Hunter PH20-30A User's Manual
Contents
1. Exchanger 19 FUNI Index Part Description 9 50734 Deflector 10 4952201 Brkt Exch 11 49355 Exhaust Conn 12 52745 Panel 13 52632 Fuse Assembly k Note To get complete set order two 49196 covers FUNI Z Fuel Ignition and Electronic Control System Index Part Description 1 52610 Electronic Control Module 2 52610 4 Ignition Cable 3 51964 Terminal Block 4 52611 Pressure Switch not Shown 5 3629 45 Flare Fitting 6 52608 Mounting Bracket 7 13819 lg NPT Connector 8 4718201 Igniter and Gasket 9 49093 Burner Head Gasket 10 50386 Solenoid Valve 11 52606 Fuel Line 12 52604 Burner Head 13 50716 R estrictor Assembly 14 COML 10 24NC Cap Screw 20 FUNI Z Blower and Motor Assembly Index Part Description 1 10599 07 Inlet Air Duct 2 50875 Cover 3 51567 Combustion Blower Wheel 4 50576 Combustion Blower Housing 5 49152 Combustion Air Hose 6 50783 Motor Mount 7 49226 Motor 12VDC 8 49976 Prop Fan 9 49399 Mounting Plate 5158212 Complete Blower and Motor Assembly 21 FUNI Comfort Control and Remote Harness Index Part Description 1 52944 6 Remote Cable 6ft 2 52621 Comfort Control Assembly complete L E D Circuit 52623 Thermostat 52624 Knob Main Switch Control Harness Partof 52621 Comfort Control 22 FUNI Z Section Six OPTIONS and ACCESSORIES 2 Duct Opening jae 3 Index Part Description 1 52944 10 10 Foot Long Remot2. Spark Ignition thermostatically controlled heater The control utilizes a microprocessor to continually and safely monitor analyze and control the proper operation of the gas burner Value added features such as combustion blower control LED diagnostic output automatic one hour reset and multiple ignition tries highlight the controls benefits Model PH 20 30A is designed for use solely with propane LP gas as fuel Combustion air is supplied by a single stage combustion air blower and fuel flow to the burner head is controlled by a solenoid valve and a restrictor in the fuel line Because the propane enters the burner head as a gas no carburetor is required Ignition of the propane is accomplished with a spark plug like igniter which is supplied with high voltage current from the Electronic Control Module ECM SPECIFICATIONS Heater case dimensions 16 in long x 11 in wide x 6 3 4 in high Shipping weight R ating 20 000 BTU Heated air outlet diameter Exhaust outlet 1 1 4NPT stainless steel pipe Combustion air inlet 1 in OD tube Fuel connection 5 8 18 UNF x 45 deg flare male fitting Electrical requirements 12 volts DC Current draw average start and run Fuel requirement Propane LP gas Fuel consumption 1 hour pound on high thermostat setting Low pressure type Ignition Electronic ignition pack ke NOTE All specifications are based on the use of a vapor withdrawal gas bottle and gas regulator part number 88301 T Operat
3. and Indicators Comfort Control Assembly Temperature Control Knob Green LED Heater on Red LED Diagnostics Main Switch Controls and Indicators figure 5 Table 2 Control and Indicator Functions Main Switch Simple on off switch Move to ON for heater to run Note Green light will come on but heater will not start until heat is called for by the temperature control or remote room thermostat Temperature Control Controls the temperature in the heated area by way of an Knob internal thermostat Temperature range is 45 95 degrees F Turn clockwise to increase The control has a detent when turned counter clockwise which locks out this thermostat This will not shut off the heater see main switch Green LED Indicates when the heater is on and ready to operate Red LED Indicates when a fault has occurred by flashing a code Remote Room An optional calibrated room thermostat kit P N 51643 can be Thermostat attached for beverage body or cargo heating not pictured Note When a remote room thermostat and the Comfort Control are used together either one will start the heater after the main switch is ON FUTI S Theory of Operation The Falconaire PH20 30A is a Microprocessor Based Direct Spark Ignition thermostatically controlled heater The control utilizes a microprocessor to continually and safely monitor analyze and control the proper operation of the gas burner Value added features such as combustion blower c
4. x Inspect Inspect fuel ines tor leaks using leak detector lines for leaks using leak detector mesieetizne A ll Hill Inspect and if necessary tighten mounting hardware Have propane tanks inspected for excess oil desiccant water etc Check electrical connections including ground i X x Operate heater during non heating season g Service Tip Use high temp anti seize compound on burner head screws 17 FUNI Section Five PARTS LIST General This section lists and illustrates the major parts of your model PH20 30A Hunter heater In general attaching parts such as screws nuts and lock washers have not been listed or illustrated since their application is obvious If a part has not been assigned a part number or the abbreviation COML appears the part can be replaced with a commercially available equivalent All available service kits are listed Parts shown with an asterisk are available only as part of a kit Installation Hardware 88301 Regulator Kit 50930 Exhaust Kit Index Number Part Number Description al 88301 T Regulator g 88014 POL Conn de 49084 Y4 20 Stud KA 51718 Exhaust Collar Assy 5 49091 Heat Shield KG 47006 1 14 Pipe Elbow Hi 47008 1 1 4 Pipe X 8 18 Case and Heat Exchanger Index HUI B WN PF CO N Part 49131 49196 493151 49828 52 12 4347 52618 49420 Description Crossbar Covers Top Cover Terminal Panel Over Heat Thermostat Case Assembly Heat
