Spheros Thermo E 200 Instruction manual

Water Heater Workshop Manual
Thermo E 200
Thermo E 320
with Control Unit 1587
08/2011
Ident. no. 11114284B

Thermo E 200 / 320 1 Introduction
1
1 Introduction
1.1 Content and purpose 101
1.2 Workshop manual validity 101
1.3 Meaning of highlighted content 101
1.4 Additional applicable documentation 101
1.5 Installation and safety regulations 101
1.5.1 Legal installation regulations 101
1.5.2 General safety regulations 101
1.5.3 Combustion air supply 104
1.5.4 Exhaust line 104
1.5.5 Temperature sensor 104
1.6 Suggestions for Improvement and change 104
2 Technical Data
2.1 Electrical components 201
2.2 Fuel 201
3 Description of assemblies and components
3.1 Burner 302
3.1.1 Combustion air fan 302
3.1.2 Fuel pump 302
3.1.3 Nozzle block preheater 303
3.1.4 Control unit 303
3.1.5 Electronic ignition unit with ignition electrodes 304
3.1.6 Temperature sensors with water temperature sensor and integrated
overheating protection 304
3.2 Heat exchanger 304
3.3 Combustion chamber 305
3.4 Circulating pump 306
3.4.1 Aquavent 5000 (U4814) and Aquavent 5000S (U4854) circulating pumps 306
3.4.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps 307
3.5 Fuel filter 307
4 Heater functions
4.1 General heater functionality description 401
4.2 Operational heater sequence 402
4.2.1 Switching on and start 402
4.2.2 Heating operation 402
4.2.3 Switching off 403
4.3 Malfunction interlock and heater interlock 404
4.4 Malfunction interlock 404
4.4.1 Malfunctions during switching-on and start procedure 404
4.4.2 Malfunctions during heater operation 404
4.4.3 Malfunctions during purge cycle 404
4.4.4 Malfunction interlock release and error clearance 405
4.5 Heater interlock 405
4.5.1 Heater interlock release 405
4.6 Error output 405

1 Introduction Thermo E 200 / 320
2
5 Troubleshooting and error correction
5.1 General 501
5.2 General error symptoms 501
5.3 Malfunction code output via flash code 503
5.4 Error symptoms during functional tests with malfunction code output 505
5.4.1 Error symptom "No start within safety period" 505
5.4.2 Error symptom "Flame interruption" 505
5.4.3 Error symptom "Low voltage" 507
5.4.4 Error symptom "Extraneous light detected prior to ignition or
during purge cycle" 508
5.4.5 Error symptom "Flame detector defective" 509
5.4.6 Error symptoms "Temperature sensor / overheating protection
defective" and "Overheating" 509
5.5 Individual component tests 510
5.5.1 General visual inspection 510
5.5.2 Heat exchanger visual inspection 510
5.5.3 Combustion chamber visual inspection 510
5.5.4 Resistance check of the temperature sensor with
integrated overheating protection 510
5.5.5 Fan and combustion air intake line visual inspection 511
5.5.6 Burner motor inspection 511
5.5.7 Electronic ignition unit inspection 511
5.5.8 Ignition electrode inspection 512
5.5.9 Flame detector inspection 512
5.5.10 Fuel pump inspection 513
5.5.11 Solenoid valve inspection 514
5.5.12 Nozzle block preheater inspection 514
6 Wiring diagrams
6.1 General 601
7 Servicing
7.1 General 701
7.1.1 Heater servicing 701
7.2 Servicing 701
7.2.1 CO2 Measurement and setting 701
8 Burner, components and heater removal and installation
8.1 General 801
8.2 Burner removal and installation 802
8.3 Removal and installation of the temperature sensor with
integrated overheating protection 803
8.4 Hood removal and installation 803
8.5 Burner motor removal and installation 803
8.6 Electronic ignition unit and ignition electrode removal and installation 805
8.7 Control unit removal and installation 807
8.8 Fuel pump removal and installation 807
8.9 Solenoid valve removal and installation 808

Thermo E 200 / 320 1 Introduction
3
8.10 Atomizer nozzle removal and installation 808
8.11 Combustion chamber removal and installation 809
8.12 Heat exchanger removal and installation 809
8.13 Heater removal and installation 810
8.14 Start-up after burner, heater or heat exchanger installation 810
8.14.1 Bleeding of the fuel system 810
8.14.2 Bleeding of the water circuit 810
9 Modifications and retrofits
10 Packing / storage and shipping
10.1 General 1001
Appendix A 1
Periodic heater maintenance A-2

