Spheros thermo 231 Workshop Manual Download Page 9

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Thermo 230 / 231 / 300 / 301 / 350

1 Introduction

103

1.7 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 / [email protected]

Summary of Contents for thermo 231

Page 1: ...al 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 1...

Page 2: ......

Page 3: ...lectrodes 203 2 8 Temperature Sensor 204 2 9 Temperature Limiter 204 2 10 Overheat Thermostat Thermo 231 and 301 only 204 2 11 Circulation Pump 204 2 11 1 Aquavent 5000 U4814 and Aquavent 5000S U4854...

Page 4: ...lenoid Valve Check 604 6 3 8 Nozzle Block Preheater Check 604 7 Circuit Diagrams 7 1 General 701 8 Servicing 8 1 General 801 8 2 Heater Servicing 801 8 3 Vehicle Servicing 801 8 4 Heater Test Run 801...

Page 5: ...fications 902 9 2 Disassembly and Assembly 906 9 2 1 Temperature Limiter Replacement 904 9 2 2 Temperature Sensor Replacement 904 9 2 3 Burner Replacement 904 9 2 4 Combustion Air Fan Replacement 906...

Page 6: ...705 System Circuit Daimler Chrysler Citaro Ident Nr 67131 706 706 System Circuit Van Hool Ident Nr 89401 707 707 System Circuit O405 O407 O408 Ident Nr 91292 708 708 System Circuit MAN Ident Nr 89404...

Page 7: ...The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times General Safety Regulations beyond the scope of these regu...

Page 8: ...above all by the provisions in Annex VII of Directive 2001 56 EC NOTE The provisions of these Directives are binding within the territory governed by EU Directive 70 156 EEC and should similarly be ob...

Page 9: ...and Improvements Deficiencies improvements or proposals for correction of this workshop manual are to be mailed to Spheros GmbH Friedrichshafener Stra e 9 11 D 82205 Gilching Telefon 49 0 8105 7721 88...

Page 10: ...1 Introduction Thermo 230 231 300 301 350 104 Page empty for notes...

Page 11: ...operates intermittently controlled by the temperature sensor The heaters Thermo 230 231 300 301 and 350 basically consist of the combustion air fan the fuel pump with nozzle block and nozzle the heat...

Page 12: ...rated into the fuel pump opens and closes the fuel supply to the atomiser nozzle Three different fuel pumps are assigned to the different heating capacity classes of the Thermo series These are identi...

Page 13: ...air mix is dispersed in the combustion chamber for combustion to heat the heat exchanger Heat exchanger Combustion chamber 2 5 Control Unit The control unit 1572 or 1572D is the central component to e...

Page 14: ...noid valve of the fuel pump When the burner overheats the thermostat causes an error lockout Overheat Thermostat 2 11 Circulation Pump The externally mounted circulation pump ensures proper coolant ci...

Page 15: ...n 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 op...

Page 16: ...he series 230 300 350 126 and 190 Rail an optional heatable fuel filter is provided as an additional option also for 124 and 155 Rail If the electrical filter heating is hooked up the temperature swit...

Page 17: ...lock preheater for extreme low temperatures Heaters with control unit 1572D only When connecting terminal 61 the heaters may operate in the auxiliary heating mode of operation Switching thresholds Con...

Page 18: ...r 300 or 350 3 1 Switch On Upon switch on the operating indicator light goes on Combustion air fan fuel pump and circulation pump start operation If fitted and temperature is 0 C nozzle block preheate...

Page 19: ...heating mode The power save mode is during auxiliary heating automa tically deactivated by the control device The lower temperature threshold for reactivation of the burner after control idle period...

Page 20: ...Pre ignition 15 Safety period 16 Run down 3 Functional Description Thermo 230 231 300 301 350 304 temperature sensor short circuit during control idle temperature sensor open circuit during combustio...

Page 21: ...approx 120 seconds Malfunctions during switch on Short or open circuit of temperature sensor flame sensor burner motor solenoid valve igniter box Malfunctions during start up short circuit of igniter...

Page 22: ...y of the timer after a malfunction NOTE When the heater is operated by means of a switch the type of error is output during heater run down via a flash code of the operating indicator light After five...

Page 23: ...fied by the vehicle manufacturer Only the type of fuel indicated on the identification plate may be used Also Diesel fuel with an addition of 5 PME vegetable oil methyl ester class EL fuel oils not fu...

Page 24: ...V 24 Operating voltage V 20 28 Operating voltage valid for application Thermo 350 190 V 19 28 Nominal power consumption without circulation pump W 65 110 140 Permissible operating ambient temperature...

Page 25: ...0 4 bar 6000 against 0 4 bar Nominal voltage V 12 or 24 24 24 24 Operating voltage range V 10 14 20 28 20 28 20 28 20 28 Nominal power consumption W 104 104 210 210 Dimensions Lenght 230 Width 100 He...

