D3LC compact Air Heater Espar - T3

D3LC compact Air Heater
Installation
Troubleshooting &
Parts Manual
Espar
D3LC compact
Heater Models
Release period
12V 25 1906 05
25 1967 05
25 1980 05
Apr’96 - Mar’97
Mar’97 - Nov’97
Nov’97 - Present
24V 25 1907 05
25 1968 05
25 1981 05
Dec’96 - Feb’97
Feb’97 - Feb’98
Feb’98 - Present
P/N: 610-102-1298
December 1998
Table of contents
Page#
Introduction
General Specifications
Heater Warnings
Introduction
Principal Dimensions
Mounting Pattern
Heater Components
3
4
5
6
6
7
Installation Procedures
Heater Location
Heater Mounting
Heater Air Ducting
Fuel System
Electrical Connections
Exhaust & Combustion Air Intake Connections
Operating Switches
8
8
8
10
12
13
13
Heater Operation
Switch On
Start Up
Temperature Setting
Temperature Control
Switch Off
Controls and Safety Equipment
Operation Flow Chart
14
14
14
14
14
14
15
Maintenance,
Troubleshooting
& Repairs
Wiring Diagrams - model 25 1980/1981
Wiring Diagrams - model 25 1967/1968
Wiring Diagrams - model 25 1906/1907
Recommended Periodic Maintenance
Basic Troubleshooting
Self Diagnostics
Fuel Quantity Test
Components Specification Chart
Repair Steps
16
17
18
19
19
20
24
24
25
Heater Parts
D3LC compact - Service Parts Diagram
D3LC compact - Parts List
28
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.
2.
3.
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
1.
2.
3.
Install heater so it will maintain a minimum distance of
2” from any flammable or heat sensitive material.
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.
Failure to follow these instructions could cause fire
resulting in serious or fatal injury.
Warning - Asphyxiation Hazard
1.
2.
3.
4.
Route the heater exhaust so that exhaust fumes cannot enter any passenger compartments.
Ensure an air tight seal will be maintained between the
heater and mounting surface and at any exhaust connection points.
Ensure that heating air supply is taken from an area
where poisonous gases will not be present.
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
CDA
1-800-387-4800
1-800-668-5676
4
General Specifications
Heat Output (±10%)
12,000
11,000
5,100
3,400
BTU/hr Boost
BTU/hr High
BTU/hr Medium
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%)
Gal/hr
Boost
High
Medium
Low
U.S.
Litre/hr
.11
.10
.05
.03
.42
.37
.18
.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
Shutdown (±10%)
240°F (116°C)
Ambient Operating
Temperature
104°F to 158°F (-40°C to 70°C)
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.
5
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 passenger 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 thermostat. It cycles through four temperature settings (boost-highmedium-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.
6
Principal Dimensions
Inches
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.
P/N: CA0 00 019
7
Heater Components
Parts List
1 Hot Air Blower Wheel
2 Blower Motor
3 Combustion Air Blower Wheel
4 Glow Plug
5 Control Unit
6 Safety Thermal Sensor
7 Combustion Chamber
8 Flame Monitor
9 Heat Exchanger
10 Operating Unit (Thermostat)
11
12
13
14
15
16
17
18
19
20
Operating Unit (Rheostat)
Outer Casing
Exhaust Line
Flange Seal
Fuel Line
Main Fuse, 25 A
Combustion Air Intake Line
Fuel Metering Pump
Fuel Strainer
7 Day Timer (optional)
F = Fresh Air
C = Combustion Air
D = Fuel
H = Hot Air
E = Exhaust
8
Installation Procedures
Heater Location
Heater Mounting
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:
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.
•
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.
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.
•
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.
Note:
Mounting Plate Installation
SILICONE GASKET
S.S. PLATE
PLATE SEAL
HEX HEAD TEK SCREW
FLAT W ASHER
NUT
SPRING WASHER
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
Tighten screws sufficiently to ensure positive seal between mounting plate and
mounting surface. Do not over tighten.
9
Return Ducting
Ducting Components
1. Protective Grill
2. Air Outlet Hood
Warning:
Caution:
3. Hose Clamp 2-2 3/4”
4. Flex Duct 3” or 90mm
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.
Do not over tighten duct clamps.
Do not position outlet so that it will
blow hot air directly at operator or at
room thermostat.
