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Rev. 12/2018

Id.No. DOK50036

Thermo G 300

with control unit 1588

Workshop Manual

HEATING SYSTEMS

Содержание Thermo G 300

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...memos...

Страница 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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