Thermo S Workshop Manual PDF
Thermo S Workshop Manual PDF
Thermo S Workshop Manual PDF
Water Heater
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400
with Control Unit 1586
Status: 01/2012
Ident.-no. 11114913B
Thermo S 160/230/300/350/400
1
Introduction
1.1
1. 2
1. 3
1. 4
1. 5
1. 5. 1
1. 5. 2
1. 5. 3
1. 5. 4
1. 6
Electrical components
Fuel
201
201
Burner
Combustion air fan
Fuel pump
N oz z le bloc k pre he a te r
Control unit
E le c tronic ignition unit with ignition e le c trode s
Temperature sensors with water temperature sensor and integrated overheating protection
Heat exchanger
Combustion chamber
Circulating pump
Aquavent 5000 (U4814) and Aquavent 5000S (U4854) circulating pumps
Aquavent 6000C (U4855 ) and Aquavent 6000SC (U4856) circulating pumps
Fuel filter
302
302
302
303
303
304
304
305
306
307
307
308
308
Heater functions
4. 1
4. 2
4.2.1
4.2.2
4..3
4.3
4.3.1
4. 4
4.5
4.5.1
4. 5. 2
4. 5. 3
4. 5. 4
4.6
4. 6. 1
4.7
101
101
101
101
101
101
102
102
104
105
Technical data
2.1
2.2
1 Introduction
401
402
402
402
403
404
405
406
406
406
406
407
407
407
407
408
General
501
1 Introduction
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.5.10
5.5.11
5.5.12
5.5.13
5.5.14
General
601
General
Heater servicing
Servicing
CO2 content adjustment
701
701
701
702
501
503
505
505
505
507
508
509
509
509
510
510
510
510
511
512
512
512
513
514
515
516
517
518
519
Servicing
7.1
7.1.1
7.2
7.2.1
Schematic diagrams
6.1
Thermo S 160/230/300/350/400
General
Burner removal and installation
Removal and installation of the temperature sensor with integrated overheating protection
Hood removal and installation
Combustion air fan removal and installation
Electronic ignition unit and ignition electrode removal and installation
Control unit removal and installation
Fuel pump removal and installation
Solenoid valve removal and installation
Atomiser nozzle removal and installation
Combustion chamber removal and installation
Heat exchanger removal and installation
Heater removal and installation
Start-up after burner or heater installation
Bleeding of the fuel system
Bleeding of the water circulation
801
802
803
803
804
806
808
808
810
810
811
811
811
812
812
812
Thermo S 160/230/300/350/400
9
1 Introduction
10 Packing / storage
and shipping
10.1
General
1001
Appendix A 1
Periodic heater maintenance
A-2
1 Introduction
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350/400
1
Introduction
1.1
1.2
1.3
WARNING
This heading is used to highlight that non-compliance
with instructions or procedures may cause injuries or
lethal accidents to personnal.
CAUTION
This heading is used to highlight that non-compliance
with instructions or procedures may cause damage
to equipment.
NOTE
This heading is used to highlight and draw specific
attention to information.
1.4
1 Introduction
1.5
NOTE
The provisions of these Regulations are binding within
the territory governed by ECE Regulations and should
similarly be observed in
regulations.
(Extract from ECE Regulation R122, Annex 7)
4. The heater must have a manufacturers label showing
the manufacturers name, the model number and type
together with its rated output in kilowatts. The fuel type
must also be stated and, where relevant, the operating
voltage and gas pressure.
7.1. A clearly visible tell-tale in the operaqtors field of view
shall inform when the combustion heater is switched on or
off.
(Extract from ECE Regulation R122, Part I)
101
1 Introduction
The safety regulations must be observed during
operation, maintenance and repair of heaters of the
Thermo S series.
For heaters in vehicles, which are not subjected to the
European Directive, inspection and approval by the
respective inspection authority is required, if applicable
regulations are in place.
The year of first start-up must be permanently marked
on the type plate by removal of not applicable dates.
The heaters are registered and licensed for the use in
vehicles according to the respective EU Directive 70/156/
ECC (e.g. 2001/56/EC). When using the heater for other
applications not subjected to this EU Directive (e.g. ships),
respective applicable r egulations must be fulfilled.
Thermo S 160/230/300/350/400
WARNING
For risk of poisoning and suffocation the heater may
not be used in closed rooms such as garages or
workshops without exhaust fume extraction. This
also applies when pre-set times/timers are used. This
also applies for burner operation during adjustment
of the CO2 content in the exhasut dumes.
For explosion risk the heater must be switched off at
gas stations and gas systems.
For explosion risk the heater must be switched off,
when combustible fumes or dust can be generated
(e.g. in the proximity of fuel, coal, wood dust, grain
storage/silos or similar).
CAUTION
CAUTION
The heaters are not approved for vehicles subjected to
Directive 94/55/EC (ADR).
The heater may only be installed in the driver's cab or
passenger compartment, if an installation box is used,
which can be tightly sealed vs. the vehicle interior. The
installation box must be sufficiently vented from the
outside.
If the temperature within the installation box exceeds the
permissible ambient temperature of the heater, the
venting opening must be increased after consultation with
Spheros.
WARNING
If operated without coolant (overheating!), the heaters
outer enclosure may reach the ignition temperature of
diesel fuel during operation!
Dripping or evaporating fuel should not accumulate
or ignite on hot parts or electrical equipment.
The heater should be installed as low as possible to
ensure automatic venting of heater and circulating
pump. This in particular applies for the circulating
pump, which does not automatically draw.
NOTE
CAUTION
CAUTION
A temperature of 110C may not be exceeded in the
heater areas (storage temperature).
Exceeding the temperature may cause heater
malfunctions and permanent damage to the
electronics.
Electrical cables must be routed avoiding isolation
damage (e.g. by pinching, heat development,
bending, fraying, etc.).
102
CAUTION
The tightening torques of the used hose clamps must
be observed.
1 Introduction
Thermo S 160/230/300/350/400
Water heating circulation system - wall heater and roof channel heater
1
2
3
4
5
6
7
8
9
Supply
Return
Thermo S 160/230/300/350/400
1.5.4 Adapter wiring harness
CAUTION
Do not put strain on the adapter wiring harness or
adapter plugs installed for testing purposes.
