Espar D7W, 25 1667, 25 1807, 20 1673, 25 1666 Installation, Troubleshooting, And Use
Table of contents
D7W Boxed
I. Introduction 1) General Specifications Page 1-5
2) Heater Warnings
3) Introduction
4) Principal Dimensions
5) Heater Components
II. Installation Procedures 1) Heater Location Page 6-15
2) Heater Mounting
3) Heater Plumbing
4) Fuel System
5) Electrical Connections
6) Exhaust Connection
7) Operating Switches
8) Optional Thermostat For Bunk Heat Exchanger
III. Heater Operation 1) Pre- Start Procedures Page 16-20
2) Start-Up
3) Running
4) Switching Off
5) Safety Equipment
6) Operational Flow Chart
7) Wiring Diagram
IV. Maintenance, 1) Recommended Periodic Maintenance Page 21-37
Troubleshooting & 2) Troubleshooting
Repairs 3) Fuel Quantity Test
4) Repair Steps
Appendix:
V. Heater Models 1) Principal Dimensions (25 1807) Page 38-48
Universal 25 1807 2) General Specifications (25 1666/25 1667)
25 1666 3) Location, Mounting, Plumbing, Fuel, Electrical, Exhaust
25 1667 4) Freightliner
Freightliner 5) Wiring Diagrams
VI. Heater Parts Section 1) Parts Diagram - Main Heater Components Page 49-59
2) D7WBoxed - Parts Diagram
3) Universal - Parts Diagram
4) Parts & Accessories Diagram
5) 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. General Specifications
Model 25 1807 05
Heat Output (±10%) 24,000 BTU (7 Kw) -High
6,000 BTU (1.75 Kw) -Low
Current at 12v (±10%) 24.6 amps/hr - Start (1-2 minutes)
5.8 amps/hr - Running High
4.2 amps/hr - Running Low
Fuel Consumption (±5%) High Low
Heat Heat
US Gal/hr 0.24 0.06
Litre/hr 0.90 0.22
Coolant Pump Flow (±10%) 420 US Gal/hr
1600 Litre/hr
Coolant Temperature 176° F to 201° F (80° C to 95° C)
Range (±5%)
Overheat Temperature 275°F (135°C)
Shutdown (±10%)
Low Voltage Shutdown 10.5 Volts
High Voltage Shutdown 15 Volts
2. 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 a heater.
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 will build 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.
Failure to follow all these instructions could cause serious or fatal injury.
Direct questions to Espar Heater Systems USA 1-800-387-4800
CDA 1-800-668-5676
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3. Introduction
The Espar D7W is a diesel fired 24,000 BTU/hr
coolant heater, quality engineered to provide a
dependable means of engine and sleeper heating. The heater can be purchased either in a
weather-resistant steel box to protect it and provide for ease of installation or in a universal form.
The heater simply pumps coolant from the
engine, heats it and returns it to the engine.
When used to provide sleeper heat, the coolant
is pumped through the sleeper heat exchanger
prior to returning to the engine. Since the heater
runs on diesel fuel and 12 volt power, it is able to
perform this completely independent of the vehicle engine. A temperature regulating switch in
the unit senses the coolant temperature and regulates the heater between a low of 176°F (80°C)
and a high of 201°F (94°C).
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The heater may be operated from the vehicle cab
by a push/pull switch, a pre-select timer or a
combination of both.
The temperature sensor and overheat switch
form only a part of the safety features which
make this heater a safe and dependable unit.
4. Principal Dimensions
D7W Boxed Model 25 1807
Figure 1A
5
8.25”
10.75”
15.25”
5. Heater Components
Figure IB
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II. Installation Procedures
1. Heater Locations
Select the best mounting location while adhering 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.
2. Heater Mounting
Mount the heater using the four (4) shock mounts
provided and one of the following mounting
methods: Figures IIA.
- Use the Cross Frame Mounting Tray (A) to
mount the heater behind the cab and on top
of the frame rails.
- Use the Side Mount Bracket (B) to mount the
heater on the side of the frame rail.
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A
B
- Use a spare step box or battery box.
Figures IIA
3. Heater Plumbing
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Connect the heater to the the engine coolant system while considering these following points
- Install hose fitting in existing holes in the engine
block (these will have blanking plugs in them).
- Full flow shut off valves should be installed on
the pickup and return hoses at the engine.
- Alternatively “T” piece connectors in existing
coolant hoses can be used if no blanking plugs
are available
- Ensure proper coolant flow by using a minimum
of 3/4” hoses.
- Keep the coolant pick up point as low as
possible on the engine to reduce air in the
system.
- Take coolant from a high pressure point and
return it to a lower pressure point. (eg. back of
block to suction side of water pump).Ensure
that engine and heater are pumping fluids in the
same direction.
Caution: If your bunk heater exchanger has a flow
control valve integrated into it, provisions
must be made to ensure that flow through
the Espar heater cannot be blocked.
