Water Heaters Workshop Manual 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 .030 and up Thermo 231 Thermo 301 model .01 and up Thermo Rail 12/2012 Ident Nr.
Thermo 230 / 231 / 300 / 301 / 350 List of Contents List of Contents 1. Introduction 1.1 1.2 1.3 1.4 1.5 Scope and Purpose ............................................................................................................................... 101 Applicability of Manual ........................................................................................................................... 101 Meaning of Warnings, Cautions and Notes ............................................................
List of Contents 5. Thermo 230 / 231 / 300 / 301 / 350 Troubleshooting 5.1 5.2 5.3 General ................................................................................................................................................. 501 General Fault Symptoms ......................................................................................................................
Thermo 230 / 231 / 300 / 301 / 350 List of Contents 8 7.5 Igniter Box, Replacement ........................................................................................................... 807 8.7.6 Flame Sensor, Replacement ...................................................................................................... 808 8.7.7 Combustion Chamber, Replacement ......................................................................................... 808 8.8 First Operation .......................
List of Contents Thermo 230 / 231 / 300 / 301 / 350 List of Figures 301 302 Functional Sequence (heaters with control unit 1572) .................................................................................... 304 Functional Sequence (heaters with control unit 1572D) ................................................................................. 305 501 General Fault Symptoms ..........................................................................................................................
Thermo 230 / 231 / 300 / 301 / 350 1. Introduction 1.1 Scope and Purpose This repair shop manual is intended to support familiarized personnel in the repair of water heaters Thermo 230, 231, 300, 301 and 350. The water heater may only be operated with the specified fuel (Diesel or also fuel oil EL) and the relevant designated type of electrical connection. 1.2 Applicability of Manual This manual is applicable only for heaters identified on the title page.
1 Introduction At filling stations and fuel depots the heater must be switched off to prevent explosions. CAUTION Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal depots, or similar installations) the heater must be switched off to prevent explosions. The heater must not be operated near flammable materials such as dry grass and leaves, cardboard boxes, paper, etc.
Thermo 230 / 231 / 300 / 301 / 350 1.7 1 Introduction Corrections and Improvements Deficiencies, improvements, or proposals for correction of this workshop manual are to be mailed to: Spheros GmbH Friedrichshafener Straße 9 - 11 D-82205 Gilching Telefon: +49 (0)8105 7721 887 Telefax: +49 (0)8105 7721 889 www.spheros.de / service@spheros.
1 Introduction Page empty for notes 104 Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 2 The heaters Thermo 230, 231, 300, 301 and 350 basically consist of 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 – – – 2 General Description heat the passenger compartment defrost the windscreen preheat water-cooled engines – – – – – the combustion air fan the fuel pump with nozzle block and nozzle the heat exchanger and the combustion chamber the igniter box w
2 General Description 2.1 Thermo 230 / 231 / 300 / 301 / 350 Combustion Air Fan Solenoid valve The combustion air fan supplies the air required for combustion from the combustion air inlet to the combustion chamber. Nozzle block pre-heater (optional) Fan motor Splash protection cover Screen Fan wheel Screen Cap O-ring Fuel Pump 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.
Thermo 230 / 231 / 300 / 301 / 350 2 General Description 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.
2 General Description Thermo 230 / 231 / 300 / 301 / 350 Igniter electrodes Igniter box (black connector cover) only in combination with control unit 1572 2.8 Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572 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.
Thermo 230 / 231 / 300 / 301 / 350 2 General Description 2.11.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps Aquavent 5000 (U4814) 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).
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.
Thermo 230 / 231 / 300 / 301 / 350 3. 3 Functional Description 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").
3 Functional Description Thermo 230 / 231 / 300 / 301 / 350 Switching thresholds for Thermo xxx Raill 230.040 Version Thermo xxx* 230.056 300.124 xxx.126 300.155 350.056 350.190 350.
Thermo 230 / 231 / 300 / 301 / 350 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.