1 Introduction Thermo E 200 / 320
4

Thermo E 200 / 320 1 Introduction
101
1Introduction
1.1 Content and purpose
This workshop manual is used to support personnel
briefed and/or trained by Spheros during maintenance
and repair of water heaters Thermo E 200 and E 320.
1.2 Workshop manual validity
The workshop manual applies to heaters listed on the title
page of this document.
It may be subjected to modifications and amendments.
The respectively currently valid version is binding. This
version can be found on the Spheros homepage under
Service / Technical Documents.
1.3 Meaning of highlighted content
In this manual sections highlighted with CAUTION,
ATTENTION and NOTE have the following meaning:
CAUTION
This caption is used, if improper adherence or non-adher-
ence to instructions or procedures may cause injuries or
fatal accidents.
ATTENTION
This caption is used, if improper adherence or non-adher-
ence to instructions or procedures may cause component
damage.
NOTE
This caption is used, if a distinctive feature is pointed out.
1.4 Additional applicable documentation
We recommend the use of additional documentation.
References are provided in the workshop manual at
appropriate locations.
The following documents can be consulted during opera-
tion and maintenance of the heaters listed on the title
page:
• Operating instruction
• Installation instruction
• Technical communications
• Technical information
• Spare parts list
• Accessories catalog
1.5 Installation and safety regulations
1.5.1 Legal installation regulations
For the heaters exist type approvals according to the ECE
Regulations:
R10 (EMV) No. 03 5742 and
R122 (Heater) No. 00 0265 for Thermo E 200
No. 00 0266 for Thermo E 320
Installation is governed above all by the provisions in
Annex VII of the ECE Regulation R122.
NOTE
The provisions of these Regulations are binding
within the territory governed by ECE Regulations and
should similarly be observed in countries without
specific regulations!
Extract from ECE Regulation R122, Annex VII:
„7.1 A clearly visible tell-tale in the operator’s field of view
shall inform when the combustion heater is switched on or
off.“
NOTE
For information and rules regarding installation of
heating devices in vehicles, see the installation in-
structions.
1.5.2 General safety regulations
General accident prevention regulations must be
observed.
"General safety regulations" beyond the scope of these
regulations are listed below.
The safety regulations must be observed during opera-
tion, maintenance and repair of heaters of the Thermo E
series.
ATTENTION
Failure to follow the installation instructions and the
notes contained therein will lead to all liability being
refused by Spheros GmbH and its companies. The
same applies if repairs are carried out incorrectly or
with the use of parts other than genuine spare parts.
This will result in the invalidation of the ECE Type
Approval for the heater.
For heaters in vehicles, which are not subjected to the
European Directive, inspection and approval by the
respective inspection authority is required, if applicable
regulations are in place.

1 Introduction Thermo E 200 / 320
102
The year of first start-up must be permanently marked on
the type plate by removal of not applicable dates.
The heaters are registered and licensed for the use in
vehicles according to the respective EU Directive 2007/46
(e.g. 2001/56/EC). When using the heater for other appli-
cations not subjected to this EU Directive (e.g. ships),
respective applicable regulations must be fulfilled.
ATTENTION
The heaters are not approved for vehicles subjected
to Directive 94/55/EC (ADR, TRS) or rail applications.
The heater may only be installed in the driver's cab or
passenger compartment, if an installation box is used,
which can be tightly sealed vs. the vehicle interior. The
installation box must be sufficiently vented from the
outside.
If the temperature within the installation box exceeds the
permissible ambient temperature of the heater, the
venting opening must be increased after consultation with
Spheros.
ATTENTION
Prior to opening the heater it must be disconnected
from the vehicle electrical system.
NOTE
The heater should always be disconnected from the
vehicle electrical system prior to disconnecting the
temperature sensor plug.
If this order is reversed, the heater will automatically
be interlocked.
Prior to removing the burner from the heat exchanger,
the temperature sensor plug must be removed.
ATTENTION
A temperature of 85°C may not be exceeded in the
heater areas (max. operating temperature).
Exceeding this temperature may cause heater mal-
functions and permanent damage to the electronics.
Electrical cables must be routed avoiding isolation
damage (e.g. by pinching, heat development, bend-
ing, fraying, etc.).
CAUTION
For risk of poisoning and suffocation the heater may
not be used in closed rooms such as garages or work-
shops without exhaust fume extraction. This also
applies when pre-set times/timers are used. This also
applies for burner operation during adjustment of the
CO2content in the exhaust fumes.
The heater may not be operated close to inflammable
materials such as dry grass and leaves, cartons,
paper etc.
If the heater is operated without coolant (overheat-
ing), the outer shell of the heater may reach a temper-
ature equalling the ignition temperature of diesel fuel!
Any dripping or evaporating fuel must neither collect
nor be ignited by hot components or electrical equip-
ment. To prevent this, if necessary, a drip pan with
defined drain holes is to be installed in the area below
the interface burner housing/fuel line connectors/
heat exchanger.
At petrol stations and other fuel filling facilities the
heater must be switched off due to the explosion
hazard. An appropriate self-adhesive label is to be
affixed next to the filler neck.
For explosion risk the heater must be switched off,
when combustible fumes or dust can be generated
(e.g. in the proximity of fuel, coal, wood dust, grain
storage/silos or similar).
ATTENTION
The heaters may only be installed in horizontal posi-
tion. (see Installation instruction).
The heater should be installed as low as possible to
ensure automatic venting of heater and circulating pump.
This in particular applies for the non-self-priming circu-
lating pump.
After coolant replacement sufficient purging of the cooling
system must be ensured. Insufficient venting during
heating operation can cause malfunctions due to over-
heating.
Proper venting can be recognized by almost noise-free
operation of the circulating pump.
The opening pressure in the vehicle cooling system,
usually indicated on the cooler lid, may not exceed 2.0 bar
working overpressure (also applies to separate heating
circulations).
Hose connections must be secured with hose clamps
against slipping.
ATTENTION
The tightening torques of the used hose clamps must
be observed.

