Valeo spheros thermo 230, spheros thermo 300, spheros thermo 231, spheros thermo 301, spheros thermo rail Workshop Manual

...

Download

HEATING SYSTEMS

Thermo 230 Thermo 300 Thermo 350

with control unit 1572 model .30 and up

Thermo 230 Thermo 300 Thermo 350

with control unit 1572D model .30 and up

Thermo 231 Thermo 301

model .01 and up

Thermo Rail

Workshop Manual

Rev. 05/2017 Id.No. 9003656C

Thermo 230 / 231 / 300 / 301 / 350 1 Table of Contents

Table of contents

1 Introduction 101

1.1 Content and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.2 Effectivity of the workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.3 Meaning of highlighted content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.5 Further documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.6 Safety information and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.6.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.7 Suggestions for improvement and change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2 General Description 201

2.1 Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

2.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

2.2.1 Nozzle block preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.3 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.4 Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.5 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.6 Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.7 Igniter Box with Igniter Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.8 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.9 Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.10 Overheat Thermostat for burner (Thermo 231 and 301 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.11 Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.11.1 Aquavent 5000 (U4814) and Aquavent 5000S (U4854) circulating pumps . . . . . . . . . 205

2.11.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps . . . . . . 205

2.12 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

3 Functional Description 301

3.1 Switch On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

3.2 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

3.3 Switch Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.4 Power Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.5 Auxiliary Heating Operation (heaters with control unit 1572D only) . . . . . . . . . . . . . . . . . . . . . . 303

3.6 Heater Lockout (heaters with control unit 1572D only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.7 Switch-off upon Failure (heaters with control unit 1572) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.8 Switch-off upon Failure (heaters with control unit 1572D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

3.9 Error Code Output (heaters with control unit 1572D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

4 Technical Data 401

4.1 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

4.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

5 Troubleshooting 501

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

5.2 General Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

5.3 Fault Symptoms during Functional Checkouts and Error Code Output or Tests with

Diagnostic Computer, Components Tester or PC Heater Diagnosis . . . . . . . . . . . . . . . . . . . . . . 503

5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

5.3.2 Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

Thermo 230 / 231 / 300 / 301 / 350 1 Table of Contents

6 Functional Checkouts 601

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.2.1 Adjustment of CO2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.3 Components Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

6.3.1 Temperature Sensor Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

6.3.2 Flame Sensor Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

6.3.3 Igniter Electrodes Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

6.3.4 Igniter Box Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

6.3.5 Fuel Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.3.6 Fan Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604

6.3.7 Solenoid Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604

6.3.8 Nozzle Block Preheater Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604

7 Circuit Diagrams 701

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

8 Servicing 801

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.2 Heater Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.3 Vehicle Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.4 Heater Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.5.1 Inspection and Attachment of the Exhaust Muffler (only heaters from

year of production 1996 and up to production date 1996, calendar week 36; 3G......) . 801

8.5.2 Burner Head Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803

8.6 Visual Inspections and Regulations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

8.6.1 Connection to Vehicle Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

8.6.2 Connection to Vehicle Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

8.6.3 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

8.6.4 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8.7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8.7.2 Temperature Limiter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8.7.3 Temperature Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8.7.4 Burner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.7.5 Igniter Box, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.7.6 Flame Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.7.7 Combustion Chamber, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.8 First Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.8.1 Water Circuit, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

8.8.2 Fuel Supply System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809

9 Repair 901

9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.1.1 Work on Components after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902

9.1.2 Incorporation of Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902

9.2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.2.1 Temperature Limiter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.2.2 Temperature Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.2.3 Burner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.2.4 Combustion Air Fan, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906

9.2.5 Control Unit, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908

9.2.6 Fuel Pump, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908

Thermo 230 / 231 / 300 / 301 / 350 1 Table of Contents

9.2.7 High Pressure Nozzle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908

9.2.8 Igniter Box, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908

9.2.9 Flame Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910

9.2.10 Heat Exchanger, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912

9.2.11 Combustion Chamber, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912

10 Packaging, Storage and

Shipping 1001

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

Appendix

Periodic heater maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

III

Thermo 230 / 231 / 300 / 301 / 350 1 Introduction

Danger to life and health!

Warning!

Hazardous to health!

Caution!

Danger to life and health!

Warning!

1Introduction

1.1 Content and purpose

This workshop manual is used during maintenance and repair of water heaters (further referred to as heaters) Thermo 230, 231, 300, 301 and 350.

ATTENTION: Work on the heater may only be performed by briefed and/or trained by Spheros personnel.

1.2 Effectivity of the workshop manual

The workshop manual applies to heaters listed on the title page of this document. It may be subjected to modifications and amendments. The respectively currently effectife version is binding. This version can be found on the Spheros homepage under Service/Downloads/Heating systems.

1.3 Meaning of highlighted content

1.4 Symbols

Symbol tightening torque value: Identifies in graphics parts (eg nuts, bolts) that are to be mounted with a specific tightening torque. The torque values are shown at the symbol and are binding.

1.5 Further documentation to be used

The use of additional service literature is required. References are provided in the workshop manual at appropriate locations. Use the following documents during operation and maintenance of the heaters:

• Operating and Service Instructions

• Installation Instructions

• Technical Information (TI)

• Spare Parts List

1.6 Safety information and regulations

Throughout this manual the emphasized words Warning!, Caution!, ATTENTION: and NOTE: used as follows:

This caption is used to indicate possible severe injuries or fatal accidents if instructions or procedures are carried out incorrectly or entirely disregarded.

This caption is used to indicate possible minor injuries if instructions or procedures are carried out incorrectly or entirely disregarded.

ATTENTION:

This caption points to actions which may cause material damage.

NOTE:

This caption is used to draw attention to an important feature.

Basically, general accident pevention provisions and the valid industrial safety directions must be adhered to. "General Safety Regulations" which exceed the framework of these provisions are listed below. The specific safety regulations which affect the present manual are issued highlighted in the individual sections or procedures.

1.6.1 General safety regulations

Read the Thermo Operating and Service Instructions before operating the heater for first time.

Familiarize yourself with the Thermo Installation Instructions before you make any modifications to the existing heater installation.

NOTE:

The Thermo Operating and Service Instructions contain safety instructions and regulations to be followed for safe operation of the heater.

The Thermo Installation Instructions contain the statutory regulations and other safety hints and regulations for the proper installation of the heater.

101

Thermo 230 / 231 / 300 / 301 / 350 1 Introduction

1.7 Suggestions for improvement and

change

Please direct any complaints, improvement or modification suggestions regarding this manual to:

service@spheros.de

102

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

4 3

Thermo 231/301

1 Burner 2 Coolant inlet 3 Temperature limiter 4 Temperature sensor 5 Coolant outlet 6 Heat exchanger 7 Exhaust outlet 8 Fuel return 9 Combustion air inlet 10 Fuel delivery 11 Splash protection cover (instead of screen)

2 General Description

The water heaters Spheros Thermo 230, 231, 300, 301 and 350 are used in combination with the vehicle’s own heating installation to

– heat the passenger compartment – defrost the windscreen – preheat water-cooled engines

The heaters Thermo 231 and 301 are variants for vertical installation. The difference in appearance are the different identification label and the Z profiles on the installation interface.

The water heater operates independent from the vehicle engine and is connected to the vehicle cooling system, the fuel system and the electrical system.

The heater designed to the heat exchanging principle operates intermittently controlled by the temperature sensor.

The heaters Thermo 230, 231, 300, 301 and 350 basically consist of

– the combustion air fan – the fuel pump with nozzle block and nozzle – the heat exchanger and – the combustion chamber – the igniter box with igniter electrodes

For control and monitoring the heater includes

– a control unit – a flame sensor – a temperature sensor – a temperature limiter – a temperature limiter without reset button for Thermo

231 and 301 and the Rail variant .126.

An external circulating pump is installed inside the vehicle, or, in the case of compact units, directly at the heater.

201

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

Nozzle block

pre-heater (optional)

Solenoid valve

Fuel Pump

Screen

O-ring

Color dots for identification of the heating capacity class

Fan motor

Fan wheel

Cap

Splash protection cover

Screen

2.1 Combustion Air Fan

The combustion air fan supplies the air required for combustion from the combustion air inlet to the combustion chamber.

The fan consists of a fan motor with fan wheel. Air is taken in through a splash protection cover or a screen and the cap. The heaters Thermo 231 and 301 are provided with a splash protection cover only.

2.2 Fuel Pump

The fuel pump is responsible for fuel supply. The pump is driven by the burner motor via a coupling. Fuel is compressed in the fuel pump to approx. 10 bar and atomised via the atomiser nozzle. The solenoid valve integrated into the fuel pump opens and closes the fuel supply to the atomiser nozzle. Three different fuel pumps are assigned to the different heating capacity classes of the Thermo series. These are identified by the heating capacity class specification as well as colour dots:

• 16 KW: 1 color dot

• 23-35 KW: 2 color dots

• 40 KW: 3 color dots

The fuel pump can be used in dual-line operation (fuel supply and return line).

If the heater is operated with

– a long fuel supply line – check valves in the fuel supply and return line – a fuel filter in the fuel supply line – single-line operation

the fuel supply line must be filled prior to first heater start-up.

202

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

Heat exchanger

Combustion chamber

Control Unit 1572

Control Unit 1572D

Flame sensor

2.2.1 Nozzle block preheater

At extremely low temperatures malfunctions may occur without a nozzle block preheater. At a temperature of < 0°C a thermostat activates the heater cartridge in the nozzle block. The heating period depends on the heat reflected within the combustion chamber. Preheating is deactivated when the thermostat ambient temperature is +8°C.

If the heater is not equipped with a nozzle block preheater a retrofit is possible.

2.3 Heat Exchanger

IThe heat exchanger transfers the heat generated by com-bustion to the coolant circuit.

2.4 Combustion Chamber

The fuel/air mix is dispersed in the combustion chamber for combustion to heat the heat exchanger.

2.6 Flame Sensor

The flame sensor continuously monitors the flame condition during operation. The flame sensor is a photo transistor changing its resistance depending on the flame intensity. The signals are supplied to the control unit for processing.

2.5 Control Unit

The control unit 1572 or 1572D is the central component to ensure controlled operation and monitoring of combustion. If the heater has a control unit 1572 installed, a retrofit of control unit 1572D is possible (see Section 9).

2.7 Igniter Box with Igniter Electrodes

The igniter box generates the high voltage for igniting the fuel/air mix by a high voltage ignition spark across the electrodes.

203

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

Igniter electrodes

Igniter Box

Temperature sensor

Temperature limiter

Overheat Thermostat

2.10 Overheat Thermostat for burner (Thermo 231 and 301 only)

The overheat thermostat is screwed onto the disk and electrically connected to the solenoid valve of the fuel pump. When the burner overheats the thermostat causes an error lockout.

2.8 Temperature Sensor

The temperature sensor senses the coolant temperature at the heat exchanger outlet as an electrical resistance. This signal is supplied to the control unit for processing.

2.11 Circulation Pump

2.9 Temperature Limiter

The temperature limiter (bimetal) protects the heater against undue high operating temperatures. The temperature limiter can be reset manually. The temperature limiter responds at a temperature in excess of 125°C to switch off the heater. In the case of Thermo 231 and 301 as well as the Rail variant .126, the temperature limiter will trip at a temperature in excess of 105°C. After the temperature has dropped, an automatic reset will occur.

The externally mounted circulation pump ensures proper coolant circulation in the vehicle and heater circuit. Depending on the application, the circulating pump is switched on via the control unit or directly via the vehicle electrical system and operated during the entire heater operation duration. The heaters can be operated with the circulation pumps Aquavent 5000 (U4814), Aquavent 5000S (U4854), Aquavent 6000C (U4855) or Aquavent 6000SC (U4856).