5. C Power supply For operating on 110VAC user supplied Propane Bottle Pipe Exhaust into A frame of truck body or to the outside Make sure body is open to the outside A warning Ground heater through ground screw provided Use a clean secure chassis ground Do not use fuel line as a ground or electrical conductor Do not rely on mounting hardware for electrical ground Fuel Inlet 45deg Flare fitting General Installation Beverage Heater Circulating Fans user supplied Room Thermostat optional Use circulating fans to push the heated air to the bottom of the body Without fans product at the bottom may be lost Body Installation FIG 5 4 Cover Removal Clearance 1 _ 15 1 8 27 32 Mens fi TOP VIEW 7 lai A es 16 412 di lin IPS Cover removal clearance a 1 1 4 IPS Heater Mounting Dimensions FIG 6 FUNI Fuel Connections A Warning This heater is designed for use with propane LP gas only Do not attempt to use gasoline as fuel since fire or explosion may result Use this heater only with gas regulator part number 88301 T and POL connector part number 88014 supplied with the heater Operation with other regulators or tampering with the regulator adjustment voids all warranties and may result in fire explosion or damage to the h
6. FLUTI lt FPalconaine Propane Heater 20 000 BTU HR Model PH20 30A With Automatic Gas Ignition Control Installation e Operation e Service FUNI A Warning EXHAUST GASES Do not operate heater in an enclosed area unless the exhaust gases are piped outside Exhaust gases may contain carbon monoxide a colorless and poisonous gas A Warning FUEL USE This heater is designed for use with propane LP gas only Do not attempt to use gasoline as fuel since fire or explosions may result Use this heater only with gas regulator part number 88301 T supplied with the heater Operation with other regulators voids all warranties and may result in fire explosion or damage to the heater A Warning ELECTRICAL Heater must be grounded through ground screw supplied Do not use the fuel line as an electrical conductor or ground connections Use of the fuel line as electrical or ground conductor may result in fire or explosion Before performing maintenance or inspection except operating tests disconnect the power source Do not operate the heater with the covers off The tilt switch is a safety device that stops heater operation in case the vehicle overturns Do not remove this switch or defeat its purpose 9 CAUTION Do not operate the heater at less than 11volts Propane flow to the burner head is constant but blower motor speed and combustion airflow vary directly with voltage Op
7. dditional ignition sequences before going into lockout The valve relay will be de energized immediately and the combustion blower will be turned off following the post purge period Recovery from lockout requires a manual reset by resetting the thermostat turning off the main power switch or removing 12 volt power for a period of 5 seconds If the thermostat Is still calling for heat after one hour the control will automatically reset and attempt to ignite the burner again 13 FUNI Starting Cab or Crew Area Flip Main switch to ON Rotate Comfort Control knob approximately 75 of full travel clock wise When temperature in the heated area is satisfactory rotate Comfort Control knob counter clock wise until a click is felt in the knob Now the cabin temperature is set The Comfort Control will maintain the current temperature Some adjusting will be necessary until the perfect setting is reached Cargo or Beverage L di 3 4 Flip Main switch to ON Rotate Comfort Control knob approximately 50 of full travel clock wise If using calibrated room thermostat set it to the desired setting If this thermostat Is to control the heater then set the Comfort Control to the lowest setting Adjust as necessary to maintain desired temperature Heating The heater will run as long as fuel and power are supplied to it If the supply voltage is below 9 0VDC when the heater is started then it will go into fault mode See faul
