Spheros Thermo S 160 Workshop Manual Download Page 1

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Water Heater

Workshop Manual

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

Summary of Contents for Thermo S 160

Page 1: ...Water Heater Workshop Manual 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...

Page 2: ......

Page 3: ...E 5 1 3 3 1 6 Temperature sensors with water temperature sensor and integrated overheating protection 304 3 2 Heat exchanger 305 3 3 Combustion chamber 306 3 4 Circulating pump 307 3 4 1 Aquavent 5000...

Page 4: ...ion unit inspection 513 5 5 9 Ignition electrode inspection 514 5 5 10 Flame detector inspection 515 5 5 11 Fuel pump inspection 516 5 5 12 Solenoid valve inspection 517 5 5 13 Nozzle block preheater...

Page 5: ...Thermo S 160 230 300 350 400 1 Introduction 3 9 Modifications and retrofits 10 Packing storage and shipping 10 1 General 1001 Appendix A 1 Periodic heater maintenance A 2...

Page 6: ...1 Introduction Thermo S 160 230 300 350 400 4...

Page 7: ...Regulations and should similarly be observed in regulations Extract from ECE Regulation R122 Annex 7 4 The heater must have a manufacturer s label showing the manufacturer s name the model number and...

Page 8: ...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 dev...

Page 9: ...agging they should secured using clamps in 10 inch 25 cm distances Fuel lines must be protected against temperature exposure Permissible fuel line dimensions must be obtained from the installationinst...

Page 10: ...arness or adapter plugs installed for testing purposes 1 6 Suggestions for Improvement and change Please direct any complaints improvement or modification suggestions regarding this manual to Spheros...

Page 11: ...S o m r e h T n o i t c u d o r t n I 1 160 230 300 350 400 105...

Page 12: ...winter diesel according to DIN EN 590 or DIN 51628 and 25 Vol vegetable oil rapeseed oil 0 5 C without preheating system 5 10 Cwithnozzleblockpreheaterandheatedfuel filter use limitationsdepending on...

Page 13: ...nter 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...

Page 14: ...to a coolant circulation system via the heater s heat exchanger In termittent operation adjusts the heater to changing heat demand cyclic operation The control unit controls heater activation and dea...

Page 15: ...e different heating capacity classes of the Thermo S series The respective heating capacity classes are indicated on the motor In addition the motors are differentiated by colour t 16 kW 30 KW Motor h...

Page 16: ...e nozzle holder and thus fuel and atomizer nozzle Fuel viscosity is reduced and atomisation improved The control unit defines the preheating time depending on vehicle electrical system voltage and sta...

Page 17: ...eating protection integrated into the temperature sensor is responsible for temperature limitation Similar to the water temperature sensor the coolant temperature is captured at the heat exchanger out...

Page 18: ...exchanger The heat exchanger transfers the heat generated by combustion to the coolant circulation system Depending on the system integration a heat exchanger with or without thread in the coolant inl...

Page 19: ...ess 1 5 mm ThecombustionchambersofThermosS160andThermo S 400 are each fitted with a stamping to distinguish the individual combustion chambers If possible the combustion chamber should be inserted int...

Page 20: ...000 U4814 and 5000S U4854 circulating pumps are equipped with a brush motor Aquavent 5000 U4814 with floating ring type shaft seal Aquavent 5000S U4854 magnetic drive no seal The circulating pump moto...

Page 21: ...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 overpressurin...

Page 22: ...r 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...

Page 23: ...maximum of 120 seconds The further sequence takes place as described 4 2 2 Heating operation After the flame is stabilised the heater is in controlled normal operation Depending on the coolant temper...

Page 24: ...The heater burner output is not reduced In auxiliary heating mode sig nal from terminal D 61 saving mode is automatica lly deactivated see 4 1 4 2 2 3 Gradient evaluation In case of low coolant flow...

Page 25: ...404 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...

Page 26: ...s started on the PC and the connection to the heater co ntrol unit is established 4 3 1 Test plug For tests using the Component test menu of SST diagnosis the temperature sensor A plug must be replace...

Page 27: ...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 va...

Page 28: ...eaterinterlock can be released see 4 6 1 Here it is differentiated between interlocks caused by overheating and interlocks caused by other errors If malfunctions occur during switching on or during th...

Page 29: ...ehicle electrical system 8 Clear the error using SST diagnosis Without SST diagnosis 6 Reconnect the switched on heater to the vehicle electrical system Note The heater automatically st arts after con...