Circulating pump

U 4814

Aquavent

5000

U 4854

Aquavent

5000S

U 4855

Aquavent

6000C

U 4856

Aquavent

6000SC

(against 0,2 bar)12or

(against 0,2 bar)

(against 0,4 bar)

Delivery rate

l/h V = V = W kg

5000

6000

Rated voltage

24 20…28 104 2,2

24 20…28 210 2,4

24 20…28 210 2,5

Operating voltage range

10…14

20…28

Rated power consumption

104 2,1

Weight

The circulating pump fuse may never be pulled, while the pump is running, and may not be replaced, when the pump is switched on.

204

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

(U4814)

(U4854)

(U4855)

(U4856)

Aquavent 5000

Aquavent 5000S

Aquavent 6000C

Aquavent 6000SC

2.11.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps

The Aquavent 6000C (U4855) andAquavent 6000SC (U4856) circulating pumps are equipped with a brushless motor.

NOTE

The Aquavent 6000C (U4855) has a floating-ring type shaft seal. The Aquavent 6000SC (U4856) is equipped wit a magnetic coupling (no seal).

Soft start

The circulating pump motor starts slowly and gently. Max. rotational speed is only reached after approx. 5 seconds.

Protection against dry running

Protection against dry running is integrated into the circulating pump motor. If the circulating pump motor consumes within a time period of approx. 45 minutes significantly less current, dry running is detected. The circulating pump motor is switched off. After approx. 2 minutes and circulating pump motor reactivation, the operation can be continued.

2.11.1 Aquavent 5000 (U4814) and Aquavent 5000S (U4854) circulating pumps

The Aquavent 5000 (U4814) and 5000S (U4854) circulating pumps are equipped with a brush motor.

Aquavent 5000 (U4814) with floating-ring type shaft seal. Aquavent 5000S (U4854) uncoupled by a magnet (no seal)

ATTENTION

The circulating pump motor is not equipped with an internal inverse-polarity protection.

NOTE

Blocking protection

If the pump wheel is blocked, the motor will be switched off via the error mode directly prior to standstill of the pump wheel.

Overload protection

Overload protection is activated after the soft start is completed. The current consumption will be limited. In case of hydraulic overpressuring of the circulating pump, the circulating pump motor will not be damaged.

Fehlermodus

In case of malfunctions the circulating pump motor is switched off via the error mode. After approx. 5 seconds the error mode switches the circulating pump motor into energy-saving sleep mode.

Sleep mode

In sleep mode internal electronics consumers of the circulating pump motor are switched off.

Reactivation of the circulating pump motor

It is possible to reactivate the circulating pump motor from sleep mode. For this purpose the power supply is disconnected for > 2 min. After the power supply is reconnected, the circulating pump motor restarts in softstart mode.

Inverse-polarity protection The circulating pump motor is not equipped with an internal inverse-polarity protection.

205

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

2.12 Fuel Filter

At compact devices of the series 230/300/350.126 and .190 Rail an optional heatable fuel filter is provided, as an

additional option also for .124 and .155 Rail. If the electrical filter heating is hooked-up, the temperature switch turns the integrated filter heating on at ≤ 0.5 ± 2.5 °C and off at ≥ 5.5 ± 2.5 °C fuel temperature.

206

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

3 Functional Description

Activation and deactivation is by means of a

•switch

•timer

• air conditioning

dependent on the type of installation.

For monitoring operation at least an operating indicator light is provided. Switch off releases a run-down procedure (see "Switch off").

The heaters may be

• operated with power save for reduced fuel

consumption (see circuit diagram)

• equipped or retrofitted with a nozzle block preheater

for extreme low temperatures.

Heaters with control unit 1572D only

When connecting terminal +61 the heaters may operate in the auxiliary heating mode of operation.

Switching thresholds

Control device Ident. No. 63482E

Ident. No. 97806B

Bus

Auxiliary heating

Upper operating point 85°C 85°C 85°C

Lower operating point 78°C 70°C 75°C

Parking heating

Upper operating point 85°C 80°C 85°C

Lower operating point 70°C 45°C 70°C

Parking heating (economic setting)

Upper operating point 70°C 20°C 70°C

Lower operating point 55°C 75°C 55°C

Ident. No. 97810B

Rail

Standard

Ident. No. 63859D

Rail

J.E.S

Gradient evaluation Yes Yes Yes

Hysteresis adaption Yes Yes Yes

301

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

Switching thresholds for Thermo xxx Raill

230.040 230.056 300.124 xxx.126 300.155 350.190

Version Thermo xxx* 350.056 350.155

„VOSSLOH“„VOSSLOH

“

973 13A 90 162 37x 90 210 12B

Scope of delivery thru 90 162 36A

973 13D 90 162 35A

Heater

Control device 638 59D 679 81C 987 10x 978 04x

Auxiliary heating

Upper operating point 85°C 85°C 85°C 85°C

Lower operating point 75°C 72°C 70°C 70°C

Parking heating Preheating

Upper operating point 85°C 75°C 60°C 60°C

Lower operating point 70°C 60°C 45°C 45°C

Parking heating (economic setting)

Upper operating point 70°C 57°C 20°C 40°C

Lower operating point 55°C 42°C 5°C 25°C

Gradient evaluation Yes Yes Yes

Hysteresis adaption Yes Yes Yes

Low voltage threshold 18.5V

* xxx means 230 or 300 or 350

3.1 Switch On

3.2 Heating Operation

keeping frost-free

(20 sec.)

Upon switch on the operating indicator light goes on. Combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 °C nozzle block preheater is also activated).

After approximately 12 seconds (run-up time) the high voltage igniter spark is available. Approximately 1 second later the solenoid valve in the fuel pump opens and the nozzle sprays fuel into the combustion chamber to be ignited by the igniter spark. A photo control circuit deactivates the igniter box after flame-up.

After reaching operating temperature the control unit takes over to provide controlled operation by activation and deactivation of the burner in order to maintain a nearly constant temperature of the heat exchanger (coolant).

The heating operation is terminated as soon as the upper operating point is exceeded. The heater now is in the control idle period. Heater operation is resumed when the temperature drops below the lower operating point.

302

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

Heaters with control unit 1572D only Gradient evaluation

In case of low coolant flow or poor coolant circuit venting the temperature quickly increases in heating operation. If gradient evaluation exists, the control unit recognises the quick temperature increase and automatically sets the upper switching threshold to a lower value. This prevents residual heat triggering the overheating protection.

Control idle period

A rise in temperature above the upper switching point makes the solenoid valve in the fuel pump shut off the fuel supply initiating the run-down. The flame extinguishes, the combustion air fan and the circulation pump however continue their operation. After approximately 90 seconds (120 seconds for heaters with control unit 1572D) run-down is completed with deactivation of the combustion air fan.

The circulation pump remains in operation during the control idle period. The operating indicator light is on.

3.3 Switch Off

Switching off the heater stops combustion. The operating indicator light goes out and run-down commences. The combustion air fan and circulation pump are deactivated after approximately 90 to 120 seconds (120 seconds for heaters with control unit 1572D).

Reactivation of the heater during run-down is permitted. The burner immediately resumes operation after the run-up time.

The lower temperature threshold for reactivation of the burner after control idle period is raised above that for normal operation and is automatically shifted up or down dependent on the combustion time of the heater (hysteresis adaptation).

Hysteresis adaptation (example)

After the first control idle period, the lower operating point is 78°C. Combustion operation is started when the temperature falls below this threshold. The length of combustion time until the upper operating point is exceeded should be 120 seconds. If combustion lasts more than 120 seconds, the lower operating point is increased by 1 Kelvin, up to max. 80°C. If combustion time is less than 120 seconds, the lower operating point is lowered by 1 Kelvin, down to minimally 70°C.

3.6 Heater Lockout (heaters with control unit 1572D only)

After the heater has performed eight start attempts due to a malfunction or after five subsequent flame-outs the heater enters a lockout and start attempts are suspended. This lockout is superior to the normal error lockout. Unlocking is performed by starting the heater and disconnection of the main power supply of the heater during error run-down.

3.7 Switch-off upon Failure (heaters with control unit 1572)

3.4 Power Save

With power save on the control temperatures of the heating circuit are kept low. Combustion performance is not reduced.

This results in a reduced heat radiation loss when limited heating performance is required (e.g. in heat hold operation) cutting down fuel consumption.

3.5 Auxiliary Heating Operation (heaters with control unit 1572D only)

When terminal +61 is connected and powered (engine is running), the heater operates in the auxiliary heating mode. The power save mode is during auxiliary heating automatically deactivated by the control device.

The heater switches off automatically when detecting one of the following malfunctions.

The operating indicator light goes off. Combustion air fan and circulation pump are deactivated after approximately 90 to 120 seconds.

Malfunctions during switch-on

– short or open circuit of temperature sensor. – short or open circuit of flame sensor. – open circuit of solenoid valve.

Malfunctions during start-up:

– flame detected by photo control circuit prior to high

voltage igniter spark.

– no flame detected after approximately 25 seconds

after heater start.

Malfunctions during heating operation:

– low voltage threshold of approximately 20V violated

for a duration of 12 seconds.

– no combustion for more than 10 seconds.

303

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

16 12 14 161412

13 15 13 15

1s 12s12s 30s 90s1s12s

max.

1s12s30s 90s1s

A H1 Operating indicator light B E1 Heater cartridge C M2 Circulation pump D U1 Igniter box E M1 Combustion air fan F Y1 Solenoid valve G B1 Flame sensor

1 Switch on 2 Start 3 Combustion operation 5 Temperature sensor – upper switching

threshold 6 Flame sensor – dark 7 Control idle 8 Temperature sensor – lower switching

threshold 9 Switch off 10 Heater – off 11 Nozzle block preheater 12 Start-up 13 Foreign light check 14 Pre-ignition 15 Safety period 16 Run-down

Fig. 301:Functional sequence (heaters with control unit 1572)

– temperature sensor short circuit during control idle. – temperature sensor open circuit during combustion. – flame sensor short circuit during combustion. – solenoid valve short circuit during combustion.

Malfunctions during run-down:

Detection of a flame after more than 30 seconds after start of run-down with the circulation pump and combustion air fan maintaining operation for the following 90 seconds.

Malfunctions by overheating:

Overheating results in deactivation of the heater by the temperature limiter. After cool down of the unit and correction of the fault the button of the temperature limiter must be reset.

An error reset for a new start standby is achieved by switching the heater off and on again.

304

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

12 141412

13 15 13 15

1s 12s12s1s12s

max.

1s12s30s1s

max.

max. 120s

max.

30s

max. 120s

A H1 Operating indicator light C M2 Circulation pump D U1 Igniter box E M1 Combustion air fan F Y1 Solenoid valve G B1 Flame sensor

1 Switch on 2 Start 3 Flame-up, combustion operation 5 Temperature sensor – upper switching

threshold 6 Flame sensor – dark 7 Control idle 8 Temperature sensor – lower switching

threshold 9 Switch off 10 Heater – off 12 Start-up 13 Foreign light check 14 Pre-ignition 15 Safety period 16 Run-down

Fig. 302:Functional sequence (heaters with control unit 1572D)

3.8 Switch-off upon Failure (heaters with control unit 1572D)

The heater switches off automatically when detecting one of the following malfunctions. Several subsequent switch-offs due to a malfunction will cause the heater to enter an error lockout condition.

Flash pulses are output via the operating indicator light. The combustion air fan and the circulation pump are switched off after approx. 120 seconds.

Malfunctions during switch-on:

Short or open circuit of – temperature sensor –flame sensor – burner motor – solenoid valve – igniter box

Malfunctions during start-up:

– short circuit of igniter box – open circuit of igniter box – flame detected by photo control circuit prior to high

voltage igniter spark.

– no flame detected after approximately 25 seconds

after heater start.

– short/open circuit or dry run (if programmed) of

circulation pump. When using the circulation pump U 4851 approximately 15 seconds after switch-on the circulation pump is automatically stopped and may only be reactivated after approximately 2 minutes should coolant be missing or the pump wheel be seized.