5. Air Outlet - Rotatable
6. Connection Piece
7. 90° Bend Ducting 2 3/8”
10
Fuel System
The fuel metering pump is the heart of the system and must
be installed properly to ensure a successful heater operation.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fuel System Overview
Note:
Fuel Pick-Up Pipe
5.0 Rubber Connector
11mm Clamp
2.0mm Black Plastic Fuel Line
Fuel Metering Pump
9mm Clamp
3.5mm Rubber Connector
1.5mm White Plastic Fuel Line
5mm Rubber Fuel Line
Butt joints and clamps on all connections.
Optional
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).
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.
12
Electrical Connections
Caution:
Install power fuse only after all electrical connections are complete.
Main Harness.......................................................................
11 core harness (red/white, green/red, blue/white, red, white,
grey/red, grey, brown, brown, brown/white and yellow).
Connect to heater control unit (mounted in heater) using the 14 pin
connector then connect glow plug connector.
Place protective hood over glow plug and control unit & secure.
Connect to other harnesses as described for each harness.
Power Harness.....................................................................
2 core harness (red and brown).
Connect red wire to fuse holder near battery.
Connect red fuse link wire to other side of fuse holder.
Connect other end of fuse link wire directly to battery positive post
using ring terminal provided.
Connect brown wire directly to battery negative post using ring terminal provided.
Run power harness to main harness - connect 2 pin connectors
Switch Harness....................................................................
6 core harness (red, brown/white, yellow, grey, brown and grey/red)
Connect to rheostat switch or thermostat (refer to switch connection
section).
Connect switch harness to main harness using 8 pin connector.
Fuel Metering Pump Harness.............................................
2 core harness (green/red and brown).
Connect to fuel metering pump using single terminals and rubber
protective boots (no polarity required).
Connect fuel metering pump harness to main harness using
two single connectors.
Electrical Connections
Fuel Metering Pump Harness
Main Harness
Resistor for models
(12V) 25 1967 05
(24V) 25 1968 05
Fuse and holder
Switch Harness
Thermostat
Power Harness
Note: All exposed electrical connections should
be coated with protective grease. (petroleum gel, Vaseline, etc.).
13
Exhaust and Combustion Air Intake Connections
Operating Switches
A 24mm flexible stainless steel exhaust pipe (39”long) and
a 20mm flexible plastic tube (39” long) for combustion air
intake are included with the heater kit. Exhaust clamps and
holders are also provided.
The heater can be controlled using a Thermostat or
Rheostat type switch. It can also be accessed by a 7 day
timer with thermostat.
Thermostat
Caution: Run exhaust and combustion air intakes so
they cannot be plugged by dirt, water or
snow. Ensure the outlets do not face into
the vehicle slip stream.
Keep exhaust and combustion air intake a
minimum of 12” apart.
Drill 1/8” holes where necessary to allow
water drainage.
Balance the exhaust pipe length with the
combustion air intake length.
Combustion air intake and exhaust lengths
can be shortened to a minimum of 8”.
•
Attach the exhaust pipe to the exhaust outlet of the
heat exchanger
•
Run to an open area to the rear or side of the vehicle
so that fumes cannot build up and enter the cab or the
combustion air inlet to the heater.
•
Install protective cap.
•
Attach the combustion air intake tube to the combustion air inlet of the heater
•
Once secure to the heater inlet, the intake pipe must
run to the underside of the vehicle where it will pick up
clean, fresh, moisture free air.
•
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 the six core switch harness to the thermostat
as shown
Brown/White
Grey/Red
Red
Yellow
Grey
- Power from battery “-”
- Temperature setting “+”
- Power from battery “+’
- Switch control to heater
- Temperature sensor
Rheostat Switch
Note:
Combustion Air Intake
(min. of 8”).
Exhaust (min. 8”).
Warning:
Warning:
The exhaust is hot, keep a minimum of
2” clearance from any heat sensitive
material
Route exhaust so that the exhaust
fumes cannot enter the passenger compartment.
When using Rheostat switch, the Return
Ducting method must be used as shown
on page 9. This allows the heater’s internal
sensor to properly monitor cab temperature.
•
Mount the rheostat switch in a location where it is easily accessible.