3 Functional Description Thermo 230 / 231 / 300 / 301 / 350 7 3 5 3 6 2 1 8 9 2 6 10 A A H1 B E1 Operating indicator light Heater cartridge C M2 Circulation pump D U1 Igniter box E M1 Combustion air fan F Y1 Solenoid valve G B1 Flame sensor B C D 1 Switch on 2 Start 3 Combustion operation 5 Temperature sensor – upper switching F 6 Flame sensor – dark G 7 Control idle E threshold 8 Temperature sensor – lower switching threshold 12s 1s 12 1s 12s max.
Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description 7 3 3 5 6 2 1 8 6 9 2 10 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 A C D 1 Switch on 2 Start 3 Flame-up, combustion operation 5 Temperature sensor – upper switching E threshold F G 6 Flame sensor – dark 7 Control idle 8 Temperature sensor – lower switching threshold 12s 1s 1s 12 14 13 max. 12s 15 max.
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.
Thermo 230 / 231 / 300 / 301 / 350 4. 4 Technical Data 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. Electrical components Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle block preheater and timer are 24V components.
4 Technical Data Thermo 230 / 231 / 300 / 301 / 350 Heater Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350 Type Thermo 350 Thermo 230 Thermo 231 Thermo 300 Thermo 301 Mark of conformity up to 4/03 ~ S230 ~ S327 ~ S229 ~ S328 ~ S228 EC type approval number 0007*-- 0010*-- 0008*-- 0011*-- 0009*-- e1*2001/56* Heater principle Heating flow High pressure atomizer KW (kcal/h) 23 (20 000) Fuel Fuel consumption 30 (26 000) Diesel / fuel oil kg/h 2.
Thermo 230 / 231 / 300 / 301 / 350 Circulation pump 4 Technical Data U 4814 Aquavent 5000 U 4854 Aquavent 5000S U 4855 Aquavent 6000C U4856 Aquavent 6000SC 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...
4 Technical Data 404 Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting 5.1 General This section describes troubleshooting procedures for the heaters Thermo 230, 231, 300, 301 and 350. 5 Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components.
5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 Symptom Probable Cause Heater operation stops because heat exchangers connected do not dissipate enough heat. Rate of flow too low, because • air in heater, in heat exchangers or in system sections. • cocks (flow regulator) throttled, contaminated or closed. • contamination in system, e.g. in areas of restricted flow. • circulation pump rate of delivery insufficient (air in pump housing).
Thermo 230 / 231 / 300 / 301 / 350 Symptom 5 Troubleshooting Probable Cause Wrong combustion CO2 value cannot be set to rated value, combustion irregular. • • • • • • • • • • air bubbles in suction line (suction line leaking). fuel filter contaminated or leaking. fuel system integration leak (suction height, low pressure in tank); observe installation instructions. fuel pump defective (pump pressure). return line throttled. filter screen in pump contaminated.
5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2 Fault Symptoms 5.3.2.1 Fault Symptom "No Start" NOTE Heaters with control unit 1572D: If the heater performs 8 consecutive 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.
Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting 5.3.2.2 Fault Symptom "Flame-out" NOTE Heaters with control unit 1572D: If the heater performs 5 consecutive 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. NO Switch on heater.
5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down" NO Has heater been in long time operation shortly before ? Flame sensor defective, replace. Control unit defective, replace. Allow heater to cool down and restart (approx. 2 min.). Does same symptom show again? Clean combustion tube. Remove coke deposits. Flame in run-down. Control unit defective, replace. YES Replace solenoid valve. 5.3.2.
Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting 5.3.2.7 Fault Symptom "Solenoid Valve Defective" NO YES Is solenoid valve supplied with electrical power ? Make electrical connections. Has safety thermostat responded ? (Thermo 231/301 only) Safety thermostat defective, replace. Investigate reason for response (e.g. check exhaust system) Replace solenoid valve. Is components test with diagnostic computer o.k. (audible click of solenoid valve)? Control unit defective, replace.
5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2.8 Fault Symptom "Temperature Limiter Defective" NO YES Is electrical power supply to components o.k.? Make electrical connections. Has temperature limiter responded? (Reset according to type of temperature limiter) Control unit defective, replace. Determine why temperature limiter has responded, e.g.
Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts 6.1 General 6 Functional Checkouts This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities. To prevent fires do not switch heater on with burner swung open. 6.2 Fastening screw Adjustments 6.2.