1.6
104
1 Introduction
1 Introduction
Thermo S 160/230/300/350/400
105
Thermo S 160/230/300/350/400
2
2 Technical data
Technical data
Thermo S 160 Thermo S 230 Thermo S 300 Thermo S 350 Thermo S 400
0208
0 226
0227
0228
0225
High-pressure atomizer
Btu/h
50,000
80,000
104,000
120,000
137,000
KW
16
23
30
35
40
Fuel
Diesel / light fuel oil
F ue l c ons umption
Gal/h (kg/h)
0.51 (1.92)
0.79 (2.5)
0.95 (3.0)
1.14 (3.6)
1.29 (4.1)
N omina l volta ge
V
24
O pe ra ting volta ge ra nge
V
20. . . 30
Electrical power consumption at 24 V
Amps (W)
2.08 (50)
2.7 (65)
3.75 (90)
5.0 (120)
7.5 (180)
Max. permissible combustion air intake temperature
F (C)
185 (85)
Permissible ambient temperature during operation
F (C)
-40...+212 (-40...+100)
Permissible storage temperature
F (C)
-40...+230 (-40...+110)
Permissible operating pressure
Psi (Bar)
max. 29 (2.0)
H e a t e x c ha nge r filling volume
US Quart (L)
1.9 (1.8)
Minimum wa te r flow
l/h
1400 200
1900 200
2400 200
2700 200
3200 200
M inimum c irc ula tion volume
US Gallon (L)
10 (37.8)
V ol %
9 . 5 1.5
CO 2 in e x ha us t a t nomina l voltage
mm)
in (mm)
23.6 x 9.73 x 8.66 (600 x 247 x 220)
Heater dimensions (tolerance
W e ight
lb (kg)
40.5 (18.4)
41.5 (18.8)
* without circulating pump
Max. continuous current of the circulating pump 10 A, maximum peak current for 0.5 s duration = 90 A - We recommend the use of Spheros circulation pumps for highest
efficiency and reliability. In order to reduce starting currents the circulating pump can be synchronized by the control unit f or a short time period during activation.
Confirm compatibility in case pumps provid ed by different manufacturers are used!
2.1
Electrical components
NOTE
Recirculating pumps must be assigned to the heaters
according to the flow resistance in the coolant circulation
system. Voltages directly app lied to the burner motor for
testing purposes may not exceed 12 V.
2.2
Fuel
201
2 Technical data
CAUTION
The listed temperature ranges, hence minimum
permissible temperatures strongly depend on the
respective fuel quality. In case of bad-quality fuel the
use limitations may deviate, e.g. in case of too high
water content.
At temperatures below 32F (0C ) commercially available
winter diesel should be used. This especially applies for
fuel extraction from a separate fuel tank.
The use of lubrication and flow improving additives is
permitted. No negative impact is known at time of the
preparation of this workshop manual.
CAUTION
When fuels are used, their respective limitations of
use must be observed and appropriate measures
(nozzle block preheater, electrically heated filter)
must be applied as needed.
In case fuel is extracted from the vehicle tank, the
vehicle manufacturer's mixing regulations shall apply.
202
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350/400
Burner Head
Combustion chamber
Heat exchanger
3
2
10
7
8
12
11
13
1
2
3
4
Burner
Coolant, intake
Sensor plug
Temperature sensor with
integrated overheating protection
5 Coolant, outlet
6 Heat exchanger
7 Exhaust outlet
8 Fuel, return
9 Combustion air, intake
10 Fuel, flow
11 Splashguard
(screen alternative)
12 Screen
13 Hot air elbow
(incl. adapter)
(screen alternative)
301
Burner
Thermo S 160/230/300/350/400
Burner motor
Combustion air fan
Fuel pump with solenoid valve and atomiser nozzle
Electronic ignition unit with ignition electrode
Nozzle block preheater, optional
Control unit with flame detector
Disc with inspection glass
Adapter wiring harness as interface to the
temperature sensor system
16 KW:
23-35 KW:
40 KW:
1 colour dot
2 colour dots
3 colour dots
Solenoid valve
Nozzle block
preheater (optional)
Coupling with
magnets
Screen
Burner motor
O-ring
Fuel pump
Shaft
circlip
Fan
302
black
Thermo S 160/230/300/350/400
the fuel supply line must be filled prior to first heater startup (see 8.14.1).
303
Disc
Thermo S 160/230/300/350/400
3.1.6 Temperature sensors with water
temperature sensor and integrated
overheating protection
The water temperature sensor captures the coolant
temperature at the heat exchanger outlet as electrical
resistance.
This signal is transmitted to the control unit, where it is
processed.
Flame detector
Window
Ignition electrode
304
Thermo S 160/230/300/350/400
3.2
Heat exchanger
Coolant inlet
Coolant outlet
Exhaust outlet
305
3.3
Thermo S 160/230/300/350/400
Combustion chamber
Welding seam
Swirl plate
16 KW
Combustion chamber
Identification
of the heating
capacity class
Three different combustion chambers are used for heaters
of the Thermo S series. Deviating from the standard
combustion chamber variant for Thermo S 230, S 300 and
S 350, the Thermo S 160 is equipped with a combustion
chamber with a sheet metal swirler and the Thermo S 400
is equipped with a burner pipe with increased wall
thickness (1.5 mm).
40 KW
NOTE
If possible, the combustion chamber should be inserted
into the heat exchanger in such a way, that the burner
pipe welding seam is between 60 and 300 in the lower
area.
At the same time it must be ensured that none of the
4 cut-outs of the combustion-chamber head points
vertically downwards (see figure on the right).
It is permissible to change t he position during maintenance
or after combustion chamber replacement vs. the previous
installation position.
306
Cut-out positions
on the combustion
chamber head
in installe d condition
Thermo S 160/230/300/350/400
3.4
Circulating pump
Aquavent 5000
(U4814)
Aquavent 5000S
(U4854)
Circulating pump
Aquavent 5000
Volume of flow
l/h
US Gal/m
5200
23
Aquavent 5000 S
5200
23
Nominal voltage
Volts
12 ... 24
Operating voltage
Volts
10 ...14/20 ... 28
Watts
mm (in.)
mm (in.)
mm (in.)
Weight
104
Aquavent 6000C
6000
26.4
104
210
4.6
. (2.1)
4.8 (2.2)
5.3 (2.4)
Aquavent 6000 SC
6000
26.4
210
Length 229 (9)
Width 115 (4.5)
Height 110 (4.3)
5.5 (2.5)
Aquavent 6000C
(U4855)
NOTE
Aquavent 5000 (U4814) with floating-ring type shaft seal.
Aquavent 5000S (U4854) magnetic drive (no seal)
Aquavent 6000SC
(U4856)
CAUTION
The circulating pump motor is not equipped with an
internal inverse-po larity protection
307
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.
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 activa ted 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.
Error mode
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. Af ter the power supply is
reconnected, the circulating pump motor restarts in softstart mode.
308
Thermo S 160/230/300/350/400
Inverse-polarity protection
The circulating pump motor is not equipped with an
internal inverse-polarity protection.