- Ensure proper heat distribution by keeping pick
up point and return point as far apart as
possible.
- Check flow rate through heater by measuring
the incoming coolant temperature and the out
going temperature. The rise in temperature
should not exceed 18°F (10°C). If the
temperature rise exceeds 18°F (10°C),
modifications should be made to increase the
flow rate. Check for restrictions in heat
exchanger and fittings.
- If a bunk heat exchanger is incorporated into the
system, proper plumbing layouts must be
followed. (Refer to Figure II B and Figures IIB 1
on following page for specific guidelines.).
D7WB plumbed for engine pre-heat
Figure IIB
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.
When being used to provide bunk heat with a heat
exchanger the D7WB should be plumbed and wired to
one of the following methods.
1. D7WB plumbed with an
Espar heat exchanger.
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Figures IIB1
2. D7WB plumbed with an
OEM heat exchanger.
Note: By pass must be used to ensure that
coolant flow can’t be completely stopped.
D7W Thermostat Options
1. D7WB wiring schematics for
the Espar heat exchanger.
2. D7WB wiring schematics for
OEM heat exchanger.
4. Fuel System
The D7WB is most commonly provided with the
fuel metering pump mounted inside the box.This
is to reduce installation time and to protect the
pump from corrosion. If specifications cannot be
met the pump must be mounted externally. Refer
to Figure IIC for connections and specifications.
All parts necessary to do the installation are
included in the kit as shown in Figure IIC.
N o t e : Fuel line limits must not be ex c e e d e d .
Ensure that the fo l l owing conditions are
m e t .
Bottom of the fuel metering pump must be
within a height of 2’6” of the bottom of the
fuel pick-up pipe.
Fuel metering pump must be within a total
distance of 6’6” from the fuel pick-up pipe.
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Fuel System Tolerances
Figure IIC
Note: Butt joints and clamps on
all connections.
1. Fuel Pick-Up Pipe 5. 9mm Clamp
2. 11mm Clamp 6. 3.5mm Rubber Connector
3. 5.0mm Fuel Line 7. 2.0mm White Plastic Fuel Line
4. Fuel Metering Pump
B) Fuel Metering Pump
If the pump needs to be mounted externally follow
these guidelines:
Choose a protected mounting location close to
the fuel pick-up pipe and heater.
Using the bracketand rubber mount provided,
install pump as shown in Figure II D.
Note: Proper mounting angle of the pump is
necessary to allow any air or vapor in the
fuel lines to pass through the pump rather
than cause a blockage.
Fuel Metering Pump Installation
Figure II D:
C) 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 inhibi
proper fuel flow.
- Make proper butt joints using clamps and
connector pieces as shown in Figure II E.
- Use a sharp utility knife to cut plastic fuel lines
to avoid burrs.
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Figure II E
D) 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 II F.
- Cut the fuel pick-up pipe to length.
- Mount the fuel pick-up pipe as shown in
FigureIIG.
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- 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.
Figure II G
Fuel Pick-Up Pipe
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.
Figure II F
Note: Drill the two 1/4” holes first.
( Optional 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 in Figure II H.
Note: NPT fittings are available in various
sizes (Refer to parts section).
End tip of the fuel pick-up
pipe should have angle
so as to avoid picking up
dirt and subsequent
blockage
Figure II H
5. Electrical Connections
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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 Harness....................................................
B) Switch Harness.....................................................
C) Fuel Metering Pump Harness...............................
All harnesses should connect to mating plugs atthe
heater box.
- 2 core harness (red and brown).
- Connect red wire to vehicle battery (+), use ring
terminal provided.
- Connect brown wire to vehicle battery (-), use ring
terminal provided.
- 5 core harness [(red, brown, yellow, blue)
black-optional, for bunk fan power supply]
- Fuel Metering Pump Harness is pre-connected
when box is provided with pump pre-mounted.
- If mounted externally, connect wires to fuel
metering pump using single terminals and rubber
protective boots provided with the heater- no
polarity required ).
- 2 core harness (green, green).
- Connect fuel metering pump harness using two
single connectors. Figure IIa.
D) Bunk Heat Exchanger (optional).......................
Figure II I
- single black wire from switch connector.
- connect as described in Heat Exchanger
plumbing section. (pg.8)
A
B
D
Note: All harnesses should be cut to length.
All exposed electrical connections should
be coated with protective grease.
Figure II Ia
C
6 Exhaust Connection
A 30mm flexible stainless steel exhaust pipe (1
meter long), exhaust clamps and holders are
provided with the heater kit. Connect the
exhaust as follows:
Caution: Run exhaust so that it cannot be
plugged by dirt, water or snow.
Ensure the outlet does not face into
the vehicle slip stream.
Install exhaust pipe with a slight
slope or drill 5mm holes in lowest
point to allow water to run off.
Any restriction in exhaust will cause
operational problems.
Feed the exhaust pipe through the silicone
(white) gasket on the bottom of the box. Run to
an open area to the rear or side of the vehicle so
that fumes can not build up and enter the cab or
the heater box.