6 Functional Checkouts 6.3 Thermo 230 / 231 / 300 / 301 / 350 Components Testing 6.3.3 Igniter Electrodes Check 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). R/y Resistance (Ohm) 10000 5000 20 °C ≅ 4419 ..... 4892 W 100 °C ≅ 319 .....
Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts 6.3.4 Igniter Box Check 6.3.5 Fuel Pump Check NOTE The igniter box may also be tested using the PC heater diagnosis (component test). 6.3.5.1 Fuel Pump Check on Heaters with Control Unit 1572 WARNING High voltage; 20.000 volts arcing across the igniter electrodes. A test gauge is required for performing the test. Such a gauge (with a range from 0 to 15 bar) can be procured from your authorized Spheros dealer.
6 Functional Checkouts Thermo 230 / 231 / 300 / 301 / 350 6.3.5.2 Fuel Pump Check on Heaters with Control Unit 1572D NOTE On heaters with control unit 1572D the fuel pump may only be checked by means of the PC heater diagnosis. The fuel pump and the fuel hoses must be replaced every 5 years. 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.
Thermo 230 / 231 / 300 / 301 / 350 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 – – 7 Circuit Diagrams The circuit diagrams (Fig. 705 through 710) show possible variants of heater circuits for Thermo 230, 231,300, 301 and 350 with control unit 1572D. switch timer 1529 (triple timer) The circuit diagrams (Fig.
7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 A 30 30 F3 6 1 5 2 4 3 F2 C S2 S4 1 D 2 or gn 3 1 br X3 4 gr S1 S3 X1 1 5 A sw or rt/ws 3 X1 D 3 2 1 4 5 1 2 3 4 5 6 1 X3 X2 3 1 3 5 7 4 6 8 1 A2 K1 M1 U1 F1/B3 B2 H1 A2 B1 Y1 E1 M2 A1 2 4 rt 2 br 6 6 bl 2 1 br M 2 sw 4 K2 B4 C + SE - U1 F1 ϑ M E1 X2 2 M1 Y1 U2 B2 B1 B3 A1 br H2 ϑ 31 31 Wire colors 1 Diagnostic connector Wire gauges < 7.5 m 7.5 - 15 m 0.
Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams A 58 75(15) 30 58 75(15) 30 F3 F6 6 1 5 2 4 3 F2 C S4 1 S3 4 2 X1 3 1 8 4 6 2 5 P 7 A X1 D 3 or rt/ws 4 F1/B3 2 3 4 5 6 X3 1 X2 3 A2 K1 3 5 7 4 6 8 3 2 1 M2 2 rt 4 2 br 6 6 bl 2 1 br M A1 2 sw X4 K2 8 7 6 5 4 B4 C + SE - U1 F1 ϑ M E1 X2 M1 Y1 U2 H2 ϑ B2 B1 B3 A1 br br 2 X4 B2 E1 1 1 3 4 B1 Y1 1 1 5 A2 2 5 sw 3 U1 1 H4 H3 M1 D 2 or gn 3 br X3 4
7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 4 1 3 3 3 3 3 3 Wire colors 1 Diagnostic connector 3 Pin assignment: 4 Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0,75 gr 0,75 or 0,75 gn 0,75 br nicht belegt nicht belegt 7wire lead 0,75 rt 0,75 or 0,75 bl 2,0 br 2,0 sw 2,0 rt/ws Wire gauges 7.5 - 15 m 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.0 mm2 2.5 mm2 4.0 mm2 with connection to terminal 61 auxiliary Remark < 7.5 m 0.75 mm2 1.0 mm2 1.
Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams 4 1 3 2 3 3 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: 3 3 3 Wire colors 4 Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0.75 gr 0.75 or 0.75 gn 0.75 br not used not used 7wire lead 0.75 rt 0.75 or 0.75 bl 2.0 br 2.0 sw 2.0 rt/ws Wire gauges < 7.5 m 7.5 - 15 m 0.