3.5
Fuel filter
Thermo S 160/230/300/350/400
4
Heater functions
4.1
4 Heater functions
the control unit.
Depending on the equipment, the heater is switched on
and off using a
t digital timer
t switch
t or climate control.
During heating operation the burner is automatically
switched on and off. The heater is switched on, when the
temperature falls short of a lower temperature threshold,
and is switched off, if the upper temperature threshold is
reached (see table 401).
The switching thresholds depend on the heater variant
and the heating operation type. They cannot be changed
and are programmed into the control unit.
For overheating protection of the heater the switching
thresholds are modified by the control unit, if specified
temperature gradients are exceeded.
If the specified minimum burning duration is not reached,
the switching thresholds will be reduced. This protects the
heater against sooting of the heat exchanger.
172 (78)
185 (85)
158 (70)
185 (85)
131 (55)
158 (70)
113 (45)
140 (60)
NOTE
Switching thresholds may deviate
per customer.
401
4 Heater functions
4.2
Thermo S 160/230/300/350/400
Signals
off
on
Terminal 61
T < T _ min
T >= T _ ma x
Flame
generation
UPFA off
Flame
generation
UPFA on
off
on ( a ux ilia ry he a ting)
Flame
generation
Main switch
Actuators
Operating display
Flame display
Combustion air motor
Circulating pump
Electronic ignition unit
Solenoid valve
Nozzle block preheater
Time in s
0..108 12
0..15
...
30
90
0..108 12
0..15
...
30
90
0..108 12
0..15
...
30
90
OFF
Standby
Start
Heating
Rundown
Standby
Start
Heating
Rundown
Standby
Start
Heating
Run-down 2
Stabilisation
Ignition
Pre-ignition
Run-down 2
Stabilisation
Ignition
Pre-ignition
Run-down 2
Stabilisation
Ignition
Pre-ignition
Look for
State
Rundown
Off
402
Thermo S 160/230/300/350/400
4 Heater functions
t
t
t
t
403
4 Heater functions
If a malfunction occurs during run-down (e.g. flame
detection), the run-down may be shorter than 120 seconds.
During run-down it is permitted to switch the heater
back on. The burner will restart after a run-down time
of 30 seconds and subsequent initial cycle time.
404
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350/400
4.3
4 Heater functions
4.3.1 Test plug
For tests using the "Component test" menu of SST
diagnosis, the temperature sensor "A" plug must be
replaced with a test plug.
24V
BUSY
PC
S p h e r o s T h e r m o Te s t
approx.
3 m cable
Thermo S
to vehicle
NOTE
For protection against moisture and contamination ensure
that the diagnosis interface is sealed using protective
caps, if not in use.
The latest SST diagnosis software can be found in the
Internet on the Spheros homepage under Service /
Technical Documents.
405
4 Heater functions
4.4
4.5
Malfunction interlock
406
Thermo S 160/230/300/350/400
Malfunction criteria:
t Short circuit and/or interruption of electrical
components:
Burner motor (stops immediately)
Circulating pump
Electronic ignition unit
Optional nozzle block preheater
t Flame or extraneous light detection by the flame
detector prior to ignition of the high-voltage ignition
spark.
t No start: No flame detection within 15 seconds
after opening the solenoid valve.
t Temperature sensor delivers unacceptable
temperature values.
t Heater operation outside the permissible temperature
range.
t Burner motor speed signal faulty.
t Voltage falling short of the low voltage threshold of
approx. 20.5 V at motor star t or within a duration of 20
seconds after a heating request.
t Voltage exceeding the high voltage threshold of approx.
30 V at motor start or within a duration of 6 seconds (rundown only, no malfunction interlock).
Thermo S 160/230/300/350/400
4.5.3 Malfunctions during run-down
NOTE
If the circulating pump is externally actuated, it will
continue operating.
Malfunction causes:
t Short circuit and/or interruption of electrical components:
Burner motor (stops immediately)
Circulating pump.
t Heater operation outside the permissible temperature
range.
t Motor speed signal faulty.
t Voltage falling short of the low voltage threshold of
approx. 20.5 V at motor start or within a duration of
20 seconds after a heating request.
t Voltage exceeding the high voltage threshold of approx.
30 V at motor start or within a duration of 6 seconds
(run-down is applied, but no malfunction interlock).
t Control unit malfunction.
4.6
Heater interlock
4 Heater functions
Heater interlock causes:
t Short circuit and/or interruption of electrical
components:
Solenoid valve
Flame detector
Overheating protection
Water temperature sensor.
t Flame not expired within 30 seconds after run-down
started. (Burner motor stops).
t Overheating protection triggered.
t Control unit error or programming error.
t Repeated malfunctions.
t Repeated flame interruptions.
407
4 Heater functions
Thermo S 160/230/300/350/400
408
4.7
Error output
Thermo S 160/230/300/350/400
5
5.1
General
Corrosion on plugs
Loose plug connections
Crimp failures on plugs and/or pins
Corrosion on cable and fuses
Corrosion on battery terminals
Cable insulation damage
CAUTION
Prior to replacing a fuse troubleshooting needs to be
performed. The heater must be disconnected from the
vehicle electrical system and the fuse must switch into
currentless state.
A properly dimensioned fuse must be inserted (see
chapter 6 Schematic diagrams).
After each error correction a functional test must be
performed in the vehicle.
5.2
Possible cause
t
t
t
F us e F 2 trigge re d.
F us e F 3 trigge re d.
No supply voltage.
Fuses.
Supply cable to the plug contacts of plug A of the
control unit.
501
Thermo S 160/230/300/350/400
Possible cause
x 860
Temperature difference t in [K] or [C]
measured on the heater between water inlet and water outlet
(e.g. using contact thermometer)
502
Thermo S 160/230/300/350/400
Possible cause
t
t
t
t
t
t
t
Fue l ta nk e mpty.
Bent, closed, clogged or
leaking lines.
Paraffin deposits or frozen water entrapments in fuel
lines or lines.
Venting opening in tank closed.
Fuel lines mixed up.
Fuel filter contaminated.
