Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on May 14, 1992.
As of Monday, December 17th, 2018 this Executive Order has not been overturned or superceeded.

Approved Parts

Models
1992 and older heavy-duty diesel powered vehicles

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-253
  • Executive Order 253 / D253
  • ARB # D-253
  • Executive Order No: D-253
  • C.A.R.B. No. D-253
  • Resolution D-253
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-253 PDF

D-253 Document:



                                                               {Page 1 of 2)

                              State of California
                              AIR RESOURCES BOARD

                             EXECUTIVE ORDER D—253
                  Relating to Exemptions Under Section 27136
                             of the Yehicle Code


                          FUEL EFFICIENCY SYSTEMS, INC.
                               THERMAL—CHARGER #500


 Pursuant to the authority vested in the Air Resources Board by Section 27156
 of the Vehicle Code; and

 Pursuant to the authority vested in the undersigned by Sections 39515 and
 39516 of the Health and Safety Code and Executive Order &—45—5;

 IT IS ORDERED AND RESOLVED: That the installation of the Thermal—Charger
 #500 manufactured by Fuel Efficiency Systems, Inc. of 4007 Pretense Ct.,
 Fair Oaks, California, 95628, has been found not to reduce the effectiveness
 of required motor vehicle pollution control systems and, therefore, is
 exempt from the prohibitions of Section 27156 of the Vehicle Code for 1992
 and older model—year heavy—duty diesel—powered motor vehicles.

 This Executive Order is valid provided that installation instructions for
 this device will not recommend tuning the vehicle to specifications
 different from those submitted by the vehicle manufacturer.

‘ Changes made to the design or operating conditions of the device, as
~ exempted by the Air Resources Board, that adversely affect the performance
 of a vehicle‘s pollution control system shall invalidate this Executive
 Order .

 Marketing of this system using an identification other than that shown in
 this Executive Order or marketing of this system for an application other
 than those listed in this Executive Order shall be prohibited unless prior
 approval is obtained from the Air Resources Board.  Exemption of a kit shall
 not be construed as exemption to sell, offer for sale, or advertise any
 component of a kit as an individual device.

 This Executive Order does not contitute any opinion as to the effect that
 the use of this device may have on any warranty either expressed or implied
 by the vehicle manufacturer.

 THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION, ACCREDITATION,
 APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESOURCES BOARD OF ANY
 CLAIMS OF THE APPLICANT CONCERNING ANTI—PQLLUTION BENEFITS OR ANY ALLEGED
 BENEFITS OF FUEL EFFICIENCY SYSTEMS, INC.‘S THERMAL—CHARGER #500.

 No claim of any kind, such as "Approved by Air Resources Soard" may be made
 with respect to the action taken herein in any advertising or other oral or
 written communication.


FUEL EFFICIENCY SYSTEMS, INC.                                  EXECUTIVE ORDER D—253
                                                               (Page 2 of 2)


Violation of any of the above conditions shall be grounds for revocation of
this order.   The order may be revoked only after a ten—day written notice of
intention to revoke the order, in which period the holder of the order may
request in writing a hearing to contest the proposed revocation.  If a
hearing is requested, it shall be held within ten days of receipt of the
request and the order may not be revoked until a determination after hearing
that grounds for revocation exist.
                                                L4
Executed at El Monte, California, this       (?z/da   f May, 1992.




                                         .    5. Summerfield
                                      Assistant Division Chief
                                      Mobile Source Division


                    State of California
                    AIR RESOURCES BOARD




         EVALUATION OF FUEL EFFICIENCY SYSTEMS, INC.
   THERMAL—CHARGER #500 FOR EXEMPTION FROM THE PROHIBITIONS
OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222,
        TITLE 13, OF THE CALIFORNIA CODE OF REGULATIONS




                          May 1992


                             State of California
                             AIR RESOURCES BOARD




                  EVALUATION OF FUEL EFFICIENCY SYSTEMS, INC.
            THERMAL—CHARGER #500 FOR EXEMPTION FROM THE PROHIBITIONS
         OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222,
                 TITLE 13, OF THE CALIFORNIA CODE QF REGULATIONS




                                        by
                              Mobile Source Division
                              State of California
                              Air Resources Board
                              9528 Telstar Avenue
                              E1 Monte, CA   91731—2990



  (This report has been reviewed by the staff of the California Air Resources
  Board and approved for publication. Approval does not signify that the
  contents necessarily reflect the views and policies of the Air Resources
  Board, nor does mention of trade names or commercial products constitute
lendorsement or recommendation for use.)


