Air Outlet Adjustable Vent
60mm Hose Clamps
60mm Return Air Inlet
Description
2Kw Air Heater

7
Heater Kit List
QTY
1
1
1
1
6
1
12
1
10
Part Number
P21A-T401
U65D-X405
U65D-X407
U65D-X414
U65D-X409
U65D-X403
U65D-X401
U65D-X402
U65D-X705
Description
Fuel Metering Pump
Fuel Pickup Tube & Fuel Tube Hardware Kit
Fuel Pump Holder
Black Rubber Fuel Line, 4.5mm ID x 0.5M
4.5mm ID x 50mm Fuel Line Connectors
Clear Nylon Fuel Line, 8M (26’),1.5 - 2.0 mm ID
Small Fuel Line Clamps, 9-11 mm x 9mm wide
Fuel Filter
Cable Ties, Medium Grade, Black, 20cm
QTY
1
2
1
2
1
7
6
10
10
6
2
Part Number
U65D-X502
U65D-X701
U65D-X707
U65D-X706
U65D-X702
NPN
NPN
NPN
NPN
NPN
NPN
Description
Exhaust Clamp, 26 – 28 mm
28mm “P” Routing Clamp
“Z” Mounting Bracket
“L” Brackets
Combustion air tube clamp
TEKS Mounting Screws ¼” -14 x 1”
M6-1 x 25 Hex Head Screw, Grade 8 Zinc Plated
M6-1 Hex Nuts – Grade 8, Zinc Plated
6mm wave washers
#8 x 20mm, Self Drilling, Phillips Head Cap
#6 x 12 mm (½”) Self-Drilling, Phillips Head Cap

8
Main Components and Operating Concept
• The fuel pump delivers fuel to the combustion chamber.
• The combustion air blower delivers air to the combustion chamber.
• A glow pin is used to ignite the fuel-air mixture.
• The heat from the ame is transferred through the heat exchanger while the exhaust
gases are expelled to the exterior of the vehicle.
• The process air blower transfers air from the cabin, over the outside of the heat
exchanger and blows hot air into the cabin.
• The heater automatically maintains the desired set temperature in the cabin by
regulating through multiple heat output modes.
1) Process Air Blower 6) Blower Motor C. Combustion Air
2) Control Unit 7) Glow Pin E. Exhaust Gas
3) Combustion Air Blower 8) Fuel Metering Pump F. Fresh Air Intake
4) Combustion Chamber & Heat Exchanger 9) Operating Switch H. Hot Air Outlet
5) Overheat Sensor D. Fuel Intake
1
2345
6
7
8
9
CE
D
F
H

9
Heater Mounting
Typically, air heaters are mounted inside a tool compartment with the OEM HVAC System.
However, the heater may be mounted anywhere inside the cabin provided you adhere to the
following conditions:
• Combustion air intake, exhaust and fuel inlet connections must be on outside of the
vehicle.
• Heater must be mounted on at surface and provide an air tight seal between heater
and vehicle.
• Refer to Figure M1 for permissible mounting orientations.
Heater Location
Figure M1
Glow Pin 90 °
30 °

10
Heater Mounting
• A mounting plate and hardware are provided with the truck heater kit.
• Refer to Figures M2 & M3 for assembly orientation. Note: If the mounting plate will not
be used, the heater ange can be used as a template to mark where the individual
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 oor to accommodate
mounting plate and seal. Refer to Figure M4.
• Secure mounting plate to vehicle with self taping“Tek” screws provided.
Mounting
Figure M2

11
Heater Mounting
Figure M3
Combustion air
Seal
Exhaust
Fuel Line
Wiring Harness
Heater Flange

12
Heater Mounting
Figure M4
2 1/8”
Ø3” x 2
4” x 5”
Rectangle
++

13
Fuel System
The PH21A fuel pump and fuel system are the heart of the heater. The fuel pump not only delivers fuel
to the heater but also controls the amount of fuel delivered. The pump is designed to operate like an
electric solenoid and works using electric pulses. Each time it is energized, it provides a measured dose of
fuel. It is critical to the heater’s operation to stay within parameters outlined in Figure F1 and only use the
components 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 oer installation
access.
• Design your fuel system so that Figure F1 fuel line limits are not exceeded.
Figure F1
1. Heater
2. Fuel Pickup Pipe
3. Fuel Metering Pump
4. Fuel Tank
5. 9-11 mm Clamp
6. 4.5 mm Rubber Fuel Line
7. 4.5 mm Rubber Connector
8. 1.5 mm Clear Plastic Fuel Line
1.

