PHP PHP-52W User manual

®
PHP-52W ENGINE HEATER
Technical Description
Installation Instructions
Operating Instructions
Troubleshooting and Parts
PHP-06.18.20-TM52W-DR16

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
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

3
Introduction
Thank you for purchasing our PHP-52W heater kit.
The PHP-52W heater is designed to preheat your engine by using 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.

4
Heater Warnings
Special Notes
Note: Highlight areas requiring special attention or clarication.
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.
• Ensure a proper mixture of water and antifreeze to prevent
coolant from Freezing.
• Ensure that the coolant ow can never be blocked while
heater is in operation.
• Blocking coolant ow 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
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

5
Specications
Performance Specifications
Heating Mode High
Heating Capacity kW/hr (BTUs/hr) 5.0 (17,060)
Fuel Consumption L/hr (US Gal/hr) 0.6 (0.16)
Power Consumption - WATT 56
Power Consumption In Standby - WATT 27
Start-up Power 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 Specications (± 10%)
15cm (5.75”)
22cm (8.5”) 9cm (3.5”)
Principal Dimensions
*Figure O1

6
Heater Kit List
QTY
1
1
QTY
1
QTY
1
QTY
1
1
2
1
1
QTY
2
2
2
1
1
16
1
2
QTY
1
Part Number
P65W-X305
NPN
Part Number
P52W-X701
Part Number
P52W-T301
Part Number
U65D-X519
U65D-X522
NPN
U65D-X505
NPN
Part Number
NPN
U65W-X604
U65W-X602
P52W-T602
U65W-X605
NPN
NPN
NPN
Part Number
P52W-T801
Description
5Kw Engine Heater Boxed Version
Note: Contents of the kit will vary for Boxed Version. Kit list is based 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 Hose Clamp
Description
3M Molded Hoses
20mm Tee Connector
20mm Straight Connector
Coolant Pump
Coolant Pump Holder
19 - 29 mm (3⁄4” -1”) Hose Clamps
M6 x 50mm Hex Head Screw
M6 Hex Nuts
Description
5Kw Engine Heater

7
Heater Kit List
QTY
1
1
1
1
1
1
8
Part Number
U65D-X405
P52W-T401
U65D-X407
U65D-X414
U65D-X409
U65D-X704
U65D-X413
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, 0.3M (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
M6 Flat Washers
Tek Screws
#8 Self Drilling Screws
6mm Lock Washers

8
Main Components and Operating Concept
Main parts of PHP-52W Engine Heaters
Here is a basic overview of the operation of the heater.
• Fuel is delivered to the heater via the heater’s fuel 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 ame is contained in a ame 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

9
Heater Mounting
Mounting Considerations:
• Protect from road spray
• Mount below engine coolant level to avoid air blockage.
• Keep coolant hoses short to maximize ow 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.

10
Heater Mounting
*Figure M1
*Figure M2 *Figure M3
Heater Mounting Bracket PHP Boxed Version
Mounting:
Mount the heater using the mounting bracket provided with the installation kit.
Provide shielding as required to protect the heater from environmental conditions.
Orientate the heater within permissible mounting congurations 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

11
Heater Plumbing
Understand that connecting your heater to the engine makes it an integral part of the engine’s cooling
system. It is impossible to describe all of the safety and operational considerations in these installation
instructions. Therefore, the technician must exercise professional judgment to achieve a safe and quality
installation. It is important to try to optimize the coolant ow 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 ttings, valves and run hoses as required.
• Bleed the air out of the system (Run engine to help circulate coolant).
• Top up coolant as required.
• Test the heater to ensure proper ow.
*Figure P1

12
Heater Plumbing
Follow these guidelines and considerations:
• There are a few plumbing accessories included with the kit (Connectors and molded hoses)
• Use 3/4” hoses to optimize coolant ow.
• Keep the pick up and return points as far apart as possible.
• Take coolant from a high pressure point of the engine (ie. back of block)
• Return coolant to a low pressure point of the engine (ie. engine’s coolant pump).
• Use ball valves to isolated the system when not in use.
• Take the coolant from a low point on the engine to minimize aeration.
• Mount heater and coolant pump low to allow the purging of air.
• Consider using insulation around the hoses.
• A heat exchange can be incorporated into the system. However, ensure that the heater ow can never be
completely blocked by a ow 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 system pressure to 15 PSI (1 bar).
• Coolant ow must never be blocked during heater operation (ie. ow control valves).
Tech Tip:
Test the ow by feeling the incoming and outgoing hoses. In a system with proper coolant ow, the output
temperature will not exceed the input temperature by more than 10°C (18°F).
The coolant liquid must contain at least 10% antifreeze all year round as a corrosion protection.
*Figure P2
Warning - Burn & Explosion Hazards
Caution