                                  SUMMARY


       Fuel Efficiency Systems, Inc. of 4007 Pretense Ct., Fair Oaks,

California, 95628, has applied for exemption from the prohibitions in Section

27156 of the California Vehicle Code for the Thermal—Charger #500 device.     The

device is designed for installation on 1992 and older model—year heavy—duty

diéseI-powered vehicles.

       Thermal Charger #500 is a heat exchanger which uses the engine coolant

to heat up the fuel supply to the engine to 155 degrees F.   This is to

achieve easy engine start—up in cold weather,.   Based on an engingering

evaluation of the device, the staff has concluded that the device will not

adversely affect exhaust emissions from the vehicles for which the exemption is

requested.



       The staff recommends that Fuel Efficiency Systems, Inc. be granted

an exemption for their Thermal—Charger #500 for installation on 1992 and

older model—year heavy—duty diesel—powered vehicles and that Executive Order

D—253 be issued.


                                              Page Number



SUMMARY

CONTENTS

I.        INTRODUCTION

II.       CONCLUSION

III.      RECOMMENDATION

IV.       DEVICE DESCRIPTION

V.        DISCUSSION

APPENDICES

          A: INSTALLATION INSTRUCTIONS

          B: DRAWINGS — FIGURE 1



                                                  ~1_
                         — FIGURE 2

                         — FIGURE 5               co




                                         i1


                  EVALUATION OF   FUEL EFFICIENCY SYSTEMS, INC.
           THERMAL—CHARGER #500   FOR EXEMPTION FROM THE PROHIBITIONS
        OF VEHICLE CODE SECTION   27156 IN ACCORDANCE WITH SECTION 2222,
               TITLE 13, OF THE   CALIFORNIA CODE OF REGULATIONS


I.     INTRODUCTION
       Fuel Efficiency Systems, Inc. of 4007 Pretense Ct., Fair Oaks,

California 95628, has applied for an exemption from the prohibitions of YVehicle

Code Section (VC) 27156 for the Thermal—Charger #500 device.     The device is

designed for installation on 1992 and older model—year heavy—duty diese!l

powered vehicles.     The applicant submitted installation instructions and

specifications of the device for evaluation.



II.    CONCLUSIONS
       Based on an engineering evaluation of the device, the staff

concludes that the device will not adversely affect exhaust emissions from

1992 and older model—year heavy—duty diesel—powered vehicles.



III. RECOMMENDATIQN

       The staff recommends that Fuel Efficiency Systems, Inc. be granted an

exemption from the prohibitions in California Vehicle Code Section 27156 for

the Thermal—Charger #500 device for installation on 1992 and older model—year

heavy—duty diesel—powered vehicles and that Executive Order D—253 be issued.


IV.     DEVICEDESCRIPTION
        The Thermal—Charger is a thermally activated diesel fuel heating and

control system consisting of a one inch outside diameter heaé exchanger, 60

inches long, coiled in a 10 inch diameter by 2 inches thick.   The interior of

the exchanger is a copper engine water coolant tube surrounded by a twisted

spiral carbon steel fuel passage that allows fuel to flow in a counter flow

direction around the inner water tube.    The dual wall heat exchanger feature

prevents water to fuel, or fuel to water contamination, should there be a

defect in either tube.

        The control valve is made of cast iron and machined to close tolerances

for accurate control of the fuel temperature.    The valve is approximately 5

inches long and 7 inches high with fuel inlet and outlet fittings connecting

various iines from the tank and engine.    These supply the fuel to the proper

ports (see drawings in Appendix B).

         The valve and heat exchanger are mounted on the frame or engine, space

permitting, as close as possible to the fuel filter inlet port in the existing

engine fuel line.

