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Summary of Contents for PHP 25AG
- Page 1 ® 25AG AIR HEATER Technical Description Installation Instructions Operating Instructions Troubleshooting...
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Page 3: Table Of Contents
Table of Contents Introduction Heater Warnings Specifications Heater Kit List Main Components and Operating Concepts Heater Mounting Fuel System Electrical Connections Operating Switch Instructions Exhaust & Combustion Air Intake Connections Heater Ducting Heater Operation Maintenance Troubleshooting Fault Code Chart Heater Components... -
Page 4: Introduction
Introduction Thank you for purchasing our 25AG heater. The 25AG heater is designed to provide cabin heating for trucks, off-highway equipment and RVs by using on-board gasoline fuel and battery systems. Operation is simple and the heater provides a safe and reliable alternative to engine idling or need for electrical plugins. -
Page 5: Heater Warnings
Heater Warnings Special Notes Highlight areas requiring special attention or clarification. Note: Caution Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed. Warning Indicates that serious or fatal injury may result if specific guidelines are not followed. Warning - Asphyxiation Hazards Warning - Installation Hazards •... -
Page 6: Specifications
Specifications Principal Dimensions 120 mm 323 mm 60 mm 60 mm 121 mm 22 mm 22 mm 29 mm 120 mm Performance Specifications Heating Mode High Range Low Range Heating Capacity kW/hr (BTUs/hr) 2.0 (5,800) 1.0 (2,900) 0.27 (0.07) 0.14 (0.04) Fuel Consumption L/hr (US Gal/hr) Air Flow M^3/min (CFM) 1.19 (42) -
Page 7: Heater Kit List
Heater Kit List Description Part Number 2 kW Air Heater P25A-T888 Description Part Number Operating Switch P65A-X388 Description Part Number Heater Mounting Plate & Seal U65A-X702 Description Part Number Wiring Harness P65A-X304 4.5M (15’) Power Harness, 20A Fuse 6M (20’) Switch Harness 4.5M (15’) Fuel Pump Harness P65D-X303 Description... - Page 8 Heater Kit List Description Part Number Fuel Metering Pump P25A-T410 Fuel Pump Holder U65D-X407 Black Rubber Fuel Line, 4.5mm ID x 0.5M U65D-X414 4.5mm ID x 50mm Fuel Line Connectors U65D-X409 Clear Nylon Fuel Line, 8M (26’),1.5 - 2.0 mm ID U65D-X403 Small Fuel Line Clamps, 9-11 mm x 9mm wide U65D-X401...
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Page 9: Main Components And Operating Concepts
Main Components and Operating Concept Main Components 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. -
Page 10: Heater Mounting
Heater Mounting Heater Location 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. - Page 11 Heater Mounting 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 flange can be used as a template to mark where the individual components openings should be made.
- Page 12 Heater Mounting Figure M3 Figure M4 4” x 5” Rectangle Ø3” x 2 2 1/8”...
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Page 13: Fuel System
Fuel System Overview The 25AG 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. - Page 14 Fuel System Connecting the Fuel System Caution Fuel systems in gasoline vehicles are sealed and electronically monitored to contain fuel vapors. When integrating the heater, you must ensure that you do not disrupt the integrity of the fuel system. Installation should only be completed by a competent technician familiar with the fuel system of the vehicle. Due to the infinite variations of fuel systems used in Gasoline powered vehicles, it is impossible to provide a standard fuel pickup device or procedure that works for every application.
- Page 15 Fuel System Auxiliary Fuel Port Method In some instances, the vehicle may have an auxiliary fuel port. It is possible to use this as fuel tank access. Consult the vehicle dealer for appropriate connections to adapt to our 4.5 mm rubber fuel line. Tee Into Fuel Line Method (NOT RECOMMENDED) Parking Heater Products recommends against Teeing into the vehicles fuel line.
- Page 16 Fuel System Auxiliary Fuel Tank Method Auxiliary fuel tanks can be used in some cases as a solution for difficult to access fuel tanks. However, these are not certified for on-road use. Standard Fuel Pickup Method (Metal tank only) Standard fuel pickup pipes can be installed in larger metal tanks only. These can be installed using existing NPT ports in the tanks for by drilling an access hole in the tanks.
- Page 17 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) Figure F3 Figure F2 15°...
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Page 18: Electrical Connections
Electrical Connections 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 chaffing and pinching. Below is a summary of the wiring connections required. - Page 19 Electrical Connections 25AG Wiring Diagram Figure E2 ECU Interfaces The following represents the wiring connector locations for the ECU. The connectors are constructed to ensure that it is impossible to connect in error. Figure E3 Socket X1 Fan Motor Socket X2...
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Page 20: Operating Switch Instructions
Operating Switch Instructions The 25AG is provided with a multi-functional operating switch. It is capable of manual and timer controlled switching of the heater and conveys heater operational parameters and diagnostics. Mount the operating switch in a suitable location using panel mount method shown in Figure S1 Route the switch harness from the heater to the Operating Switch and connect. - Page 21 Operating Switch Instructions Buttons & Display Icons Buttons: ON / OFF On / Off Control Adjust heat settings < Toggle through menu > Adjust heat settings Toggle through menu Select Menu settings Icons: Heating Mode Fan Mode Not Used Program Mode Clock Settings...
- Page 22 Operating Switch Instructions Set Time of Day / Day of Week: 1. Press “OK” Icons Displayed and heat symbol flashing 2. Press “>” or “<” repeatedly to select “Clock” Icon Clock Icon flashes 3. Press “OK” Days of week are displayed 4.
- Page 23 Operating Switch Instructions On / Off Control 1. Press “OK” Icons Displayed and heat symbol flashing 2. Press “>” or “<” repeatedly to select “Heat” Icon Heat Icon flashes Press “OK” Heater commences start up mode Current Power Level Setting or Target Temperature Setting of heater is displayed.