Malfunctions during heating operation:

– low voltage threshold of approximately 21V violated

for a duration of 20 seconds. – no combustion for more than 10 seconds. – temperature sensor short or open circuit. – flame sensor short or open circuit. – solenoid valve short or open circuit.

Malfunctions during heating operation: (valid for application Thermo 350.190)

– low voltage threshold of approximately 18.5V violated

– no combustion for more than 10 seconds. – temperature sensor short or open circuit. – flame sensor short or open circuit. – solenoid valve short or open circuit.

for a duration of 20 seconds.

305

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

Malfunctions during run-down:

Detection of a flame after more than 30 seconds after start of run-down with the circulation pump and combustion air fan only maintaining operation for the following 90 seconds.

Malfunctions by overheating:

Overheating results in deactivation of the heater by the temperature limiter/thermostat. Dependent on heater configuration: – the reset button on the temperature limiter must be

reset.

– the reset of the thermostat is performed automatically

after cool down.

An error reset for a new start standby is achieved by switching the heater off and on again.

Malfunctions by overheating of the burner (Thermo 231 and 301):

Overheating of the burner causes the overheat thermostat to initiate an error lockout at 150°C. The solenoid valve closes, the fuel supply is cut off and a run-down is launched. An auto-reset occurs after cooldown of the thermostat.

3.9 Error Code Output (heaters with

control unit 1572D)

When equipped with a standard timer an error code readout appears on the display of the timer after a malfunction.

NOTE

When the heater is operated by means of a switch the type of error is output during heater run-down via a flash code of the operating indicator light. After five short signals the long flash pulses are counted. The flash pulses correspond to the error number in the following table:

F 01 no start

F 02 flame-out *

F 03 low voltage or excess voltage

F 04 foreign light detected during run-up and run-down

F 05 flame sensor defective

F 06 temperature sensor defective

F 07 solenoid valve defective

F 08 fan motor defective

F 09 circulation pump defective **

F 10 temperature limiter defective / overheating

F 11 igniter box defective

F 12 error lockout due to repeated malfunction or

repeated flame-out (8x no start-up or 5x flame-out)

* A response of the overheat thermostat will be stored

in the control unit as a flame-out (F 02) (Thermo 231 and 301).

** The error 09 is indicated only if the heater is equipped

with a circulation pump monitoring (see table below).

Table: Programmed SG1572D with integrated circulation pump monitoring

EOL-Data record for SG 1572D

EOLData record

63317F 63860E 67980D X 67981D 96774B 97805C 97807C X 97810C 97809C X 97810C 97811B X 97812A 97813A 97815A

Circulation pump monitoring

Yes No

Ctr. device programmed

306

Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data

4 Technical Data

Where no threshold values are specified technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 20 °C and at nominal voltage.

4.1 Electrical components

Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle block preheater and timer are 24V components. Temperature limiter, flame sensor, temperature sensor and switches are voltage independent components.

NOTE:

The allocation of circulation pumps to heater units must be in accordance with coolant resistances.

4.2 Fuel

Suitable fuel is the diesel fuel specified by the vehicle manufacturer. Only the on the model plate of the heater specified fuel must be used.

The following table lists the by Spheros approved fuels and their specifications.

ATTENTION:

While using the fuels, their operating limits must be considered and if necessary, suitable measures (nozzle preheating, electrical heated filter) should be applied.

If fuel is supplied from the vehicle tank, follow the vehicle manufacturer’s instructions on additives.

Fuel Requirements

acc.

Summer diesel DIN EN 590

Winter diesel DIN EN 590

Arctic diesel and Diesel for a strong winter climate

Bio diesel (FAME)

Paraffinic diesel fuel from synthesis or hydrogenation (HVO)

Further information on approved fuels contains the TI

(Technical Information) Fuels. It can be found on the Spheros homepage under Service/Technical Updates/Heating systems.

In case of air temperatures below 0°C a commercial available winter Diesel fuel must be used.

The usage of flow improvers respectively additives is permitted. There are no negative influences due to additives known.

DIN EN 590

DIN EN 12214

DIN EN 15940

401

Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data

Heater Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350

Type

Mark of conformity up to 4/03 ~ S230 ~ S327 ~ S229 ~ S328 ~ S228 EC type approval number e1*2001/56* 0007*-- 0010*-- 0008*-- 0011*-- 0009*-Heater principle High pressure atomizer Heating flow KW

Fuel Diesel / fuel oil Fuel consumption kg/h 2.9 3.3 3.7 Nominal voltage V- 24 Operating voltage V- 20 ... 28 Operating voltage

(valid for application Thermo 350.190) Nominal power consumption

(without circulation pump) Permissible operating ambient

temperature range (heater, control unit, circulation pump)

Permissible storage temperature °C +110 max. Permissible operating overpressure bar 0.4 ... 2.0 Heat exchanger capacity l 1.8 Minimum capacity of circuit l 25

in exhaust at nominal voltage Vol.-% 10 ±0.5 related to 500 m above S.L.

in exhaust at nominal voltage

(valid for application Thermo 350.190) Dimensions heater

(tolerance ± 3 mm)

Weight kg 19

(kcal/h)

Vol.-%

Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350

(20 000)

V-

°C –40 ... +85

mm mm mm

65 110 140

19 ... 28

9.2 ... 10.1

length 610

width 246 heigh 220

(26 000)

(30 000)

Circulation pump U 4814

Aquavent 5000

Volume flow I/h 5000 (against 0.2 bar) 5000 (against 0.2 bar) 6000 (against 0.4 bar) 6000 (against 0.4 bar)

Nominal voltage V = 12 or 24 24 24 24

Operating voltage range V = 10...14 / 20...28 20...28 20...28 20...28

Nominal power consumption W 104 104 210 210

Dimensions Lenght 230

Width 100

Height 103

Weight kg 2.1 2.2 2.4 2.5

U 4854

Aquavent 5000S

Lenght 249

Width 100

Height 105

U 4855

Aquavent 6000C

Lenght 226

Width 115

Height 118

U4856

Aquavent 6000SC

Lenght 231

Width 115

Height 118

Optional Fuel Filter Heater

Filter Heater

Nominal power consumption W 240

Nominal voltage V - 24

Switch-on point C° 0.5 ± 2.5

Switch-off point C° 5.5 ± 2.5

402

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

5 Troubleshooting

Troubleshooting is normally limited to the isolation of

5.1 General

This section describes troubleshooting procedures for the heaters Thermo 230, 231, 300, 301 and 350.

ATTENTION:

Troubleshooting requires profound knowledge about components of the heater and their theory of operation and may only be performed by trained personnel.

In case of doubt functional interrelations may be derived from Sections 2 and 3.

Error symptom Possible cause

defective components.

The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunction:

corrosion on connector loose contact on connector wrong crimping on connector corrosion on wiring and fuses corrosion on battery terminals

After any fault correction a functional checkout in the vehicle has to be performed.

5.2 General Fault Symptoms

The following table (Fig. 501) lists possible fault symptoms of general nature.

ATTENTION:

Error in the electrics

Operation indicator does not light and the heater does not function.

Fuse F2 triggered. Short circuit in the circulating pump or in the

Fuse F3 triggered. Short circuit in the supply cable to the heater/ burner

Heater is functional, however the operation indicator does not light.

Error in the water system

Circulating pump not operating (only U 4851 and Aquavent 6000SC only).

• No supply voltage.

• Fuses.

• Supply cable to the plug contacts of plug A of the control unit.

supply cable to the heater.

motor/ nozzle block preheater (if installed).

Operation indicator defective or cables to the operation indicator interrupted or shorted.

• Failure mode activated

The failure mode switches the motor off in case of malfunctions. After approx. 5 sec the failure mode switches the motor to the power saving sleep mode.

In the sleep mode the internal consumers of the motor electronics are switched off. The power consumption in this mode then amounts to < 2 mA.

The motor can be reactivated out of the sleep mode by disconnection of the power supply for approx. 2 minutes. After power reconnection the motor will again run up with a soft start.

Fig. 501 General Fault Symptoms (Sheet 1 of 3)

501

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

Error symptom Possible cause

Heater stops as the connected heat exchangers provides insufficient heat.

Approximate flow rate determination:

Flow rate too small, because

• Air in the heater, heat exchangers or in system sections.

• Taps/valves (flow controllers) throttled, contaminated, closed.

• Contaminations in the system, e.g. filters or at bottlenecks.

• Circulating pump delivery rate insufficient (air in pump housing), wrong sense of rotation – check wiring colors (black + / brown –).

• Insufficient frost protection.

• System resistance too high (especially high in the cold).

• Circulating pump defective.

Heat exchanger provides not enough heat, because

• Air in the heat exchangers and/or system sections.

• Contaminated heat exchanger surfaces (outside).

• Insufficient air entry or air exit.

• Fan: Insufficient delivery rate / incorrect direction of rotation / resistance too high.

• Antifreeze content too high.

• Heat exchanger of too low capacity.

Heat flow [kW] according to type plate

Flow rate in [l/h] = x 860

Temperature difference Δt in [K] or [°C] measured on the heater between water inlet and water outlet (e.g. using contact thermometer)

Error in the fuel supply

No fuel delivery to the heater. • Fuel tank empty.

• Bent, closed, clogged or leaking lines.

• Paraffin deposits or frozen water entrapments in fuel filters or lines.

• Venting opening in tank closed.

• Fuel lines mixed up.

• Fuel filter contaminated.

• Fuel screen (filter) in pump contaminated.

Fig. 501 General Fault Symptoms (Sheet 2 of 3)

502

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

Error symptom Possible cause

Error in the combustion

value cannot be adjusted to nominal value.

Irregular combustion.

Fig. 501 General Fault Symptoms (Sheet 3 of 3)

• Air bubbles in fuel supply line (leaking fuel supply line).

• Fuel filter contaminated or leaking.

• Fuel integration leaking (suction lift, low pressure in tank), observe installation instructions.

• Fuel pump defective (pump pressure).

• Return line throttled

• Screen (filter) in fuel pump contaminated.

• O-ring seal on the fuel pump ineffective (aging prozess).

• Atomizer nozzle defective.

• Combustion air and exhaust lines throttled or closed.

• Burner motor speed too low.

5.3 Fault Symptoms during Functional Checkouts and Error Code Output or Tests with Diagnostic Computer, Components Tester or PC Heater Diagnosis

5.3.1 General

Error Code Output

NOTE:

Only heaters with a control unit 1572D provide an error code output. When equipped with a standard timer an error code readout is available after a malfunction on the display of the timer. When the heater is operated by means of a switch a coded flashing of the operating indicator light during run-down of the heater or until switch-off indicates the type of error (see 3.9).

Diagnostic Computer

NOTE:

Checks with the diagnostic computer may only be performed on heaters equipped with control unit 1572.

By use of the diagnostic computer heaters may be checked in the vehicle. The following tests are available:

by means of four push button switches.

For details refer to operating instructions for "Diagnostic Computer".

Components Tester

NOTE:

Checks with the components tester may only be performed on heaters equipped with control unit 1572.

Using the components tester several types of faults and component malfunctions may be analyzed in the vehicle. The test of the individual components with the components tester is not intended. Faults like short or open circuits may be detected with the components tester but cannot be localized.

For details refer to operating instructions for "Components Tester".

PC Heater Diagnosis

By use of the PC heater diagnosis heaters (with control unit 1572 or 1572D) may be tested in the vehicle.

For details refer to operating instructions for "PC Heater Diagnosis".

The up to date software is in the internet available.

• indication of measured values: water temperature,

control unit supply voltage, flame sensor bright/dark.

• indication and erasure of faults stored in the control

unit.

Operation of the diagnostic computer is menu controlled

503

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

Switch on heater. Is combustion air fan operating?

Motor and fan wheel free to move?

Is fan wheel caught in cap?

Is voltage present on plug contact A3?