        Depending on the engine power settings, the fuel flowing from the

injector bypass line (formerly returned to the fuel tank) varies in temperature

and volume.    This warm/hot fuel is now routed back through the Thermal—

Charger‘s control vaive and blended with additional hot fuel from the heat

exchanger or with fresh fuel from fuel tank to maintain a desired 155 degrees

F.    Fuel flowing into the control valve from the fuel tank is routed through

either the dual wall heat exchanger or directly into mixing chamber to dilute

hot fuel returning from the fuel injector bypass line.    A temperature sensing

wax motor valve element controls and stabilizes the temperature at 155 degrees

F.


    v.     BISCUSSTON
           Cold ambient temperatures frequently causes problems in the operation of

E'the internal combustion engines, especially diesel engines.       Pre—heating

    the fuel for a diesel engine before injection could improve the engine

    operation.    As with other fuel pre—heaters available in the market, the

    Thermal—Charger #500 uses hot coolant to preheat the fuel.     The manufacturer

    claims the device is distinct from other pre—heaters because the diesel fuel is

    heflted and controlled at 155 degrees F before injection into the combustion

    chamber.     This results in reduced viscosity of the fuel and facilitates smaller

    injector spray droplets producing a more complete combustion of the fuel.



           Staff did not conduct any test to confirm manufacturer‘s claims.       The

    staff has evaluated the design and operation of the Thermal—Charger #500.

    Based on engineering principles, the staff has determined that the device when

     installed in series with the diesel engine fuel system will not adversely

}.affect the performance of the factory equipped emission control systems on 1992

    and older model—year heavy—duty diesel—powered vehicles.


APPENDIX A


           THERMAL—CHARGER DIESEL FUEL HEATER INSTALLATION PROCEDURE

Blow out all parts with compressed air before starting installation.  Refer
to the flow schematic for proper routing of fuel lines.  If no fuel pump is
installed in line ahead of the injector pump, it is best to pour fuel into
port #12 with a hose and funnel, held higher than the fitting connecting
the filter from port #20.   Loosen the fitting connecting port #20 to the
filter so that all air in the system can bleed out.      It is important that
control valve port #20 be mounted in the up position so that all air is
purged from the valve during normal operating conditions.   If an auxiliary
pump is installed so that it pumps fuel through the fuel heating system,
bleed the air out through the fitting connecting port #20 to the filter.

BE SURE TO WIPE UP ANY FUEL SPILLED DURING THE AIR BLEEDING PROCEDURE SO
THAT A FIRE DOES NOT START FROM THIS FUEL AND NO POLLUTION OCCURS.

Cold fuel enters the temperature control valve from the fuel tank through
port #12, flows out port #24 to the fuel inlet on the outer shell of the
heat exchanger.   It then travels through the heat exchanger and reenters
the control valve as hot fuel at port #22.    Hot fuel that formerly was
bypassed from the injectors and returned to the tank is now routed through
the vapor separator, at port #32 and is mixed with additional hot fuel from
port #22 and new cold fuel from port #12 to blend into the optimum
temperature of 155 degrees Fahrenheit.

  e    use of 90 degree fittings during installation may       cause   loss   of
      sepower due to increased resistance in the fuel lines.

The    vapor line fitting #36 from the vapor separator will    be   connected to
the     old  fuel bypass line returning to the tank.

Cut the cab heater hose, (from the pressure side of the water pump and
before the heater water control valve) and install a "Y" fitting in the
heater hose.  Run additional heater hose from the "Y" to the   center tube
on the end of the heat exchanger that is connected to port #22 (hottest
water in to hot fuel out).   Install additional heater hose to the center
tube outlet, (cooler water out to cold fuel in)} and run it to a "Y" and
install it into the heater line returning to the suction side of the water
pump .


APPENDIX B


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                                                                         72
            _                                                                  To
            T0 WATER PUMP INLET           67                               XC—"¥" IN HEATER HOSE
                       "Y"IN HEATER HoSE


                                                         TEMPERATURE                       HOT WATER
                                                           CONTROQL                        CENTER COPPER TUBE
                                                            VALVE
                                                          ADJUSTER            63
                                                    64
                                                                                    OPTIONAL

            2L
                                         FUEL                EUEL                        FUEL             —
    to      +—IInuector         I]      ricter              HEATER                       PUMP !«        FUEL
             £3]     PUMP .              40                  VALVE
                                                               o                          31       »|   TaANK
indectors 53 +—
            t         34                    «—~UP                  43
                                          l                                              EUEL            30
                   HOoT FuEL            varor                      45                    uTEr
                     yPASS             SEPARATOR          TEMP Prose                     TuBE
                                          33             Hot rueL avrass
                                                              32A                    eat
                               36—                                                  EXCHANGER
         FIG. 2                                                                     14
                                     ,NAPORS TO TANK
                                                                        246





Document Created: 2005-09-01 12:40:04
Document Modified: 2005-09-01 12:40:04

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