Thermo E 200 / 320 1 Introduction
103
Coolant level verification and cooling system purging
must be performed according to the vehicle manufac-
turer's specifications. The coolant in the heating circula-
tion system should contain at least 20 % of an anti-
freezing agent recommended by the vehicle manufac-
turer.The anti-freezing agent content should not exceed
60 %.
Fuel hoses may not be bent or twisted during installation.
In order to avoid sagging, they should secured using
clamps in 25 cm distances.
Fuel lines must be protected against temperature expo-
sure.
Permissible fuel line dimensions must be obtained from
the installation instruction.
It is to be ensured that the fuel is supplied to the heater
clean and without bubbles.
If a shut-off fitting is installed in the return line, an informa-
tion plate must be installed at a well visible location.
Fig. 101 Heater installation example in a bus
1 Wall heater with fan
2 Heat exchanger at the entrance
3 Heater
4 Circulation pump
5 Roof heat exchanger
6 Vehicle engine
7 Shut-off valve
8 Driver seat heater
9 Control element
Water heating circulation system - wall heater and roof channel heater
Supply
Return
Fig. 102 Information placard

1 Introduction Thermo E 200 / 320
104
1.5.3 Combustion air supply
ATTENTION
The combustion air intake opening may not point into
driving direction. It should be arranged to effectively
avoid contaminations as well as snow plastering and
splash water intake. Furthermore the combustion air
intake opening should be protected against object
penetration by installing a grid or other suitable
measures.
Combustion air intake and exhaust fume outlet must be
arranged to ensure that no air pressure difference (e.g.
suction) will occur in any vehicle operating condition.
Permissible dimensions of the optional, application-
depending combustion air intake line must be obtained
from the installation instruction.
Condensation water accumulations must be drained. If
necessary, a condensation water drain hole with a dia-
meter of 4 mm must be implemented.
1.5.4 Exhaust line
The exhaust pipe must be secured to the heater using e.g.
a clamp.
Permissible dimensions of the optional, application-
depending exhaust line are to be obtained from the instal-
lation instruction.
ATTENTION
The heater exhaust pipe port may not be partially or
completely obstructed by leafs, soil, snow, mud, etc.
(this may occur when the vehicle is driving in
reverse). The exhaust pipe port may not point into
driving direction.
Combustion air intake and exhaust fume outlet must
be arranged to ensure that no air pressure difference
(e.g. suction) will occur in any vehicle operating
condition.
If the exhaust line is installed in close proximity to
temperature-sensitive parts, then it must be insu-
lated.
If exhaust fumes exit downwards under the vehicle,
an exhaust gas deflection is absolutely necessary.
CAUTION
For permissible exhaust gas deflections for the
Thermo E 200 heater, see Installation instruction.
1.5.5 Temperature sensor
ATTENTION
The temperature sensor cable may not be mechani-
cally stressed (pull on the cable, carry the heater at
the cable etc.).
1.6 Suggestions for Improvement and
change
Please direct any complaints, improvement or modifica-
tion suggestions regarding this manual to:
[email protected]
STOP!