Fuel screen (filter) in pump contaminated.
t
t
t
t
t
t
t
t
t
t
5.3
Thermo S 160/230/300/350/400
Flash code
Low voltage
Extraneous light (flame detector "Bright" prior to ignition) or (flame detector "Bright" in run-down 2)
Flame detector short circuit after terminal 31 or interruption or short circuit after terminal 30
Coolant temperature sensor short circuit after terminal 31 or interruption or short circuit
after terminal 30
Overheating protection te mperature sensor short circuit after terminal 31 or interruption or short circuit
after terminal 30
Solenoid valve short circuit after terminal 31 or interruption or short circuit after terminal 30
Motor short circuit after terminal 31 or interruption or fuse F1 defective or short circuit after terminal 30
Circulating pump short circuit after terminal 31 or interruption or short circuit after terminal 30
10
Electronic ignition unit short circuit after terminal 31 or interruption or short circuit after terminal 30
Heater interlock - release required (caused by repeated malfunctions or repeated
flame interruptions)
12
Nozzle block preheater sensor short circuit after terminal 31 or interruption or short circuit after
terminal 30
13
Nozzle block preheater heating element short circuit after terminal 31 or interruption or short circuit
after terminal 30
13
14
15
504
Thermo S 160/230/300/350/400
5.4
5.4.1
NOTE
505
Thermo S 160/230/300/350/400
NO
YES
Are the combustion air intake opening and line and the
exhaust line clean and securely mounted?
Properly secure the fan wheel. Make sure that all screw
connections are tightened an d that no air escapes.
506
Re-tighten screw
connections. Replace
or open all lines as
needed.
Thermo S 160/230/300/350/400
NO
YES
electrical connection to
pins, etc.)
the heater.
Start heater: Is the voltage permanently applied to the heater during heater
507
Thermo S 160/230/300/350/400
NO
YES
heat exchanger?
exchanger.
or damaged?
heat exchanger.
508
installed?
Thermo S 160/230/300/350/400
5.4.5
NO
Are the temperature sensor plugs,
component.
YES
Are the adapter wiring harness
plugs, contacts and cables OK?
Correct error
509
Thermo S 160/230/300/350/400
NOTE
Prior to disconnecting the temperature sensor plug
connection, disconnect the heater from the vehicle
electrical system.
For tests using the "Component test" menu of SST
diagnosis, the temperature sensor must be replaced
with a test plug.
CAUTION
Soot and deposits in the heat exchanger must be
removed, as they impact the heat transfer to the coolant.
Severe outer deformations may impact coolant flow.
CAUTION
The general safety regulations according to chapter 1
must be observed.
NOTE
Cracks in longitudinal direction at the end of the welding
seam shorter than 80 mm are permissible.
t
510
Thermo S 160/230/300/350/400
Pin 3 & 4
Water
temperature sensor
Pin 1 & 2
Overheating protection
Fig. 503
5.5.4
WARNING
Resistance vs. temperature chart
1500
150
Inspection
1400
140
130
120
1200
110
1100
100
1000
0
20
40
60
80
100
120
140
Temperature [C]
Fig. 505
511
Thermo S 160/230/300/350/400
Inspection
Fan
Hood
Shaft
circlip
Fig. 507
Motor
Fig. 510
512
Thermo S 160/230/300/350/400
Inspection using SST diagnosis
t
WARNING
High voltage: The voltage received by the ignition
electrode is >13,000 Volt.
During operation or testing of the electronic ignition unit, the
ignition electrode may not be contacted by persons or items.
CAUTION
10k :
Fig. 511
513
Thermo S 160/230/300/350/400
WARNING
Inspection
NOTE
The distance between the electrodes may b measured
using checking gauge, item number 310646.
t
CAUTION
Do not damage the electronic ignition unit when
removing the ignition electrode.
514
8 0,5
4+ 1
Fig. 512
5 0,5
Thermo S 160/230/300/350/400
Disc
Inspection
t
Flame detector
Window
Fig. 513
515
Thermo S 160/230/300/350/400
NOTE
CAUTION
The pump pressure of the fuel pump is adjusted to a
fixed value in the factory.
It is not permitted to change the pump pressure.
If the specified pressure cannot be reached, the fuel
pump must be replaced.
According to the manufacturer's specifications the fuel
pump and fuel hoses must be replaced after 5 years.
WARNING
The ignition electrode must be removed during the
pump pressure check.
NOTE
The fuel pump pressure can be checked while the burner
is disassembled, using the Component Test menu of SST
diagnosis.
A pressure test unit with a display range from 0 to 15 bar
is required (Fig. 514).
The pressure test unit can be obtained from a Spheros
Service Center or a distribution partner.
516
Heater
CO2
[Vol.-%]
without fuel
delivery by
nozzle
[bar]
with
fuel
delivery by
nozzle
[bar]
S160
9.5 + 1.5
10.1 0.3
10.0 0.4
S230
9.5 + 1.5
10.2 0.3
9.8 0.4
S300
9.5 + 1.5
10.6 0.3
10 0.4
S350
9.5 + 1.5
10.9 0.3
10.4 0.4
S400
9.5 + 1.5
9.5 0.3
9.1 0.4
Thermo S 160/230/300/350/400
Manual inspection:
Fig. 514
Opening voltage:
Power consumption at
24V and 20C:
Nominal current at 24V:
t
t
517
Thermo S 160/230/300/350/400
Manual inspection
t
t
t
518
Heating element
Pin 1
Pin 2
Fig. 516
Thermo S 160/230/300/350/400
519
520
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350
6
Schematic diagrams
6.1
General
/4 0 0
6 S c h e m a ti c d i a g r a m s
CAUTION
In case of vehicle cable lengths up to 7.5 m the cable
cross-sections must be at least of the same size as the
respectively corresponding cable of the heater wiring
harness.
In case of vehicle cable lengths between 7.5 m and 15 m
the cable cross-sections in the vehicle must be larger
dimensioned than the respective ly corresponding cable of
the heater wiring harness. The cable cross-sections
indicated in the table must be applied.
601
6 S c h e m a ti c d i a g r a m s
T h e r mo S 160/230/300/350/400
30
31
61
F1
(HG)
F2
(UP)
F3
A1
Heater wiring
harness
1
2
X1
UP M
UP 1
2,5mm
br
UP +
2,5mm
bl
Terminal 30 (1)
Terminal 30(2)
2.5mm
2,5mm 2
2,5mm 2
br
A2
rd
rd/wt
bl
13
BA +
0,75mm 2
S3
UPFA
0,75mm 2
or
S1
HS
0,75mm
bl
BA
Terminal 61 (D+)
X3
5
Saving mode 2
0,75mm
rd/wt
rd
0,75mm
L-line or CAN-L
0,75mm2
bl
Diagnosis -
0,75mm2
br
0,75mm
or
10
0,75mm
rd
bl
FA
FA +
Vcc
DVW
MV
K-line or CAN-H
Operating mode
1
4
3
2
Controller
Terminal 31
SE
R
3
2
1
Vcc
T
4
3
BA +
0,75mm
BA -
0,75mm 2
br
14
0,75mm2
ye
rd
11
br
12
coolant
C1
C2
150C
125C
-50C
2
1
BA (Test)
D1
W-BUS S
Diagnosis +
0,75mm
Diagnosis -
0,75mm
overheating
Control unit
X1
X3
X2
D1
D2
A1
Item
BA
BM
DVW
F1
F2
F3
FA
HS
MV
S1
S2
S3
S4
UP
UPFA
UPL
Legend
Description
Operating display max. 5W
Combustion air motor
Nozzle block preheater
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 5A according to DIN 72581 part 3
Flame display max. 5W
Main switch
Solenoid valve
Main switch - heater On/Off
Switch - operating mode - saving mode
Switch - UP On/Off (without heating function)
Switch UP 2 On/Off
Circulating pump
External circulating pump actuation
Optional circulating pump display for testing, max. 5W
Item
BA (Test)
ZFG
14
13
Description
Optionally connec tible lamp for diagnosis
purposes, max. 5W
Electronic ignition unit
Legend (cont.)
