Valeo spheros thermo 230, Workshop Manual

Page 1: ...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 Works...

Page 2: ...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 Functi...

Page 3: ...ing 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 8...

Page 4: ...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 Sh...

Page 5: ...ce literature is required References are provided in the workshop manual at appropriate locations Use the following documents during operation and main tenance of the heaters Operating and Service Ins...

Page 6: ...02 Thermo 230 231 300 301 350 1 Introduction 1 7 Suggestions for improvement and change Please direct any complaints improvement or modifica tion suggestions regarding this manual to service spheros d...

Page 7: ...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...

Page 8: ...rated 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 identi...

Page 9: ...air mix is dispersed in the combustion chamber for combustion to heat the heat exchanger 2 5 Control Unit The control unit 1572 or 1572D is the central component to ensure controlled operation and mon...

Page 10: ...overheats the thermostat causes an error lockout 2 11 Circulation Pump The externally mounted circulation pump ensures proper coolant circulation in the vehicle and heater circuit Depending on the ap...

Page 11: ...ted The circulating pump motor is switched off After approx 2 minutes and circulating pump motor reactivation the operation can be continued Blocking protection If the pump wheel is blocked the motor...

Page 12: ...he 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 swit...

Page 13: ...lock 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 Con...

Page 14: ...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 H...

Page 15: ...heating mode The power save mode is during auxiliary heating automatically deactivated by the control device The lower temperature threshold for reactivation of the burner after control idle period i...

Page 16: ...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 Fig 301 Functional sequence heaters with c...

Page 17: ...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 m...

Page 18: ...y 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...

Page 19: ...ollowing table lists the by Spheros approved fuels and their specifications Further information on approved fuels contains the TI Technical Information Fuels It can be found on the Spheros homepage un...

Page 20: ...missible operating overpressure bar 0 4 2 0 Heat exchanger capacity l 1 8 Minimum capacity of circuit l 25 CO2 in exhaust at nominal voltage Vol 10 0 5 related to 500 m above S L CO2 in exhaust at nom...

Page 21: ...Possible cause Error in the electrics Operation indicator does not light and the heater does not function No supply voltage Fuses Supply cable to the plug contacts of plug A of the control unit Fuse...

Page 22: ...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...

Page 23: ...ic 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...

Page 24: ...ctrics 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...

Page 25: ...he 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 contami nated Is the nozzle free of foreign matter and deposits Is the fuel filter...

Page 26: ...e 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 repl...

Page 27: ...Investigate the reason for the response e g check the exhaust system Replace the solenoid valve Make electrical connections Safety thermostat in the burner defec tive replace Is the component test wi...

Page 28: ...ter 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 temper...

Page 29: ...uts nozzle replacement Setting procedure measure control unit power supply voltage operate heater for approximately 5 min measure CO2 contents and soot level and compare with relevant diagram soot lev...

Page 30: ...Ohm uncover flame sensor glass bulb and expose to light of strong lamp check resistance rated value 400 Ohm 6 3 3 Igniter Electrodes Check NOTE The insulator of the igniter electrodes must show no dam...

Page 31: ...re 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 pressure despit...

Page 32: ...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...

Page 33: ...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...

Page 34: ...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 connection...

Page 35: ...n 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 X4...

Page 36: ...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 W2 wire harness 2 A P...

Page 37: ...or 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...

Page 38: ...clature 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 cartrid...

Page 39: ...572 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...

Page 40: ...sor 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 Li...

Page 41: ...r 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 noz...

Page 42: ...ty B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating B5 Temperature sensor external observe polarity B6 Thermostat alternative to B3 E1 Heating cartrid...

Page 43: ...tion 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 F...

Page 44: ...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 he...

Page 45: ...k 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...

Page 46: ...nnection 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 b...

Page 47: ...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 lack...

Page 48: ...n in a Passenger Bus 4 8 3 1 1 1 1 2 7 5 6 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...

Page 49: ...mstances 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 contamina tion impact...

Page 50: ...cle and of circulation pump 2 Disconnect combustion air intake on heater if required 3 Loosen clamp on exhaust outlet 4 Loosen fuel supply and return line connections disconnect and fit dummy plugs Cl...

Page 51: ...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...

Page 52: ...uel 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...

Page 53: ...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...

Page 54: ...ection 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 mat...

Page 55: ...trol 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 conne...

Page 56: ...l 1 Disconnect electrical connection to temperature sensor Prior to replacement of temperature sensor in in stalled condition relief overpressure in cooling sys tem by opening the cooling circuit seal...

Page 57: ...t Rubber cap Temperature Retaining clip 8 7 6 5 4 3 2 1 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 m...

Page 58: ...ashers 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 fla...

Page 59: ...231 300 301 350 9 Repair Fig 902 Combustion Air Fan Replacement 1 2 3 4 5 6 7 8 9 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 connect...

Page 60: ...ately 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...

Page 61: ...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 th...

Page 62: ...ner 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...

Page 63: ...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...

Page 64: ...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 electri...

Page 65: ...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 l...

Page 66: ...e 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 allow...

Page 67: ...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 insid...

Page 68: ...must be tight 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 cle...

Page 69: ...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 maintenanc...

Page 70: ...memos...

Page 71: ...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...