Thermo E 200 / 320 2 Technical Data
201
2 Technical Data
Unless limiting values are defined, the technical data
should be understood with tolerances of ±10% common
for heaters at an ambient temperature of +20°C and at
nominal voltage.
Table 201 Technical Data
2.1 Electrical components
All heater components as well as the circulating pump and
the timer are designed for 24V nominal voltage. The
temperature sensor voltage is regulated by the control
unit.
NOTE
Circulating pumps must be assigned to the heaters
according to the flow resistance in the coolant circu-
lation system.
2.2 Fuel
Only fuels listed on the type plate as well as fuels
approved by Spheros may be used. The fuel use limita-
tions in the heater listed below must be observed.
– Diesel fuel according to DIN EN 590 and DIN 51628:
The limitations of use of the standard apply, hence
winter diesel down to -20°C, Arctic diesel down
to -40°C
– Light fuel oil according to DIN 51603 (above 0°C)
– Mixture of 70 Vol-% diesel fuel (winter diesel) accord-
ing to DIN EN 590 or DIN 51628 and 30 Vol-% Bio-
diesel according to DIN EN 14214: -5 .. -10 °C without
preheating system, -15°C with nozzle block preheater
and heated fuel filter (use limitations depending on
fuel quality).
At temperatures below 0°C commercially available winter
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 the preparation of this work-
shop manual.
ATTENTION
The listed temperature ranges, hence minimum per-
missible temperatures strongly depend on the re-
spective fuel quality. In case of bad-quality fuel the
use limitations may deviate, e.g. in case of too high
water content.
When fuels are used, their respective limitations of
use must be observed and appropriate measures
(nozzle block preheater, electrically heated filter)
must be applied as needed.
In case fuel is extracted from the vehicle tank, the
vehicle manufacturer's mixing regulations shall
apply.
Heater Thermo E 200 Thermo E 320
Design High-pressure atomizer
Heat flow rate kW 20 32
Fuel Diesel / light fuel oil
Fuel consumption kg/h /l/h 2.0 / 2.7 3.2 / 4.1
Nominal voltage V (DC) 24
Operating voltage range V (DC) 20.5...30.0
Electrical power consumption at 24 V * W 55 100
Combustion air intake temperature °C -40...+ 85
Ambient temperature during operation °C -40...+ 85
Storage temperature °C -40...+ 90
Operating overpressure bar max. 2.0
Heat exchanger filling volume l 1.8
Minimum water flow ± …l/h 2400 ± 200 2700 ± 200
Minimum coolant circulation volume l min. 25.0
CO2in exhaust at nominal voltage Vol % 9.5 ± 0.5 10.0 ± 0.5
Heater dimensions
(tolerance ±3 mm) mm Length 593 / Width 247 / Height 224
Weight kg 16.5 17.3
* without circulating pump
Max. continuous current of the circulating pump 8.75 A, max. peak current for 0.5 s duration = 90 A - We recommend the use of Spheros
circulation pumps for highest efficiency and reliability! In order to reduce starting currents the circulating pump can be synchronized by the
control unit for a short time period during activation.
Confirm compatibility in case pumps provided by different manufacturers are used!

2 Technical Data Thermo E 200 / 320
202

Thermo E 200 / 320 3 Description of assemblies and components
301
3 Description of assemblies and
components
The water heaters Spheros Thermo E 200 and E 320,
are used in conjunction with the vehicle heating system
– to heat the passenger compartment
– to defrost the windows as well as
– to preheat water-cooled vehicle engines.
The water heater operates independently from the vehicle
engine and is connected to the cooling system, the fuel
system and the electrical system of the vehicle. It is bolted
to the vehicle chassis or is secured using an additional
cross beam.
Heat is generated by combustion of liquid fuels. The heat
it transferred to a coolant circulation system via the
heater's heat exchanger. Intermittent operation adjusts
the heater to changing heat demand.
The control unit controls heater activation and deactiva-
tion based on the temperature sensor signals.
The heaters of the Thermo E series mainly consist of the
following main components:
– Burner
– Combustion chamber
– Heat exchanger
A circulating pump, preferably controlled by the control
unit, is externally installed in the system, or for compact
devices directly on the heater. An external control of the
circulating pump (UPFA) is for the Thermo E not provided.
.
1
2
3
5
6
7
8
9
10
11
4
1 Burner
2 Coolant, intake
3 Sensor plug
4 Temperature sensor
with integrated over-
heating protection
5 Coolant, outlet
12
6 Heat exchanger
7 Exhaust outlet
8 Fuel, return
9 Combustion air, intake
10 Fuel, flow
11 Splashguard
(screen alternative)
12 Screen
13 Hot air elbow
(incl. adapter)
(screen alternative)
13