7.5 - 15m
0.75 mm 2
0.75 mm 2
1.5 mm 2
1.0 mm 2
1.0 mm 2
1.5 mm 2
1.5 mm 2
1.5 mm 2
2.5 mm 2
2.5 mm 2
2.5 mm 2
4.0 mm 2
4.0 mm 2
4.0 mm 2
6.0 mm 2
Note:
For cable lengths below 7.5 m in the vehicle, at least the
same cable cross-sections as in the heater wiring harness
must be used. For cables lengths between 7.5 m and 15 m
in the vehicle, the cable cross sections must be enlarged
according to the table.
Heater
A2
1
3
ZFG
Vcc
D2
BM
4
6
S2 (3-step switch)
1
2
X2
Saving mode 1
normal
Line colours
bl
br
ye
ge
gr
or
rd
bl
vi
wt
rd/wt
blue
brown
yellow
green
grey
orange
red
black
violet
white
red/white
Thermo S 160/230/300/350
/4 0 0
6 S c h e m a ti c d i a g r a m s
75(15)
58
30
31
61
F1
(HG)
F2
(UP)
F3
A1
Heater wiring
harness
1
2
X1
UP 1
M
UP -
2,5mm
br
UP +
2,5mm
bl
1
4
3
2
X2
12
Terminal 30 (1)
Terminal 30(2)
S3
Terminal 31
2.5mm
2,5mm 2
2,5mm 2
BA +
UPFA
HS
Terminal 61 (D+)
X4
K-line or CAN-H
Saving mode S2 (3-step switch)
1 normal
Saving mode 2
FA
FA +
13
0,75mm 2
0,75mm 2
or
0,75mm
bl
0,75mm
rd/wt
0,75mm
rd
0,75mm2
bl
0,75mm2
br
0,75mm
or
10
0,75mm
rd
bl
Item
BA
BM
DVW
F1
F2
F3
FA
HS
MV
S1
S2
S3
S4
UP
UPFA
UPL
SE
-
ZFG
R
4
3
2
T
4
Vcc
BA -
0,75mm
br
14
0,75mm2
ye
rt
11
br
12
0,75mm
Diagnosis -
0,75mm
coolant
C1
C2
150C
125C
-50C
overheating
Control unit
D1
D2
A1
Description
Operating display max. 5W
Combustion air motor
Nozzle block preheater
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 5A according to DIN 72581 part 3
Flame display max. 5W
Main switch
Solenoid valve
Main switch - heater On/Off
Switch - operating mode - saving mode
Switch - UP On/Off (without heating function)
Switch UP 2 On/Off
Circulating pump
External circulating pump actuation
Optional circulating pump di splay for testing, max. 5W
Item
BA (Test)
ZFG
14
13
Description
Optionally connec tible lamp for diagnosis
purposes, max. 5W
Electronic ignition unit
Legend (cont.)
7.5 - 15m
0.75 mm 2
0.75 mm 2
1.5 mm 2
1.0 mm 2
1.0 mm 2
1.5 mm 2
1.5 mm 2
1.5 mm 2
2.5 mm 2
2.5 mm 2
2.5 mm 2
4.0 mm 2
4.0 mm 2
4.0 mm 2
6.0 mm 2
Note:
For cable lengths below 7.5 m in the vehicle, at least the
same cable cross-sections as in the heater wiring harness
must be used. For cables lengths between 7.5 m and 15 m
in the vehicle, the cable cross sections must be enlarged
according to the table.
Legend
Heater
A2
1
3
2
3
X3
MV
0,75mm
Diagnosis +
X2
Vcc
D1
X1
2
1
BA +
W-BUS S
Vcc
DVW
BA (Test)
Digital timer P
BM
D2
A2
rd
rd/wt
bl
X3
br
Controller
11
4
6
10
1
2
Line colours
bl
br
ye
ge
gr
or
rd
bl
vi
wt
rd/wt
blue
brown
yellow
green
grey
orange
red
black
violet
white
red/white
6 S c h e m a ti c d i a g r a m s
T h e r mo S 160/230/300/350/400
30
31
61
F1
(HG)
F2
(UP)
F3
A1
X2
S1
2,5mm br
Terminal 30(1)
2,5mm rd
Terminal 30(2)
2,5mm rt/wt
HS
L-line
K-line
UP -
0,75mm bl
2
0,75mm bl
2
0,75mm rd
2,5mm br
UP +
1
4
3
2
DVW
2,5mm br
2,5mm bl
Vcc
MV
1
5
UPL
UPFA
S3
BA
BA +
0,75mm bl
0,75mm or
Terminal 61 (D+)
K-line
13
0,75mm bl
4
7
0,75mm rd/wt
0,75mm rd
Controller
X3
UP monitoring
Operating mode
FA
0,75mm or
0,75mm rd
Vcc
T
4
3
6
Vcc
BA +
0,75mm bl
BA -
0,75mm br
14
1
W-BUS S
0,75mm2 ye
Diagnosis +
0,75mm rd
Diagnosis -
0,75mm br
11
12
X3
X2
6
5
C2
150C
125C
-50C
D1
D2
A1
Heater
A2
14
13
1
2
6
5
overheating
Control unit
1
3
Description
Operating display max. 5W
Combustion air motor
Nozzle block preheater
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 5A according to DIN 72581 part 3
Flame display max. 5W
Main switch
Solenoid valve
Main switch - heater On/Off
Switch - operating mode - saving mode
Switch - UP On/Off (without heating function)
Switch UP 2 On/Off
Circulating pump
External circulating pump actuation
Optional circulating pump di splay for testing, max. 5W
Item
BA (Test)
ZFG
Description
Optionally connec tible lamp for diagnosis
purposes, max. 5W
Electronic ignition unit
Legend (cont.)