Page 30: ...isconnected 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...

Page 31: ...d t Contaminationsinthesystem e g filtersoratbottlenecks t Circulating pump delivery rate insufficient air in pump housing t Insufficient frost protection t Systemresistancetoohigh especiallyhighinthe...

Page 32: ...N t Bent closed clogged or leaking lines t Paraffin deposits or frozen water entrapments in fuel lines or lines t Venting opening in tank closed t Fuel lines mixed up t Fuel filter contaminated t Fue...

Page 33: ...Overheatingprotectionte mperaturesensorshortcircuitafterterminal31 orinterruption orshortcircuit after terminal 30 6 Solenoid valve short circuit after terminal 31 or interruption or short circuit aft...

Page 34: ...n safety period error symptom does not always indicate that no ignition took place This symptom occurs as well if the heater fails to enter heating operation heating or auxiliary heating state after s...

Page 35: ...Is the atomizer nozzle clean without deposits and properly screwed in Does the atomizer nozzle properly atomise Replace or properly mount t he atomizer nozzle Do not clean it Is the fuel used suitabl...

Page 36: ...eatable filters NO YES Is the battery charge condition permanently greater than 20 5V 0 5V Ensure permanent battery voltage greater than 20 5V 0 5V Disconnect the A1 plug from the control unit Isthevo...

Page 37: ...ring run down Is the combustion air inlet clean free Is the motor OK and can rotate freely Is the exhaust outlet clean free Is the burner pipe coked contaminated or damaged Is the heat exchanger soote...

Page 38: ...nterruption The Circulating pump interruption error can also be triggered by dry operation of the circulating pump Are the temperature sensor plugs contacts and cables OK Are the adapter wiring harnes...

Page 39: ...r co rrosion and tight fit Repair as needed 5 5 2 Heat exchanger visual inspection t Inspect heat exchanger interior for damage corrosion sooting and deposits t Inspect heat exchanger for outer damage...

Page 40: ...ance measurements The water temperature sensor and the overheating protection should indicate values according to the charts Preferably the resistance should be measured at an approx consistent temper...

Page 41: ...using t Connect temperature sensor t Install hood see 8 4 5 5 6 Fan and combustion air intake line visual inspection t Inspect a possibly available combustion air intake line for contamination conditi...

Page 42: ...ed of SST diagnosis t After the test is completed exit SST diagnosis as needed t Disconnect the heater from the vehicle electrical system t Disconnect the test plug and reconnect the temperature senso...

Page 43: ...inal condition Ignition sparks the ignition electrode jump over with a rate of 6Hz t After the test is completed install the electronic ignition unit see 8 6 and attach the ignition electrode t Instal...

Page 44: ...electrical system t Connect the SST diagnosis adapter to the heater and a PC via the interface in the heater wiring harness Start SST diagnosis and establish the connection to the heater t Cover the...

Page 45: ...t Was the fuel filter in thefuel pre flow line replaced t Are the filters screens in the pump inlet clean t Is the fuel delivered without bubbles Attach a transparent hose for testing Inspection using...

Page 46: ...using SST diagnosis t Remove burner see 8 2 t Connect the test plug to the adapter wiring harness t Connect the heater to the vehicle electrical system t Connect the SST diagnosis adapter to the heat...

Page 47: ...ter to the heater and a PC via the interface in the heater wiring harness Start SST diagnosis esta blish connection to the heater and open the Component Test menu t Select the optional nozzle block pr...

Page 48: ...he cooling system for leak tightness t Connect the heater to the vehicle electrical system t Connect the SST diagnosis adapter to the heater and a PC via the interface in the heater wiring harness Sta...

Page 49: ...5 Troubleshooting and error correction Thermo S 160 230 300 350 400 520...

Page 50: ...vehicle electrical system are shown 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...

Page 51: ...motor DVW Nozzle block preheater F1 Vehicle blade type fuse 25 A according to DIN 72581 part 3 F2 Vehicle blade type fuse 25 A according to DIN 72581 part 3 F3 Vehicle blade type fuse 5A according to...

Page 52: ...rness coolant overheating Item Description BA Operating display max 5W BM Combustion air motor DVW Nozzle block preheater F1 Vehicle blade type fuse 25 A according to DIN 72581 part 3 F2 Vehicle blade...

Page 53: ...Combustion air motor DVW Nozzle block preheater F1 Vehicle blade type fuse 25 A according to DIN 72581 part 3 F2 Vehicle blade type fuse 25 A according to DIN 72581 part 3 F3 Vehicle blade type fuse 5...