•
Connect the six core switch harness
as shown
14
7 Day Timer
a - Power from battery “+”
b - Switch control to heater
c - Power from battery “-”
d - Diagnostics from heater
e - Temperature setting “+”
f - Temperature setting “-”
g - Vehicle dimmer switch for light display
h - Vehicle ignition accessories for continuous operation of heater
Temperature Control
Heater Operation
Warning: To prevent fire, the heater must be
switched off while filling fuel tanks.
To prevent asphyxiation, the heater
must not be operated in enclosed areas
•
The temperature is monitored constantly at the heater
intake or thermostat.
•
This temperature is compared to the set temperature
on the adjusting dial.
•
The heater cycles through Boost, High, Medium and
Low heat modes to maintain the desired temperature.
•
If the desired temperature is exceeded while the heater
is operating in low heat mode the heater will switch off.
This is a comfort feature.
•
The heater will re-start in medium heat mode once heat
is again required.
Switch On
•
Switch the heater on using the room thermostat’s,
On/Off switch (1=On, 0=Off ) or the rheostat switch.
Start Up
On start up the indicator light illuminates and the following
sequences take place:
•
Control unit does a systems check (glow plug, flame
sensor, temperature sensor, safety thermal sensor).
•
Blower starts slowly and begins to accelerate.
•
Glow plug is energized and starts preheating the combustion chamber.
•
After a short delay (approximately 15 seconds) the fuel
pump delivers fuel.
Switch Off
Once switched off either manually or automatically, the
heater begins a controlled cool down cycle.
•
The fuel pump stops delivering fuel.
•
The glow plug is re-energized for a 15 second after-glow.
•
The blower continues to run for 3 minutes and automatically switches off.
•
Ignition will take place as the fuel/air mixture contact
the glow plug.
•
Blower speed and fuel delivery are slowly increased.
Controls and Safety Equipment
•
Once flame is established the glow plug will switch off.
•
•
Heater will begin heating.
If the heater fails to ignite within two 90 second start
attempts, a "no start" shut down occurs.
•
If a flame out occurs after the heater has started, the
heater will attempt to restart.
Temperature Setting
•
Using the adjusting dial, set the desired temperature range.
From 1-4
If repeated flame outs occur within 10 minutes the
heater will not restart.
•
Overheat shut down will occur if there is a restriction of
the heating air flow (i.e. blocked inlet or outlet). The
overheat switch will automatically reset once the heater
has cooled down. Once the air flow restriction is
removed, the heater can be re-started by switching the
heater off then back on.
•
If the voltage drops below 10.5 volts or rises above
15.9 volts the heater will shut down (21volts and 30
volts for 24 volt systems).
•
If the glow plug circuit or fuel metering pump circuit are
interrupted the heater will not start.
•
The blower motor is checked on start up and every 4
minutes. Shut down will occur if the blower does not
start or maintain proper speed.
•
Lowest Setting - approx. 10°C (50˚F)
•
Mid - Setting - approx. 18°C (65˚F)
•
Highest Setting - approx. 30°C (85˚F)
Operating
indicating
light
Low
High
15
Operational Flow Chart
16
Wiring Diagram
D3LCcompact
Glow plug positive pulsed
Models:
25 1980 05 (12v)
25 1981 05 (24v)
17
Wiring Diagram
D3LCcompact
Glow plug positive pulsed
with current regulator
Models:
25 1967 05 (12v)
25 1968 05 (24v)
18
Wiring Diagram
D3LCcompact
Glow plug negative pulsed
Models:
25 1906 05 (12v)
25 1907 05 (24v)
19
Maintenance, Troubleshooting and Repairs
Basic Troubleshooting
Recommended Periodic Maintenance
Check LIst:
•
Remove the glow plug and inspect for carbon build up.
Clean or replace.
What happens when the heater is switched on and ....
•
Remove the glow plug screen and inspect for carbon
build up. Clean or replace. If cleaning is required, use
brass brush (Espar part number CA0 05 003).
•
Make sure vent hole is open. Espar recommends the
use of non detergent 100% volatile carburetor
cleaner and an air gun will also help. Remove loose
carbon from the glow plug chamber.
•
Inspect the ducting, the air intake screen and air outlet
for restriction or blockage.
•
Inspect combustion air intake and exhaust for blockage.
•
Run your heater and check for proper operation during
regular preventative maintenance throughout the year.
•
Maintain your batteries and all electrical connections in
good condition. With insufficient power the heater will
not start. Low and high voltage cutouts will shut the
heater down automatically.