7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 61 30 30 A 1 6 DEUTSCH 61 5 F1 F2 F3 2 3 4 F S4 2 1 S3 1 X3 UPFA Signal UP 6 D+ 7 5 1 SP FA K BA 3 1 2 4 D rt/sw or br sw bl sw rt 6 7 1 2 3 W1 X1 A F 1 3 2 2 4 1 C 4 C D 1 S1 3 1 sw 5 3 rt/ws 3 4 rt 2 br 2 1 X1 4 sw 2 6 X3 5 B3/B5 U1 M1 B2 2 br M2 A2 B1 Y1 E1 sw A1 X2 - U1 M 1 H1 B4 + SE B3 M E1 M1 H2 X2 ϑ Y1 ϑ B2 B1 U2 A2 A1 31 31 Wire colors 1 D
Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams A 30 30 1 F2 F3 DEUTSCH 6 5 2 3 4 C S2 1 S4 9 S3 6 D 5 gr or gn 8 br S1 X1 1 A 2 sw 5 3 or rt/ws 1 1 2 3 D 3 2 1 4 4 A 3 X1 6 5 1 4 2 8 9 3 10 7 A K1 15 7 10 rt br sw 16 4 14 13 12 15 11 6 K2 2 X2 1 16 bl 4 M1 F1/B3 U1 B2 E1 A1 3 M2 W1 rt H1 B1 Y1 2 rt B5 A2 4 C 3 B4 br + SE U1 M 1 - B3 M E1 M1 H2 ϑ ϑ Y1 B2 B1 U2 sw A2 A1 X2 -31 -31 Fuse acc.
7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 A 30 30 1 F3 F2 DEUTSCH 6 5 2 3 4 C S2 S4 1 3 2 or gn 4 1 D br X3 gr S1 W2 S3 W1 A X1 1 or rt/ws 5 D 3 2 1 1 4 2 3 5 sw 4 X1 1 3 3 1 2 3 4 5 6 K1 X2 1 M1 F1/B3 U1 B1 Y1 E1 rt 4 2 br 6 6 bl 2 1 br 2 sw 2 K2 X3 B4 M2 M X2 A1 + SE C - U1 M1 U2 A2 F1 ϑ M E1 3 5 2 4 6 Y1 B2 B1 B3 A1 -31 Fuse acc.
Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams 61 30 30 A 1 6 DEUTSCH 61 5 2 3 4 F2 F1 C 1 5 rt/sw FA K M 3 2 1 rt 1 X2 SP 4 D X3 br L sw S1 1 D+ or S4 bl S2 1 W2 S3 W1 A X1 1 sw 5 5 or 1 3 F 2 3 1 2 4 rt/ws 4 F 4 1 2 1 3 3 2 D 2 1 X1 3 3 rt 8 4 2 M1 B3/B5 U1 B2 2 br 6 bl 4 1 2 7 5 7 7 6 X2 C 1 + M A2 B1 Y1 E1 A1 sw 2 SE - U1 M2 A2 A X3 B4 H1 B3 M E1 M1 H2 ϑ Y1 ϑ B2 B1 U2 A1 A 31 31 1 5
7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 1 1 ϑ ϑ ϑ ϑ Wire colors 1 Diagnostic connector Wire gauges < 7,5 m 7,5 - 15 m 0,75 mm2 1,0 mm2 1,5 mm2 1,5 mm2 1,5 mm2 2,5 mm2 ? mm2 4,0 mm2 6,0 mm2 2,0 mm2 2,5 mm2 4,0 mm2 bl br ge gn gr or rt sw vi ws blue brown yellow green gray orange red black violet white Item Nomenclature Remark Pos.
Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams 1 Diagnostic connector 2 Timer P: with plus to connection 4 = continuous operating during immediate heating without plus to connection 4 = heating period 1 hour 3 Pin assignment: 4 Item A1 A2 B1 B2 B3 B4 B5 B6 E E1 F1 F2 F3 F4 F5 F6 F7 H1 H2 H4 K4 M1 M2 Wire colors Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0,75 gr 0,75 or 0,75 gn 0,75 br not used not used 7wire lead 0,75 rt 0,75 or 0,75 bl 2,0 br 2,0 sw 2,0 rt/ws Option Nomenclature Heater
7 Circuit Diagrams 712 Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 8. Servicing 8.1 General 8 Servicing • • 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.