Check fuses F1/F2/F3 and relais K1, K2 and replace as required (control unit 1572 only). Does trouble persist?

Check motor electrics and replace as required.

Replace cap and fan wheel.

Is voltage too low? Rated value >20,5 volts (± 0,5 volts)

Check electrical wiring and connections. Does trouble persist?

Low voltage switch off during start-up. Check battery.

Control unit defective, replace.

Is fuel free of bubbles in supply and return?

Is fuel filter contaminated?

Fuel suction line leak?

Fuel lines empty? Are O-rings in fuel

pump? Is pump mounted securely?

Replace fuel filter. Retighten line

connections, replace lines as required.

Repeat start (several times if necessary) until lines are filled.

Fuel pump defective, replace.

Is solenoid valve connected to electrics?

Connect solenoid valve.

Is gap between igniter electrodes ok?

Check gap between igniter electrodes.

Is nozzle free of foreign matter and deposits and properly secured?

Replace nozzle.

YES

Is viewing glass of flame sensor contaminated?

Clean window and viewing glass.

Fuel pump defective, replace. Replace O-rings and screen as needed.

5.3.2 Fault Symptoms

5.3.2.1 Fault Symptom "No Start"

NOTE

Heaters with control unit 1572D: If the heater performs 8 subsequent attempts to start due

to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply during run-down.

504

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

YES

Switch on the heater. Is the combustion air fan operating?

Are the power supply, fuses, plug contacts, relays o.k.? (control unit 1572 only)

Replace defective electrical components.

Is the fuel free of bubbles in supply and return?

Is the solenoid valve o.k.? (5.3.2.7)

Is the sight glass of the flame sensor contaminated?

Is the nozzle free of foreign matter and deposits?

Is the fuel filter contaminated or jellied?

Replace solenoid valve

Clean disc and sight glass.

Replace nozzle.

Replace filter or check the low temperature rating of the fuel.

Is the fan wheel free to move?

Control unit defective, replace.

Is the motor o.k.?

Check the hood, motor and fan wheel.

Replace the motor.

Is voltage present on plug contact A3? Is electrical wiring

o.k.?

Make electrical connections.

Replace power supply line.

YES

Disconnect heater from battery supply. Is battery properly charged?

Connect heater. Is voltage between plug contacts A3 and A6 approx. 0.5 volts less than on battery?

Control unit defective, replace.

Is electrical power supply line to heater o.k.?

Control unit defective, replace.

5.3.2.2 Fault Symptom "Flame-out"

NOTE:

Heaters with control unit 1572D: If the heater performs 5 subsequent attempts to start due to a malfunction, the heater enters an error lockout and

stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply during run-down.

5.3.2.3 Fault Symptom "Low Voltage"

505

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

YES

Has the heater been in long time operation shortly before?

Allow heater to cool down and restart (approx. 2min.). Does same symptom show again?

Flame in run-down.

Replace solenoid valve.

Flame sensor defective, replace. Control unit defective, replace.

Clean combustion tube. Remove coke deposits.

Control unit defective, replace.

Flame sensor defective, replace.

YES

If replacement of flame sensor does not cure the problem, replace control unit.

Are electrical lines and contacts to and on temperature sensor o.k.?

YES

Temperature sensor defective, replace.

WARNING: Water may escape!

If replacement of temperature sensor does not cure the problem, replace control unit.

Make contacts or replace component.

WARNING: loss of water!

5.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down"

5.3.2.5 Fault Symptom "Flame Sensor Defective"

5.3.2.6 Fault Symptom "Temperature Sensor Defective"

506

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

YES

Is the solenoid valve supplied with electrical power?

Has the safety thermostat responded? (Thermo 231/301 only)

Investigate the reason for the response (e.g.check the exhaust system)

Replace the solenoid valve.

Make electrical connections.

Safety thermostat in the burner defective, replace.

Is the component test with the diagnostic computer or the PC heater diagnosis (menu component test) o.k. (audible click of solenoid valve)?

Does fuel leak from the nozzle in run-down?

Replace the solenoid valve.

Control unit defective, replace.

5.3.2.7 Fault Symptom "Solenoid Valve Defective"

507

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting

Is electrical power supply to components o.k.?

YES

Has temperature limiter responded (reset limiter)?

Determine why temperature limiter has responded, e.g.:

• check shut-off elements,

• check water circulation in system is free from bubbles,

• check circulation pump sense of rotation,

• check coolant low temperature resistance. Can no fault be detected?

Make electrical connections.

Control unit defective, replace.

Replace temperature limiter.

If symptom shows again after testing: control unit defective, replace.

5.3.2.8 Fault Symptom "Temperature Limiter Defective"

508

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts

Danger of suffocation!

Warning!

Fastening screw

1 +0.5 Nm

18 20 22 24 26 28 30 32

Voltage

- setting at 500 m NN

(Vol.-%)

6 Functional Checkouts

6.1 General

This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability.

The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities.

ATTENTION:

To prevent fires do not switch heater on with burner swung open.

6.2 Adjustments

6.2.1 Adjustment of CO2 Contents

Setting procedure

– measure control unit power supply voltage – operate heater for approximately 5 min. –measure CO

contents and soot level and compare

with relevant diagram – soot level target value acc. Bacharach ≤ 4 – loosen fastening screw (refer to Fig.) and reposition

setting ring with fastening screw until rated value is

obtained. – tighten fastening screw and apply screw seal varnish.

It is allowed to change the manufacturer’s setting for combustion air quantity by rotation of the setting ring.

NOTE

setting depends on fuel (viscosity) and on geodetic

altitude (0.1 % per 100 m). If proper setting cannot be obtained, proceed as follows: – check burner head air side for damage and replace if

required – Check the fuel pump pressure acc. to para. 6.3.5 and

readjust as necessary or replace the fuel pump. – Inspect fuel filter and fuel pump filter (screen) for

contamination and replace as needed. – replace fuel nozzle – measure burner motor speed

Measurement of the CO

value of the exhaust gas

must be performed followed by an adjustment of the combustion air quantity as required in case of: – repairs on the burner – irregularities in combustion – functional checkouts – nozzle replacement

601

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts

Water temperature °C

Resistance (Ohm)

1005010

1000

5000

10000

R/y

T/°C

20 °C ≅ 4419 ..... 4892 W

100 °C ≅ 319 ..... 348 W

Viewing glass

Glass bulb

High voltage!

Danger to life!

Warning!

Igniter electrodes 13,000 Volt

10kOhm

6.3 Components Testing

6.3.1 Temperature Sensor Resistance Check

When checking the temperature sensor with a digital multimeter the values of the following diagram must be obtained. Resistance checking is preferably performed at ambient temperatures between 20 °C and approximately 100 °C (immerse sensor in water).

6.3.3 Igniter Electrodes Check

NOTE:

The insulator of the igniter electrodes must show no damage. Igniter electrodes with a gap out of tolerance or not working properly must be replaced.

Check

– inspect insulators of igniter electrodes for damage

6.3.4 Igniter Box Check

NOTE:

The igniter box may also be tested using the PC heater diagnosis (component test).

High voltage; 13,000 volts arcing across the igniter electrodes.

ATTENTION:

Do not apply voltage to igniter box without electrodes.

6.3.2 Flame Sensor Resistance Check

NOTE:

The glass bulb of the flame sensor and the viewing glass of the window (refer to Fig.) are to be cleaned if contaminated. In case of damage or not obtaining the rated values replace flame sensor.

Check

– cover flame sensor glass bulb – check resistance (rated value: < 20 kOhm) – uncover flame sensor glass bulb and expose to light

of strong lamp.

– check resistance (rated value: < 400 Ohm)

Check

– apply 24V as shown on figure – normal condition: spark between electrodes.

602

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts

Pump pressure test gauge with bleeding feature

2500 3000

8,5

9,5

10,5

4000 5000 6000 7000 8000 8500

Thermo 350

Thermo 300

Thermo 230

Speed (min-1)

Pump pressure in relation to speed

Pump pressure (bar)

Adjustment screw pump pressure

Note: Pump displayed when removed.

6.3.5 Fuel Pump Check

6.3.5.1 Fuel Pump Check on Heaters with Control Unit 1572

A pressure test gauge with a display range from 0 to 15 bar as well as a bleeding feature is required (see Fig. below). The pressure test gauge can be obtained from a Spheros Service Center or a distribution partner.

pressure despite readjustment not be achieved or

occur leaks, the fuel pump must be replaced. – switch off heater. – unscrew test gauge.

As prescribed, the fuel pump and the fuel hoses must be replaced every 5 years.

The igniter box must be removed for safety reasons.

Check

– remove igniter box (refer to 9.2.8.1). – remove nozzle. – screw on test gauge. – cover flame sensor. – switch on heater. – Open the bleed port at the pressure test gauge until

some fuel escapes, collect it e.g. with a cloth. Close the bleed port and read the present pressure at the gauge.

– after approximately 13 sec. pump pressure is

indicated (refer to diagram).

– If the specified pressure cannot be reached, it can be

readjusted. For that rotate the adjusting screw (see Fig. below) max. one revolution. If the prescribed

ATTENTION:

Do not tuch or damage nozzle bore.

– Screw in nozzle and tighten (see 9.2.7.2). – Install igniter box (refer to 9.2.8.2).

6.3.5.2 Fuel Pump Check on Heaters with

Control Unit 1572D

NOTE:

The fuel pump check of heaters with control unit 1572D can also be done using the PC heater diagnosis in the menu component test.

As prescribed, the fuel pump and the fuel hoses must be replaced every 5 years.

Check

– remove nozzle.

603

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts

20 22 24 26

30 32

2500

3000

3500

4000

4500

5000

5500

6000

6500

7000

7500

8000

Thermo 350

Thermo 300

Thermo 230

Voltage

Speed (1/min.)

– screw on the test gauge with bleeding feature. – Follow the instructions in the menu component test of

the PC heater diagnosis.

– Open the bleed port at the pressure test gauge until

some fuel escapes, collect it e.g. with a cloth. Close the bleed port and read the present pressure at the gauge.

– after approximately 13 sec. pump pressure is

indicated (refer to the diagram above).

– If the specified pressure cannot be reached, it can be

readjusted. For that rotate the adjusting screw max. one revolution. If the prescribed pressure despite readjustment not be achieved or occur leaks, the fuel pump must be replaced.

– screw in nozzle and torque with 20 Nm.

ATTENTION:

Do not tuch or damage nozzle bore.

6.3.6 Fan Motor Check

NOTE:

The fan motor check is performed with the burner installed. If normal conditions are not obtained the fan motor must be replaced.

6.3.7 Solenoid Valve Check

NOTE:

A solenoid valve leaking valve seat shows by rather long smoke emissions during run-down. In this case fuel keeps dripping through the fuel nozzle. Short smoke emissions are normal caused by clearing the area between solenoid valve and nozzle bore.

Check

ATTENTION:

Disconnect solenoid valve connector from control unit to avoid damage to the control unit.

– Check electrics for the following values:

• break voltage 17.0 Volts

• operating voltage 19.2 ... 28.8 Volts

• power consumption at

nominal voltage and 20 °C 10 Watts

• nominal current 0.42 Amps

NOTE:

On heaters with control unit 1572 the solenoid valve may also be checked by means of the PC heater diagnosis (component test).

Check

– check fan motor bearing condition(binding) – measure heater power supply voltage – switch on heater – measure speed and compare with the diagram below

Thermo 230/231 4400 ±350 24 Volt Thermo 300/301 5200 ±420 24 Volt Thermo 230 6200 ±500 24 Volt

6.3.8 Nozzle Block Preheater Check

NOTE:

At a temperature of < 0 °C the heater cartridge in the nozzle block is activated. The heating period depends on the heat reflected within the combustion chamber. Preheating is deactivated when the thermostat ambient temperature is +8 °C. Power consumption is 130 ±13 Watts at 24 Volt.

