Valeo Thermo G 300 Workshop Manual Download

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Valeo Thermal Commercial Vehicles Germany GmbH
Friedrichshafener Str. 7 -

Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889

82205 Gilching - Germany -

www.valeo-thermalbus.com - [email protected]

Summary of Contents for Thermo G 300

Page 1: ...Rev 12 2018 Id No DOK50036 Thermo G 300 with control unit 1588 Workshop Manual HEATING SYSTEMS...

Page 2: ...perature sensor and integrated overheating protection 304 3 5 Gas pressure regulator 305 3 5 1 Heating of the gas pressure regulator 305 3 6 Circulating pump 305 4 Heater functions 401 4 1 General hea...

Page 3: ...601 7 Servicing 701 7 1 General 701 7 2 Heater Servicing 701 7 3 Vehicle Servicing 701 7 4 Heater test run 701 7 5 Servicing 701 7 6 Measurement and adjustment of the exhaust CO2 content 702 7 6 1 Me...

Page 4: ...Thermo G Content 3 10 Packing storage and shipping 1001 10 1 General 1001 Appendix Scheduled heater maintenance A 1...

Page 5: ...eful hints for the correct installation of the heater Spare parts required during maintenance and repair you can order using the Thermo G Spare Parts List at Valeo If necessary Valeo will publish Tech...

Page 6: ...NTION The temperature sensor cable may not be mechani cally stressed pull on the cable carry the heater at the cable etc 1 5 Suggestions for Improvement and change Please direct any complaints improve...

Page 7: ...atural gas classes H L Combustion gas pressure when it enters the heater 2 5 mbar Fuel cosumption at CNG class H 2 95 kg h Rated voltage 24 Volt Operating voltage range 20 5 30 Volt Rated power consum...

Page 8: ...10 mg m3 2 4 Circulating pump All desired information about the Valeo circulation pumps can be found under www valeo thermalbus com eu_en Products Pumps Gas pressure regulator Test certificate ECE R11...

Page 9: ...hanger of the heater the heat is dissipated to a coolant circuit The adaptation to the changing demand of heat is reached by intermittent operation An integrated control device controls on the basis o...

Page 10: ...d with the gas in the mixing chamber If an air intake extension is used the combustion air is sucked in through this extension 3 1 2 Control device The control unit 1588 ensures the operating sequence...

Page 11: ...is measured in the control device Thereby the presence or absence of a flame can be clearly detected The flame monitoring is part of the control 3 1 6 Flame tube The flame tube ensures a defined homog...

Page 12: ...ng protection integrated into the tempera ture sensor is responsible for temperature limitation Similar to the water temperature sensor the coolant temperature is captured at the heat exchanger outlet...

Page 13: ...lator is connected with the water outlet and the water inlet at the heater Heated water is branched off at the water outlet and flows through the gas regulator Then it re enters the heater through the...

Page 14: ...ignition sparks The flame recognition is carried out by an in the ZF module electronic ignition unit integrated flame guard The principle is based on the measurement of the ionisa tion current throug...

Page 15: ...e heating mode NOTE If during the start the main switch is turned off or the water temperature rises above the upper temperature threshold or a fault is detected the system switches into the purge cyc...

Page 16: ...atically sets the upper switching thres hold to a lower value The quicker the temperature increases the lower the swit ching threshold for starting the controlled break is set In addition the burner i...

Page 17: ...operation Malfunction causes Short circuit and or interruption of electrical compo nents temperature sensor combustion air motor circulating pump solenoid valves 1 and 2 electronic ignition unit of th...

Page 18: ...detection after flushing Flame detection during the purge cycle 2 Control device fault or programming error Repeated malfunctions 8 Repeated flame interruptions 5 4 5 1 Heater interlock release ATTENT...

Page 19: ...ter is in 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 General err...

Page 20: ...nations in the system e g filters or at bottle necks Circulating pump delivery rate insufficient air in pump housing insufficient frost protection antifreeze System resistance too high especially high...

Page 21: ...ycle starts with 5 short flashes again and so on The meaning of the number of long pulses is shown in the table below Error in the fuel supply No fuel supply to the heater empty gas tank bent closed c...

Page 22: ...sensor short circuit Temperature sensor interruption Temperature sensor overheat protection non plausible Overheat protection short circuit Overheat protection interruption 7 Solenoid valve 1 or 2 def...

Page 23: ...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 after a successful ignition e g in case the...

Page 24: ...ion electrodes OK Adjust ignition electrodes properly see 5 5 9 respectively check the correct installation of the ZF module NO JES Switch heater on Does the combustion air motor start Are all electri...

Page 25: ...g NO JES Is the battery charge condition permanently greater than 20 5V measured at heater Ensure permanent battery voltage greater than 20 5V Disconnect the C plug from the control unit Is the voltag...

Page 26: ...eater stopped or the voltage disconnected before or during purge cycle Is the combustion air intake clean free Is the motor OK and can rotate freely Is the exhaust outlet clean free Is the flame pipe...

Page 27: ...e Chapter 3 Section 3 5 Is the plug T of the temperature sensor system plugged in correct ly Is the plug the pins and the cables of the temperature sensor system OK Is the temperature sensor incl over...