8 Servicing Thermo 230 / 231 / 300 / 301 / 350 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.
Thermo 230 / 231 / 300 / 301 / 350 8.5.2 Burner Head Opening and Closing or Removal and Installation WARNING 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 and fixing burner head, reconnect connectors in the vehicle. NOTE Maintenance on the heater is easy.
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.
Thermo 230 / 231 / 300 / 301 / 350 8 Servicing Water heating circuit – Sidewall radiators and roof duct heating 5 3 6 7 4 1 1 1 2 1 9 8 Vorlauf Supply Rücklauf Return 1 2 3 4 5 6 7 8 Sidewall radiator with fan Heat exchanger, entrance Heater unit Circulation pump Heat exchanger, roof Vehicle engine Cockpit heating Control element Fig.
8 Servicing Thermo 230 / 231 / 300 / 301 / 350 When installing a shut-off device in the return line a clearly visible information label must be provided. CAUTION Operation with the return line shut off causes damage to the fuel pump. Fuel may escape. Danger of fire. It must be located so that no clogging by contamination, impact of snow, or intake of splash water is to be expected.
Thermo 230 / 231 / 300 / 301 / 350 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. Permissible exhaust line dimensions: – inner diameter: 70 mm – max. length: 5 m without the exhaust extension – max. bend: 270° As an alternative an exhaust deflector must be installed cleared by Spheros. 8.
8 Servicing Thermo 230 / 231 / 300 / 301 / 350 8.7.6 Flame Sensor, Replacement 8.8.1 Water Circuit, Bleeding NOTE The replacement procedure for the flame sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.8. NOTE Bleeding must always be performed in accordance with manufacturer’s instructions. For bleeding the circulation pump must not be switched on. WARNING The igniter box operates on high voltage.
Thermo 230 / 231 / 300 / 301 / 350 9 Repair 9.1 General 9 Repair This section describes the repairs that may be performed on the heaters Thermo 230, 231, 300, 301 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. WARNING The igniter box operates on high voltage.
9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.1.1 Work on Components after Disassembly 9.1.2 Incorporation of Modifications CAUTION All gaskets located between disassembled components must always be replaced and discarded. 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 9.1.1.
Thermo 230 / 231 / 300 / 301 / 350 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.
9 Repair 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.
Thermo 230 / 231 / 300 / 301 / 350 1 2 3 4 5 6 7 8 9 Repair Temperature limiter Temperature sensor Connector Coolant outlet Cotter pin Nut (2) Hinge bolt (2) Burner Rubber cap Temperature limiter Retaining clip 3 2 4 1 5 6 8 7 NOTE Cotter pin (5) may be fitted on other side as required for burner head to swing open in opposite direction. Fig.
9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.4 Combustion Air Fan, Replacement 9.2.4.2 Installation 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. NOTE Fan motor (7, Fig. 902) to be aligned with control unit (recess in mounting flange) and with clutch (by rotating drive shaft). 9.2.4.1 Removal 1. Loosen screws (3, Fig. 902) and withdraw cap (2) from burner. 2.
Thermo 230 / 231 / 300 / 301 / 350 9 Repair 5 6 4 8 2 9 7 1 3 1 2 3 4 5 6 7 8 9 Splash protection cover Cap Screw (2) Fan wheel Slide lock Screw (3) Fan motor Clutch Electrical connector Fig.
9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.5 Control Unit, Replacement 9.2.6.2 Installation 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. 903). 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. 1. Install solenoid valve (7, Fig.
Thermo 230 / 231 / 300 / 301 / 350 9 Repair 1 Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572 23 Control unit 1572D Overheat thermostat (Thermo 231 / 301 only) 26 5 2 1 6 3 8 7 4 9 Igniter box (black connector cover) only in combination with control unit 1572 5 25 6 10 11 12 24 13 Control unit 1572 14 15 16 17 18 23 19 22 21 20 1 Igniter box 2 Screw (2) 3 Igniter electrodes 4 High pressure nozzle 5 Viewing gla
9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.8 Igniter Box, Replacement 9.2.9 Flame Sensor, Replacement 9.2.8.1 Removal 9.2.9.1 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 screws (2) with lock washers. 5. Withdraw igniter box (1) and remove. 6. Perform procedures on components after disassembly (refer to 9.1.1). 1. Remove burner if required (refer to 9.2.3.1). 2.