Page 26: ...4 Technical Data Thermo 230 231 300 301 350 404...

Page 27: ...fault symptoms of general nature Symptom Probable Cause Fault in electrical system Operating indicator light is not on no heater operation no power supply fuses wiring to terminals of connector A of...

Page 28: ...cause air in heat exchangers or in system sections contaminated heat exchanger surfaces external insufficient air intake or exit fan rate of delivery low wrong sense of rotation resistance too high to...

Page 29: ...refer to operating instructions for Diagnostic Computer Components Tester NOTE Checks with the components tester may only be performed on heaters equipped with control unit 1572 Using the components...

Page 30: ...s trouble persist Check motor electrics and replace as required Replace cap and fan wheel Is voltage too low Rated value 20 5 volts 0 5 volts Check electrical wiring and connections Does trouble persi...

Page 31: ...onents Is fuel filter contaminated or jellied Is fan wheel free to move Check cap motor and fan wheel Is motor o k Is viewing glass of flame sensor contaminated Clean window and viewing glass Replace...

Page 32: ...n and restart approx 2 min Does same symptom show again Clean combustion tube Remove coke deposits Control unit defective replace Flame in run down Replace solenoid valve Flame sensor defective replac...

Page 33: ...nents test with diagnostic computer o k audible click of solenoid valve Make electrical connections Control unit defective replace Does fuel leak from nozzle in run down Replace solenoid valve Investi...

Page 34: ...temperature limiter Determine why temperature limiter has responded e g check shut off elements check water circulation in system is free from bubbles check circulation pump sense of rotation check c...

Page 35: ...ustion functional checkouts nozzle replacement Setting procedure measure control unit power supply voltage operate heater for approximately 5 min measure CO2 contents and smoke spot number and compare...

Page 36: ...glass of the window refer to Fig are to be cleaned if contami nated In case of damage or not obtaining the rated values replace flame sensor Check cover flame sensor glass bulb check resistance rated...

Page 37: ...ed every 5 years CAUTION The electronic ignition coil must be removed for safety reasons Check remove igniter box refer to 9 2 7 1 remove nozzle screw on tester cover flame sensor switch on heater aft...

Page 38: ...y clearing the area between solenoid valve and nozzle bore Check CAUTION Disconnect solenoid valve connector from control unit to avoid damage to the control unit Check electrics for the following val...

Page 39: ...350 with control unit 1572 and with switch timer 1529 triple timer The circuit diagrams Fig 703 and 704 show possible heater circuits for Thermo 230 231 300 301 and 350 with control unit 1572D and wit...

Page 40: ...ark S3 Switch external trigger circulation pump S4 Switch power save operation U1 Igniter box U2 Igniter electrodes A Plug connections 6 pole C Plug connections 1 pole D Plug connections 4 pole X1 Plu...

Page 41: ...ter B4 Thermostat opens at T 8 C E1 Heating cartridge for nozzle preheating F2 Fuse 25A flat fuse SAE J 1284 F3 Fuse 25A flat fuse SAE J 1284 F6 Fuse 5A flat fuse SAE J 1284 H3 Light in item P symbol...

Page 42: ...idge for nozzle preheating F1 Fuse 5 A flat fuse DIN 72581 part 3 F2 Fuse 25 A flat fuse DIN 72581 part 3 F3 Fuse 25 A flat fuse DIN 72581 part 3 H1 Light operation indicator light H2 Light flame indi...

Page 43: ...ns 1 pole D Plug connections 4 pole F Plug connections 2 pole X1 Plug connections 6 pole X2 Plug connections 2 pole X3 Plug connections 8 pole X4 Plug connections 12 pole Y1 Solenoid valve Item Nomenc...

Page 44: ...sensor observe polarity B2 Temperature sensor polarity optional B3 Temperature limiter B4 Thermostat for nozzle preheating E1 Heating cartridge for nozzle preheating F1 Fuse 25 A flat fuse DIN 72581...

Page 45: ...preheating B5 Fire sensor Van Hool E1 Heating cartridge F2 Fuse see table F3 Fuse see table H1 Light operation indicator light H2 Light flame indicator K1 Relay in item A2 for circulation pump motor K...

Page 46: ...ting cartridge for nozzle preheating F2 Fuse see table F3 Fuse see table H1 Light operation indicator light H2 Light flame indicator K1 Relay for circulation pump motor K2 Relay for combustion air fan...

Page 47: ...5 A flat fuse DIN 72581 part 3 F3 Fuse 25 A flat fuse DIN 72581 part 3 H1 Light operation indicator light H2 Light flame indicator M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on of...