•
Use fuel suitable for the climate (see engine manufacturers recommendations). Blending used engine oil
with diesel fuel is not permitted.
Heater does not ignite
Blower motor does not run
Check: • Fuse in power harness.
• Power to control unit.
• Power to switch.
• Electrical connections.
Blower motor runs approximately 20 seconds and then
shuts off
Check: • Ensure voltage at control unit remains
above 9.5 volts during start up with glow
plug circuit on.
Blower motor runs/fuel metering pump starts and then
shuts down after two 90 second start up cycles
Check: • Fuel lines and fuel filter.
• Fuel quantity.
• Combustion air or exhaust tube blockage.
Blower motor runs/no fuel metering pump
Check: • For electrical pulses at fuel metering pump.
• If pump is frozen.
• Blocked fuel line.
Heater ignites
Shuts down at random
Check: • Fuel metering pump quantity.
• Possible overheat.
• Control unit input voltage.
Heater smokes and carbons up
Check: • Exhaust pipe blocked.
• Combustion air intake blocked.
• Exhaust entering combustion air intake pipe.
• Short cycling, rapid on/off operation.
• Fuel system.
• Fuel metering pump quantity.
• Motor rpm.
20
Self Diagnostics
The heater is equipped with self diagnostic capability. To
retrieve information on the heaters last 5 faults, a retrieval
device is required (part # CA1 05 020).
Connect the fault code retrieval device as shown
Equipment Face and Controls
Symbols that are seen on the display face are as follows:
AF
Actual fault.
F1-F5
Up to five stored faults can be accessed.
The AF and F1 are the same number.
This sign is displayed when the heater is
in operation.
DIAG
The word (Diagnostic) will come on when
the diagnostic number is requested.
000
Three digit diagnostic fault code number.
On/Off
Retrieval Device
P/N: CA1 05 020
•
Switch the fault code retrieval device on and wait 10
seconds.
•
Press the "D" button.
•
Wait 3-5 seconds for the current fault code to appear
(AF).
•
To review the previous faults use the arrow buttons
(F1= Most Recent, F5= Oldest).
•
To erase the faults that are in memory press both "L"
keys at the same time.
•
Consult the fault code chart for code number descriptions.
Retrieval Device
P/N: CA1 05 020
21
Note: If there are no heater faults, the heater will go
through a normal start cycle and regulate
based on thermostat setting.
Fault Code
Fault Description
Causes / Repair
000
Normal Operation
001
Warning - overvoltage
Check vehicle charging system.
002
Warning - undervoltage
Check batteries and connections.
004
Warning - short in blower signal
Check for short between pin 1 to blower relay.
If no short exists replace control unit.
005
Warning - short circuit in anti-theft
Check for short between pin 2 and alarm relay.
alarm output
009
TRS - shut down
Check for change of signal from (+) to (-) at pin
10 or a (+) signal at pin 12.
010
Overvoltage
Check voltage between terminals 5 and 11 on control unit.
This must be less than 15.9 volts or [31.8]
(15.2 [30.4] volts with glow plug on).
Check vehicle charging system. *[24V systems]
011
Undervoltage shut down
Check voltage between control unit pins 5 and 11.
This must be greater than 10.5 volts (9.5 volts with glow plug on).
Check batteries and connections.
012
Overheat
Check for possible causes of overheat. Check overheat switch
resistance values.(see component value chart).
013
Overheat at flame sensor
Flame sensor senses temperature above 340°C (resistance
value above 2270 Ω ). Check flame sensor resistance
values and overheat switch resistance values
(see component value chart).
015
Too many overheats
Control unit limits heater to 3 consecutive overheats
(fault code12,13). Remove cause of over heat.
Reset control unit using control unit tester or fault code retrieval
device to unlock control unit.
020
Open circuit - glow plug
Check glow plug for break in coils.
Check resistance across glow plug
leads (1-2 Ω). Check for continuity between pins 6 and 9. If afore
mentioned checks okay, replace control unit.
021
Short circuit - glow plug
24 volt equipment only. A 12V glow plug is fitted. test glow plug
for short circuit or examine for carbon deposits on element.
Change if necessary.
22
Fault Code
Fault Description
025
Diagnostics output short
033
Burner motor speed deviation
Causes / Repair
Check for short between pin 4 and diagnostics output connection.
