PHP PHP-52W Manuale utente
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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
Specications 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 clarication.
Warning
Caution
Caution - Operational Considerations
Indicates that personal injury or damage to equipment may occur unless specic guidelines
are followed.
Indicates that serious or fatal injury may result if specic 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
Specications
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 Specications (± 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 congurations 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
Indice
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