13
Fuel System
The PHP-52W 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 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 fuel pickup pipe that is close to the heater and oers installation
access.
• Design your fuel system so that Figure F1 fuel line limits are not exceeded.
*Figure F1

14
Fuel System
Fuel Pump Mounting
• Using the bracket and rubber mount provided, install fuel pump as shown. (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.
• Teeing into the existing vehicle fuel lines is not recommended.
• There are three common methods to install a fuel pickup tube.
• Use NPT / compression ttings if available
• Use spare fuel gauge plate if available
• Drill dedicated holes into the tank.
Fuel Pickup Pipe
*Figure F2 *Figure F3
*Figure F4

15
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. (Figure F5)
• Drill a 7/8” hole. (Figure F6)
• Mount the fuel pick-up assembly pipe as shown.
• Position pick-up pipe 4” from bottom of tank (1”for at 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 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.
Fuel System
*Figure F5 *Figure F6

16
Electrical Connections
Electrical System Installation
Connect the heater harness as follows:
• 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.
• Cut each harness section to length and install terminals and connectors as required.
• Below is a summary of the wiring connections required.
*Figure E1

17
Main Harness Wiring Legend
Note: There are no corresponding numbers on the connector. Numbers are for reference only.
Open end view of main heater harness connector
Electrical Connections
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, 5M (16’) Long – Red & Black
• Route power harness section from heater to vehicle batteries.
• Cut to required length.
• Connect red wire to fuse link and install terminal.
• Attach ring terminal to battery (+).
• Connect brown wire to battery (-) using ring terminal provided.
• Install 20 amp main fuse (Last step of installation)
C. Switch Harness 5 Core, 8M (25’) Long – Red, Brown, Yellow, Blue, Green
• Route switch harness section 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 pump harness to fuel pump.
• Cut to required length.
• Install wiring terminals, protective seals and connector block (No polarity required –
Connect either wire to either terminal).
E. Coolant Pump Harness 2 Core, 0.3M (1’) Long – Black & Orange
• Connector is pre-installed.
• Route coolant pump harness to coolant pump and connect.
Terminal Wire Color Function
1. Red Main “+” Positive Feed
2. Yellow Spare
3. Green Switch
4. Orange Coolant Pump “+”
5. White Fuel Pump
6. Black Main “-” Negative Feed
7. Brown Switch
8. Blue Switch
9. Black Coolant Pump “-”
10. Purple Fuel Pump

18
Operating Switch
The PHP-52W 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.
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

19
Operating Switch
PHP Water Heater Control Switch Operation Instructions
PHP Coolant Heater Operating Switch Instructions R4_DallasEDIT.doc 1 June 9, 2020
Overview:
The PHP Control Switch allows you to turn the heater on and off, regulate temperature, 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. Indicates Error
65ºC
Water
Temp
A/C
TIM
Error
On
Off

20
Operating Switch
PHP Water Heater Control Switch Operation Instructions
PHP Coolant Heater Operating Switch Instructions R4_DallasEDIT.doc 2 June 9, 2020
On / Off Control:
Press and hold 3 sec. to start heater Displayed for 3 seconds
Displays max. then actual coolant
temp.
Press and hold 3 sec. to stop heater
NOTE: Heater will initiate a 3 minute cool down cycle.
Displayed for 3 seconds
Disappears
Operating Modes:
The heater is designed to function in two different operating modes.
“Water Temp”mode allows you to control the maximum engine coolant temperature that the heater
will maintain. This is the most common operating mode. This mode allows you to set the desired
maximum operating temperature from 30℃to 75℃. While operating in this mode, the heater will switch
on and off according to the requirements 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 heater will maintain a coolant temperature between
60℃and 75℃. However, once the maximum cabin temperature is reached, the heater will go into
standby mode.
When heater is initially started for the first time it will start in “WaterTemp” Mode. Subsequent starts will
be in the last used mode “WaterTemp” or “ A/C”
Switching Between Operating Modes:
To switch heater between “WaterTemp” Mode and “A/C”
Mode;
Press. three times.
“WaterTemp” or “A/C” mode will be
indicated by the corresponding icon.
Or
The corresponding, current Engine Coolant
Temperature or Cabin Temperature will also
be displayed.
On
Off
WaterTemp A/C
40ºC