Page 48: ...or M1 Motor combustion air fan M2 Motor circulation pump S1 Switch on off S2 Continuity switch on water cock Pos Nomenclature Remark S3 Switch external trigger circulation pump required if S2 not inst...

Page 49: ...part 3 H1 Light operation indicator light H2 Light flame indicator H4 Heating symbol on the display Power on indicator in item P K4 Relay M1 Motor combustion air fan M2 Motor circulation pump Item No...

Page 50: ...7 Circuit Diagrams Thermo 230 231 300 301 350 712...

Page 51: ...ds difficulties in the start up at least once a year in case of contaminated fuel more often the fuel filter or filter cartridge as well as the filter screen of the fuel pump must be replaced to avoid...

Page 52: ...ler is upstream in exhaust pipe If muffler is dislocated in the exhaust pipe arrest muffler as described in NOTE Slot or drill exhaust pipe and refit 4 If the exhaust muffler has been lost it may be o...

Page 53: ...al connection s to the temperature limiter and temperature sensor Opening or removal 1 Disconnect electrical connections to temperature limiter and temperature sensor 2 Loosen nuts 3 Fig 801 enough to...

Page 54: ...n using the circulation pump Aquavent 6000 U4851 or Aquavent 6000S U4852 or Aquavent 6000SC U4856 the circulation pump automatically is switched off approx 15 seconds after switch on if coolant is lac...

Page 55: ...senger Bus Vorlauf R cklauf 4 8 9 3 1 1 1 1 2 7 5 6 Water heating circuit Sidewall radiators and roof duct heating 1 Sidewall radiator with fan 2 Heat exchanger entrance 3 Heater unit 4 Circulation pu...

Page 56: ...snow or intake of splash water is to be expected The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle Pe...

Page 57: ...and fasten with hose clamps Torque clamps with 1 5 Nm Open water cocks 4 Connect fuel supply and return lines and tighten connections or screw tight with banjo bolt and new gaskets 5 Secure combustion...

Page 58: ...isconnection of the heater power supply within 120 sec during run down 8 8 1 Water Circuit Bleeding NOTE Bleeding must always be performed in accordance with manufacturer s instructions For bleeding t...

Page 59: ...The following components may also be replaced with the heater installed unless restricted space prevents access temperature limiter temperature sensor combustion air fan burner igniter box flame senso...

Page 60: ...ction Inspect exhaust ducting in heat exchanger for sooting deposits damage and corrosion NOTE Deposits are to be removed with water jet and brush Inspect heat exchanger for exterior damage defor mati...

Page 61: ...identification label Procedure CAUTION Control unit 1572D may only be used in combination with the igniter box delivered green connector cover The electrical connector is coded 1 Remove control unit...

Page 62: ...al 1 Disconnect electrical connection to temperature sensor WARNING Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by opening the cooling circu...

Page 63: ...eplacement Rubber cap Temperature Retaining clip 8 7 6 5 4 3 2 1 1 Temperature limiter 2 Temperature sensor 3 Connector 4 Coolant outlet 5 Cotter pin 6 Nut 2 7 Hinge bolt 2 8 Burner limiter NOTE Cotte...

Page 64: ...thdraw fan motor 7 5 Perform procedures on components after disassembly refer to 9 1 1 9 2 4 2 Installation NOTE Fan motor 7 Fig 902 to be aligned with control unit recess in mounting flange and with...

Page 65: ...0 231 300 301 350 9 Repair 907 Fig 902 Combustion Air Fan Replacement 1 2 3 4 5 6 7 8 9 1 Splash protection cover 2 Cap 3 Screw 2 4 Fan wheel 5 Slide lock 6 Screw 3 7 Fan motor 8 Clutch 9 Electrical c...

Page 66: ...d 4 Disconnect electrical connector 8 NOTE During the following step ensure that escaping fuel is immediately neutralized and properly disposed of 5 Remove screws 9 with lock washers 6 Withdraw fuel p...

Page 67: ...D and also control unit 1572 1 Control unit 1572D 15 Flame sensor 16 Screw 17 Burner housing 18 Strain relief clamp 2 19 Screw 2 20 Base plate for relays 21 Relay 22 Relay 23 Control unit 24 Heating c...

Page 68: ...5 Install burner refer to 9 2 3 2 9 2 9 Flame Sensor Replacement 9 2 9 1 Removal 1 Remove burner if required refer to 9 2 3 1 2 If required lever off igniter electrodes Fig 904 from igniter box using...

Page 69: ...it 1572D and also control unit 1572 1 Control unit 1572D 15 Flame sensor 16 Screw 17 Burner housing 18 Strain relief clamp 2 19 Screw 2 20 Base plate for relays 21 Relay 22 Relay 23 Control unit 24 He...