Check

– swing burner head open or remove – disconnect electrical connector from nozzle – connect ohmmeter to connector – using cooling spray cool down thermostat or bridge – resistance (max. 4.5 Ω).

604

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

7 Circuit Diagrams

7.1 General

The circuit diagrams (Fig. 701 and 702) show possible heater circuits for Thermo 230, 300 and 350 with control unit 1572 and with

–switch – timer 1529 (triple timer)

The circuit diagrams (Fig. 703 and 704) show possible heater circuits for Thermo 230, 231, 300, 301 and 350 with control unit 1572D and with

–switch – standard timer 1531

The circuit diagrams (Fig. 705 thru 710) show possible heater circuits for Thermo 230, 231, 300, 301 and 350 with control unit 1572D

701

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572 B1 Flame sensor B2 Temperature sensor B3 Temperature limiter B4 Thermostat open at T > 8 °C E1 Heating cartridge for nozzle preheating F2 Fuse 25A flat fuse SAE J 1284 F3 Fuse 25A flat fuse SAE J 1284 H1 Light operation indicator light K1 Relay (in item A2) for circulation pump K2 Relay (in item A2) for combustion air fan /

heating cartridge M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on / off S2 Continuity switch on water cock

Item Nomenclature Remark

S3 Switch,

Ext. pump trigger S4 Switch power save operation U1 Igniter box U2 Igniter electrodes A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole X1 Plug connections, 6-pole X2 Plug connections, 2-pole X3 Plug connections, 8-pole Y1 Solenoid valve

1 Diagnostic connector

rt/ws

H2H1

F1/B3E1B2

F3 F2

8765432

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Fig. 701: Automatic Control Circuit with Control Unit 1572 and Switch

702

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572 B1 Flame sensor B2 Temperature sensor B3 Temperature limiter B4 Thermostat open at T > 8 °C E1 Heating cartridge for nozzle preheating F2 Fuse 25A flat fuse SAE J 1284 F3 Fuse 25A flat fuse SAE J 1284 F6 Fuse 5A flat fuse SAE J 1284 H3 Light in pos. P symbol lighting H4 Symb. “Heating“ on display operation indicator light K1 Relay (in item A2) for circulation pump K2 Relay (in item A2) for combustion air fan /

heating cartridge M1 Motor combustion air fan M2 Motor circulation pump P Pre-selection timer (1529) for pre-selection operation

Item Nomenclature Remark

S2 Continuity switch on water cock S3 Switch,

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

2648

rt/ws

12345678

8765432

F1/B3E1B2

75(15)

58 75(15)

F3 F6 F2

1 Diagnostic connector

2 to vehicle terminal +75 if available, otherwise terminal 15

3 Timer P:

with plus to connection 4 = continuous operation during immediate heating without plus to connection 4 = heating period 1 hour

4 vehicle lighting terminal 58

Fig. 702: Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer)

703

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

Item Nomenclature Remark

S3 Switch ext. pump trigger S4 Switch power save operation U1 Igniter box U2 Igniter electrodes W1 wire harness (1) W2 wire harness (2) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole F Plug connections, 2-pole X1 Plug connections, 6-pole X2 Plug connections, 2-pole X3 Plug connections, 8-pole Y1 Solenoid valve

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

1 Diagnostic connector

3 Pin assignment: Pin assignment 4wire lead 7wire lead

D1 0,75 gr 0,75 rt D2 0,75 or 0,75 or D3 0,75 gn 0,75 bl D4 0,75 br 2,0 br F1 nicht belegt 2,0 sw F2 nicht belegt 2,0 rt/ws

4 with connection to terminal 61 auxiliary

Fig. 703: Automatic Control Circuit with Control Unit 1572D and Switch

704

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

1 Diagnostic connector

2 Timer P:

with plus to connection 10 = continuous operating during immediate heating terminal 10 not connected = duration of heating programmable (10 min to 120 min);

3 Pin assignment: Pin assignment 4wire lead 7wire lead

D1 0,75 gr 0,75 rt D2 0,75 or 0,75 or D3 0,75 gn 0,75 bl D4 0,75 br 2,0 br F1 not used 2,0 sw F2 not used 2,0 rt/ws

4 with connection to terminal 61 auxiliary

Item Nomenclature Remark

A1 Heater A2 Control unit SG 1572D B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating B5 Thermostat alternative to B3 B6 Thermostat for vertical installation (MV Y1) E1 Heating cartridge for nozzle preheating F1 Fuse 5A flat fuse acc. DIN 72581 part 3 F2 Fuse 25A flat fuse acc. DIN 72581 part 3 F3 Fuse 25A flat fuse acc. DIN 72581 part 3 H1 Light operation indicator light H2 Light flame indication light H4 Symb. “Heating“ on display operation indicator light (in pos. P) M1 Motor combustion air fan M2 Motor circulation pump P Pre-selection timer for pre-selection operation

Item Nomenclature Remark

Fig. 704: Automatic Control Circuit with Control Unit 1572D and Standard Timer

705

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

rt/ws

DEUTSCH

rt/sw

D+

FA K

Signal UP

UPFA

Y1 E1

B3/B5

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

A1 Heater A2 Control unit SG 1572D B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating E1 Heating cartridge for nozzle preheating F1 Fuse 25A flat fuse acc. DIN 72581 part 3 F2 Fuse 25A flat fuse acc. DIN 72581 part 3 F3 Fuse 5A flat fuse acc. DIN 72581 part 3 H1 Light operation indicator light H2 Light flame indication light M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on / off

Item Nomenclature Remark

S3 Switch ext. pump trigger S4 Switch power save operation U1 Igniter box U2 Igniter electrodes W1 wire harness (1+2) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole F Plug connections, 2-pole X1 Plug connections, 7-pole X2 Plug connections, 2-pole X3 Plug connections, 7-pole Y1 Solenoid valve

1 Diagnostic connector

Fig. 705: System wiring diagram Daimler Chrysler Citaro, Ident no. 67131

706

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

rt/ws

-31

F1/B3E1B2

DEUTSCH

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572 B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter alternative to F1 B4 Thermostat for nozzle preheating B5 Fire guard Van Hool E1 Heating cartridge F2 Fuse see table F3 Fuse see table H1 Light operation indicator H2 Light flame indicator K1 Relay for circulation pump K2 Relay for combustion air fan M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on / off

Item Nomenclature Remark

S2 Continuity switch on water cock S3 Switch,

Ext. pump trigger

required, if S2 does not exist

S4 Switch power save operation U1 Igniter box U2 Igniter electrodes W1 Wiring harness Van Hool A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole X1 Plug connections, 16-pole X2 Plug connections, 4-pole Y1 Solenoid valve

1 Diagnostic connector

Fuses acc. to SAE J 1284

DW230 DW300 DW350 F2 25A / 16A 25A / 16A 25A / 16A F3 25A / 16A 25A / 16A 25A / 16A

Fig. 706: System wiring diagram Van Hool, Ident no. 89401

707

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

rt/ws

H2H1

F1/B3E1B2

F3 F2

-31

654

DEUTSCH

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572 B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter alternative to F1 B4 Thermostat for nozzle preheating E1 Heating cartridge F2 Fuse see table F3 Fuse see table H1 Light operation indicator H2 Light flame indicator K1 Relay for circulation pump K2 Relay for combustion air fan M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on / off

Item Nomenclature Remark

S2 Continuity switch on water cock S3 Switch,

Ext. pump trigger

required, if S2 does not exist

S4 Switch power save operation U1 Igniter box U2 Igniter electrodes W1 Wiring harness (1) W2 Wiring harness (2) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole X1 Plug connections, 6-pole X2 Plug connections, 2-pole X3 Plug connections, 8-pole Y1 Solenoid valve

1 Diagnostic connector

Fuses acc. to SAE J 1284

DW230 DW300 DW350 F2 25A / 16A 25A / 16A 25A / 16A F3 25A / 16A 25A / 16A 25A / 16A

Fig. 707: System wiring diagram O405 / O407 / O408, Ident no. 91292

708

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

rt/ws

rt/sw

D+

LFAK

Y1 E1

B3/B5

DEUTSCH

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572D B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating E1 Heating cartridge for nozzle preheating F2 Fuse 25A flat fuse acc. DIN 72581 part 3 F3 Fuse 25A flat fuse acc. DIN 72581 part 3 H1 Light operation indicator H2 Light flame indicator M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on / off S2 Continuity switch on water cock S3 Switch,

Ext. pump trigger

required, if S2 does not exist

S4 Switch power save operation

Item Nomenclature Remark

U1 Igniter box U2 Igniter electrodes W1 Wiring harness (1) W2 Wiring harness (2) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole F Plug connections, 2-pole X1 Plug connections, 6-pole X2 Plug connections, 2-pole X3 Plug connections, 8-pole Y1 Solenoid valve

1 Diagnostic connector

Fig. 708: System wiring diagram MAN, Ident no. 89404

709

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

rt/ws

-31

DEUTSCH

D+

FA K

rt/ws

654

X4/X5

Y1 E1

B3/B6

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

S3 Switch, Ext. pump trigger required, if S2 does not exist S4 Switch power save operation U1 Igniter box U2 Igniter electrodes W1 Wiring harness (1) W2 Wiring harness (2) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole F Plug connections, 2-pole X1 Plug connections, 10-pole X2 Plug connections, 2-pole X3 Plug connections, 8-pole X4 Plug connections, 4-pole X5 Plug connections, 4-pole Y1 Solenoid valve Y2 Shut-off valve with filter

1 Diagnostic connector

Fig. 709: System wiring diagram SETRA, Ident no. 90972

710

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams

1 Diagnostic connector

2 Timer P:

with plus to connection 10 = continuous operating during immediate heating terminal 10 not connected = duration of heating programmable (10 min to 120 min);

3 Pin assignment: Pin assignment 4wire lead 7wire lead

D1 0,75 gr 0,75 rt D2 0,75 or 0,75 or D3 0,75 gn 0,75 bl D4 0,75 br 2,0 br F1 not used 2,0 sw F2 not used 2,0 rt/ws

5 Option

bl br ge gn gr or rt sw vi ws

Wire colors

blue brown yellow green gray orange red black violet white

Wire gauges

< 7,5 m 7,5 - 15 m

0,75 mm

1,0 mm

1,5 mm

2,5 mm

4,0 mm

1,5 mm

2,5 mm

4,0 mm

6,0 mm

Item Nomenclature Remark

A1 Heater not grounded A2 Control unit SG 1572 B1 Flame sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating B5 Thermostat alternative to B3 B6 Thermostat for vertical installation (MV Y1) E Filter heating E1 Heating cartridge for nozzle preheating F1 Fuse 5A flat fuse acc. DIN 72581 part 3 F2 Fuse 25A flat fuse acc. DIN 72581 part 3 F3 Fuse 25A flat fuse acc. DIN 72581 part 3 F4 Fuse 25A flat fuse acc. DIN 72581 part 3 F5 Fuse 5A flat fuse acc. DIN 72581 part 3 F6 Fuse 5A flat fuse acc. DIN 72581 part 3 F7 Fuse 5A flat fuse acc. DIN 72581 part 3 H1 Light operation indicator H2 Light flame indicator H4 Symb. “Heating“ on display operation indicator light (in pos. P) K4 Relay M1 Motor combustion air fan M2 Motor circulation pump P Pre-selection timer for pre-selection operation

Item Nomenclature Remark

S1 Switch on / off S3 Switch ext. pump trigger S4 Switch power save operation S5 Switch aux. heating S6 Switch filter heating on T Temperature switch filter heating U1 Igniter box U2 Igniter electrodes W1 Wiring harness (1) W2 Wiring harness (2) W3 Wiring harness (3) A Plug connections, 6-pole C Plug connections, 1-pole D Plug connections, 4-pole F Plug connections, 2-pole O Plug connections, 2-pole Q Plug connections, 2-pole X1 Plug connections, 4-pole X2 Plug connections, 2-pole X3 Plug connections,7-pole X4 Plug connections, 12-pole X5 Plug connections, 4-pole Y1 Solenoid valve

Fig. 710: Automatic Control Circuit Rail with Control Unit 1572D, standard timer and filter heating

711

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

Heaters manufactured from beginning of 1996 up to 1998, calendar

week 36; 3G......)

