Espar D3LC Installation Troubleshooting And Parts Manual
D3LC compact Air Heater
Installation
Troubleshooting &
Parts Manual
Espar
December 1998
P/N: 610-102-1298
D3LC compact
Heater Models Release period
12V 25 1906 05 Apr’96 - Mar’97
25 1967 05 Mar’97 - Nov’97
25 1980 05 Nov’97 - Present
24V 25 1907 05 Dec’96 - Feb’97
25 1968 05 Feb’97 - Feb’98
25 1981 05 Feb’98 - Present
Table of contents Page#
Introduction General Specifications 3
Heater Warnings 4
Introduction 5
Principal Dimensions 6
Mounting Pattern 6
Heater Components 7
Installation Procedures Heater Location 8
Heater Mounting 8
Heater Air Ducting 8
Fuel System 10
Electrical Connections 12
Exhaust & Combustion Air Intake Connections 13
Operating Switches 13
Heater Operation Switch On 14
Start Up 14
Temperature Setting 14
Temperature Control 14
Switch Off 14
Controls and Safety Equipment 14
Operation Flow Chart 15
Maintenance, Wiring Diagrams - model 25 1980/1981 16
Troubleshooting Wiring Diagrams - model 25 1967/1968 17
& Repairs Wiring Diagrams - model 25 1906/1907 18
Recommended Periodic Maintenance 19
Basic Troubleshooting 19
Self Diagnostics 20
Fuel Quantity Test 24
Components Specification Chart 24
Repair Steps 25
Heater Parts D3LC compact - Service Parts Diagram 28
D3LC compact - Parts List 32
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.
This publication was correct at the time of print. However, Espar Inc. has a policy of continuous improvement and reserves the
right to amend any specifications without prior notice.
3
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.
Warning - Explosion Hazard
1. Heater must be turned off while re-fueling.
2. Do not install heater in enclosed areas where com-
bustible fumes may be present.
3. Do not install heaters in engine compartments of gasoline powered boats.
Warning - Fire Hazard
1. Install heater so it will maintain a minimum distance of
2” from any flammable or heat sensitive material.
2. Install the exhaust system so it will maintain a minimum distance of 2” from any flammable or heat
sensitive material.
3. Ensure that the fuel system is intact and there are no
leaks.
Failure to follow these instructions could cause fire
resulting in serious or fatal injury.
Warning - Asphyxiation Hazard
1. Route the heater exhaust so that exhaust fumes can-
not enter any passenger compartments.
2. Ensure an air tight seal will be maintained between the
heater and mounting surface and at any exhaust connection points.
3. Ensure that heating air supply is taken from an area
where poisonous gases will not be present.
4. If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
Failure to follow these instructions could cause oxygen
depletion resulting in serious or fatal injury.
Direct questions to Espar Heater Systems
USA 1-800-387-4800
CDA 1-800-668-5676
4
General Specifications
Heat Output (±10%) 12,000 BTU/hr Boost
11,000 BTU/hr High
5,100 BTU/hr Medium
3,400 BTU/hr Low
Current Draw at 12v (±10%) 20.0 amps/hr - Start
3.0 amps/hr - Boost
3.0 amps/hr - High
1.0 amps/hr - Medium
0.7 amps/hr - Low
Current Draw at 24v (±10%) 10.0 amps/hr - Start
1.50 amps/hr - Boost
1.50 amps/hr - High
0.5 amps/hr - Medium
0.35 amps/hr - Low
Fuel Consumption (±10%) U.S. Litre/hr
Gal/hr
Boost .11 .42
High .10 .37
Medium .05 .18
Low .03 .12
Air Flow (±10%) 78 cfm Boost
78 cfm High
39 cfm Medium
32 cfm Low
Operating Voltage Range 10V or 20V (minimum on 12 or 24V system)
14V or 28V (maximum on 12 or 24V system)
Overheat Temperature 240°F (116°C)
Shutdown (±10%)
Ambient Operating 104°F to 158°F (-40°C to 70°C)
Temperature
Weight 14.3 lbs. (6.5Kg)
Note: The heater control unit is equipped with a low voltage cutout to prevent vehicle battery drain and a high voltage cutout
to protect heater electrical parts.
Introduction
Espar D3LC Compact Air Heater
The Espar D3LCcompact is a diesel-fired 11,000 BTU/HR air
heater, quality engineered to provide a dependable means of
space heating in applications such as small cargo, marine and
cab utilities. This heater is uniquely designed for inside
mounting and an easy installation.
The heater provides a comfortable atmosphere for passen-
ger comfort. Since the heater runs on diesel fuel and
12 or 24 volt power, it is able to perform this completely
independent of the vehicle engine.
The D3LCc is operated by a rheostat switch or room thermo-
stat. It cycles through four temperature settings (boost-high-
medium-low) in order to maintain the desired temperature. If,
in special cases, even less heating capacity is required than
the supplies in the “Low” setting, it switches to the “Off” setting.
Temperature and overheat limit switches, and a specially
designed heat exchanger are among the safety features which
make this heater a safe an dependable unit.
5
6
Mounting Pattern
If fastening to the vehicle wall/floor, make penetrations in
accordance with the hole pattern shown. A pre-punched
mounting kit is also available as shown.