Page 54: ...Nozzle block preheater F1 Vehicleblade type fuse25 Aaccording toDIN 72581part3 F2 Vehicleblade type fuse25 Aaccording toDIN 72581part3 F3 Vehicle blade type fuse 5A according to DIN 72581 part 3 FA F...

Page 55: ...r e h T s m a r g a i d c i t a m e h c S 6 mo S 160 230 300 350 400 606...

Page 56: ...rview on the Spheros homepage under Service Technical Documents Recommended maintenance t In order to prevent malfunctions the fuel filter and or strainer as well as the fuel pump filter screen must b...

Page 57: ...sooted heat exchanger see 5 5 2 t After a combustion period of approx 3 min measure the CO 2 content in the exhaust and compare it to the target value in Table 701 t Determine smoke number as needed T...

Page 58: ...d 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 If component...

Page 59: ...ove burner 1 Do not bent any lines when placing the burner down Burner installation 1 Bring burner 1 Fig 801 in assembly position and ensure centre alignment and correct fit 2 Place nuts 2 and alterna...

Page 60: ...8 4 Hood removal and installation Removing the hood provides access to the following components for maintenance inspection and repair purposes t Fan t Burner motor t Motor cross member t Control unit...

Page 61: ...r motor 3 Fig 803 to the motor cross member 5 For this purpose align the burner motor withthe motor cross member Observethemotorcrossmemb erinstallationposition Screw the countersunk screws 7 into the...

Page 62: ...e h T 805 Fig 803 Combustion air fan removal and installation 1 Shaft circlip 2 Fan 3 Burner motor 4 Motor plug 5 Motor cross member 6 Screws 3 7 Countersunk screws 3 8 Hood 9 Screws 2 10 Coupling wit...

Page 63: ...ry perform a general visual inspection see 5 5 1 or test see 5 5 8 Installation 1 Bring electronic ignition unit 1 Fig 804 into installation position attach ready for connection and secure with screws...

Page 64: ...unit 2 Screw 2 3 Ignition electrode 4 Atomizer nozzle 5 Disc 6 Solenoid valve 7 Nozzle block preheater optional 8 Support 9 Fuel pump 10 O rings 2 11 Filter insert 12 Screws 3 13 Burner housing 14 Con...

Page 65: ...nect 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 6 Pull fuel pump 9 with the solenoid valve 6 off and remove it 7...

Page 66: ...unit 2 Screw 2 3 Ignition electrode 4 Atomizer nozzle 5 Disc 6 Solenoid valve 7 Nozzle block preheater optional 8 Support 9 Fuel pump 10 O rings 2 11 Filter insert 12 Screws 3 13 Burner housing 14 Con...

Page 67: ...unit 14 Fig 806 5 Fit disc 5 Fig 806 onto the nozzle holder and align withtheflamedetectorinthecontrolunit 14 Fig 806 and the electronic ignition unit 1 Fig 806 6 Fit ignition electrode 3 Fig 806 7 I...

Page 68: ...nt inlet 5 and the coolant outlet 6 and seal with blank plugs Caution if coolant temperature is increased 7 Remove screws and washers of the heat exchanger stand 4 8 Remove heat exchanger from the veh...

Page 69: ...fill the supply line prior to first heater start up 8 14 2 Bleeding of the water circuit The water circuit must be principally bleeded according to manufacturer specification Risk of injuries for coo...

Page 70: ...tions and retrofits 901 9 Modifications and retrofits For further optimization the heaters are continuously improved Units in the field can usually be upgraded or retrofitted For this purpose respecti...

Page 71: ...9 Modifications and retrofits Thermo S 160 230 300 350 400 902...

Page 72: ...and packaged to ensure that handling transport and storage will not damage them If a complete heater is sent back it must be completely drained Packaging and or shipping must ensure that no fuel or c...

Page 73: ...10 Packing storage shipping Thermo S 160 230 300 350 400 1002 Empty page for notes...

Page 74: ...x i d n e p p A A 0 0 4 0 5 3 0 0 3 0 3 2 0 6 1 S o m r e h T A 1 Appendix A Periodic maintenance...

Page 75: ...place fuel filter insert with gasket c If available open fuel shut off valves d Fuel pump and fuel lines NOTE Observe technical information if bio diesel or FAME is used e Replace fuel screen with gas...

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Spheros Thermo S 160, Workshop Manual

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