Motor speed varies from specification by more than 10% for
longer than 30 seconds. If too slow, check for restriction, and
check for short in motor circuit or control unit. If none found,
replace blower. If too fast, check for damage to magnetic sensor
control on control unit. Replace blower motor if damaged.
Replace control unit otherwise.
047
Short circuit - fuel metering pump
Check for short between pin 3 and fuel metering pump.
Test fuel metering pump.
048
Open circuit - fuel metering pump
Check for open circuit between pins 3 at control unit and fuel
metering pump.
050
Too many no start attempts
Control unit restricts heater to 10 start attempts
(20 starts if no flame is detected during start attempts).
Check fuel, glow plug, combustion air and exhaust flow.
Use control unit tester or fault code retrieval device to unlock
control unit.
051
Faulty flame recognition
Allow heater to cool 15 minutes then try restart.
Resistance value at flame sensor > 57°C (1220Ω)
Check flame sensor resistance value.
052
No start safety time exceeded
No flame detected on start attempt.
Temperature at flame sensor <100°C(1380 Ω ).
Check flame sensor resistance values. Check fuel, glow plug,
combustion air and exhaust flows.
053
Flame cutout in boost mode
054
Flame cutout in high mode
Check fuel supply. Check combustion air and exhaust flow.
055
Flame cutout in medium mode
If combustion is O.K., check flame sensor resistance value
056
Flame cutout in low mode
check flame sensor, replace if necessary.
060
Open circuit - external temperature
Temperature sensor detects a value beyond it's range.
061
Short circuit - external temperature
sensor
sensor
Heater has started successfully the flame has extinguished.
Check connections.
Check sensor resistance values between pins 8 &13.
>2800 Ω - open circuit
<280 Ω - short circuit
062
063
Open circuit - set point
Potentiometer values outside of range
potentiometer (control switch)
Check resistance between pins 7 and 13.
Short circuit - set point
>2800 Ω - open
potentiometer (control switch)
<280 Ω - short
Normal range 1750 Ω- 2080 Ω (+/- 80Ω).
064
Open circuit - flame sensor
Sensor is sensing value outside of range
065
Short circuit - flame sensor
>3200 Ω - open
<200 Ω - short
23
Fault Code
Fault Description
071
Open circuit - overheat sensor
072
Short circuit - overheat sensor
Causes / Repair
Overheating sensor signals values outside of range.
Check connecting leads.
>3200 Ω - open circuit
<200 Ω - short circuit. See sensor values on next page
090
Control unit defect
Internal failure in microprocessor. Replace control unit.
091
External voltage disturbance
Check vehicle charging system.
092
Control unit defective
Internal failure in microprocessor. Replace control unit.
093
Control unit defective
RAM fault
094
Control unit defective
EEPROM fault
096
097
Control unit defective (internal
Internal failure.
temperature sensor)
Replace control unit or use external temperature sensor.
Control unit defective (power failure)
Internal failure. Replace control unit.
24
Fuel Quantity Test
Component Specification Chart
The fuel quantity should be tested if the heater has difficulty
starting or maintaining a flame:
Component values given are reference numbers only
(at room temperature). Actual component values may
vary ±10%.
Preparation
•
Detach the fuel line from the heater.
•
Insert the fuel line into a measuring glass (20 cm3
size).
•
Switch the heater on and allow fuel system to bleed out
air for approx. 25 seconds.
•
Switch the heater off and empty the measuring glass.
Motor Speeds
Boost
High
Medium
Low
Recirculation
4,200 RPM
4,200 RPM
2,200 RPM
3,000 RPM
1,000 RPM
0 RPM
(when using internal
temperature sensor)
when using external
temperature sensor)
Resistance Values
Metering pump 12V
Metering pump 24V
Glow Plug 12V
Glow Plug 24V
Operating control/setpint pot.
approx. 10Ω
approx. 36Ω
approx. 0.6 Ω
approx. 2 Ω
1740-2180 Ω (±80Ω)
Exhaust Gas
Measurement
•
Switch heater on.
•
Hold the fuel line in the measuring glass while fuel is
being delivered. Hold the graduated measuring glass at
glow plug height during measurement
•
The pump will stop automatically after delivering fuel
for 90 seconds.
•
Once fuel pump stops, switch heater off. A restart will
occur if heater is not shut off.