Identification label

Exhaust muffler

8 Servicing

8.1 General

This section describes the servicing procedures allowed on the heater when installed.

8.2 Heater Servicing

As long as the heater is in operation or in run-down the battery main power supply must not be disconnected to prevent the heater from overheating by response of the overheat protection. When performing long time repairs on the heater its removal is appropriate. After working on the heating circuit replenish with a coolant mix prepared with water and anti-freeze and bleed circuit afterwards according to manufacturer’s instructions.

8.3 Vehicle Servicing

8.5.1 Inspection and Attachment of the Exhaust Muffler (only heaters from year of production 1996 and up to production

date 1996, calendar week 36; 3G......)

NOTE:

If the exhaust muffler is already secured with a sheet metal screw, the following procedure need not be performed.

General

The exhaust muffler of heaters manufactured from the beginning of 1996 up to a manufacturing date of 1998

(calendar week 36; 3G.......) (for year or date of production

refer to identification label) the exhaust muffler may get loose or lost under certain circumstances. Therefore an inspection for proper attachment of the muffler should be performed.

In the vicinity of the heater a temperature of 110 °C must under no circumstances be exceeded (e.g. during paint work on the vehicle).

8.4 Heater Test Run

The heater must not be operated, not even with the timer, in enclosed areas like garages or workshops not equipped with exhaust ventilation facilities.

8.5 Maintenance

The heater should be inspected in periodic time intervals, latest at the beginning of the heating period (time of increased heater usage due to present weather conditions), refer to Maintenance plan in Appendix A-1.

ATTENTION:

801

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

Sheet metal screw B 3.9 x 25

Hole

2.5 mm Ø

Hole

2.5 mm Ø

Exhaust muffler (ident. no. 206 91D)

Exhaust end pipe

Exhaust deflector (ident. no. 849 70A)

Exhaust pipe

Slot exhaust pipe

Heater without exhaust pipe

Heater with exhaust pipe

Inspection and Attachment

NOTE:

The exhaust muffler must always be secured with a sheet metal screw. Drill a hole with a diameter of 2.5 mm into the exhaust end pipe and muffler and arrest muffler with a sheet metal screw B 3.9 x 25 (see figure).

1. Check exhaust end pipe for presence of muffler. For checking remove exhaust end pipe as required.

2. If muffler is found in exhaust end pipe fasten as described in NOTE. Slot or drill exhaust end pipe and refit.

3. If no muffler is found in exhaust end pipe check if muffler is upstream in exhaust pipe. If muffler is dislocated in the exhaust pipe, arrest muffler as described in NOTE. Slot or drill exhaust pipe and refit.

4. If the exhaust muffler has been lost it may be ordered from Spheros (ident. no. 206 91D). Fasten muffler according to NOTE. Slot or drill exhaust pipe and refit.

5. If heater is operated without exhaust pipe, fasten muffler according to NOTE. An exhaust deflector must be additionally fitted.

802

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

High voltage!

Danger to life!

Warning!

NOTE

Depending on the burner head direction of swing the cotter pin may be located on the opposite side.

7.5 +1 Nm

8.5.2 Burner Head Opening and Closing

The igniter box operates with high voltage. Prior to opening the burner head the connectors of the cable harness in the vehicle have to be disconnected to prevent lethal injuries.

After closing burner head, reconnect connectors in the vehicle.

NOTE:

Maintenance on the heater is easy. By swinging the burner head open the following components become accessible: – fuel pump and fuel nozzle – solenoid valve – igniter box – igniter electrodes –flame sensor – combustion chamber – nozzle block preheater (if installed)

In order to obtain a convenient burner head opening angle it is required to disconnect the electrical connection(s) to the temperature limiter and temperature sensor.

Opening

1. Disconnect electrical connections to temperature limiter and temperature sensor.

2. Loosen nuts (3, Fig. 801) enough to release hinge bolts (2).

3. Swing hinge bolts (2) outwards.

4. Swing burner head (4) away.

Closing

1. If required engage burner head (4, Fig. 801) into the hinge and secure it using the cotter pin (1).

2. Swing burner head (4) into closed position.

3. Swing hinge bolts (2) into lock position and secure with nuts (3).

4. Tighten nuts (3).

5. Reconnect electrical connections to the temperature limiter and temperature sensor.

NOTE

When making electrical connections observe wiring color codes.

Fig. 801 Swinging Burner Head open

803

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

8.6 Visual Inspections and Regulations for Installation

8.6.1 Connection to Vehicle Cooling System

The installation of the heater should be in a location as low as possible to ensure self-venting of the heater and circulation pump. This applies in particular for the circulation pump because it is not self-sucking.

The heater is to be connected to the vehicle cooling system according to Fig. 802. The cooling system coolant capacity must be at least 10 liters.

The vehicle cooling system or the separate heating circuit must use only pressure relief valves with an opening pressure of at least 0.4 bar and of max. 2.0 bar.

It is a basic requirement to use the coolant hoses supplied by Spheros, otherwise the hoses must at least meet the specifications of DIN 73411. The hoses have to be installed free of kinks and for proper venting in an inclination. Hose connections must be secured against slippage with hose clamps.

8.6.2 Connection to Vehicle Fuel System

Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel tank.

8.6.2.1 Fuel Lines

In order to avoid air from being captured in fuel lines, they should only be installed with an incline. The fuel line joints are to be secured against slipping with hose clamps should no screwed mechanical unions be in use.

Should fuel hoses be installed always use the hoses supplied or offered by Spheros. If other hoses are used they must at least meet the specifications of DIN 73379. Fuel hoses must not be kinked or twisted and must be secured with clamps every 25 cm.

For routing fuel also fuel lines may be used consisting of materials standard in the manufacturing of vehicles, e.g. steel, copper or plastic lines made of unhardened, light and temperature stabilized PA11 or PA12 (e.g. Mecanyl RWTL) according to DIN 73378 observing the applicable jointing instructions.

NOTE:

The specified tightening torques of the hose clamps used must be complied with.

Prior to the heater’s first operation or after replacement of the coolant, attention must be paid to carefully bleed the cooling system. Heater and lines must be installed so that static venting is guaranteed.

Improper venting may cause malfunctions by overheating in equipment operation.

Proper venting may be identified by a circulation pump almost noiseless in operation.

When using the circulation pump Aquavent 6000 (U4851) or Aquavent 6000S (U4852) or Aquavent 6000SC (U4856) the circulation pump automatically is switched off approx. 15 seconds after switch-on if coolant is lacking or the pump wheel is jammed.

In combination with control unit 1572D (Thermo label colored) and with programmed circulation pump check the heater also switches off when coolant is missing.

Basic rules for the routing of fuel lines are:

• Protect against undue temperatures.

ATTENTION:

In overheat condition the heater outer shell may reach Diesel fuel inflammation temperature!

• Protect lines from stone strike.

• Dripping or evaporating fuel may neither accumulate nor ignite on hot components or electrical equipment.

804

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

Water heating circuit – Sidewall radiators and roof duct heating

1 Sidewall radiator with fan 2 Heat exchanger, entrance 3 Heater unit 4 Circulation pump 5 Heat exchanger, roof 6 Vehicle engine 7 Cockpit heating 8 Control element

Supply

Return

Fig. 802 Example of a Heater Installation in a Passenger Bus

805

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

Information label

Danger to life and health!

Warning!

When installing a shut-off device in the return line a clearly visible information label must be provided.

ATTENTION:

Operation with the return line shut off causes damage to the fuel pump. Fuel may escape. Danger of fire.

8.6.3 Combustion Air Supply

Observe official regulations concerning the installation (see 1.6).

Combustion air must under no circumstances be extracted from rooms with persons.

ATTENTION:

The combustion air inlet must not point towards the forward direction of motion. It must be located so that no clogging by contamination, impact of snow, or intake of splash water is to be expected.

The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle.

Permissible dimensions of combustion air intake line:

• inner diameter: 55 mm

• max. length: 5 m

• max. bend: 270°

Loose fuel lines must be secured in order to avoid sagging.

The installation of an additional fuel pump is not allowed.

Fuel lines permissible dimensions:

• inner diameter for suction and return line:

• 6 mm (other diameters upon request).

• max. permissible length for each suction and return line: 10 m

• Max. permissible suction height: 2 m

• Max. permissible priming pressure: 0.3 bar for suction and return line.

8.6.2.2 Fuel Filter

A by Spheros supplied with or approved fuel filter is to be installed. Installation position possibly vertical with horizontal direction of flow. To avoid operating malfunctions replace filter or filter cartridge once a year or more often if fuel is contaminated.

The combustion air inlet must be located so that no exhaust fumes can enter.

NOTE:

If the combustion air intake line cannot be routed upwards, a water drain hole Ø 4 mm is to be provided at the lowest point.

If the heater is located near the fuel tank in a common installation compartment, combustion air must be taken in from and the exhaust routed to the exterior. The feedthroughs must be sealed against splash water.

If the heater is located in a closed installation box, a vent port is required:

Thermo 230, 231, 300 and 301 30 cm Thermo 350 35 cm

If the temperature in the installation box exceeds the permitted ambient temperature of the heater (see Technical Data), the vent port must be enlarged consulting Spheros.

2 2

806

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

Danger to life and health!

Warning!

Risk of scalding!

Caution!

8.6.4 Exhaust Line

Observe official regulations concerning the installation (see 1.6).

ATTENTION:

The exhaust pipe outlet opening must not point in the direction of motion.

The exhaust pipe outlet opening must be located so as not to expect clogging by snow or mud.

The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle.

Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only. The exhaust pipe is secured to the air heater e.g. with a clamp.

4. Loosen fuel supply and return line connections, disconnect and fit dummy plugs. Close water cocks as applicable.

5. Loosen hose clamps on coolant hoses, disconnect hoses and fit dummy plugs.

6. Remove 3 screws and washers or 4 screws and washers.

7. Remove heater.

8.7.1.2 Installation

1. Locate heater for installation and secure with 3 screws and washers or 4 screws and washers.

2. Secure line on exhaust outlet using clamp.

3. Slide on coolant hoses and fasten with hose clamps. Torque clamps with 1.5 Nm. Open water cocks.

4. Connect fuel supply and return lines and tighten connections.

5. Secure combustion air inlet line on heater as applicable.

6. Connect electrical connectors of cable harness in vehicle and to circulation pump.

7. Bleed fuel supply system.

8. Bleed coolant circuit.

Permissible exhaust line dimensions: – inner diameter: 70 mm – max. length: 5 m without combustion air intake exten-

sion line

– max. bend: 270°

As an alternative an exhaust deflector must be installed approved by Spheros.

8.7 Removal and Installation

CAUTION

In installed condition only the following disassembly or removal procedures are permitted should enough space for removal allow such action:

– replacement of temperature limiter – replacement of temperature sensor – replacement of combustion air fan – replacement of burner – replacement of igniter box – replacement of flame sensor – replacement of combustion chamber

8.7.2 Temperature Limiter, Replacement

NOTE:

The replacement procedure for the temperature limiter is identical with the heater installed or removed. Perform replacement in accordance with 9.2.1.

8.7.3 Temperature Sensor, Replacement

NOTE:

The replacement procedure for the temperature sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.2.

Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by opening the cooling circuit sealing element.

If required also allow heater to cool down and have collector vessel ready to collect escaping coolant.

8.7.1 Heater, Removal and Installation

8.7.1.1 Removal

1. Disconnect connectors of cable harness in vehicle and of circulation pump.

2. Disconnect combustion air intake on heater if required.

3. Loosen clamp on exhaust outlet.

807

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

High voltage!

