Valeo Thermo E+ 120, Workshop Manual

Page 1: ...Rev 03 2020 Id No DOK50059 001 Thermo E 120 Thermo E 200 Thermo E 320 12 24V Workshop manual HEATING SYSTEMS...

Page 2: ...308 3 2 W rme bertrager 309 3 3 Combustion chamber 309 3 4 Circulating pump 310 3 5 Heated fuel filter 310 4 Heater functions 4 1 General heater functionality description 401 4 2 Operational heater se...

Page 3: ...nt and setting 701 8 Burner components and heater removal and installation 8 1 General 801 8 2 Burner removal and installation 802 8 3 Removal and installation of the temperature sensors 803 8 4 Hood...

Page 4: ...echnical Updates TI Heating systems 202 202 Pumps http www valeo thermalbus com eu_en Products Pumps 310 Technical Updates TI http www valeo thermalbus com eu_en Service Technical Updates TI Heating s...

Page 5: ...actions which may cause ma terial damage NOTE This caption is used to draw attention to an important feature 1 4 Symbols 1 5 Further documentation to be used The use of additional service literature...

Page 6: ...r safety information 1 6 2 1 Fuel systen ATTENTION If there are signs of leakage in the fuel system drops on the heater or under the vehicle the cause should be analyzed and remedied before continuing...

Page 7: ...oltage range V 10 15 20 5 30 Rated power consumption at 12 24 V 2 W 45 55 110 Switching thresholds C 72 82 Permitted temperature of sucked combustion air 3 C 40 65 85 Permitted ambient temperature dur...

Page 8: ...tures below 18 C a Diesel for arctic climate conditions must be used The usage of flow improvers respectively additives is per mitted There are no negative influences due to additives known ATTENTION...

Page 9: ...the heat is dissipated to a coolant circuit The adaptation to the changing demand of heat is reached by intermittent operation The control device controls on the basis of the signals of a temperature...

Page 10: ...air fan consists of the burner motor and the fan wheel Air is drawn in through the air intake opening in the hood This air intake opening is equipped with a splashguard a protective grid or an intake...

Page 11: ...g In the control device the flameguard is integrated Fig 303 Control device SG1590 Port C Port T temperature sensors Port P circulating pump Flame guard Port ignition unit Port Port burner motor Port...

Page 12: ...ending on the flame bright ness and in this way the applied to it voltage The light from the combustion chamber passes through the dust protection tube into the opening in the housing of the control d...

Page 13: ...fuel pump opens and closes the fuel supply to the fuel nozzle Depending on the heating capacity class and the opera ting voltage different fuel pumps are installed in the heaters 3 1 4 Fuel nozzle Th...

Page 14: ...an lead to the failure of the heater so please pay attention to the correct use use 11121236_ with the electronic control unit 11121234_ 12V only use 11121237_ with the electronic control unit 1112123...

Page 15: ...zation improved The heating time depends on the temperature of intake air and the heat reflection from the combustion space Above 8 C the thermostat switches off The use of the nozzle block preheater...

Page 16: ...olant temperature is captured at the heat exchanger outlet as electrical resistance and transmitted to the control device Overheating protection prevents inadmissibly high heater operating temperature...

Page 17: ...ion chambers depending on the heating capacity class They differ in length and the swirl plates see figure below The combustion chamber of the Thermo E 120 has addi tional a thermal insulation The com...

Page 18: ...nal control of the circulation pumps independent of the heater operation is possible Further information on the installation and operation of the circulating pump is contained in the Thermo E Installa...

Page 19: ...The nozzle block preheater heats the nozzle holder with the atomizer nozzle at temperatures below 0 C and thus the fuel The fuel air mixture is ignited in the combustion chamber via a high voltage ig...

Page 20: ...ed and purge cycle initiated The solenoid valve is closed the flame expires however the combustion air fan and circulating pump continue running The purge cycle ends approx after 120 seconds The combu...

Page 21: ...f the minimum combustion period of 120 seconds the lower switching value is lowered by 1K for the following combustion process The upper switching threshold remains as is This can be repeated until th...