14
Fuel System
Fuel Pump Mounting
• Using the bracket and rubber mount provided, install fuel pump as shown in Figure F2.
• Isolating the pump with the rubber holder helps to minimize noise created during operation.
• Ensure that the proper mounting angle is observed to avoid cavitation. (Figure F3)
Fuel Source
• Connect directly into the fuel tank using our dedicated fuel pickup tube. (Figure F4)
• Teeing into the existing vehicle fuel lines is not recommended.
• There are three common methods to install a fuel pickup tube.
o Use NPT / compression ttings if available
o Use spare fuel gauge plate if available
o Drill dedicated holes into the tank.
Fuel Pickup Pipe
Figure F2 Figure F3
Figure F4

15
Fuel System
Fuel Pick-Up Pipe Installation (Drill Option)
• Drill mounting holes in tank to accommodate pick-up pipe as shown in Figure F4
• Drill the two (1/4”) holes rst as shown in Figure F5.
• Drill a 7/8” hole as shown in Figure F6.
• Mount the fuel pick-up assembly pipe as shown in Figure F4.
• Position fuel pick-up 4”from bottom of tank for round tanks and 1” for at 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 ow)
• 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.
Figure F6Figure F5

16
Electrical Connections
Fuel Pump
Battery
Operating Switch
Heater
20 amp Fuse
Electrical System Installation
The heater harness has all the electrical connections pre-assembled for easy installation.
• Route cables using either an existing cable passage or drill holes as required.
• Seal the hole around the cables and make sure they are protected from chang and pinching.
• Below is a summary of the wiring connections required.
A. Main Heater Harness Combines switch, fuel and power harness.
Connects to the heater’s main connector.
Refer to Main Harness Wiring Legend for details.
B. Power Harness 2 Core, 4.5M (15’) Long
Red (+), Brown (-)
• Route power harness section from heater to vehicle batteries.
• Connect red wire to battery (+)
• Connect brown wire to battery (-)
• Install 20 amp main fuse (Last step of installation)
C. Switch Harness 4 Core, 6M (20’) Long
Yellow, Brown/White, Red, Grey/Red, Grey, Blue/White, Brown
• Route switch harness section from heater to switch location.
• Connect to operating switch harness
D. Fuel Metering Pump Harness 2 Core, 4.5M (15’) Long
Green / Red, Brown
• Route fuel metering pump harness to fuel pump.
• Connect to fuel pump
Figure E1
1

17
Electrical Connections
Main Harness Wiring Legend
Terminal Wire Color Function
1. Red Main Power “ + ”
2. Brown / White Switch
3. Blue / White Switch
4. Yellow Switch
5. Open
6. Red Switch “ + ”
7. Grey Switch
8. Open
Open end view of main heater harness connector Figure E4
2 3 4 5 6 7 81
9 10 11 12 13 14 15 16
Glow Pin
ECU Electrical Connections
Green
Yellow
Black
Black
Black
Red
Blower
Motor
Temperature
Sensor
Terminal Wire Color Function
9. Open
10. Green / Red Fuel Metering Pump
11. Brown Fuel Metering Pump
12. Open
13. Open
14. Brown Switch
15. Open
16. Brown Main Power “ = “

18
Electrical Connections
Figure E5
Operating Switch Wiring
Brown Brown
Black
Red
Red / White
Brown / White
Red
Yellow
Grey
Blue / White
Grey / Red
1
22
33
44
55
66
1
456
1 2 3
65 4
321
Male
Viewed from
wire side
of connectors
Female

19
Operating Switch Instructions
Overview:
The PHP Operating Switch allows you to regulate cabin temperature, set operating mode, monitor heater
operations and access diagnostic information.
Operation Buttons & Display Icons:
Temperature Setting
Battery
Fuel Level
Flame
Glow Pin
Blower Motor
Altitude
Cabin Temperature
Combustion Eciency
Fuel Pump
Fuel Reservoir
Operating Switch

20
Operating Switch Instructions
On / O Control:
Press and hold the Operating Switch for 3 seconds to
turn the heater either ON or OFF.
Operating Modes:
The heater has two dierent operating modes.
“Power Mode” Controls the heat output level.
“Automatic Mode” Establishes target cabin temperature for heater to maintain. (Primary operating mode
for cargo and cabin heating applications)
Note:
Internal temperature sensor inside heater is used to regulate the cabin temperature. Temperature
displayed on switch, only reects temperature at operating switch.
Note: Once combustion process starts, switching
o heater will initiate a 4 minute cool down
period.
ON / Off Control:
Press and hold the Operating Switch for 3 seconds
to turn the heater either ON or OFF.
Note: Once combustion process starts,
switching off heater will initiate a 4 minute cool
down period.
Press & Hold
ON / Off Control:
Press and hold the Operating Switch for 3 seconds
to turn the heater either ON or OFF.
Note: Once combustion process starts,
switching off heater will initiate a 4 minute cool
down period.
Press & Hold