Thermo 230 / 231 / 300 / 301 / 350 9 Repair 1 Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572 23 Control unit 1572D Overheat thermostat (Thermo 231 / 301 only) 26 5 2 1 6 3 8 7 4 9 Igniter box (black connector cover) only in combination with control unit 1572 5 25 6 10 11 12 24 13 Control unit 1572 14 15 16 17 18 23 19 22 21 20 1 Igniter box 2 Screw (2) 3 Igniter electrodes 4 High pressure nozzle 5 Viewing gla
9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.10 Heat Exchanger, Replacement 9.2.11 Combustion Chamber, Replacement 9.2.10.1 Removal 9.2.11.1 Removal 1. 2. 3. 4. 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). Remove temperature limiter (refer to 9.2.1.1).
Thermo 230 / 231 / 300 / 301 / 350 10 10 Packaging / Storage / Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Spheros 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.
10 Packaging / Storage / Shipping Page empty for notes 1002 Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 Annex A Annex A Scheduled Maintenance A-1
Annex A Heater, Scheduled Maintenance * The heater should be checked in regular intervals at least at the beginning of the heating season (point of time when weather conditions cause increased use of heater). Check / Maintenance Thermo 230 / 231 / 300 / 301 / 350 The maintenance intervals indicated below apply to applications and requirements typical of busses. Should the heaters be used in other vehicles or applications, these intervals may have to be adapted, i.e. shortened or extended.
Spheros-Service Sie haben ein technisches Problem? Spheros bietet Ihnen in Zusammenarbeit mit Webasto ein weltweites Servicenetz! Spheros service telephone. Do you have a technical problem? Spheros offers in co-operation with Webasto a world-wide service net. Spheros BR CND RC D Brasilien Spheros Brasil S.A. Tel. +55 54 21015700 Canada Spheros North America, Inc., Canton, MI 1-888-270-2226 China Spheros (Yangzhou) Limited Tel. +86 514 5881 226 Deutschland Gilching Tel.
Für diese Druckschrift wurde ein umweltschonendes, aus 100% chlorfrei gebleichtem Zellstoff hergestelltes Papier verwendet. Printed in Germany · 12.12 Druck: Steffendruck Friedland Änderungen vorbehalten Subject to modification Sous réserve de modifications © Spheros GmbH Spheros GmbH Friedrichshafener Straße 9-11 · D-82205 Gilching Tel. +49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 01-2008 Observance and affixing of the placard ”Switch off auxiliary heating system before refuelling” Statutory regulations require that this placard, in the respective language of the destination country, shall be affixed by the bus manufacturer near the fuel filler. The bus operator shall observe this note categorically. The placard in 9 languages and in the new Spheros-Design is provided with each by the factory delivered SPHEROS-Heater since 21.07.08 as depicted.
Technical Information 04-2008 Usage of the spare parts bag „Small parts for magnetic coil cpl.“, ident. no. 386650Z for heaters and spare parts note for the new solenoid valve 2710806B Please consider that the spare parts bag “Small parts for magnetic coil cpl.“, ident. no. 386650Z, may only be used for the below stated heaters: ¾Heater Thermo 230/231/300/301/350, with magnetic coil ident. no. 29313_ ¾ Heater DBW 230 (2020)/300/350 for 12 V, version with magnetic coil ident. no.
Technical Information 05-2008 Splash water protection of magnetic clutch pumps through technical changes For all magnetic clutch pumps new / changed parts will be provided: - Shroud with changed design - Additional gasket and a membrane - The bearing splash guard is no longer used By means of these technical changes the pump is completely protected against splash water.