Page 22: ...nge Voltage falls short of the low voltage threshold of approx 20 5 10 Volt at motor start or within a dura tion of 20 seconds after a heating request Voltage exceeding the high voltage threshold of a...

Page 23: ...detector Overheating protection Water temperature sensor Flame not expired within 30 seconds after purge cycle started Burner motor stops Overheating protection triggered Control device error or prog...

Page 24: ...t be performed in the vehicle 5 2 Disconnecting the heater from the vehicle electrical system Some troubleshooting procedures require to disconnect the heater from the vehicle electrical system ATTENT...

Page 25: ...osed Contaminations in the system e g filters or at bottlenecks Circulating pump delivery rate insufficient air in pump housing Insufficient frost protection antifreeze or incorrect mixing ratio Syste...

Page 26: ...rticular single pipe operation Error in the combustion CO2 value cannot be adjusted to nominal value Irregular combustion Air bubbles in fuel supply line leaking fuel supply line or resistance negativ...

Page 27: ...6 Temperature sensor overheat protection defective Temperature sensor short circuit Temperature sensor interruption Temperature sensor overheat protection non plausible Overheat protection short circu...

Page 28: ...t supply of electrical energy sig nals fuel and air respective the discharge of fuel and exhaust gas must be checked The procedure for a heater lock out release is outlined in point 4 4 2 1 Table 503...

Page 29: ...maged seals in the fuel system including fuel pump Check fuel system for leaks and repair if necessary inclu ding fuel pump Clutch malfunction Check coupling and replace if necessary check cause The s...

Page 30: ...Although a combustion hea ter start is heard but the flame is not detected Diagnosis The view of the flame guard on the flame is not ensured Ensure the view of the flame guard on the flame clean or i...

Page 31: ...dition permanently an operating voltage in the permissible range1 Ensure permanent battery voltage in the permissible range1 Disconnect the C plug from the control device Is the voltage between pin G...

Page 32: ...re unusually high Is the combustion air inlet clean free Is the motor OK and can rotate freely Is the exhaust outlet clean free Is the burner pipe OK not coked conta minated or damaged Is the heat exc...

Page 33: ...and cables OK Is the temperature sensor OK Is the proper temperature sensor installed confusion hazard with the Thermo E temperature sensor possible Is sufficient cooling and coolant flow ensured Are...

Page 34: ...t exchanger must be removed as they impact the heat transfer to the coolant The exhaust gas temperature can rise sharply and components in the burner can be damaged by heat Severe outer deformations m...

Page 35: ...should indicate values according to the charts Fig 503 and Fig 504 Preferably the resis tance should be measured at an approx consistent temperature of 20 C and approx 100 C immerse sensor up to the c...

Page 36: ...r see 8 5 Reinstall burner see 8 2 Inspection using the DTT diagnosis Disconnect the heater from the vehicle electrical system Observe 5 2 Inspect the motor for bearing conditions stiffness Connect th...

Page 37: ...ctrodes NOTES How can it be determined whether the control device or the electronic ignition unit EIU is defec tive If a resistance greater than 1 Ohm primary winding is measured at the connector of t...

Page 38: ...rd in the burner housing and engage into the burner housing The electronic part of the flame guard is permanently integrated into the control device and cannot be replaced The functional test is done...

Page 39: ...the nozzle screw the pressure test gauge into the nozzle block 20 Nm 2 NOTE Excert counter pressure at the key face of the nozzle block of the fuel pump using a suitable tool Connect to motor and sole...

Page 40: ...r from control device Remove the DTT diagnosis adapter wiring harness as required Reinstall burner see 8 2 5 6 10 Solenoid valve inspection The coil of the solenoid valve can heat up in switched on co...

Page 41: ...the thermostat switches the heating element on The heating duration depends on the temperature of the intake air and the heat reflection from the combustion space Above 8 C 3 C the ther mostat switche...

Page 42: ...eter on the wires that come directly from the heating element one measuring tip on the plug another measuring tip on the thermostat contact to the heating element Limits 12V Version 1 3 Ohm 24V Versio...

Page 43: ...options of the heater to the vehicle electrical system ATTENTION The repair or replacement of cables and or plugs must be carried out in accordance with the instruc tions in the Thermo E Installation...