Page 70: ...1 2 4 Install temperature sensor refer to 9 2 2 2 9 2 11 Combustion Chamber Replacement 9 2 11 1 Removal 1 Disconnect electrical connections to temperature limiter and temperature sensor 2 Swing burn...

Page 71: ...d packaged so that they are protected against damage during handling ship ping and storage CAUTION When shipping a complete heater assembly it must be drained completely No coolant is allowed to escap...

Page 72: ...10 Packaging Storage Shipping Thermo 230 231 300 301 350 1002 Page empty for notes...

Page 73: ...Thermo 230 231 300 301 350 Annex A A 1 Annex A Scheduled Maintenance...

Page 74: ...tions for leaks b Replace fuel filter cartridge with gasket c If existing open fuel shut off valves d Fuel pump e Replace fuel filter screen with gaskets in pump Check for leak proof connections in fu...

Page 75: ...43 1 6043780 Belgien 8263 BC Kampen NL Tel 31 38 3371 137 Bosnien Herzegovina siehe Slowenien Bulgarien 1839 Sofia Tel 359 2 9420 555 Wei russland 220004 Minsk Tel 37 50172201894 Kroatien siehe Slowen...

Page 76: ...s Papier verwendet Printed in Germany 12 12 Druck Steffendruck Friedland nderungen vorbehalten Subject to modification Sous r serve de modifications Spheros GmbH Spheros GmbH Friedrichshafener Stra e...

Page 77: ...elling 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 observ...

Page 78: ...ts bag Small parts for magnetic coil cpl ident no 386650Z may only be used for the below stated heaters Heater Thermo 230 231 300 301 350 with magnetic coil ident no 29313_ Heater DBW 230 2020 300 350...

Page 79: ...gh 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...

Page 80: ...uropa GmbH Abteilung After Sales Friedrichshafener Stra e 9 11 82205 Gilching Tel 49 0 8105 7721 887 Fax 49 0 8105 7721 889 www spheros de service spheros de Technical Information 05 2008 Shroud desig...

Page 81: ...opa GmbH Abteilung After Sales Friedrichshafener Stra e 9 11 82205 Gilching Tel 49 0 8105 7721 887 Fax 49 0 8105 7721 889 www spheros de service spheros de Technical Information 05 2008 New gasket and...

Page 82: ...n 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 For installation reverse the sequence Before installing the coil body the...

Page 83: ...rews 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 It contains the i...

Page 84: ...vice spheros de 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 e...

Page 85: ...105 7721 889 www spheros de service spheros de Technical Information 02 2009 Step 2 Shield pre assembly Position thermostat into the shield Install serrated lock washer and hand tighten the nut For re...

Page 86: ...8105 7721 889 www spheros de service spheros de Step 3 Substep 1 Insert the heating element Substep 2 Secure the heating element with the retaining clamp Substep 3 Remove dummy connector plug in the n...

Page 87: ...8105 7721 889 www spheros de service spheros de 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 ignitio...

Page 88: ...e spheros de Final result Thermo heater with retrofitted heating element Attention Please consider during all other activities done at the heater in regard to this retrofit the instructions given in t...

Page 89: ...ros quality optimized spray character spray angle Below of emission limitation permitted per law Labeled with Spheros logo heating power and identification number Warranty and product liability only i...

Page 90: ...used necessarily Content spare parts kit 1 strainer 7 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 the 1302999B small parts...

Page 91: ...0 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...

Page 92: ...pump 11114892A continue to use the heating element 83933C without heating element pump 11114892A pump 11114957A continue to use the heating element 83933C and thermostat 98640B 82233A B only two pipe...

Page 93: ...the heater fault lock out the related instructions of the appropriate Thermo Thermo S Workshop Manual should be considered see www spheros de Service Tech nische_Dokumente Heizsysteme aspx In this wa...

Page 94: ...he previous generation Thermo 230 300 350 heaters now the optimized version of Thermo S 230 300 350 heaters can be used In length and diameter it is identical to the Thermo 230 300 350 series The opti...

Page 95: ...kW 1st letter production month A January M December Nomenclature of production date recurring since 2008 2nd letter production year A 2001 K 2010 A January G July B February H August C March I Septemb...

Page 96: ...ation Power Ident number Spheros label Thermo S 160 16kW 2710233B yes 230 23kW 2710234B yes 300 30kW 2710235B yes 350 35kW 2710236B yes 400 40kW 2710237B yes Thermo E 200 20kW 2711057A yes 320 32kW 27...

Page 97: ...just the CO2 content according to the technical data if combustion air supply or exhaust gas applications are used After heater installation bleed the water system and the fuel supply system carefully...

Page 98: ...heater locking will be reduced to a minimum with the new pump The fuel pumps can be exchanged 1 1 in the field All spare part kits contain fastening bolts Heater Fuel pump Spare part kit fuel pump The...

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