8. e Cable 52944 20 20 Foot Long Remote Cable 2 51643 Thermostat Calibrated 3 47060 Defroster Kit y not included 23 FUNI Remote Calibrated Thermostat Installation Plug Thermostat In Here PH20 30A Heater rear view Calibrated Thermostat P N51643 Plug the remote thermostat into the rear of the heater using the spade connectors supplied Use 20ga wire 24 FUNI Z External Diagnostic Light Installation VA Comfort Control White wire for external light Connector The Ph20 30A comes with a additional power lead on the back of the Comfort Control to attach a remote or external diagnostic light On some applications itis necessary to monitor the heater operation from outside the vehicle This circuit will handle 1 amp maximum Attach one power lead positive to the connector on the Comfort Control The negative lead may be attached to chassis ground or heater ground Use 20ga wire when making connections The remote light circuit operates on the inverse of the red LED That is to say that when the red LED is off the remote light is on This allows you to monitor normal heater operation For example when the heater is turned on and is running normally the remote light will be on When a fault code is flashed the remote light will blink along with the red LED 25
9. eater 1 Locate and mount the propane tank gas bottle away from the engine and heater exhaust ports The location should also protect the tank from accidental mechanical damage g CAUTION Use only propane tanks which are designed or modified for vapor withdrawal _ Connect the heater to the VAPOR port on the tank Damage to the heater and _ regulator will result if connections are not made properly 2 The propane tank must be a gas bottle designed or modified for vapor takeoff only Install POL put on left connector fig 2 atthe IN porton regulator and install these assembled parts into the propane tank shutoff valve as shown in figure 2 ke NOTE POL connector part number 88014 incorporates an excess flow valve Use of an excess flow valve is a safety requirement of the Department of Transportation DOT 3 Fuel line from the regulator to the heater should be 3 8 inch diameter tube If available a short piece of flexible fuel line may be used at the regulator to make bottle changing more convenient Flexible line must be approved 300 psi test neoprene hose which can normally be obtained from the propane supplier g CAUTION Use of flexible fuel line is recommended If rigid line is used it i must withstand vehicle vibration which may cause rigid line to crack FUT lt Electrical Connections A Warning Ground the heater electrically through the ground screw provided on the heater case and connect t
10. eration on low voltage will produce poor burning smoke and unburned fuel mixtures FUNI Table of Contents Section One Introduction and Description Description Section Two INSTALLATION INSTRUCTIONS Pre Installation Inspection Location and Mounting Electrical Requirements FIG 1 Fuel Requirements FIG 2 Exhaust and Combustion Air Requirements FIG 3 Heater Mounting Dimensions FIG 6 Fuel Connections Electrical Connections Section Three OPERATION Controls and Indicators Theory of Operation Starting Section Four TROUBLESHOOTING and DIAGNOSTICS Fault Codes Troubleshooting Burner Head Maintenance Preseason Maintenance Annual Service Section Five PARTS LIST Installation Hardware Case and Heat Exchanger Fuel Ignition and Electronic Control System Blower and Motor Assembly Comfort Control and Remote Harness Section Six OPTIONS and ACCESSORIES Remote Calibrated Thermostat Installation External Diagnostic Light Installation Hunter Mfg 1999 W 0 0 Jd A AA A UW jm SUN N bea nn po pk IAA A bea Co NN NN e me Ne COC SF N Go WN WN Mm B Oe FUNI Z Section One Introduction and Description This manual contains installation operation maintenance and repair instructions for Model PH 20 30A Heaters manufactured by Hunter Manufacturing Company Solon Ohio Description The Falconaire PH20 30A is a 12 VDC Microprocessor Based Direct
11. ion under other fuel conditions voids all warranties This regulator provides the mandatory pressure 11 inches H20 required by the calibrated burner head orifice FUNI Section Two INSTALLATION INSTRUCTIONS Pre Installation Inspection A Warning 1 Inspectthe heater for damage that may have occurred Read all warning during shipment Check against the packing list or tags supplied invoice for lost parts with the heater Perform all duties 2 Inspectthe controls for loose or missing hardware indicated on the tags 3 Inspectall lines tubing and fittings to see that they are secure and free of breaks kinks or other damage xe NOTE A warranty card is packed with each heater leaving the factory Attached is a return postal card It is the duty of the dealer to ensure that both the owner s copy and the registration card are completed and the registration card returned to Hunter Manufacturing Company To be certain that you obtain the benefits of the above warranty this card should be returned within 10 days from the date you purchased this equipment Location and Mounting g CAUTION The heater is designed for use in the horizontal position with the heat exchanger exhaust outlet down Other permissible positions are those which retain the motor shaft in the horizontal plane Operation in any other attitude voids all warranties and may result in damage or rapid heater wear unless modified for s