Evaluation
•
Read the amount of fuel delivered.
•
Fuel quantity should be between
7.1 cm3/90 seconds and 9.5 cm3/90 seconds
8.3 cm3/90 seconds is the nominal value
•
If the fuel quantity is outside this range, check for and
remove any restriction in fuel system or replace the fuel
metering pump. (Check screen in suction side of pump)
Note:
The fuel quantity is not affected by voltage
variances.
•
CO2 concentration in exhaust gas when heater is running in High heat mode 9-11%.
•
Smoke test value from exhaust gas when heater is
running in High heat mode <4.
25
Repair Steps
Inspection, Removal and Replacement of the:Glow Plug
Caution:
Remove power from the heater prior
to any disassembly by unplugging main
connection or removing main fuse.
Atomizer Screen
Control Unit
Heater Casing Disassembly
Overheat Sensor
Flame Sensor
Blower Removal and Replacement
Heat Exchanger Cleaning
Disconnect
Glow Plug Removal, Inspection and Replacement
•
Remove glow plug connector.
•
Remove glow plug.
•
Inspect coils for carbon build up, breaks or metal fatigue.
•
Clean or replace if necessary.
•
Re-install in reverse order using a new gasket.
1. Glow Plug
2. Atomizer Screen
3. Glow Plug Connector
Atomizer Screen Removal, Inspection and Replacement
•
Remove atomizing screen using the metal tab and a
pair of pliers.
•
Clean screen using varsol, brass wire brush and compressed air.
•
Inspect screen for deterioration and replace if necessary.
•
Clean the glow plug chamber to remove carbon build up.
•
Ensure air vent hole and fuel port are clear.
•
Re-install fuel screen.
Note:
Ensure seam of screen and tab do not
block the air vent hole or fuel port.
Control Unit Removal and Replacement
•
Unplug main harness and motor connectors. (1)
•
To remove Control Unit, unlock and slide out. (2)
•
Unplug overheat switch & flame sensor connectors. (3)
•
Re-install in reverse order.
Control Unit
Fuel port &
Air vent hole
26
Heater Casing Disassembly
•
Remove internal hex screw and cap.
•
Pry off air outlet hood using a flat screw driver.
•
Remove rivets by punching center pin through and prying out base.
•
Remove rubber seal at base of heat exchanger.
•
Separate outer casing.
•
Re-assemble in reverse order using new rivets.
Overheat Sensor
Flame Sensor
•
Release Duo-Clip locking devices with a screw driver
and detach insulating brackets.
•
Use new locking devices when installing
Overheat Sensor Replacement
•
Using a small flat screw driver, pry off holding clips.
•
Lift sensor from mounting studs.
•
Install replacement sensor using new holding clips.
•
Ensure the sensor is securely mounted against heat
exchanger.
1. Outer Casing
2. Air Outlet Hood
3. Cap with Internal Hex Screw
27
Flame Sensor Replacement
•
Using a small flat screw driver, pry off holding spring.
•
Remove spring and flame sensor.
•
Install replacement sensor using a new mounting spring.
•
Ensure the sensor is securely mounted against heat
exchanger
1. Blower
2. Heat Exchanger
3. Gasket
Air Blower
•
Remove four mounting screws.
•
Separate blower from heat exchanger.
•
Re-assemble using new gasket.
1
2
3
Heat Exchanger
•
Remove two mounting screws and baffle plate.
•
Remove and replace gasket.
•
Clean excessive carbon from inside heat exchanger
using a brass wire brush, varsol and compressed air.
•
Inspect felt ring and replace if damaged.
•
Re-assemble in reverse order using new gaskets.
1. Baffle Plate
2. Gasket
3. Seal Ring
2
1
3
28
Parts Diagram
D3LCcompact
29
30
31
32
Parts List
Heater model
D3LCcompact
Ref.Description
Part Number
No.