7.5 - 15m
0.75 mm 2
0.75 mm 2
1.5 mm 2
1.0 mm 2
1.0 mm 2
1.5 mm 2
1.5 mm 2
1.5 mm 2
2.5 mm 2
2.5 mm 2
2.5 mm 2
4.0 mm 2
4.0 mm 2
4.0 mm 2
6.0 mm 2
Note:
For cable lengths below 7.5 m in the vehicle, at least the
same cable cross-sections as in the heater wiring harness
must be used. For cables lengths between 7.5 m and 15 m
in the vehicle, the cable cross sections must be enlarged
according to the table.
C1
1
2
Heater wiring
harness
coolant
D1
Legend
ZFG
10
FA +
BA (Test)
Item
BA
BM
DVW
F1
F2
F3
FA
HS
MV
S1
S2
S3
S4
UP
UPFA
UPL
D2
Saving mode 2
SE
S2 (3-step switch)
X1
2
3
Saving mode 1
normal
BM
A2
UP 1
X1
UP M
Terminal 31
Line colours
bl
br
ye
ge
gr
or
rd
bl
vi
wt
rd/wt
blue
brown
yellow
green
grey
orange
red
black
violet
white
red/white
6 S c h e m a ti c d i a g r a m s
T h e r mo S 160/230/300/350/400
30
31
61
F1
(HG)
F2
(UP)
F3
A1
X2
Terminal 30(1)
2,5mm rd
2,5mm rd/wt
HS
2,5mm br
Terminal 30(2)
S1
Terminal 31
0,75mm bl
B
M
BM
UP -
UP 1
2,5mm br
X1
UP M
UP +
1
4
3
2
V
DVW
2,5mm br
2,5mm bl
A2
Vcc
M
MV
1
5
S3
BA
UP monitoring
UPFA
0,75mm or
BA +
0,75mm bl
Terminal 61 (D+)
0,75mm rd/wt
0,75mm bl
Controller
X3
UPL
13
7
2
2
Vcc
0,75mm or
0,75mm rd
10
4
3
FA +
6
Vcc
D2
1
0,75mm bl
BA -
0,75mm br
D11
0,75mm ye
Diagnosis +
0,75mm rd
Diagnosis -
0,75mm br
W-BUS S
14
1
7
6
5
Legend
150C
125C
-50C
Control unit
D1
A1
D2
Heater
A2
14
13
1
2
6
5
overheating
12
Description
Operating display max. 5W
Combustion air motor
Nozzle block preheater
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Vehicle blade-type fuse 5A according to DIN 72581 part 3
Flame display max. 5W
Main switch
Solenoid valve
Main switch - heater On/Off
Switch - operating mode - saving mode
Switch - UP On/Off (without heating function)
Switch UP 2 On/Off
Circulating pump
External circulating pump actuation
Optional circulating pump display for testing, max. 5W
Item
BA (Test)
Description
Optionally connec tible lamp for diagnosis
purposes, max. 5W
Electronic ignition unit
ZFG
Legend (cont.)
7.5 - 15m
0.75 mm 2
0.75 mm 2
1.5 mm 2
1.0 mm 2
1.0 mm 2
1.5 mm 2
1.5 mm 2
1.5 mm 2
2.5 mm 2
2.5 mm 2
2.5 mm 2
4.0 mm 2
4.0 mm 2
4.0 mm 2
6.0 mm 2
Note:
For cable lengths below 7.5 m in the vehicle, at least the
same cable cross-sections as in the heater wiring harness
must be used. For cables lengths between 7.5 m and 15 m
in the vehicle, the cable cross sections must be enlarged
according to the table.
C2
11
X3
X2
C1
Heater wiring
harness
coolant
BA +
BA (Test)
Item
BA
BM
DVW
F1
F2
F3
FA
HS
MV
S1
S2
S3
S4
UP
UPFA
UPL
ZFG
Operating mode
FA
Saving mode 2
S2 (3-step switch)
X1
SE
Saving mode 1
normal
2
3
1
11111293_
Line colours
bl
br
ye
ge
gr
or
rd
bl
vi
wt
rd/wt
blue
brown
yellow
green
grey
orange
red
black
violet
white
red/white
6 S c h e m a ti c d i a g r a m s
606
T h e r mo S 160/230/300/350/400
Thermo S 160/230/300/350/400
7
Servicing
7.1
General
7 Servicing
Recommended maintenance:
Mandatory is:
Yearly atomizer nozzle replacement.
The atomizer nozzle is a consumable (not covered by
warranty).
7.2
Servicing
Mandatory maintenance:
t
NOTE
If bio diesel or FAME is used, the fuel pump and fuel lines
must be replaced according to the latest technical
information.
You can find the latest overview on the Spheros
homepage under Service / Technical Documents.
701
7 S ervicing
Thermo S 160/230/300/350/400
t
in case of modifications to the optional, applicationdependent combustion air intake and exhaust line.
Heater
S160
S230
CO 2 target
value
S300
S350
S400
Adjustment procedure
t Switch heater on.
NOTE
The exhaust should not be measured directly at the exhaust
outlet of the heat exchanger, as this may cause inaccuracies.
Exhaust fumes should be sampled from the exhaust pipe
in a distance of 350 mm after the heat exchanger. The
exhaust fume temperature should be measured at the
same location.
Increased exhaust temperature may indicate a sooted
heat exchanger (see 5.5.2).
t
702
NOTE
An upper and lower speed limiting value is stored per
heating capacity class in the control unit.
This should prevent incorrect adjustments during
maintenance/service.
SST diagnosis displays the speed limiting values.
Table 701 CO2 heater target values
Thermo S 160/230/300/350/400
8.1
8 Repair
WARNING
Prior to disassembling components the heater must be
disconnected from the vehicle electrical system.
CAUTION
Sealing elements between disassembled components
must be principally scrapped and replaced.
This does not apply to the temperature sensor gasket ring,
as it is permanently attached.
Screws with coated threads must be scrapped and
replaced.
It is permitted to remove components from the heater,
while the heater is installed in the vehicle, assuming that
sufficient space is availabl e and no components will be
damaged.
NOTE
If components are disassembled to a degree not covered
in this workshop manual, any warranty claim shall be
voided.
Only genuine Spheros spare parts should be used.
Removing the burner provides access to the following
components:
t
t
t
t
t
t
t
t
Atomizer nozzle
Fuel pump and solenoid valve
Electronic ignition unit and ignition electrodes
Disc with inspection glass for flame detector
Nozzle block preheater (option)
Flame detector (integrated into control unit)
Combustion chamber
Coupling with magnets
801
8 Repair
8.2
Thermo S 160/230/300/350/400
Burner removal
1. Disconnect the heater from the vehicle electrical
system and from the circulating pump as needed.