12. n block yourself in Service must be Electrical Requirements FIG 1 POL Connector Liquid Propane Gas Use vapor takeoff only Use P N 88301 Regulator supplied with heater Bottle mounted l I upright only Line pressure should be 11 Horizontal mounting inches water column with will cause fuel to slosh the heater running into valve 45 deg Flare fitting Fuel Requirements FIG 2 FUT Z General Installation Hot air rises Make sure exhaust products are not picked up by fresh air intakes AWarning Exhaust products contain carbon monoxide A oid ha ing them drawn back into the passenger area Exhaust collar assy supplied Pitch exhaust down to drain condensed water If LI ANPI di O Tr DT lin flexible duct 4ft maximum pipe needs to go up drill 1 8in drain hole at lowest point Duct combustion Maximum 4ft air intake to lt 3 90deg bends total p outside per DOT Regulations Exhaust and Combustion Air Requirements FIG 3 Comfort Control Exhaust Pipe Operators Console Always pitch down 2 Combustion Air Intake control cable l l Behind Seat Mounting Duct in from outside KEEP THIS Upright Mounting AREA CLEAR Comfort Control mounted on cab wall Use spacers dt To mount heater in this position turn the tip over switch so that the rounded end is up This only applies to propane Cab Installations FIG 4 models FUT Comfort Control 12VD
13. o a clean secure chassis ground Do not use the fuel line as a ground or electrical conductor Use of the fuel line as an electrical or ground conductor can result in fire or explosion Do not rely on heater mounting studs to provide electrical ground 1 Refer to the wiring diagram in figure 7 locate the power and ground connections on your heater The ground terminal is located one inch to the left of the fuel inlet Connect this terminal to a good clean chassis ground using the wire size listed in Table 1 2 Refer to the wiring diagram and connect the red power lead from the heater fuse to the vehicle electrical system using the wire size specified in Table 1 This line Should be hot at all times so the heater can purge even if the vehicle ignition is off Protect the vehicle with a circuit breaker or 10 amp fuse in the feed line Less Than 10 10 gauge 10 to 30 8 gauge Over 30 6 gauge Table 1 Wire Sizes 10 FUNI Z ELK TEL BLUTES FEDTBII i 12 VDC FUSE 10 AMF WHT BREN UWeal AHL Electrical Diagram PH20 30A figure 7 Symbol Description B1 Blower Motor ECM Electronic Control Module El Igniter L1 Solenoid Valve LED1 L E D Assembly PS1 Pressure Switch S1 Tilt Switch S2 Overheat Thermostat S3 Room Thermostat optional S4 Comfort Control Thermo SW1 Main Switch TB Terminal Block LT1 External Diagnostic Light optional 11 FUNI Section Three OPERATION Controls
14. ontrol LED diagnostic output automatic one hour reset and multiple ignition tries highlight the controls benefits OPERATION POWER UP STANDBY When the main power switch is turned on the control will reset perform a self check routine initiate full time flame sensing and enter the thermostat scan State HEAT MODE When a call for heat is received from the thermostat the control will check the combustion pressure switch for normally open contacts The blower is then energized and once the combustion pressure switch contacts close a 3 second prepurge delay begins Following the prepurge period the gas valve is energized and sparks commence for the trial for ignition TFI period When flame is detected during TFI sparks are shutoff immediately and the gas valve and combustion blower remains energized The thermostat combustion pressure switch and main burner flame are constantly monitored to assure the system continues to operate properly When the thermostat is Satisfied and the demand for heat ends the main valve is de energized immediately the control senses the loss of flame signal and initiates a 60 second postpurge period before de energizing the combustion blower FAILURE TO LIGHT LOCKOUT Should the main burner fail to light or flame is not detected during the first TFI period the gas valve is de energized and the control goes through an interpurge delay before another ignition attempt The control will attempt two a