1
Heat exchanger
2
Combustion air blower
25 1882 06 00 00
•
12 Volt 25 1906 99 20 00
24 Volt 25 1907 99 20 00
•
•
•
•
•
•
•
•
•
•
•
3
Flame sensor
25 1895 99 35 00
•
•
•
•
•
•
4
Safety thermal sensor
25 1895 41 00 00
•
•
•
•
•
•
*includes cable section
5
Lower half of casing
25 1822 01 01 00
•
•
•
•
•
•
6
Upper half of casing
25 1906 01 06 00
•
•
•
•
•
•
7
Control unit
25 1895 50 00 03
25 1896 50 00 02
25 1976 51 00 03
25 1977 51 00 02
•
12 Volt
24 Volt
12 Volt
24 Volt
•
•
•
•
•
* If replacing the contol unit on heater models 25 1906 and 25 1967
to the latest control unit 12 Volt 25 1976 51 00 03 you must replace the
main heater harness with the p/n. CA1 60 120 harness or follow the conversion
instructions provided with the control unit to modify the existing harness
* If replacing the contol unit on heater models 25 1907 and 25 1968
to the latest control unit 24 Volt 25 1977 51 00 02 you must replace the
main heater harness with the p/n. CA1 60 120 harness or follow the conversion
instructions provided with the control unit to modify the existing harness
8
Flange seal
25 1822 01 00 02
•
•
•
•
•
•
9
Cable cover
25 1895 01 02 00
•
•
•
•
•
•
12 Volt 25 1830 01 01 00
24 Volt 25 1831 01 01 00
•
11 Seal ring
25 1830 01 01 01
•
•
•
•
•
•
12 Glow plug screen
25 1822 06 04 00
•
•
•
•
•
•
13 Gasket, blower
25 1822 01 00 03
•
•
•
•
•
•
14 Gasket, heat exchanger
25 1822 06 00 02
•
•
•
•
•
•
15 Seal ring, heat exchanger
25 1862 06 00 03
•
•
•
•
•
•
16 Spring, flame sensor
25 1895 01 00 03
•
•
•
•
•
•
171 42 082
•
•
•
•
•
•
25 1822 01 00 04
•
•
•
•
•
•
19 Grub screw M6x20 DIN 835
106 10 022
•
•
•
•
•
•
20 Fillister head bolt M5x20
103 10 461
•
•
•
•
•
•
25 1688 01 00 03
•
•
•
•
•
•
131 31 051
•
•
•
•
•
•
•
•
10 Glow plug
17 Clip
18 Heater bracket
21 U-Clip
22 Rivet, black plastic
•
•
•
•
•
23 Fillister head bolt M3x10
25 1822 01 00 05
•
•
•
•
24 Gasket
25 1822 80 09 01
•
•
•
•
25 Cable connection
25 1895 01 03 00
•
•
•
•
109 00 044
•
•
•
•
•
•
CA0 00 019
•
•
•
•
•
•
28 Angle bracket
20 1348 03 00 02
•
•
•
•
•
•
29 Rubber mount
20 1673 80 01 01
•
•
•
•
•
•
29a Rubber mount 6mm
20 1185 00 00 01
•
•
•
•
•
•
30 Clamp for fuel metering pump
152 00 144
•
•
•
•
•
•
31 Plastic fuel line 1.5mm ID
090 31 118
•
•
•
•
•
•
26 Tapit Screw M5x16
27 Mounting plate with hardware & seal
33
Heater model
Ref.Description
Part Number
No.