Page 28: ...and or replace the component NO JES Replace gas regulator NOTE Replacement of the solenoid valves is not permitted Is it ensured that sufficient cooling and coolant flow are available Are all shut off...

Page 29: ...amination and deposits 5 5 4 Combustion chamber visual inspection 1 Remove combustion chamber see 8 10 2 Check combustion chamber for scaling and coke deposits and remove them if necessary 3 Inspect c...

Page 30: ...the control unit 7 Install mixing chamber to the fan housing see 8 5 8 Install burner head see 8 4 5 5 8 ZF module inspection NOTE It can only be verified by visual inspection of the igni tion electro...

Page 31: ...e damaged Ignition electrodes not functioning properly must be replaced 1 Remove burner head see 8 4 2 Check distance of the electrode tips to the flame pipe see Fig 504 3 Check the distance between t...

Page 32: ...tests Check the plug pins for corrosion and tight fit Was the gas pressure regulator replaced after 4 years of operation When the heater is switched off no gas may escape through the outlet to the hea...

Page 33: ...e DC voltage 5 Reconnect the plug V to the control unit 5 5 11 4 Testing the safety valve on the gas pressure regulator If the intake valve is open MV1 no gas must escape at the safety valve s hose co...

Page 34: ...agrams 6 1 General The following figures represent heater connection options to the vehicle electrical system The in the table below shown cable cross sections are to be used Cable length 7 5m Cable l...

Page 35: ...2 0 75mm 2 C BM I P D T V 1 2 Terminal 58 Terminal 15 Terminal 30 permanent plus Terminal 31 ground T 31 HG T 30 HG T 31 UP T 30 UP Ground Electronic Gas free Overheating Protection Coolant Temperatur...

Page 36: ...valve 2nd stage gas regula tor UP Circulating pump UPFA Circulating pump external control ZF Modul Electronic ignition module in the heater Legend for the wiring diagrams Connector Description C To v...

Page 37: ...t ventilation facilities 7 5 Servicing In order to ensure long term functional reliability the follo wing maintenance activities should be performed The openings of the combustion air intake grid and...

Page 38: ...the heat exchanger In the case no exhaust pipe is connected for the measu rement a flexible pipe of 500 mm length see accessory catalog can be used At this point also the measurement of the exhaust ga...

Page 39: ...following components fan motor fan wheel ZF module 8 2 Removal and installation of the temperature sensor with integrated overheating protection Prior to removing the temperature sensor the over press...

Page 40: ...connect gas supply hose and seal it with a blank plug 5 Unscrew nuts 2 6 Remove burner head 1 Burner head installation 1 Bring burner head 1 Fig 802 together with a new gasket ring 6 into assembly pos...

Page 41: ...mixing chamber seal 5 Fig 803 from fan housing and or from the mixing chamber 2 Bring the the fan housing 2 in assembly position with the mixing chamber 6 During this ensure the new mixing chamber gas...

Page 42: ...gement of the circlip in the groove Verify the fan wheel is freely rotatable 3 Attach fan housing to the mixing chamber see 8 5 8 8 Fan motor removal and installation Removal 1 Separate the fan housin...

Page 43: ...tion of components 1 2 3 4 5 6 7 8 9 10 11 12 13 1 Hood 2 Fan motor 3 Fan housing 4 Fan wheel 5 Control device 6 Gas port 7 circlip 8 ZF module 9 Gasket ring Mixing chamber 10 Mixing chamber 11 Heat p...

Page 44: ...Pull combustion chamber 1 Fig 805 out of the heat exchanger 2 see 8 10 4 If necessary loosen the exhaust line clamp on the exhaust outlet 3 5 If available close water taps Prior to disconnecting the...

Page 45: ...ator together with the washer and spring washer Installation 1 Place gas pressure regulator together with the washer and spring washer into installation position and attach it using the nut tightening...

Page 46: ...mp and the vehicle heating fan After the engine motor cooled down the heater must automatically start and stop as soon as the upper swit ching threshold is reached If the heater does not start automat...

Page 47: ...retrofits For further optimization the heaters are continuously improved Units in the field can usually be upgraded or retrofitted For this purpose respective modification kits will be available For I...

Page 48: ...aned and packaged to ensure that handling transport and storage will not damage them ATTENTION If a complete heater is sent back it must be completely drained Packaging and or shipping must ensure tha...

Page 49: ...ons and the wiring harness for visible damages replace as required 2 Heat exchanger a Check for external damage discoloration caused by over heating and leaks b Clean the heat exchanger inside remove...

Page 50: ...ount burner head Ensure proper fit and tight connection to the heat exchanger d Combined nuts M8 for burner head attachment tightening torque 7 5 1 Nm secure them e Measurements Target values and proc...

Page 51: ...memos...

Page 52: ...ial Vehicles Germany GmbH Friedrichshafener Str 7 Tel 49 0 8105 7721 0 Fax 49 0 8105 7721 889 82205 Gilching Germany www valeo thermalbus com service valeobus valeo com Valeo Thermal Commercial Vehicl...

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