Technical Information 05-2008 Shroud design changes Shroud old Shroud new prepared on 22.10.2008 Spheros Europa GmbH, Abteilung After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 05-2008 New gasket and membrane New gasket New membrane prepared on 22.10.2008 Spheros Europa GmbH, Abteilung After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 06-2008 Replacement of the solenoid valve at DBW and Thermo Heaters Old solenoid valve New solenoid valve DBW 12 V --> 322083 + 2710247A DBW 24 V --> 322091 + 2710248A Thermo --> 29313_ 2710808A 2710807A 2710806B SW 16 (11.5 Nm) SW 8 (2 Nm) SW 16 (5 Nm) SW 12 (1,5 Nm) NOTE: To replace the solenoid valve, first loosen the nut SW 8 resp. SW 12 (ref. figure) and remove the coil body. Thereafter the armature sleeve SW 16 can be loosened more easily.
Technical Information 01-2009 (supersedes TI 07-2008) Introduction of a new Electronic Ignition Unit and a new Spare Parts Kit for Thermo Heaters The new electronic ignition unit 2710213A supersedes the previous version 14845C. Do not reuse the combination screws M5x16 with spring ring when replacing the old ignition unit 14845C by the new version 2710213A. If required, please order in the future the 11113935A ignition unit spare parts kit.
Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit Spheros spare parts kit to be used: 86711B – Retrofit bag heating element Bag content: - Heating element with thermostat - Shield assy - Retaining clamp - Serrated lock washer - Nut Step 1: Remove installed shield Further use delivered shield prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.
Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit Step 2: Shield pre-assembly: Position thermostat into the shield; Install serrated lock washer and hand-tighten the nut. For retaining clamp installation, refer to step 3. prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit Step 3: Substep 1: Substep 2: Insert the heating element Secure the heating element with the retaining clamp Substep 3: Remove dummy connector; plug in the new connector prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit Step 4: Substep 1: Place the pre-assembled shield onto the burner head and align it so the ignition electrodes can be plugged in. Substep 2: Install ignition electrodes prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.
Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit - Final result: Thermo heater with retrofitted heating element Route cables as shown above Attention: Please consider during all other activities done at the heater in regard to this retrofit the instructions given in the workshop manual. prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.
Technical Information 04-2009 (supersedes TI 03-2008) Usage of new, optimized, downward compatible Spheros atomizing nozzles for Thermo Heaters ¾ Usage of hollow cone nozzles ¾ Selected for Spheros quality – optimized spray character / spray angle ¾ Below of emission limitation permitted per law ¾ Labeled with Spheros logo, heating power and identification number ¾ Warranty and product liability only if genuine parts are used ¾ Torque to 20 ± 2 Nm; (when tightening or loosen the nozzle, support the nozzle
Technical Information 05-2009 New spare parts kit for the current Spheros fuel pump Please consider the following: For repair purposes of the current Spheros fuel pump 11112615A the new identification no. 11113051A (spare parts kit - gaskets) is to be used necessarily. Content spare parts kit: 1 strainer Ø7,4-0,1 mm and 2 O-rings 7,65 x 1,78 For the previous fuel pump 82233A/B the 19977D (small parts fuel pump – bag 1 repair) resp.
Technical Information 01-2010 New Spheros ident. no. for „Small parts for magnetic coil“ As of now, the spare parts kit „Small parts for magnetic coil“ can be ordered only, using the new Spheros ident. no. 11113599B (previously 386650Z). The bag content remains unchanged, solely the package was adapted. Pin Pressure spring Armature cpl. O-ring Please consider the Technical Information 04-2008 when using the „Small parts for magnetic coil“. 13.01.
Technical Information 02-2010 New Fuel Pumps for Thermo Heaters Pumps to be replaced Ident. No. 82233A/B 82233A/B (only (only two-pipe two-pipe operation) operation) 11112615A 11112615A (two-pipe (two-pipe operation) operation) Application without heating element pump: 11114892A with “heating element with thermostat“ 83933B pump: 11114892A heating element with thermostat: 83933C as vertical burner (only Thermo 231.001 + 301.
Technical Information 03-2010 Heater reset after a lock-out and fault analysis In the context of product quality monitoring and quality analysis we increased note the submission of control devices which are ok (without any findings) in our plant in Neubrandenburg. Against this backdrop, we would like to advice you, that the deletion of saved faults by the Spheros Thermo Test Diagnosis (ID. 11112249A) will not automatically remove the heater / control device fault lock-out too.