2. Disconnect the temperature sensor plug (5, Fig. 801).
3. If necessary, disconnect the combustion air intake line
from the heater.
NOTE
Make sure that any fuel leaking during the following work
step is immediately bound and professionally disposed of.
Burner installation
1. Bring burner (1, Fig. 801) in assembly position and
ensure centre alignment and correct fit.
2. Place nuts (2) and alternately tighten them slightly.
3. Tighten nuts (2) with 7.5 Nm + 1 Nm.
4. If applicable, bolt fuel lines down with 16 1 Nm using
a banjo bolt and new gaskets, or slide on fuel lines and
secure with hose clamps.
5. If applicable, secure the combustion air intake line to
the heater.
6. Connect the temperature sensor plug (5).
7. Connect heater with the vehicle electrical system and
the circulating pump as needed.
NOTE
Do not bent any lines when placing the burner down.
5
1
2
3
4
5
Burner
Nuts (2)
Screws (2)
Hood
Temperature
sensor plug
802
Thermo S 160/230/300/350/400
8.3
8 Repair
8.4
t
t
t
t
t
t
t
Installation
Removal
Removal
Fan
Burner motor
Motor cross member
Control unit
Coupling with magnets
Main wiring harness plug
Adapter wiring harness plug
Installation
1
2
Temperature sensor
Coolant outlet
803
8 Repair
8.5
Thermo S 160/230/300/350/400
CAUTION
The shaft circlip may not be overstretched.
Removal
1. Remove hood (see 8.4).
2. If applicable, remove the fa n (2, Fig. 803). For this
purpose remove the shaft circlip (1) from the motor
shaft using suitable pliers.
3. Disconnect plug (4) of the burner motor from the
control unit.
4. Remove screws (6) and pull motor (3) including the
motor cross member (5) off the burner housing.
5. If necessary, remove moto r cross member (5) from
the burner motor (3). For this purpose loosen and
unscrew screws (7) from the motor flange.
804
Installation
1. If necessary, reconnect the burner motor (3, Fig. 803)
to the motor cross member (5). For this purpose align
the burner motor withthe motor cross member.
Observe the motor cross memb er installation position.
Screw the countersunk screws (7) into the dedicated
recesses of the motor flange. Next tighten the
countersunk screws (7) with 5 Nm + 1 Nm.
2. If necessary, slide the coupling with magnets (10)
onto the fuel pump shaft.
3. Align motor cross member (5) with the burner housing
(11) observing the specified installation position of the
motor cross member. Align the burner motor with the
coupling by turning the burner motor shaft.
4. Secure burner motor and motor cross member with
screws (6).
5. Tighten screws (6) with 5 Nm + 1 Nm.
6. Connect plug (4) of the burner motor with the control
unit.
7. If applicable, install the fan (2). For this purpose slide
the fan onto the motor shaft and, using suitable pliers,
secure a new shaft circlip (1) onto the motor shaft.
8. Install hood (see 8.4).
Thermo S 160/230/300/350/400
8 Repair
11
6
10
7
2
4
8
1
2
3
4
5
6
7
8
9
10
11
Shaft circlip
Fan
Burner motor
Motor plug
Motor cross member
Screws (3)
Countersunk screws (3)
Hood
Screws (2)
Coupling with magnets
Burner housing
9
Fig. 803 Combustion air fan removal and installation
805
8 Repair
8.6
Thermo S 160/230/300/350/400
Removal
1. Remove burner (see 8.2).
2. Lift off ignition electrode (2, Fig. 804) from the
electronic ignition unit by twisting a screwdriver
sideways.
3. Remove disc (3).
4. Removes screws (4) with retaining washers.
5. Pull electronic ignition unit (1) off and remove it.
6. If necessary, perform a general visual inspection (see
5.5.1) or test (see 5.5.8).
1
2
3
4
Installation
1. Bring electronic ignition unit (1, Fig. 804) into
installation position, attach ready for connection and
secure with screws (4).
2. Tighten screws (4) with 5 Nm +1 Nm.
3. Fit disc (5) onto the nozzle holder of the fuel pump
(9, Fig. 805) and align with the flame detector in the
control unit (14, Fig. 805) and the electronic ignition
unit.
4. Fit the ignition electrode (2, Fig. 804).
5. Install burner (see 8.2).
1
2
806
Thermo S 160/230/300/350/400
8 Repair
1
2
8
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5
7
11
12
10
9
17
16
13
14
15
807
8 Repair
8.7
Thermo S 160/230/300/350/400
Removal
1. Remove burner (see 8.2).
2. Disconnect solenoid valve plug (6, Fig. 806) and, if
applicable, the optional nozzle block preheater (7)
from the control unit (14).
3. Remove electronic ignition unit (see 8.6).
4. Remove hood (see 8.4).
5. Remove combustion air fan (see 8.5).
6. Disconnect the adapter wiring harness (16) and the
heater wiring harness (15) from the control unit (14).
7. Carefully pull control unit (14) from the burner housing
(13) and remove it.
Installation
1. Align control unit (14, Fig. 806) with the burner
housing (13).
2. Carefully slide control unit (14) into the burner housing
(13) as far as it will go.
3. Connect the adapter wiring harness (16) and the
heater wiring harness (15) to the control unit (14).
4. Install combustion air fan (see 8.5).
5. Install hood (see 8.4).
6. Install electronic ignition unit (1) (see 8.6).
7. Connect solenoid valve plug (6) and, if applicable, the
optional nozzle block preheater (7) to control unit (14).
8. Install burner (see 8.2).
8.8
Removal
1. Remove burner (see 8.2).
2. Lift off ignition electrode (3, Fig. 806) from the
electronic ignition unit by twisting a screwdriver
sideways. (see Fig. 804)
3. Remove disc (5).
4. Disconnect the solenoid valve plug (6, Fig. 806) and
the optional nozzle block preheater (7) from the
control unit (14).
5. Remove and scrap screws (12).
808
6. Pull fuel pump (9) with the solenoid valve (6) off and
remove it.
7. Remove and scrap O-rings (10) and filter insert (11).
8. If applicable, remove the nozzle block preheater (7).
For this purpose, remove support (8) from the nozzle
holder using suitable tools.
9. If necessary, remove the so lenoid valve (6) from the
fuel pump (9). (see 8.9)
Installation
1. If necessary, attach solenoid valve (6, Fig. 806) to the
fuel pump (9). (see 8.9)
2. If applicable, install nozzle block preheater (7) and
mount support (8) to the nozzle holder using suitable
tools.
3. Attach new O-rings (10) and a new filter insert (11) to
the fuel pump (9).
4. Slide the coupling with magnets onto the fuel pump
shaft.