3 Description of assemblies and components Thermo E 200 / 320
302
3.1 Burner
The burner consists of components
• Burner motor
• Combustion air fan
• Fuel pump with solenoid valve
• Atomizer nozzle
• Electronic ignition unit with ignition electrode
• Control unit with flame detector
• Disc with inspection glass
• Nozzle block preheater (optional)
3.1.1 Combustion air fan
The combustion air fan transports the air required for
combustion from the combustion air intake to the combus-
tion chamber.
The combustion air fan consists of burner motor and fan.
Air is drawn in through the air intake opening in the hood.
The air intake opening is equipped with a splashguard, a
protective screen and a hot air elbow.
Two different motors are assigned to the different heating
capacity classes of the Thermo E series. This assignment
is clearly beyond the material number. The motors must
not be interchanged.
NOTE
The positioning of the engine to the housing is safely
defined by a pin and a hole (see Fig. 803).
3.1.2 Fuel pump
The fuel pump is responsible for fuel supply.
The pump is driven by the burner motor via a coupling.
Fuel is compressed in the fuel pump to approx. 10 bar and
atomized via the atomizer nozzle.
The solenoid valve integrated into the fuel pump opens
and closes the fuel supply to the atomizer nozzle.
Identical fuel pumps are installed in heaters of both
heating capacity classes.
The fuel pump is designed for dual-line operation (fuel
supply and return line).
ATTENTION
If the heater is operated with
– a long fuel supply line (> 15m)
– check valves in the fuel supply and return line
(> 0,07 bar)
– a fuel filter in the fuel supply line
the fuel supply line and fuel filter are to be filled prior
to first heater start-up (see 8.14.1).
Burner motor
Fan
Shaft
circlip
Coupling
Solenoid valve
Fuel pump
Screen
O-ring

Thermo E 200 / 320 3 Description of assemblies and components
303
3.1.3 Nozzle block preheater
In case of very low temperatures fuel may exhibit severely
modified viscosity. Due to insufficient fuel atomization
functional heater malfunctions may occur.
Depending on the fuel used, these temperatures vary.
When used in cold regions or if fuels different from diesel
fuel are used, we recommend the use of a nozzle block
preheater.
The nozzle block preheater consists of a heating element
with an integrated temperature sensor.
At a temperature of < 5°C the heating element heats the
nozzle holder and thus, fuel and atomizer nozzle. Fuel
viscosity is reduced and atomization improved.
The heating duration depends on the intake air tempera-
ture and on the reflected by the burner heat.
Above 8°C the thermostat turns the preheater off.
The use of the nozzle block preheater is optional. It is
possible to retrofit this capability without modifications to
the control unit.
3.1.4 Control unit
The control unit 1587 ensures the operating sequence
and burner operation monitoring.
The flame detector is integrated into the control unit.
3.1.4.1 Flame detector
The flame detector monitors the flame conditions during
heater operation.
The fame detector is a photo transistor, which changes its
resistance as a function of flame luminous intensity and
thus, the voltage applied.
Nozzle block preheater
Thermostat
Heating element
Control unit 1587
Flame detector

3 Description of assemblies and components Thermo E 200 / 320
304
3.1.5 Electronic ignition unit with ignition
electrodes
The electronic ignition unit induces the high voltage
required for ignition of the fuel-air mixture. Ignition is trig-
gered by a high voltage spark, which is initiated on the
ignition electrode.
3.1.6 Temperature sensors with water
temperature sensor and integrated
overheating protection
The water temperature sensor captures the coolant
temperature at the heat exchanger outlet as electrical
resistance.
This signal is transmitted to the control unit, where it is
processed.
The overheating 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 as
electrical resistance and transmitted to the control unit.
Overheating protection prevents inadmissibly high heater
operating temperatures.
At a temperature greater than 125°C heater deactivation
and interlocking is initiated.
It is not necessary to manually reset the overheating
protection.
3.2 Heat exchanger
The heat exchanger transfers the heat generated by
combustion to the coolant circulation system.
Flame detector Window
Electronic ignition unit Disc
Electronic ignition unit
Ignition electrode
Temperature
sensor
Coolant inlet
Coolant outlet
Exhaust outlet