31a Fuel hose
360 75 300
•
•
•
•
•
•
32 Fuel hose
360 75 350
•
•
•
•
•
•
33 Plastic fuel line 2mm ID
090 31 125
•
•
•
•
•
•
25 1830 45 00 00
25 1831 45 00 00
•
35 Fuel screen
20 1312 00 00 06
•
•
•
•
•
•
36 Hose connection
20 1621 45 00 00
•
•
•
•
•
•
34 Fuel metering pump
•
•
•
•
•
37 Rubber boots
320 31 120
•
•
•
•
•
•
38 Terminals 18 AWG - fuel metering pump
CA1 90 060
•
•
•
•
•
•
39 Main Harness
CA1 60 105
CA1 60 107
CA1 60 120
•
•
•
•
•
•
*40 Fuel pick up pipe (Compression fitting type)
CA0 12 042
•
•
•
•
•
•
*41 Compression fittings 1/4” NPT
3/8” NPT
1/2” NPT
CA0 12 044
CA0 00 031
CA0 12 005
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
42 Standard fuel pick up pipe 2mm
CA0 12 056
•
•
•
•
•
•
43 Flat plug connector
CA1 90 006
•
•
•
•
•
•
44 Connector housing
206 31 009
•
•
•
•
•
•
45 Socket housing
206 31 301
•
•
•
•
•
•
46 Socket connections
206 52 120
•
•
•
•
•
•
20 1280 09 01 03
•
•
•
•
•
•
48 Tie clips 197mm
CA1 00 005
•
•
•
•
•
•
49 "C" Clamp 10mm
152 00 139
•
•
•
•
•
•
50 Current regulator
25 1966 30 01 00
25 1830 30 01 00
47 Grommet
•
•
51 Clamp 9mm
10 2063 00 90 98
•
•
•
•
•
•
52 Clamp 11mm
10 2063 01 10 98
•
•
•
•
•
•
53 Blade Fuse (25amp)
204 00 089
•
•
•
•
•
•
54 Fuse holder with terminals
CA1 07 001
•
•
•
•
•
•
55 Terminals
CA1 90 043
•
•
•
•
•
•
*56 Plastic Screen 75mm
25 1729 89 00 05
•
•
•
•
•
•
*57 Flange for outlet grill
25 1226 89 00 12
•
•
•
•
•
•
*58 Clamp 52mm-82mm
CA1 10 041
•
•
•
•
•
•
59 Safety screen 75mm
25 1552 05 01 00
•
•
•
•
•
•
60 Outlet hood 75mm
25 1822 80 01 00
•
•
•
•
•
•
CA1 10 041
CA1 10 042
•
•
•
•
•
•
•
•
•
•
•
•
62 Flexible air hose 75mm
10 2114 34 00 00
•
•
•
•
•
•
63 Deflector 75/100mm
22 1050 89 21 00
•
•
•
•
•
•
*64 90° Air outlet hood
22 1000 01 00 03
•
•
•
•
•
•
152 10 051
•
•
•
•
•
•
25 1774 80 01 00
•
•
•
•
•
•
61 Clamp 3 inch(75mm)
Clamp 4 inch(100mm)
65 C clamp
66 Flexible exhaust hose
34
Heater model
Ref.Description
Part Number
No.
67 Clamp 26mm
152 61 102
•
•
•
•
•
•
68 Clamp
10 2064 02 00 32
•
•
•
•
•
•
69 Air intake silencer
20 1451 01 01 00
•
•
•
•
•
•
152 10 047
•
•
•
•
•
•
70 C clamp
71 End sleeve with cross bar
25 1729 89 00 02
•
•
•
•
•
•
*72 Fibre ring adapter 90mm- 4” (Wooden)
90-100mm (Plastic)
CA2 02 002
20 1602 80 00 01
•
•
•
•
•
•
•
•
•
•
•
•
73 End sleeve with cross bar
25 1729 80 06 00
•
•
•
•
•
•
74 Switch/ Thermostat harness (15’)
CA1 70 111
•
•
•
•
•
•
75 Fuel metering pump harness (20’)
CA1 75 015
•
•
•
•
•
•
76 Power harness (13’)
CA1 65 106
•
•
•
•
•
•
12 Volt 301 00 154
24 Volt 301 00 153
•
12 Volt 25 1895 71 00 00
24 Volt 25 1896 71 00 00
•
22 1000 30 40 00
•
•
•
•
•
•
CA1 90 014
•
•
•
•
•
•
77 Thermostat
*78 Operating switch (rotary)
*79 7 day timer
80 3/8” Ring terminal 10-12G
•
•
•
•
•
•
•
•
•
•
81 Plug and socket connector
206 00 040
•
•
•
•
•
•
82 Terminals
CA1 900 21
•
•
•
•
•
•
610 102 1298
•
•
•
•
•
•
CA1 05 020
•
•
•
•
•
•
83 D3LCc North American manual (not shown)
*84 Fault code retrieval device (shown pg. 20)
*
indicates optional features
Service History Notes
Serial N°:________________________
Date installed:_______________________
Model N°:________________________
Date
Service Details
1st. Printing - November 1998
Printed in Canada
P/N: 610-102-1298
Espar Products, Inc.
6435 Kestrel Road
Mississauga, Ontario
Canada L5T 1Z8
17672 N. Laurel Park Drive
Suite 400E
Livonia, Michigan
United States
48152-3984
Canada (Tel):
Fax:
905-670-0960
800-668-5676
905-670-0728
U.S. (Tel):
800-387-4800
A member of the Worldwide Eberspächer GmbH Group of Companies
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