CAUTION
In order to avoid damage to th e O-rings, to not twist fuel
pump (9) during assembly.
New screws with coated threads must be used for
installing the fuel pump.
5. Align fuel pump (9) with the burner housing (13) and
bring it into installation position. Align the coupling
with magnets (17) with the burner motor by turning the
burner motor shaft.
6. Mount the fuel pump (9) using new screws (with
coated threads) (12) and tighten the screws
with 5 Nm +1 Nm.
7. Connect solenoid valve plug (6) and, if applicable, the
optional nozzle block preheater (7) to control unit (14).
8. Fit disc (5) onto the nozzle holder and align it with the
flame detector in the control unit (14) and the
electronic ignition unit (1).
9. Fit ignition electrode (3).
10. Install burner (see 8.2).
Thermo S 160/230/300/350/400
8 Repair
1
2
8
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5
7
11
12
10
9
17
16
13
14
15
809
8 Repair
8.9
Thermo S 160/230/300/350/400
Removal
1. Remove burner (see 8.2).
2. Lift off ignition electrode (1, Fig. 804) from the
electronic ignition unit by twisting a screwdriver
sideways. (see Fig. 804)
3. Remove disc (5, Fig. 806).
4. Disconnect the solenoid valve plug (6, Fig. 806) from
control unit (14, Fig. 806).
5. Using suitable tools loosen the hexagon, wrench size
16 (6, Fig. 807) of the solenoid valve (6, Fig. 806) from
the fuel pump (9, Fig. 806) and unscrew the solenoid
valve (6).
1
2
3
4
5
6
1
2
NOTE
We recommend to use nozzle wrench item no. 66971_ for
nozzle disassembly and assembly.
4. Unscrew atomizer nozzle (4 ). If no nozzle wrench is
used, a tool must be used to counter on the hexagon
of the fuel pump nozzle holder (9).
Installation
3
4
6
7
8
10
9
Fig. 807 Solenoid valve
Installation
1. Gasket ring (10, Fig. 807)towards the fuel pump must
be replaced. Make sure stay, spring and lifter are
correctly assembled, observe installation position
(see Fig. 807).
2. Attach solenoid valve (6, Fig. 806) to the fuel pump
(9, Fig. 806).
810
CAUTION
If the nut, wrench size 12 (1, Fig. 807) was loosened, then
it must be tightened with a tightening torque of 1.5 Nm +
0.3 and subsequently secured using sealing wax.
Thermo S 160/230/300/350/400
8 Repair
Removal
Removal
1
4
3
4
1
2
3
4
5
6
Combustion chamber
Heat exchanger
Exhaust outlet
Stand
Coolant inlet
Coolant outlet
Installation
1. Slide combustion chamber (1, Fig. 808 into the heat
exchanger (2) as far as it goes.
If possible, the combustion chamber should be inserted
into the heat exchanger in such a way, that the burner
pipe welding seam is approx. in the 200 position in the
lower area.
It is permissible to change the combustion chamber
position during maintenance or after combustion chamber
replacement vs. the previous installation position.
Installation
1. Bring heat exchanger (2, Fig. 808) into installation
position and mount stand (4) using screws, nuts and
washers to the vehicle according to the mounting
points used.
2. If necessary, secure the exhaust line using a clamp to
the exhaust outlet (3).
3. Fit coolant hoses onto the coolant inlet (5) and the
coolant outlet (6) and secure with hose clamps
applying a tightening torque of 6 0.6 Nm.
4. If available, open water taps.
5. Install burner (see 8.2).
6. Purge coolant circuit (see 8.14.2).
Removal
2. Install burner (see 8.2).
Installation
1. Install heat exchanger (see 8.12).
2. Install burner (see 8.2).
3. Purge coolant circuit (see 8.14.2).
811
8 Repair
8.14 Start-up after burner or heater
installation
Thermo S 160/230/300/350/400
8.14.2 Bleeding of the water circuit
NOTE
WARNING
Risk of injuries for coolant with increased temperature.
The Aquavent 5000 (U4814) and Aquavent 6000S
(U4855) circulating pumps may only be switched on
for bleeding, after dry operation can be excluded.
The Aquavent 5000S (U4854) and Aquavent 6000SC
(U4856) circulating pumps may even in dry operation
be switched on for bleeding.
Adjust the vehicle heating system to "warm" and refill
coolant.
As soon as it is confirmed th at the vehicle engine is filled
with coolant, run vehicle engine with increased idle speed.
Once the cooler thermostat opens, switch the vehicle
engine off and check the coolant level.
Refill coolant as needed.
While the vehicle engine is switched off, switch on the heater
with the circulating pump and the vehicle heating fan.
After the engine motor cooled down, the heater must
automatically start and stop as soon as the upper
switching threshold is reached.
If the heater does not star t automatically, it must be
verified, whether the heater overheating protection is
triggered and the heater is interlocked.
Release the heater (see 4.6) and repeat the bleeding
process.
812
Thermo S 160/230/300/350/400
9
901
902
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350/400
10
Packing / storage
and shipping
10.1 General
The heater or its components, which are sent to Spheros
for inspection or repair, must be cleaned and packaged to
ensure that handling, transport and storage will not
damage them.
CAUTION
If a complete heater is sent back, it must be completely
drained. Packaging and/or shipping must ensure that no
fuel or coolant can leak.
Coolant inlet and outlet fittingsas well as the fuel lines
must be plugged and sealed using blank plugs.
The temperatures described in section 4 may not be
exceeded during storage.
1001
1002
Thermo S 160/230/300/350/400
Thermo S 160/230/300/350/400
A A ppendix
Appendix A
Periodic maintenance
A-1
A Appendix
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).
Thermo S 160/230/300/350/400
The maintenance intervals mentioned below refer to
common applications and requi rements in omnibuses. 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 Spheros
partner for further information.
Important information
Inspection
result
OK
1. Electrical connections
a) Loosen electrical plug connection s to the wiring harness, inspect for
oxidation, spray and reconnect after completing point 5.
b) Inspect electrical fuses for oxidation and/or contact
resistances.
2. Heat exchanger
a) Inspect for dark burn marks on the paint (local overheating).
b) Inspect for leak marks.
Determine overheating
cause as needed (e.g.
water circulation system);
check overheat
temperature limiter.
Ensure connections to
fuel flow and return lines
are sealed tight!
Re-tighten screw
connections and hose
clamps.
Replace pump and pipes
every 5 years.
Observe technical bio
diesel / FAME
information!
4. Burner head
a) Inspect combustion air intake opening for clear passage.
b) Inspect hood for damage.
f)
A-2
not
OK
Measured values
Executed
repairs