Danger to life!

Warning!

High voltage!

Danger to life!

Warning!

High voltage!

Danger to life!

Warning!

High voltage!

Danger to life!

Warning!

8.7.4 Burner, Replacement

NOTE:

The replacement procedure for the burner is identical with the heater installed or removed. Perform replacement in accordance with 9.2.3.

The igniter box operates on high voltage. Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.

8.7.5 Igniter Box, Replacement

NOTE:

The replacement procedure for the igniter box is identical with the heater installed or removed. Perform replacement in accordance with 9.2.8.

The igniter box operates on high voltage. Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.

8.7.6 Flame Sensor, Replacement

NOTE:

The replacement procedure for the flame sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.9.

8.8 First Operation

After heater installation the coolant circuit and the fuel supply system must be thoroughly bled observing the vehicle manufacturer’s instructions. During test runs all coolant and fuel line connections have to be checked for security and no leakage. Should the heater in operation enter a fault condition, perform troubleshooting (refer to Section 5).

NOTE:

Heaters with control unit 1572D: If the heater performs 5 subsequent attempts to start due to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply within 120 sec. during run-down.

8.8.1 Water Circuit, Bleeding

NOTE:

Bleeding must always be performed in accordance with manufacturer’s instructions. For bleeding the circulation pump must not be switched on.

Set vehicle own heating system to "warm" and replenish coolant which must consist of at least 30 % anti-freeze (on glycol base) (protection against corrosion). When using pure water there will be no protection against corrosion and due to the lower boiling point of the water when overheating loss of cooling water may result requiring continuous replenishment. Additives in the coolant must not affect metals, plastics or rubber and leave no deposits.

The igniter box operates on high voltage. Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.

8.7.7 Combustion Chamber, Replacement

NOTE:

The replacement procedure for the combustion chamber is identical with the heater installed or removed. Perform replacement in accordance with 9.2.11.

The igniter box operates on high voltage. Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.

Then operate engine at increased idle until radiator thermostat opens. Shut down engine, check coolant level and replenish as required.

Switch on heater and vehicle heating fan with engine shut down. After a certain cool-down period the heater must automatically switch on and control to off. In case of no restart attempt the temperature limiter on the heater has responded because the heater has not been bled properly. Reset temperature limiter (push button on temperature limiter) and repeat complete bleeding procedure.

NOTE:

The heater may be equipped with an automatically resetting temperature limiter. The manual reset is not necessary.

808

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing

8.8.2 Fuel Supply System, Bleeding

The whole fuel supply system including the fuel filter must completely filled with fuel before initial start-up.

NOTE:

Never use the fuel pump to fill / bleed the fuel system!

ATTENTION:

In the event no fuel comes to the fuel pump during initial start-up, there is a risk that the fuel pump will be damaged!

809

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

9 Repair

9.1 General

This section describes the repairs that may be performed on the heaters Thermo 230, 300 and 350 when removed. Any further disassembly will void the warranty. For re-assembly only components of the proper spare part kits are to be used.

The following components may also be replaced with the heater installed unless restricted space prevents access:

– temperature limiter – temperature sensor – combustion air fan – burner – igniter box –flame sensor – combustion chamber

NOTE:

Symbol tightening torque value: Identifies in graphics parts (eg nuts, bolts) that are to be mounted with a specific tightening torque. The torque values are shown at the symbol and are binding.

901

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

9.1.1 Work on Components after Disassembly

ATTENTION:

All gaskets located between disassembled components must always be replaced and discarded.

9.1.1.1 Visual Inspection, General

• Examine all components for damages (cracks, deformation, wear, etc.) and replace as necessary.

• Examine connectors and wiring for corrosion, loose contacts, wrong crimping, etc. and repair as necessary.

• Check terminals for corrosion and contacts for security. Repair as required.

9.1.1.2 Combustion Chamber, Visual Inspection

– Check swirl ring for security. – Inspect combustion chamber for oxidizing and coke

deposits and remove as required.

– Check welding seem for cracks.

NOTE:

Longitudinal cracks up to 80 mm are allowed.

9.1.2 Incorporation of Modifications

NOTE:

Continuous enhancement of heater design is for optimizing performance and avoiding failures and malfunctions. Normally equipment in use may be retrofitted using available modification kits.

The following modifications may be incorporated during repair procedures:

• installation of control unit 1572D as substitute for control unit 1572 (see 9.1.2.1)

9.1.1.3 Heat Exchanger, Visual Inspection

– Inspect exhaust ducting in heat exchanger for sooting,

deposits, damage and corrosion.

NOTE:

Deposits are to be removed with water jet and brush.

– Inspect heat exchanger for exterior damage, defor-

mation, etc.

NOTE:

Heavy deformation may cause restricted flow of coolant.

ATTENTION:

When replacing the combustion chamber on heaters installed vertically, remove deposits in heat exchanger using a suitable tool.

9.1.1.4 Combustion Air Fan Wheel, Visual Inspection

– Check fan wheel for contamination and cracks. – Check cover plate for security. – Check slide lock for proper sealing.

902

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Control unit 1572D

Control unit 1572

Thermo label

Igniter box

9.1.2.1 Installation of Control Unit 1572D as Substitute for Control Unit 1572

General

Due to the progress in the development of processors control unit 1572 can no longer be supplied. The retrofit of control unit 1572D is performed according to the following procedure:

The modification kit consists of:

• control unit 1572D

• igniter box

• thermo identification label

Procedure

ATTENTION:

Control unit 1572D may only be used in combination with the igniter box delivered (green connector cover). The electrical connector is coded.

1. Remove control unit according to 9.2.5.1 and discard.

2. Remove igniter box according to 9.2.8.1 and discard.

3. Install new igniter box according to 9.2.8.2.

4. Install new control unit according to 9.2.5.2.

5. Apply new thermo label onto existing label to indicate retrofit.

903

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Risk of scalding!

Caution!

9.2 Disassembly and Assembly

9.2.1 Temperature Limiter, Replacement

9.2.1.1 Removal

1. Disconnect electrical connection to temperature limiter.

2. Withdraw rubber cap. Using screw driver lever off retaining spring and remove temperature limiter (1, Fig. 901).

9.2.1.2 Installation

1. Slide rubber cap of temperature limiter (1, Fig. 901) back until temperature limiter can be located for installation.

2. Position temperature limiter (1) in connector (3) and push in retaining clip.

ATTENTION:

The retaining spring must be located in the groove of the housing and must be latched in position both perceptibly and audibly (twice) at the collar of the locating socket. Only then will the temperature limiter be in proper contact with the heat exchanger jacket.

2. Unscrew temperature sensor (2, Fig. 901) and remove.

9.2.2.2 Installation

1. Manually screw temperature sensor (2, Fig. 901) into coolant outlet (4).

2. Tighten temperature sensor.

3. Restore electrical connections.

NOTE:

Observe electrical wiring color coding when making connections to temperature sensor.

9.2.3 Burner, Replacement

9.2.3.1 Removal

1. Disconnect electrical connections on burner and loosen fuel lines.

2. Loosen nuts (6, Fig. 901) until hinge bolts are free.

3. Swing hinge bolts (7) open and remove cotter pin (5).

4. Remove burner (8).

5. Perform procedures on components after disassembly (refer to 9.1.1).

3. After the rubber cap has been placed in position, the cable must be aligned in the cable sleeve, free from strain. Connection cables must not be routed over reset button.

NOTE:

Observe electrical wiring color coding when making connections to temperature limiter.

4. Make electrical connections.

9.2.2 Temperature Sensor, Replacement

9.2.2.1 Removal

1. Disconnect electrical connection to temperature sensor.

9.2.3.2 Installation

1. Position burner (8, Fig. 901) for installation, swing hinge bolts closed and secure temporarily using screws (6).

2. Insert cotter pin (5) according to the intended opening swing direction.

3. Tighten nuts (6).

4. Connect fuel lines.

5. Restore electrical connections.

NOTE

Observe electrical wiring color coding when making connections to temperature limiter and temperature sensor.

Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by opening the cooling circuit sealing element.

If required also allow heater to cool down and have collector vessel ready to collect escaping coolant.

904

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Rubber cap

Temperature

Retaining clip

1 Temperature limiter 2 Temperature sensor 3 Connector 4 Coolant outlet 5 Cotter pin 6 Nut (2) 7 Hinge bolt (2) 8 Burner

limiter

NOTE

Cotter pin (5) may be fitted on other side as required for burner head to swing open in opposite direction.

20 +5 Nm

7.5 +1 Nm

Fig. 901 Temperature Limiter, Temperature Sensor and Burner, Replacement

905

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Closing slide lockOpening slide lock

9.2.4 Combustion Air Fan, Replacement

NOTE:

For replacement of the combustion air fan the burner may be left installed. In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged.

9.2.4.1 Removal

1. Loosen screws (3, Fig. 902) and withdraw cap (2) from burner.

2. Using suitable tool (e.g. mandrel 3 mm) open slide lock (5) until fan wheel can be pulled off.

3. Disconnect electrical connector (9).

4. Remove screws (6) with lock washers and withdraw fan motor (7).

5. Perform procedures on components after disassembly (refer to 9.1.1).

9.2.4.2 Installation

NOTE:

Fan motor (7, Fig. 902) to be aligned with control unit (recess in mounting flange) and with clutch (by rotating drive shaft).

1. Align fan motor (7) and position for installation.

2. Attach fan motor using screws (6) and lock washers.

3. Tighten screws.

4. Connect electrical connector (9).

5. Bring slide lock (5) on fan wheel in installation position.

6. Slide fan wheel onto drive shaft and using suitable tool (e.g. mandrel 3 mm or pliers) close slide lock until fan wheel is locked.

7. Locate cap (2) and secure with screws (3).

8. Tighten screws.

906

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

1 Splash protection cover 2 Cap 3 Screw (2) 4 Fan wheel 5 Slide lock 6 Screw (3) 7 Fan motor 8 Clutch 9 Electrical connector

5 +1 Nm

2 Nm

Fig. 902 Combustion Air Fan, Replacement

907

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

High voltage!

Danger to life!

Warning!

9.2.5 Control Unit, Replacement

NOTE:

For replacement of the control unit the burner head may be left installed and must only be swung open for disconnection of electrical connector (8, Fig. 904). In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged. If a control unit 1572 is substituted with a control unit 1572D, perform procedure according to 9.1.2.1.

9.2.5.1 Removal

1. Disconnect all electrical connections from control unit (23, Fig. 904).

2. Swing burner head open (refer to 8.5.2) and disconnect electrical connector (8).

3. Remove flame sensor (refer to 9.2.9.1).

4. Remove combustion air fan (refer to 9.2.4.1).

5. Carefully withdraw control unit (23) in axial direction from burner head (17) and remove.

6. Perform procedures on components after disassembly (refer to 9.1.1).

9.2.5.2 Installation

1. Carefully push control unit (23, Fig. 904) in axial direction against stop into burner head (17).

2. Install combustion air fan (refer to 9.2.4.2).

3. Make all electrical connections on control unit (23).

4. Install flame sensor (refer to 9.2.9.2).

5. Connect electrical connector (8).

9.2.6 Fuel Pump, Replacement

9.2.6.1 Removal

1. Remove burner (refer to 9.2.3.1).

2. Using screwdriver lever off igniter electrodes (3, Fig. 904) from igniter box (1) and remove.

3. Remove disc (6) with heating cartridge (if installed).

4. Disconnect electrical connector (8).

9.2.6.2 Installation

1. Install solenoid valve (7, Fig. 904) on fuel pump (10) if required.

2. Fit new O-rings (12) and filter screen (11) on fuel pump (10).

3. Position fuel pump (10) for installation and secure with new screws (9) (with threadlock coating).

4. Tighten screws.

5. Connect electrical connector (8).

6. Plug on disk (6) and mount heating cartridge.

7. Plug on igniter electrodes (3).

8. Install burner (refer to 9.2.3.2).

9.2.7 High Pressure Nozzle, Replacement

9.2.7.1 Removal

1. Remove burner (refer to 9.2.3.1).

2. Using screwdriver lever off igniter electrodes (3, Fig.

904) from igniter box (1) and remove.

