Valeo Thermo H 160 Workshop Manual Download | Manualshive

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Thermo H plus

Content

Heater servicing

HV heater servicing

D heater servicing

Components and heater removal and installation

HV control head

Temperature guards (temperature limiter, control thermostat) removal/installation.

Hood removal/installation

Housing removal/installation (incl. cable connections)

Small distribution board removal/installation

Heating cartrides/screw plugs removal/installation

HV DC wiring harness removal/installation

HV AC wiring harness removal/installation

LV DC control wiring harness removal/installation

Diesel burner head

Burner removal/installation

Removal/installation of the temperature sensor with integrated overheating protection

Hood removal/installation

Combustion air fan removal/installation

Heat exchanger removal/installation

Heater removal/installation

Start-up after burner or heater installation

Bleeding the fuel system

Bleeding of the coolant circuit

Modifications and retrofits

10 Packing/storage/shipping

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Summary of Contents for Thermo H 160

Page 1: ...Rev 02 2021 Id No DOK50065 001 Thermo H 160 Thermo H 230 Thermo H 300 Thermo H 350 Workshop Manual HEATING SYSTEMS...

Page 2: ...burner head 304 4 Functions of the heater 4 1 General functional description of the heater 401 4 2 HV heater 401 4 2 1 Switching on 401 4 2 2 Heating operation 401 4 2 3 Switching off 401 4 3 D heater...

Page 3: ...removal installation 804 8 2 6 HV DC wiring harness removal installation 806 8 2 7 HV AC wiring harness removal installation 806 8 2 8 LV DC control wiring harness removal installation 807 8 3 Diesel...

Page 4: ...procedures are carried out incorrectly or entirely disregarded ATTENTION This caption points to actions which may cause ma terial damage NOTE This caption is used to draw attention to an important fe...

Page 5: ...acc to DIN VDE 0105 100 and this state must be ensured for the duration of the work The following safety precautions must be observed switch off the power supply to the heater ensure it cannot be swi...

Page 6: ...eat exchanger l 7 Minimum water flow l h 1500 Minimum capacity of the water system l 35 Antifreeze ratio in the cooling system 30 up to 60 Depending on the heat flow taken by the vehicle a minimum bur...

Page 7: ...ENTION While using the fuels their operating limits must be considered and if necessary suitable measures nozzle preheating electrical heated filter should be applied If fuel is supplied from the vehi...

Page 8: ...addi tional cross beam The hybrid function of the heater includes the generation of heat a by burning liquid fuel and b by electric current The diesel burner head see Fig 301 is responsible for heat...

Page 9: ...xchanger 8 3 1 1 Small distribution board The small distribution board 3 Fig 302 includes the components required for the electrical part of the heater which are mounted on a 35mm top hat rail The top...

Page 10: ...e front has receiving openings with threads for the heating cartridges At the rear the Diesel burner head is fixed 3 2 1 Combustion chamber The combustion chamber 8 Fig 303 is located inside the heat...

Page 11: ...diesel burner head is used to generate the diesel air mixture which is burned in the combustion chamber Components for the control of the combustion process are integrated Further information can be f...

Page 12: ...rotection see 3 2 They constitute the control loop of the HV control head If all of the following three conditions are met 1 24V DC is applied to the external control input 2 The control thermostat ha...

Page 13: ...ignition spark The flame is monitored by a flame detector integrated into the control device Depending on the equipment the heater is switched on and off using a digital timer switch or climate contr...

Page 14: ...e The burner motor does not run during the entire preheating time It starts at the latest 12 seconds before the expiry of the determined preheating time with the initial cycle The time of the initial...

Page 15: ...smoke formation A minimum burner combustion period of 120 second is targeted For ambient and operating conditions this target is not always achieved In order to achieve the minimum combustion period t...

Page 16: ...id valve No start No flame detection within 15 seconds after opening the solenoid valve Temperature sensor delivers unacceptable tempera ture values Burner motor speed signal faulty Voltage falls shor...

Page 17: ...or interruption of electrical compo nents Solenoid valve Flameguard Overheating protection the temperature sensor overheat protection water temperature sensor is unplugged Flame is not expired within...

Page 18: ...the HV control wiring harness 24V defective or contact not established Plug of the temperature sensors not connected Temperature sensors defective HV small distribution board defective HVIL Interloop...

Page 19: ...t does not transmit a HVIL signal HVIL contact is not established Hood not correctly mounted HV cable not connected HV control wiring harness 24V not connected or cable defective Heating power too low...

Page 20: ...tallation given in the Thermo H Installation and operating instructi on The document is available for download at www va leo thermalbus com eu_en Service Downloads Heating systems Thermo H plus With t...

Page 21: ...602 Thermo H plus 6 Wiring diagrams HV heater Fig 601 Housing removal for devices Thermo H plus DC DC 7 0 7 0 kW heater ident no acc to model plate 11143458A and 11143457A...

Page 22: ...603 Thermo H plus 6 Wiring diagrams HV heater Fig 602 Housing removal for devices Thermo H plus AC 20 0 kW heater ident no acc to model plate 11139571A and 11143481A...

Page 23: ...s 6 Wiring diagrams HV heater Fig 603 Housing removal for devices Thermo H plus DC 20 0 kW heater ident no acc to model plate 11139574A and 11142595A HV Cable Id no Heater Id no 11124288 11139574A 111...