15. roblems that may arise TABLE 5 TROUBLESHOOTING CHART Cause and or Remedy Heater fails to start 1 Check fuse motor does not run 2 Check all electrical connections including ground green light is not A Check motor Replace if necessary on Is itturned on Heater fails to start 1 Check to see if Comfort Control is turned up motor does not run green light is on S uo o omomemo0de amp 0 0mmn00nnmnuplnunRlee6 bi Burner Head Maintenance The PH20 30A is designed so that the igniter should never have to be replaced If for some reason the igniter is broken or the burner head requires cleaning and the igniter is removed the igniter gap should be checked Set the gap to 125 03 00 It is important that the gap be set correctly for flame ignition and flame sensing mm b d0 E To set the spark gap l bend the center electrode slightly i 2 check with feeler gage between igniter tip and center electrode NOTE igniter should not need to be bent Adjust center electrode only 16 FLINT lt Preseason Maintenance Annual Service The following service procedures if performed as indicated will help ensure proper operation and extend the life of your heater Description Daily Weekly Monthly Pre season Inspect propane tank regulator and excess flow valve Inspect combustion air inlet for obstructions Inspect exhaust pipe for blockages IENA x X
16. s shown in figure 3 The heater case becomes hot in this area during operation and the heat shield is required to protect the vehicle from excessive heat Set the heater over the mounting holes and secure with mounting studs using the nuts and lock washers Supplied with the heater A Warning Exhaust gas must be piped to the outside of the heated compartment Do not allow the exhaust gas to exit directly beneath the vehicle 5 Direct the exhaust away from the compartment using elbow and nipple and additional 11 4 inch nipples as required If the exhaust must pass through an additional vehicle body panel or floor use exhaust collar to protect paint and or trim Cut a hole in the panel 2 7 8 to 3 inches in diameter to ensure adequate clearance between the hot pipe and the painted panel and to provide access for later servicing Cover the opening with exhaust collar and direct the exhaust pipe through it 6 If the heater is mounted entirely within the cab connect a 1 inch rubber or plastic hose to the air inlet and run it outside the cab to provide fresh air for combustion FUT Z General Installation AWarning DO NOT BLOCK THE HEATED AIR OUTLET OR RETURN INLET Voltage at the Heater should be 12VDC Measure at the heater or within 12 inches with the OVERHEATING CAN OCCUR heater running Battery 12V 10 Gauge supply Over 10ft use 8 Gauge Remote Control Panel with integral a a Comfort Control S SICC o
17. t codes As long as the green light is on and the red light is not blinking the heater is ready to run Shutdown L 2 Flip Main switch to OFF The green indicator light should go out immediately The heater will go into a 60 second postpurge then shut off The Comfort Control does not have to be turned down It is recommended for ease of operation that you set it and forget it 14 FUNI Section Four TROUBLESHOOTING and DIAGNOSTICS Fault Codes The PH20 30A has built in diagnostic capabilities When the microprocessor based control detects a fault it displays an error code by flashing the red LED To clear an error code turn off the main switch Except for low voltage Table 3 Error Codes Problem Combustion pressure fault Check voltage at heater while running Pressure switch did not Check combustion pressure tube between burner close during TFI head and pressure switch Check combustion air inlet for blockages Check motor 2 Flame is detected in the Check solenoid valve for open condition combustion chamber ata time it should not be 3 Burner has failed to ignite Check fuel supply after TFl sequence The blower will run for approximately 5 minutes before this code is flashed During this time the unit will not heat 15 FUT Troubleshooting The diagnostic features of the ECS will cover most problems that you may have with your heater Table 5 Troubleshooting chart addresses some other p
18. uch use by Hunter Manufacturing Co The heater is normally installed within the compartment being heated It can be installed outside the compartment being heated by using a flexible heat duct to direct the heated air into the compartment The heater must be shielded against direct contact from rain and snow A Warning The tilt switch is a safety device that stops heater operation in case the vehicle overturns Do not remove this switch or defeat its purpose FUNI Z LOCATION AND MOUNTING cont 1 Mount the heater horizontally as shown in figure 4 Choose a mounting location that will enable mounting the heater on a level surface with adequate room around the heater for removal and service Check that the tilt switch is upright Refer to figure 6 for mounting dimensions and clearances 2 After selecting a location remove all combustible material from area within two inches of where the heater will be located This includes carpeting rubber mats plywood flooring etc 3 Cut holes as required for air inlet and exhaust Remove cross bar and covers Set heater in place over inlet and exhaust holes and mark mounting holes Remove heater and drill 5 16 inch diameter holes for mounting studs page 8 g CAUTION Use heat shield and exhaust collar as described below to prevent damage to paint and furnishings of vehicle from excessive heat 4 Position heat shield page 17 around the hole for the exhaust connection a
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