Page 44: ...le cross section or Blind plug 1 A short circuit of the positive lead of the CP against another plus or a third or backfeed supply can lead to potential shifts functional impairments and component dam...

Page 45: ...eration indicator max 5 W UP Circulating pump HS Main switch UPFA Circulating pump external control T Connector connection of temperature sensors C Connector connection to vehicle P Connector connecti...

Page 46: ...ed Increased exhaust temperature may indicate a sooted heat exchanger see 5 6 2 or a non switched filter heating 1 After a combustion period of approx 3 min measure the CO2 content in the exhaust and...

Page 47: ...he values in table in 5 6 6 replace if necessary Check the fuel filter for contamination and replace if required clogged clouding flocculation of paraffin different fuels used filled different fuels d...

Page 48: ...t is permanently attached Screws with coated threads must be renewed Before installing components always check whether the correct version is available with regard to the voltage for which the heater...

Page 49: ...ugs 7 Unscrew combination nuts 2 8 Remove burner 1 NOTE Do not bent any lines when placing the burner down Back to 8 7 Disc and dust protection tube removal 8 9 Solenoid valve removal 8 13 Combustion...

Page 50: ...3 Fig 801 ATTENTION The temperature sensors are positioned directly in the coolant circuit To prevent coolant from escaping as far as possible the coolant hoses are to be closed with pinch off pliers...

Page 51: ...2 Position motor 5 onto the fuel pump 9 NOTE The coupling part on the motor shaft must engage in the coupling part of the fuel pump When positioning the motor the stud on the fuel pump housing must be...

Page 52: ...804 Component removal and installation 1 1 Hood 2 Screws hood 2 3 Shaft circlip 4 Fan wheel 5 Burner motor 6 Screws motor 3 7 Motor connector 8 Coupling two part 9 Fuel pump 10 Control device 5 1 2 3...

Page 53: ...k preheating 6 Fig 805 using a serrated washer 3 and a nut 4 2 Pre assemble disc 5 dust protection tube 11 and spring 10 3 Place disc 5 via fuel nozzle 1 and electronic ignition unit 7 onto the nozzle...

Page 54: ...e block preheater heating element see 3 1 6 2 Plug the connector of the nozzle block preheating 6 into the control device 10 Fig 805 3 Install disc with dust protection tube see 8 7 8 12 Fuel pump rem...

Page 55: ...1 Dust protection tube 12 Adjustment ring 13 Screw 14 Solenoid valve assy 15 Solenoid valve coill 16 Sleeve with hexagon 17 Spring washer 18 Screw 19 Gasket ring 20 Heating element retaining clip nozz...

Page 56: ...iehen 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...

Page 57: ...of the heat exchanger 2 9 If necessary remove temperature sensors see 8 3 10 Remove heat exchanger from vehicle Installation 1 Position the combustion chamber 1 correctly into the heat exchanger 2 see...

Page 58: ...g initial start up dry running there is a risk that the fuel pump will be damaged 8 16 2 Bleeding of the coolant circuit NOTE The coolant circuit must be principally bleeded according to the manufactu...

Page 59: ...tions and retrofits For further optimization the heaters are continuously improved Units in the field can usually be upgraded or retrofitted For this purpose respective modification kits will be avail...

Page 60: ...ensure that handling transport and storage will not damage them ATTENTION If a complete heater is sent back it must be comple tely drained While packaging and or shipping it must be ensured that no f...

Page 61: ...sured values accomplished repairs OK not OK 1 Electrical connections a Examine electrical plug connections and the wiring harness for visible damages replace as required 2 Heat exchanger a Check for e...

Page 62: ...the diag nostic tool STT solenoid valve 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...

Page 63: ...ace water filter insert 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 heate...

Page 64: ...memos...

Page 65: ...rcial Vehicles Germany GmbH Friedrichshafener Str 7 Tel 49 8105 7721 0 Fax 49 8105 7721 889 82205 Gilching Germany www valeo thermalbus com service valeobus valeo com Valeo Thermal Commercial Vehicles...