Secure the exhaust pipe internally at the heater
and externally using clamps and holders provided. Figure II J.
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Warning: The exhaust is hot, keep a
minimum of 2” clearance from any heat
sensitive material
Warning: Route exhaust so that the
exhaust fumes cannot enter the passenger compartment.
Figure II J
7. Operating Switches
A Push/Pull Switch is supplied with the heater, an
optional 99 Hour Digital Timer or a 7 Day Timer are
also available. Connect the operating switch as follows.
A. Push/Pull Switch
- Mount switch in a location where it is easily
accessible.
- Mount using hardware supplied.
- Connect the 25’ switch harness to the
connector at the heater and run the harness to
the switch location.
- Cut harness to length at the switch and install
terminals.
- Connect wiring as shown in Figure II K.
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Figure II K
Control Wiring
Push/Pull Switch
Brown - 31
Red - K (15)
Yellow - 15 (K)
Note Wired as above the switch light glows
when pulled out and is off when
pushed in.
B. 99 Hour Digital Timer
This timer is pre-set by Espar to operate the heater
for one (1) hour only. If an alternative run time setting is desired refer to the instructions provided with
the timer.
- Mount the timer using a 2” hole in the dash or
the optional mounting bracket.
- Mount timer using hardware supplied.
- Connect the 25’ switch harness to the
connector at the heater and run the harness to
the switch location.
- Cut harness to length and terminate wires.
- Attach using connector provided.
Red-Red
Yellow-Yellow
Brown-Brown
Figure II L
C. 7 DayTimer
The 7 day timer is capable of setting up to 3 preset
start times within 24 hrs. or 1 start time with in 7
days. It also has other functions such as a current
time display and a heater numeric fault code. Refer
to instructions provided with timer for setting
options.
- Mount timer and bracket in a suitable location.
- Connect the 25’ switch harness to the
connector at the heater and run the harness to
the switch location.
- Cut harness to length at the switch and install
terminals.
- Connect switch harness to timer..Figure II M
- Refer to timer instructions for other wiring
options.
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Figure II M
8. Optional Thermostat for Bunk Heat Exchanger
This thermostat is used to control the fan motor of
the heat exchanger (OEM or optional Espar Heat
Exchanger) inside the truck’s sleeper, thereby
allowing for interior cab heating.
- Mount the thermostat in a location where it is
easily accessible and it’s temperature sensor is
representative of the area being heated.
- Mount using the mounting slots in it’s base.
- Connect wiring as shown on page 8
Figure II N
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III Heater Operation
1. Pre-Start Procedures
Upon completion of installation prepare the heater
as follows:
- Check all fuel, electrical and plumbing
connections.
- Refill the engine coolant
- Bleed air from the coolant system by loosening
the top heater hose to allow air to escape.
Resecure the heater hose.
- Run engine to further bleed the system.
- Top up engine coolant.
2. Start Up
Once switched on the following sequence occurs:
3. Running
Once ignition is successful the following
operations take place:
- Heater runs in full heat mode.
- Once coolant reaches 194°F (90°C) the
heater automatically switches to low heat mode
and continues to run.
- If coolant temperature drops to 176°F (80°C) the
heater will automatically switch back to full
heat mode.
- If coolant temperature continues to rise, the
heater will automatically switch off once coolant
temperature reaches 201°F (94°C).
- The water pump will continue to circulate
coolant to allow the heater to monitor engine
temperature.
- The heater will automatically re-start once
coolant temperature reaches 176°F (80°C).
- Combustion air blower starts.
- Water pump starts.
- Control unit checks all functions.
- Glow plug begins to preheat combustion
chamber.
- Control unit checks input voltage (under or over
voltage will cause heater to shut down).
- After the 20-50 second combustion chamber
preheat the fuel pump will start.
- Once ignition takes place the flame sensor will
automatically switch the glow plug off
(ignition time: 1-3 minutes maximum).
Note: If the heater fails to start the first time it will
automatically attempt a second start. If
unsuccessful the heater will shut down
completely.
Note: On initial start up the heater may require
several start attempts to self prime the fuel
system
- The heater will continue to run as described
above until it is switched OFF, either manually,
automatically by a timer or heater malfunction
shutdown.
Note: While in running mode if the heater should
shut down due to flame out, it wil
automatically attempt one restart, if
successful it will continue to run, if not it
shuts down completely.
Note: During operation the heater continually
senses the input voltage from the batteries,
if the input voltage drops to approximately
10.0 volts (20.0 V for a 24 V system) the
heater will automatically shut down.
4. Switching Off
When the heater is switched off, manually or automatically, it starts a controlled cool down cycle.
- The fuel metering pump stops delivering fuel
and the flame is extinguished.
- The glow plug is re-energized for a 15 second
after glow.
- The combustion air blower and water pump
continue to run for a three (3) minute cool down
cycle, then switch OFF.
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