PHP PHP-20A User manual

®
Technical Description
Installation Instructions
Operating Instructions
Troubleshooting
PHP-20A 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 18
Exhaust & Combustion Air Intake Connections 25
Heater Ducting 27
Heater Operation 28
Maintenance 31
Troubleshooting 32
Fault Code Chart 34

3
Introduction
Thank you for purchasing our PHP-20A heater kit.
The PHP-20A 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.
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 (6,825) 1.6 (5,460) 1.3 (4,436) 0.9 (3,071)
Fuel Consumption L/hr (US Gal/hr) 0.25 (0.07) 0.21 (0.05) 0.16 (0.04) 0.10 (0.03)
Air Flow - CFM 49 41 28 20
Power Consumption - watts 34 23 13 9
Power Consumption at Start - watts ≤ 100
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 2.8 kg (6 lbs)
Above Specications (± 10%)

6
Heater Kit List
QTY
1
1
QTY
1
1
QTY
1
QTY
1
1
2
1
1
QTY
1
1
2
QTY
1
Part Number
P65D-T303
NPN
Part Number
U65A-X702
U65A-X701
Part Number
NPN
Part Number
U65D-X518
U65D-X507
NPN
U65D-X401
NPN
Part Number
U20A-X603
U20A-X602
U20A-X604
Part Number
P20A-T802
Description
Operating 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
60mm Hot Air Ducting 1M (3’) Length
60mm Air Outlet Adjustable Vent
60mm Hose Clamps
Description
2Kw Air Heater
Heater Only

7
Heater Kit List
QTY
1
1
1
1
1
1
8
Part Number
U65D-X405
P20A-T401
U65D-X407
U65D-X414
U65D-X704
U65D-X403
U65D-X401
Description
Fuel Pickup Tube & Fuel Tube Hardware Kit
- Compression Fitting
- Large Flat Washer
- Small Flat Washer
- Large Rubber Gasket
- Large 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 Screw
M6 Hex Nuts
Heater Mounting Studs
“L” Brackets

8
Main Components and Operating Concept
1) Process Air Blower Wheel 6) Blower Motor C. Combustion Air
2) Electronic Control Unit 7) Glow Pin E. Exhaust Gas
3) Combustion Air Blower Wheel 8) Heat Exchanger F. Fresh / Process Air Intake
4) Combustion Chamber 9) Fuel Pump H. Hot / Process Air Outlet
5) Overheat / Flame Sensor
10) Operating Unit / Controller
D. Fuel Intake
How the PHP-23A Air Heater Works
• 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.
10

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

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 PHP-20A 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. 5.0 mm Rubber Fuel Line
7. 5.0 mm Rubber Connector
8. 1.5 mm Clear Plastic Fuel Line

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
30 amp Fuse
Electrical System Installation
The heater harness has all the electrical connections preassembled 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 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, Green, Blue
• Route switch harness section from heater to switch location.
• Attached connector to operating switch
D. Fuel Metering Pump Harness 2 Core, 2.5M (8’) Long – Yellow, Yellow
• Route fuel metering pump harness to fuel pump.
• Connect to fuel pump
Figure E1

17
Electrical Connections
Main Harness Wiring Legend
Note: There are no corresponding numbers on the connector.
Numbers are for reference only.
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 / White 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
5
1
6
2
7
3
8
4

18
Operating Switch
The PHP-20A is provided with a multifunctional controller. It is capable of manual and timer controlled
switching of the heater and conveys heater operational parameters and diagnostics. Refer to the Operating
Switch Instructions for operational details.
Mount the operating switch in a suitable location.
It should be located where it will be accessible to the operator and be 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 accidental shorting, connect the heater to the battery and install the fuse as the last step.
This should only be completed once all other installation steps are completed.
Caution
Figure E2
Figure E3

19
Operating Switch
PHP Gen II Air Heater Control Switch - Operation Instructions
Overview:
The PHP Control Switch allows you to set and regulate temperature, set operating mode, timed shutdown
and timed startup functions. It also facilitates troubleshooting by providing diagnostic codes.
PHP Gen II Air Heater Control Switch - Operation Instructions
Overview:
The PHP Control Switch allows you to set and regulate temperature, set operating mode and set
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 Timer Active
6. Indicates Error
7. Gear Level
On / Off Control:
Press and hold 3 sec. to start heater
displays and heater begins start-up
Press and hold 3 sec. to stop heater
display flashes during 5 minute cool
down then disappears, heater shuts
down.
20
ºC
GEAR
A/C
TIM
Error
2L
20ºC

20
Operating Switch
Operating Modes:
The heater is designed to function in two dierent operating modes.
“Gear” mode (Manual) allows you to control the heater output in 4 operating levels.
“Automatic Climate - A/C” mode allows you to control the target cabin temperature that the heater will
maintain. This is the more common operating mode and is practical for use with cargo and cabin heating
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.
PHP Gen II Air Heater Control Switch - Operation Instructions
Operating Modes:
The heater is designed to function in two different operating modes.
mode (Manual) allows you to control the heater output in 4 operating levels.
- mode allows you to control the target cabin temperature that the
heater will maintain. This is the more common operating mode and is practical for use with cargo
and cabin heating applications. This mode allows you to set the target cabin temperature from 8ºC
to 36ºC (As measured at the Control Switch).
Switching Operating Modes
To switch heater between Gear Mode and Automatic
Temperature Control Mode the heater must be
running.
Switch between modes by pressing
Heater will alternate between two operating modes.
For A/C Mode:
A/C and actual temperature displayed
in °C
For Gear Mode:
Gear and Gear Level displayed
Gear (Manual) Mode Setting - Heater Turned On
Heater will start in Gear mode.
This mode allows you to set the desired heat output /
gear level 1, 2, 3, or 4 (Low to High)
To switch between Heat Output / Gear Levels:
Rotate Clockwise or Counterclockwise
In a snapping motion.
Desired heat output level
Will be displayed with 1, 2, 3, or 4
(Low to High)
Automatic Temperature Control Setting - Heater Turned On
Change desired temperature setting from 8º to 36º:
Rotate Clockwise or Counterclockwise
In a snapping motion
A/C and Temperature set point will be
displayed in °C
Temperature set point will flash during
adjustment then revert to actual
temperature display.
GGEEAARR
20º
A/C
2L
20º
A/C
2L
GEAR