- Page 24 Operating Switch Instructions Adjusting Power Mode With heater operating in “Power Mode”, Press “>” or “<” to adjust setting from 1-7 1 is lowest and 7 is highest Display will show current target Power Mode setting Heater will continue to operate in this heat output level.
- Page 25 Operating Switch Instructions 3. Press “OK” Fan Speed Setting is displayed 4. Press “>” or “<” to adjust fan speed setting 1-7 Fan Speed Setting is displayed 5. Press the “On / Off” Button to switch off the fan Home Screen displayed Programmed Startup The operating switch has the ability to automatically start the heater using programmed start up and shut down.
- Page 26 Operating Switch Instructions 5. Press “OK” to select desired profile setting Status “On” or “Off” displayed. 6. Press “>” or “<”to select “ON” or “OFF” Status “On” or “Off” displayed. 7. Press “OK” Run Time displayed 8. Press “>” or “<” to adjust run time for this profile. 10 -990 minutes Run Time displayed 9.
- Page 27 Operating Switch Instructions 13. Press “OK” Days of Week settings are displayed. “Mo” flashing 14. Press “>” or “<”to adjust between “On” or “Off” to activate or deactivate programmed start for that day. “Off” or “On” displayed 15. Press “OK” to proceed to next day Days of Week settings are displayed.
- Page 28 Operating Switch Instructions Fuel System Priming On initial start up after installing the heater, the system has the ability to conduct a fuel system priming function. 1. Press “OK” Icons Displayed and heat symbol flashing 2. Press “>” or “<” repeatedly to select “Clock” Icon Clock Icon flashes 3.
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Page 29: Exhaust & Combustion Air Intake Connections
Exhaust & Combustion Air Intake Connections Figure A1 22mm Combustion Air Intake 22mm Exhaust Min. 0.4M (8”) Min. 0.4M (8”) Max. 1.0M (39”) Max. 2.0M (78”) Figure A2 Direction of travel... - Page 30 Exhaust & Combustion Air Intake Connections The combustion air intake tube channels clean air into the heater. The exhaust tube channels exhaust safely away from the heater and vehicle. It also assists in providing a required amount of back pressure required to balance the combustion process. Connect the combustion air intake tube and exhaust as shown in Figure A1 Exhaust Considerations: •...
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Page 31: Heater Ducting
Heater Ducting Hot Air Ducting Distribute heat efficiently throughout the cabin by using the high temperature, 60mm flex-ducting and rotatable outlet and return air inlet provided in the installation kit. IMPORTANT NOTE: The heater uses a temperature sensor on the inlet side of the heater to regulate the cabin temperature. Use return air ducting for best heating regulation and efficiency. - Page 32 Heater Operation 25AG Operation Note: It is important to understand that this heater does not simply turn on and turn off. Rather, it has a sophisticated operating system similar to a household furnace to provide reliable heating comfort. The operator should familiarize themselves with the normal operation of the heater.
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Page 33: Heater Operation
Heater Operation “Vent Mode” Runs the blower fan only to provide cabin ventilation. The operator can adjust the fan speed in a range from 1-7. Note: Running the fan in vent mode for extended periods will diminish the life expectancy of the motor. Automatic Start Times The heater can has the capability of starting and running automatically with pre defined start up and run times. - Page 34 Heater Operation Safety Systems The heater is equipped with several control features to protect itself and the operator. Systems Check: The heater will not attempt to start if one of the components is detected by the control unit to be defective.
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Page 35: Maintenance
Maintenance • Switch heater ON at least once monthly for 10 minutes • Clear combustion air supply and the exhaust system after longer standstill periods. • Ensure that the vehicle batteries are maintained • Inspect and clean all electrical connections and apply dielectric grease. •... -
Page 36: Troubleshooting
Self Diagnostics The 25AG has an automatic built in error code detection system. When the heater detects a fault, it should display a two-digit error code on the Operating Switch. Refer to the Fault Codes section of this manual for further direction. - Page 37 Troubleshooting Fuel Ensure you are supplying a good quality diesel fuel. Fuel is not frozen or gelled Fuel system falls within parameters outlined in installation section. All connections are secure and there are no air leaks Try removing the fuel line at the heater during start up to ensure that fuel is being delivered. Check for fuel filter or fuel metering pump blockage.
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Page 38: Fault Code Chart
Fault Code Chart Fault Code Cause of trouble Remedy Failure to start on two attempts Check for combustion issues (see manual section) Failure to start on three attempts Check for combustion issues (see manual section) Failure to recognize start, flame sensor Check for combustion issues (see manual section) temperature not high enough. - Page 39 Fault Code Chart Fault Code Cause of trouble Remedy Blower Motor Open Circuit Replace as necessary Blower Motor Short Circuit Replace as necessary Blower Speed Too Slow Replace as necessary Blower Speed Too High Replace as necessary Blower Speed Measurement Fault Replace as necessary Glow Pin Short Circuit Should be approximately 0.7 Ω...
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Page 40: Heater Components
Heater Components 25AG Replacement Parts Heater Casing... - Page 41 Heater Components 25AG Replacement Parts Item Description Part Number Heat Exchanger Burner Gasket P25A-X101 Burner Tube P25A-X102 Burner Insert P25A-X103 Blower Gasket P25A-X104 Combustion Blower Blades Assembly Fan Motor Bracket Blower Motor P25A-T101 ECU - Electronic Control Unit P25A-T301 Blower Fan...
- Page 44 ® Vancouver Toronto Dallas help@dksi.com 877-508-3900 DKSI.com PHP-032023-TM25A-REV00...
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