Principal Dimensions
Inches
P/N: CA0 00 019
7
Parts List
1 Hot Air Blower Wheel 11 Operating Unit (Rheostat) F = Fresh Air
2 Blower Motor 12 Outer Casing C = Combustion Air
3 Combustion Air Blower Wheel 13 Exhaust Line D = Fuel
4 Glow Plug 14 Flange Seal H = Hot Air
5 Control Unit 15 Fuel Line E = Exhaust
6 Safety Thermal Sensor 16 Main Fuse, 25 A
7 Combustion Chamber 17 Combustion Air Intake Line
8 Flame Monitor 18 Fuel Metering Pump
9 Heat Exchanger 19 Fuel Strainer
10 Operating Unit (Thermostat) 20 7 Day Timer (optional)
Heater Components
Heater Air Ducting
Installation
A 90mm flexible duct 40 inches long, hot air outlet and
clamps are provided with the heater kit. In routing and
installing the ducting the following criteria must be
observed:
• Run ducting with smooth bends. Avoid crushing duct.
• Position hot air outlet so that it cannot be obstructed.
• Use protective air intake grille on air inlet side of heater
to prevent objects from being sucked in.
• Ensure provisions are made for proper air return ventilation.
• Use return air ducting for best heating efficiency
8
Mounting Plate Installation
HEX HEAD TEK SCREW
FLAT WASHER
NUT SPRING WASHER
SILICONE GASKET
S.S. PLATE
PLATE SEAL
Installation Procedures
Heater Location
Depending on the type of vehicle, the best location for mounting the heater will vary. Typically, heaters are
mounted inside tool or luggage compartments. However, the
heater may be mounted anywhere inside the
vehicle provided you adhere to the following conditions:
• Combustion air intake, exhaust and fuel inlet must be
located outside of vehicle.
• Heater must be mounted on flat horizontal surface providing
an air tight seal between heater and vehicle.
• Do not mount the heater outside the vehicle, unless care
is taken to protect the heater from the weather.
When selecting the location, consider the following:
• Combustion air and exhaust connections.
• Ducting.
• Fuel line connections.
• Electrical connections.
Heater Mounting
Amounting plate and hardware are provided with the heater kit.
• Choose heater location.
• Using template provided, drill and cut center hole. Cut
one (1) four and one half inch (41/2”) diameter hole or
one rectangular hole four (4”) by five (5”) inches.
• Mount heater on mounting plate with nuts and spring
washers provided.
• For ease of installation make the exhaust, combustion
air intake and fuel connections at base of heater before
mounting the heater into the vehicle.
• Position heater in vehicle and secure with “Tek” screws
provided.
Note: Tighten screws sufficiently to ensure posi-
tive seal between mounting plate and
mounting surface. Do not over tighten.
9
Warning: Do not use existing vehicle ducting or
outlets. Ducts and outlets must be
capable of withstanding a minimum
of 300°F operating temperatures.
To avoid exhaust leakage, the
heater must always be operated
with an end cap installed.
Caution: Do not over tighten duct clamps.
Do not position outlet so that it will
blow hot air directly at operator or at
room thermostat.
Ducting Components
1. Protective Grill 3. Hose Clamp 2-2 3/4” 5. Air Outlet - Rotatable 7. 90° Bend Ducting 2 3/8”
2. Air Outlet Hood 4. Flex Duct 3” or 90mm 6. Connection Piece
Return Ducting
Fuel Pick-Up Pipe Installation (Standard Pick-Up)
• Choose a protected mounting location close to the fuel
pump and heater. A spare fuel sender gauge plate provides an ideal mounting location.
• Drill the mounting holes as shown
• Cut the fuel pick-up pipe to length.
• Mount the fuel pick-up pipe as shown.
• 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.
(Custom Pick-Up Pipe with NPT fitting)
• Remove an existing plug from the top of the fuel tank.
• Cut the fuel pick-up pipe to length.
• Secure the fuel pick-up pipe into position using the
combined NPT compression fitting as shown.
Note: NPT fittings are available in various sizes
(Refer to parts section).
10
Fuel System
The fuel metering pump is the heart of the system and must
be installed properly to ensure a successful heater operation.
Fuel System Overview
Note: Butt joints and clamps on all connections.
Optional
1. Fuel Pick-Up Pipe
2. 5.0 Rubber Connector
3. 11mm Clamp
4. 2.0mm Black Plastic Fuel Line
5. Fuel Metering Pump
6. 9mm Clamp
7. 3.5mm Rubber Connector
8. 1.5mm White Plastic Fuel Line
9. 5mm Rubber Fuel Line
NPT fitting and pipe
11
Fuel Metering Pump
• Choose a protected mounting location close to the
fuel pick-up pipe and heater.
• Using the bracket and rubber mount provided, install
fuel pump as shown
Note: Proper mounting angle of the fuel pump is
necessary to allow any air or vapor in the
fuel lines to pass through the pump rather
than cause a blockage.
Fuel Line
• Route fuel lines from the fuel pick-up pipe to the fuel
metering pump then to the heater.
• Use fuel lines provided.
• Other sizes or types of fuel lines may inhibit proper
fuel flow.
• Make proper butt joints using clamps and connector
pieces as shown on page 8
• Use a sharp utility knife to cut plastic fuel lines to
avoid burrs.
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