Page 24: ...605 Thermo H plus 6 Wiring diagrams HV heater Fig 604 Housing removal for devices Thermo H plus AC 20 0 kW heater ident no acc to model plate 11142671A...

Page 25: ...606 Thermo H plus 6 Wiring diagrams HV heater Fig 605 Housing removal for devices Thermo H plus AC 7 0 kW heater ident no acc to model plate 11142686A...

Page 26: ...AC 20 0 kW heater ident no acc to model plate 11139571A 11143481A and 11142671A 1 2 3 4 5 6 7 8 9 HLP DC Connecting HLP Anschluss HLP HLP orange cable oranges Kabel blue cable blaues Kabel 1 DC2 DC3 4...

Page 27: ...for devices Thermo H plus AC 7 0 kW heater ident no acc to model plate 11142686A 1 2 3 4 5 6 7 8 9 HLP DC Connecting HLP Anschluss HLP HLP orange cable oranges Kabel blue cable blaues Kabel 1 DC16 DC...

Page 28: ...in front of the heater Note for F2 The max possible for the design value is shown The fuse is to be adapt under circumstances acc to the smaller cable cross section of the connected circulating pump...

Page 29: ...ax 25A min 7 5A because of DVW Terminal 30 permanent plus Terminal 31 ground Overheat protection Coolant temperature sensor Terminal 61 D SG 1589 BM UP 1 U V W 1 2 4 3 4 1 2 2 1 2 3 1 1 5 2 2 6 3 3 8...

Page 30: ...ZFG Electronic ignition unit in the heater MV Solenoid valve in the heater BM Combustion air motor in the heater Legend for wiring diagrams Connector Description C To vehicle Power C1 Terminal 30 UP D...

Page 31: ...unning while the heater is switched on for tests inspections 7 2 HV heater servicing The necessary service work can be found in the main tenance plan for the Thermo AC DC heater series This can be dow...

Page 32: ...hile the heater is installed in the vehicle assuming that sufficient space is available and no components will be damaged NOTE If components are disassembled to a degree not covered in this workshop m...

Page 33: ...cap 4 of the temperature limiter 2 back until it can be put in its installation position 4 Position temperature limiter 2 in the reception neck 5 and push in the retaining clip 3 ATTENTION The retaini...

Page 34: ...errated washer 10 and vehicle grounding cable lug 7 Remove nuts 16 and washers 15 NOTE During the next step pay attention that the cables are not jammed or are still connected Danger of damage 8 Remov...

Page 35: ...ctions to be established refer to wiring diagrams in Chapter 6 depending on the heater version Compare the heater ident number under the wiring diagram with that on the model plate of your heater 5 In...

Page 36: ...805 HV Control head Removal and Installation of components 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 8 1 Nm 1 5 0 3 Nm 16 1 Nm 15 1 Nm 5 1 Nm 2 0 5 Nm 10 1 Nm 10 1 Nm 8 1 Nm 27 28 20 21 23 22 24 15...

Page 37: ...nnected Danger of damage 8 Loosen cable gland 17 Fig 805 and screw it with the appropriate cable harness from out the housing 12 Installation NOTE During the next step pay attention that the cables ar...

Page 38: ...all supply cables from vehicle electrical system 3 Remove hood see 8 2 2 4 Remove housing see 8 2 3 5 If necessary disconnect connectors from the HVIL socket Fig 808 6 Remove ties wich bundle disconne...

Page 39: ...e heater and secure it for duration of the work Observe 1 6 3 2 If necessary disconnect the combustion air intake line from the heater 3 If required disconnect heater wiring harness plug from control...

Page 40: ...tection Risk of injuries if coolant temperature is increased Removal 1 Establish voltage free state of the heater and secure it for duration of the work Observe 1 6 3 2 Disconnect the temperature sens...

Page 41: ...between 2 and 10 o clock not upwards Fig 811 A position change during maintenance is permissible and affects the expected service life of the combustion chamber positively Position the cut outs in the...

Page 42: ...gs 21 refer to 8 2 5 3 Screw the plug screw 7 Fig 809 in and tighten it 4 Install the screw in socket 8 Fig 801 and tighten it 5 Install the stud bolts 18 using new gasket rings 13 and tighten them 6...

Page 43: ...Place the heater into the installation position and secure with 4 nuts and 4 washers via the vibration damper 4 Fig 811 to the vehicle Tighten nuts as required 3 Reconnect the fuel lines for fuel sup...

Page 44: ...acturer specification Risk of scalds if coolant temperature is increased The Aquavent 5000 U4814 and Aquavent 6000S U4855 circulating pumps may only be switched on for bleeding after dry operation can...

Page 45: ...retrofits 9 Modifications and retrofits 9 1 General For further optimization the heaters are continuously improved Units in the field can usually be upgraded or retrofitted For this purpose respectiv...

Page 46: ...sure that handling transport and storage will not damage them ATTENTION If a complete heater is sent back it must be comple tely drained While packaging and or shipping it must be ensured that no fuel...

Page 47: ...memos...

Page 48: ...rcial Vehicles Germany GmbH Friedrichshafener Str 7 82205 Gilching Germany Tel 49 8105 7721 0 Fax 49 8105 7721 889 www valeo thermalbus com service valeobus valeo com Valeo Thermal Commercial Vehicles...

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