3. Remove disk (6) with heating cartridge (if installed).

4. Disconnect electrical connector (8) of the heating cartridge.

5. Unscrew high pressure nozzle (4).

NOTE:

Ensure cleanliness is maintained when installing the nozzle. Only touch the nozzle at its hexagon surface.

9.2.7.2 Installation

1. Screw in high pressure nozzle (4, Fig. 904) and tighten.

2. Connect electrical connector (8) of the heating cartridge.

3. Plug on disk (6) and mount heating cartridge.

4. Plug on igniter electrodes (3).

5. Install burner (refer to 9.2.3.2).

9.2.8 Igniter Box, Replacement

NOTE:

During the following step ensure that escaping fuel is immediately neutralized and properly disposed of.

5. Remove screws (9) and discard.

6. Withdraw fuel pump (10) together with solenoid valve (7) and remove.

7. Remove and discard O-rings (12) and filter screen (11).

8. Remove solenoid valve (7) from fuel pump (10) as required.

9. Perform procedures on components after disassembly (refer to 9.1.1).

The igniter box operates with high voltage. Prior to opening the burner head the connectors of the cable harness in the vehicle have to be disconnected to prevent lethal injuries.

908

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

1 Igniter box 2 Screw (2) 3 Igniter electrodes 4 High pressure nozzle 5 Viewing glass 6 Disk 7 Solenoid valve 8 Electrical connector 9 Screw (3) 10 Fuel pump 11 Filter screen 12 O-ring (2) 13 Rotating ring 14 Screw

15 Flame sensor 16 Screw 17 Burner housing 18 Strain relief clamp (2) 19 Screw (2) 20 Base plate 21 Relay 22 Relay 23 Control unit 24 Heating cartridge with thermostat 25 Clip 26 Overheat thermostat (Thermo Top 231 / 301 only) only)

Control unit

1572

Control unit 1572D

Overheat thermostat only Thermo 231 / 301

20 Nm

5 +1 Nm

Fig. 903 Control Unit and Fuel Pump, Replacement

909

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Igniter box

Igniter electrodes

Removal and installation of igniter electrodes

Flame sensor

9.2.8.1 Removal

1. Remove burner if required (refer to 9.2.3.1).

2. Using screw driver lever off igniter electrodes (Fig. 904) from igniter box and remove.

3. Remove disk (6).

4. Remove combination screws (2).

5. Withdraw igniter box (1) and remove.

6. Perform procedures on components after disassembly (refer to 9.1.1).

9.2.8.2 Installation

1. Locate igniter box (1, Fig. 904) for installation, plug on making correct electrical connections and secure with combination screws (2).

2. Tighten combination screws (2).

3. Plug on disk (6) and align.

4. Plug on igniter electrodes (3).

5. Install burner (refer to 9.2.3.2).

9.2.9 Flame Sensor, Replacement

9.2.9.1 Removal

1. Remove burner if required (refer to 9.2.3.1).

2. If required lever off igniter electrodes (Fig. 904) from igniter box using screw driver and remove.

3. Remove disk (6).

4. Remove screw (14) and lock washer.

5. Withdraw flame sensor (15) and remove.

6. Perform procedures on components after disassembly (refer to 9.1.1).

9.2.9.2 Installation

1. Position flame sensor (15, Fig. 904) for installation, plug on to make correct electrical connections and secure with screw (14) and lock washer.

2. Tighten screw (14).

3. Plug on disk (6) and align.

4. Plug on igniter electrodes (3).

5. Install burner (refer to 9.2.3.2).

Fig. 904 Igniter Box and Flame Sensor, Replacement (Sheet 1 of 2)

910

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Control unit

1572

Control unit 1572D

Overheat thermostat only Thermo 231 / 301

20 Nm

5 +1 Nm

Fig. 904 Igniter Box and Flame Sensor, Replacement (Sheet 2 of 2)

911

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

Position of the welding seam

Position of the cut-outs in the combustion chamber head when installed

when installed

Cut-outs

o.k.

Not permitted!

9.2.10 Heat Exchanger, Replacement

9.2.10.1 Removal

1. Remove temperature limiter (refer to 9.2.1.1).

2. Remove temperature sensor (refer to 9.2.2.1).

3. Remove burner (refer to 9.2.3.1).

4. Withdraw combustion chamber (1, Fig. 905) from heat exchanger (2).

5. Remove heat exchanger (2).

6. Perform procedures on components after disassembly (refer to 9.1.1).

9.2.10.2 Installation

1. Install combustion chamber (refer to 9.2.11.2).

2. Install burner (refer to 9.2.3.2).

3. Install temperature limiter (refer to 9.2.1.2).

4. Install temperature sensor (refer to 9.2.2.2).

9.2.11 Combustion Chamber, Replacement

9.2.11.1 Removal

1. Disconnect electrical connections to temperature limiter and temperature sensor.

2. Swing burner open (refer to 8.5.2).

3. Withdraw combustion chamber (1, Fig. 905) from heat exchanger (2) and remove.

4. Perform procedures on components after disassembly (refer to 9.1.1).

Fig. 905 Heat exchanger and combustion chamber replacement

912

Thermo 230 / 231 / 300 / 301 / 350 9 Repair

9.2.11.2 Installation

ATTENTION:

When replacing the combustion chamber, ensure that the new combustion chamber corresponds to the heating capacity class of your heating appliance.

1. Slide combustion chamber (1, Fig. 905) fully into the heat exchanger (2) against stop. Pay attention to a) the welding seam position, and b) the position of cut-outs in the combustion chamber head

NOTE:

– The combustion chamber should be inserted into the

heat exchanger in such a way that its welding seam is positioned between 2 and 10 o clock (not upwards!) (Fig. 905). A position change during maintenance is permissible and affects the expected service life of the combustion chamber positively.

– Position the cut-outs in the combustion chamber head

as shown in Fig. 905. Dripping from nozzle fuel is so collected in a reservoir between disc and burner head and will be burned at the next burner operation instead to soil the heater.

2. Swing burner closed (refer to 8.5.2).

NOTE:

Observe electrical wiring color coding when making connections.

3. Make electrical connections to temperature limiter and to temperature sensor.

913

Thermo 230 / 231 / 300 / 301 / 350 10 Packaging, Storage and Shipping

10 Packaging, Storage and

Shipping

10.1 General

The heater or its components shipped to Webasto Thermosysteme GmbH for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage.

CAUTION

When shipping a complete heater assembly it must be drained completely. No coolant is allowed to escape when packaging or shipping.

Dummy plugs must be fitted to the coolant inlet and outlet as well as to the fuel lines.

In storage the ambient temperatures specified in Section 4 must not be exceeded.

1001

Maintenance plan

Address of the operator Date of maintenance

Vehicle data

Heater data

Type of heater: Operating/ control device data

Fuel

Diesel fuel

Biodiesel

Date of commision

Heating oil EL

Ident. no.:

Serial no.:

acc. to diagnosis STT (Spheros Thermo Test)

for heaters of type Thermo, Thermo E, Thermo S and Thermo plus in buses und railway vehicles

Periodic heater maintenance

The heater should be inspected in periodic time intervals, latest at the beginning of the heating period (time of increased heater usage due to present weather conditions). In principle the regulations of the vehicle manufacturers as well as the relevant regulations of the German Federal Railway Authority (EBA) and its technical service must be

adhered. If there no such regulations, Valeo prescribes the here shown maintenance intervals for common applications. For the execution of the work, the corresponding workshop manual is to be used. If heaters should be used in other vehicles and/or applications, the maintenance intervals may be shortened or extended. In such cases please contact your dedicated Valeo partner for further information.

Check / Maintenance Important notes Check result Measured values,

1. Electrical connections

a) Examine electrical plug connections and the wiring harness

for visible damages, replace as required.

2. Heat exchanger

a) Check for external damage, discoloration caused by over-

heating and leaks.

b) Clean the heat exchanger inside and outside, remove soot

and debris.

3. Fuel system

a) Inspect fuel lines and connections for leakage. b) Replace fuel filter insert with gasket. resp. replaceable filter.

Determine overheating cause as needed (e.g. water circulation system), check overheat protection.

Ensure connections to fuel flow and return lines are sealed tight! If biodiesel is used a semi annual filter change is prescribed by the manufacturer.

Re-tighten screw connections and hose clamps.

Änderungen vorbehalten. Für Übersetzungen ist die deutsche Fassung rechtlich bindend. Die aktuelle Fassung dieses Dokumentes steht unter www.valeo-thermalbus.com zum Download bereit. / Subject to modification. For translations the german version is binding. Latest version of this document is provided for download on www.valeo-thermalbus.com.

OK not

accomplished repairs

A-1

Maintenance plan

for heaters of type Thermo, Thermo E, Thermo S and Thermo plus in buses und railway vehicles

Check / Maintenance Important notes Check result Measured values,

OK not

accomplished repairs

c) Fuel pump / fuel lines

Note: Observe technical information if biodiesel

or FAME is used!

d) Replace fuel screen with gasket in the pump.

4. Burner head

a) Inspect combustion air intake opening for clear passage. b) Inspect hood for damage.

c) Clean flame detector inspection glass (in the disk). d) Inspect condition of the ignition electrodes, if required adjust

or replace them. e) Replace atomiser nozzle. f) Check solenoid valve for leaks.

5. Exhaust system

a) Inspect exhaust line for clear passage or damage, clean or

replace it as needed. b) Remove combustion chamber from heat exchanger, inspect

for damage and contamination, clean and replace as

needed. c) Insert combustion chamber and mount burner head. Ensure

proper fit and tight connection to the heat exchanger.

Replace the fuel pump every 5 years, if biodiesel is used this interval is shortened

Technical Information Biodiesel / FAME see www.valeo-

thermalbus.com

Replace damaged parts.

Activate combustion air motor using the diagnostic tool (STT), solenoid valve must be tight

d) Combined nuts (M8) for burner head attachment, tightening

torque 7.5 +1 Nm, secure them. e) Measurements

Target values and procedures are outlined in the workshop manual

Ambient temperature (° C) Exhaust temperature (° C)

(Vol.-%) at 24V

Thermo plus 230

Thermo plus 300/350

Smoke spot number acc. to Bacharach (all devices)

Fuel pump pressure according to Workshop Manual

Thermo, Thermo S

Thermo E 200, Thermo plus

6. Water system

a) If available, inspect, clean as needed or replace water filter

insert.

Thermo Thermo E 200 Thermo E 300

Thermo S

(ppm) at 19V

Rail versions

Thermo E 320

Secure them with locking compound

Limits acc. to Regulation ECE-R 122

see technical data heater

10 ±0.5

9.5 ±0.5

10.0 ±0.5

9.5 +1.5

9.0 +1.5

9.5 +1.5

_<1000 _< 4

10 bar 8 +1 bar 9 +1 bar

A-2

Maintenance plan

for heaters of type Thermo, Thermo E, Thermo S and Thermo plus in buses und railway vehicles

7. Functional check

a) If available, open shut-off valve of the fuel return line and

water line.

b) Check fault memory, clear it as needed using the diagnostic

tool (STT).

c) Check heater functionality.

Attention:

During the maintenance, check all screw connections for tightness (for corresponding torque values see Workshop Manual).

after at least 10 min heater operation

A-3

memos

Valeo Thermal Commercial Vehicles Germany GmbH Postfach 1371 - 82198 Gilching - Germany - Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889 www.valeo-thermalbus.com - service-valeobus@valeo.com

Valeo spheros thermo 230, spheros thermo 300, spheros thermo 231, spheros thermo 301, spheros thermo rail Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual