Espar D24 W, D30 W Installation & Parts Manual
D
24 W / D30
W Water Heater
Installation
Troubleshooting &
Parts Manual
Espar
May 1997
For Heater Models
D24W D30W
25 1869 01 00 00 25 1871 01 00 00
25 1870 01 00 00 (NP) 25 1872 01 00 00 (NP)
25 1869 05 00 00 (C) 25 1871 05 00 00 (C)
25 1870 05 00 00 (C) (NP) 25 1872 05 00 00 (C) (NP)
(C) - Compact
(NP)-Nozzle Prepheat
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This publication was cor
rect at the time of going to print. However, Espar Inc. has a
policy of continuous improvement and reserves the right to amend any specifications
without prior notice.
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Table of Contents
I. Introduction 1.
Heater Warnings Page 1-5
2. Introduction
3. Specifications
4. Heater Components
5.
Principal Dimensions
II. Installation Procedures 1. Heater Location Page 5-15
2. Heater Mounting
3. Heater Plumbing
4. Fuel System
5. Electrical Connections
6. Exhaust & Intake Connections
7. Operating Switches
III. Heater Operation 1. Pre-Start Procedures Page 15-19
2. Start-Up
3. Running
4. Switching Off
5. Safety Equipment
6. Operational Flow Chart
7. Wiring Diagrams Model # 25 1869 01/05
25 1871 01/05
25 1870 01/05
25 1872 01/05
IV. Maintenance, 1. Recommended Periodic Maintenance Page 20-31
Troubleshooting & 2. Troubleshooting
Repairs 3. Fuel Quantity Test
4. Adjusting the combustion air
5. Dismantling the water pump
6. Repair Steps
VII. Heater Components 1. Parts Diagram Page 32-39
2. Description & Part #’s
Special Notes
Note: Highlight areas requiring special attention or clarification.
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.
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1
1. Heater Warnings
Warning To Installer
• Correct installation of this heater is necessary to ensure safe and proper operation.
Read and understand this manual before attempting to install the heater. Failure to follow all
these instructions could cause serious or fatal injury
Warning - Explosion Hazard
• Heater must be turned off while re-fueling.
• Do not install heater in enclosed areas where combustible fumes may be present.
• Do not install heaters in engine compartments of gasoline powered boats.
Warning - Fire Hazard
• Install the exhaust system so it will maintain a minimum distance of 2” from
any flammable or heat sensitive material.
• Ensure that the fuel system is intact and there are no leaks.
Warning - Asphyxiation Hazard
• Route the heater exhaust so that exhaust fumes cannot enter any
passenger compartments.
• If running exhaust components through an enclosed compartment, ensure that it is
vented to the outside.
Warning - Safety Hazard on Coolant Heaters Used With Improper Antifreeze Mixtures
• The use of Espar coolant heaters requires that the coolant in the system to be heated
contain a proper mixture of water and antifreeze to prevent coolant from freezing
or slushing.
• If the coolant becomes slushy or frozen, the heater’s coolant pump cannot move the
coolant causing a blockage of the circulating system. Once this occurs, pressure willbuild
up rapidly in the heater and the coolant hose will either burst or blow off at the connection
point to the heater
.
• This situation could cause engine damage and/or personal injury. Extreme care should
be taken to ensure a proper mixture of water and antifreeze is used in the coolant system.
• Refer to the engine manufacturer’s or coolant manufacturer’s recommendations
for your specific requirements.
Note: During electrical welding work on the vehicle disconnect the power to the heater in order to protect
the control unit.
Direct questions to Espar Heater Systems USA 1-800-387-4800
CDA 1-800-668-5676
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2
2. Introduction
Espar’s D24W / D30W Coolant Heater
Quality engineered to provide a dependable means
of heating, the Espar D24W and D30W are diesel
fired coolant heaters capable of putting out between
82,000 to 102,000 BTU’s/hr
.
The heater pumps coolant from the engine, heats it
and returns it to the engine. By routing the hot
coolant through heat exchangers it is also possible
to heat the interior of the vehicle. It is also possible
to route the coolant through stainless steel tubing to
pre-heat hydraulic fluid and fuel in off-road applications.
Since the heater runs on diesel fuel and 24 volt
power, it is able to perform this completely independently of the vehicle engine. A temperature regulating switch in the unit regulates the coolant temperature between a low of 149°F (65°C)
and a high of 176°F (80°C) by automatically
cycling the heater.
The D24W /D30W can be operated from
the vehicle cab by
an on/off
switch, a
preselect timer
or a combination
of both.
T
emperature regulating and overheat
shut down switches are among the safety
features which make the D24W / D30W a safe
and dependable heating system.
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3
3. Specifications - heater
Model (24V) D24W D30W
Heat output (±10%) 82,000 BTU (24Kw) 102,000 BTU (30Kw)
Current draw (±10%) 5 amps 5.5 amps
(without water pump)
Fuel consumption (±10%) 2.90 l/hr (0.76 gal/hr) 3.65 l/hr (0.96 gal/hr)
Operating Voltage Range
Minimum Voltage 20V 20V
Maximum Voltage 28V 28V
W
orking pressure 0.4 - 2.0 bar 0.4 - 2.0 bar
6-29 psi 6-29 psi
Water capacity 2.6 l 2.6 l
Ambient temperature (minimum) -40°C to +70° C -40°C to +70° C
Overheat temperature Shutdown (±5%) 221°F (105°C)
Weight 55 lbs. (25 kg.)
Controls available On/Off switch, 99hr. timer or 7 day timer.
Specifications - water pump Standard High capacity
Voltage 24 V ± 20% 24 V ± 20%
Current draw 4.6 amps 10.4 amps
Water throughput 5000 l/hr - 200mbar 6000 l/hr - 200mbar
Note: The heater is equipped with a high voltage
cutout as well a low voltage cutout.
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4
4. Heater Components
1 Combustion air blower wheel
2
Ignition electrode
3 Flame monitor
4 Mixing head
5
Fuel nozzle
6 Fuel nozzle pre heating (optional)
7 Fuel line
8 Air baffle plate
9 Combustion air control plate
10 Electric motor
11 Silencer
12 Fuel connection
13 Fuel pump
14 Fuel compression line
15 Control unit
16 Fuel solenoid valve
17 Diagnostics Display
18 Ignition spark generator
19 Fuel filter
20 Heat exchanger with flame pipe
21 Outer casing
22 Water connection socket - outlet
23 Water connection socket - inlet
24 Safety thermal cut-out switch
25 Temperature Probe
26 Water pump
27 Push/Pull switch
28 99 hr timer
29 7 day timer
A = Combustion air
E = Exhaust
F = Fuel supply line
FR = Fuel return line
WO = Water Outlet
WI = Water Inlet
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II. Installation Procedures
1. Heater Location
Mount the heater in a protected area eg: storage
compartment or engine compartments. When
mounting the heater adhere to the following
conditions:
• Situate the heater below the normal coolant
level of the engine.
• Guard against excessive road spray.
• Keep coolant hoses, fuel lines and electrical
wiring as short as possible (see fuel line &
electrical wiring specs on pgs.9-11)
5
5. Principal Dimensions
* All measurements in millimeters
25.4mm = 1”
2. Heater Mounting
Using the hole pattern shown above to mount
the heater using the following mounting methods:
• Fabricate support brackets.
• Use an existing compartment floor ( if available).
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6
3. Heater Plumbing
The heater can either be incorporated into the
engines cooling system for engine preheating or can
be provided with its own circulation system for space
heating (ie. marine)
Engine Plumbing
To pre heat engines, follow these guidelines and
refer to engine plumbing diagram shown below.
• Install fittings into the block for pick up and
returns.
• Use existing holes in the engine block (ie.
remove blanking plugs when possible).
• Use shut off valves to ensure the system can be
isolated from the engine when not in use.
• Provide 1.5" (37.5mm) hose barbs for hose
connections.
• Use 1.5” (37.5mm) hoses to ensure adequate
coolant flow
.
D24W / D30W plumbed for engine pre-heat
Isolated Circulating System
To provide space heat independent from the engines
coolant system follow these guidelines and illustrations shown.
• Provide an expansion tank
• Provide a pressure relief valve.
0.4-2.0 bars (6-29 psi)
•
Ensure proper direction of coolant flow.
• Check flow rate through heater by comparing the
incoming and out going coolant temperatures. If the
rise in temperature exceeds 18°F (10°C), coolant
flow must be increased by modifying plumbing .
• The heater and water pump should be installed as
low as possible to allow for the purging of air.
• Use a minimum of 1.5” (37.5mm) hose to and from
the heater.
• Keep the pick up and return points as far apart
as possible to ensure good heat distribution.
• Take the coolant from a low point on the engine
to reduce aeration in the system.
• Ensure proper direction of coolant flow by taking
coolant from a high pressure point in the engine and
returning it to a low pressure point. (ie. pickup from
back of block and return to the suction side of the
engine's water pump).
• Ensure adequate flow rate through the heater by
comparing the incoming and outgoing coolant
temperatures. If the rise in temperature exceeds
18°F (10°C), coolant flow must be increased by
modifying the plumbing.
• Ensure the heater and water pump are installed as low
as possible to allow the purging or air.
• See plumbing diagrams for alternative plumbing
methods.
1
2
3
4
5
1 Heater
2
Water pump
3 Shut-off valve
4
Engine
5 Radiator
6 Heat Exchanger
7 Expansion Tank
8 Safety valve
Note: The coolant must contain a minimum of
10% antifreeze at all times as a protection
against corrosion. Fresh water will corrode
internal heater parts.
D24W / D30W plumbed in isolated circuit
8
6
1
3
2
7
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7
Bus Plumbing Diagram
D24W / D30W plumbed for hydraulic and fuel pre-heat with heat exchanger
1 Heater 3
Shut-off valve 5 Radiator 7
Fuel tank
2 Water pump 4 Engine 6 Hydraulic fluid tank 8 Heat exchanger
4
2
3
1
5
6
7
8
1 Heater 4 Vehicle engine
2 Water pump 5 Front heater
3 Fuel Tank connect 6 Floor Heater
Adding Heat Exchangers, Fuel warmers or
Hydraulic warmers
• Maintain proper flow through heater at all times
• Provide air relief cocks at the heat exchanger.
• If the water piping cannot be run with a continuos
rise to the heat exchangers, provide air relief
cocks at high points.
• Connect plumbing circuits in parallel to avoid
reduction of plumbing hose size and avoid restriction of flow.
• Ensure thermostat and flow control valves do not
completely close off flow through heater
• Refer to plumbing diagrams for examples
Warning: Ensure that a coolant flow path
is open at all times while the
heater is operating to avoid
overheating conditions. Failure to
do so may result in bursting of
coolant hoses with the release of
hot coolant and steam
6
5
1
2
3
4
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8
Off-road
plumbing
diagram
1 Heater 5
Front heater
2 Water pump
6 Floor Heater
3 Fuel Tank connect 7 Hydraulic Tank
4 Vehicle engine
6
7
5
1
1
2
2
3
4
4
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9
4. Fuel System
To connect the fuel supply to the heater (at the fuel filter), a supply line and a return line to the tank are
necessar
y. To accommodate these lines at the tank, a
fuel pick-up pipe with a return stem is available.
The fuel filter is located into the feed line near the
heater. It is recommended that a shut off valve be fitted near the heater on both the intake and return
lines. (fuel filter and shut off valves are already
attached to the heater in the compact version). Refer
to Figures below for connections and specifications.
Fuel System Tolerances
1. Fuel Pick-Up Pipe
2. 11mm Clamp
3. 5.0mm Fuel line
S = Fuel Supply
R = Return fuel
If the D24W / D30W heater is situated within 1.5 m
(5’) above the fuel tank, a permissible 25 meters
(82.5’) of fuel line can be used.
If it is between 5 -10’ (1.5 - 3 m) above the fuel
tank a maximum fuel line of 15 m (48.5’) is permissible.
Fuel pick up pipe with return
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10
Fuel Pick-Up Pipe Installation (Standard Pick-Up)
Choose a protected mounting location close to the
pump and heater. A spare fuel sender gauge plate
provides an ideal mounting location.
• Drill the mounting holes as shown in Figure 1.
• Cut the fuel pick-up pipe to length.
• Mount the fuel pick-up pipe as shown in
Figure 2.
• Lower the fuel pick-up pipe (with reinforcing
washer) into the tank using the slot created by
the two 1/4” holes.
• Lift the assembly into position through the 1”
hole.
• Assemble the rubber washer, metal cup washer
and nut.
Note: Drill the two 1/4” holes first.
Figure 2
ø 1.0” (2.5cm)
ø 1/4” (2 Holes)
(ø 0.625 cm)
9/16”
(1.5 cm)
9/16”
(1.5 cm)
Fuel Pick-Up Pipe Return
Fuel Pick-Up Pipe Supply
Nut
Sheet Metal Washer
Rubber Gasket
Steel Safety Washer
Holding Tabs
Allow 4” from fuel pick-up to tank bottom.
Allow only 1” for flat bottom tanks.
End tip of the fuel pick-up pipe should have
angle so as to avoid picking up dirt and subsequent blockage.
Figure 1
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Note: All harnesses should be cut to length.
All exposed electrical connections should
be coated with protective grease.
5.
Electrical Connections
Caution: To avoid potential short circuit damage
during installation, make connection to
the positive terminal at battery after all
electrical connections are complete.
A. Power/ • 3 core harness (red, red, brown).
Pump • Connect red wires to vehicle battery (+)
Harness via fuse link provided, using ring
terminal provided.
• Connect brown wire to vehicle battery (-)
using ring terminal provided.
B. Switch • 3 core harness (red, brown, yellow).
Harness • Run to location of switch.
C.
Main • Connects the above harnesses to
Heater control unit and other components
Harness inside the heater cover.
A
B
D
C
11
D.
Pump • 2 core harness(red, brown)
Harness Connects to pump and main heater
Extension harness (Universal model only)
Universal model
Compact version
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