Thermo E 200 / 320 3 Description of assemblies and components
305
3.3 Combustion chamber
The combustion chamber is used for generation and
combustion of the fuel air mixture. The generated exhaust
gas heats the coolant flowing through the heat exchanger.
Depending on heating capacity class, different combus-
tion chambers are used.
They have different swirler (E 200 sheet metal, E 320 cast
iron). The combustion chamber of the Thermo E 320 is
additionally equipped with a flame stabilization pipe.
The combustion chambers have an identification stamp
according to the associated heater (E 200 or E 320).
CAUTION
Heater operation with a combustion chamber of a
other heating capacity class is not permitted.
NOTE
The combustion chamber should be inserted into the
heat exchanger in such a way that its welding seam is
positioned between 2 and 10 o clock (not upwards!).
A position change during maintenance is permissible
and affects the expected service life of the combus-
tion chamber positively (see graphic below).
NOTE
It should be ensured that none of the 4 cut-outs of the
combustion chamber head points vertically down-
wards (see graphic below).
Dripping from nozzle fuel is so collected in a reservoir
between disc and burner head and will be burned at
the next burner operation instead to soil the heater.
.
Combustion chamber
Identification
of the heating
capacity class
Welding seam
Swirler
32 KW
20 KW
permissible
not permissible
Position of welding seam
Cut-out positions
on the combustion
chamber head
in installed position

3 Description of assemblies and components Thermo E 200 / 320
306
3.4 Circulating pump
The externally arranged circulating pump ensures coolant
transport within the vehicle and/or heater circulation
system.
Depending on the application, the circulating pump is
switched on via the control unit or directly via the vehicle
electrical system and operated during the entire heater
operation duration.
Heaters can be operated with Aquavent 5000 (U4814),
Aquavent 5000S (U4854), Aquavent 6000C (U4855) or
Aquavent 6000SC (U4856) circulating pumps.
ATTENTION
The circuit breaker of the circulating pump may never be
pulled, while the pump is running, and may not be
replaced, when the pump is switched on.
3.4.1 Aquavent 5000 (U4814) and Aquavent
5000S (U4854) circulating pumps
The Aquavent 5000 (U4814) and 5000S (U4854) circu-
lating pumps are equipped with a brush motor.
NOTE
Aquavent 5000 (U4814) with floating-ring type shaft
seal
Aquavent 5000S (U4854) with magnetic drive (no seal)
ATTENTION
The circulating pump motor is not equipped with an
internal inverse-polarity protection.
Circulating pump Flow rate Nominal voltage Operating voltage range Nominal power consumption Weight
l/h V = V = W kg
U 4814
Aquavent
5000
5000
(against 0.2 bar) 24 20…28 104 2.1
U 4854
Aquavent
5000S
5000
(against 0.2 bar) 24 20…28 104 2.2
U 4855
Aquavent
6000C
6000
(against 0.4 bar) 24 20…28 210 2.4
U 4856
Aquavent
6000SC
6000
(against 0.4 bar) 24 20…28 210 2.5
(U4814)
(U4854)
(U4855)
(U4856)
Aquavent 5000
Aquavent 5000S
Aquavent 6000C
Aquavent 6000SC

Thermo E 200 / 320 3 Description of assemblies and components
307
3.4.2 Aquavent 6000C (U4855) and Aquavent
6000SC (U4856) circulating pumps
The Aquavent 6000C (U4855) and Aquavent 6000SC
(U4856) circulating pumps are equipped with a brushless
motor.
HINWEIS
The Aquavent 6000C (U4855) has a floating-ring type
shaft seal.
The Aquavent 6000SC (U4856) is equipped wit a
magnetic coupling (no seal)
Soft start
The circulating pump motor starts slowly and gently. Max.
rotational speed is only reached after approx. 5 seconds.
Protection against dry running
Protection against dry running is integrated into the circu-
lating pump motor.
If the circulating pump motor consumes within 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 reac-
tivation, the operation can be continued.
Blocking protection
If the pump wheel is blocked, the motor will be switched
off via the error mode directly prior to standstill of the
pump wheel.
Overload protection
Overload protection is activated after the soft start is
completed. The current consumption will be limited.
In case of hydraulic overpressuring of the circulating
pump, the circulating pump motor will not be damaged.
Error mode
In case of malfunctions the circulating pump motor is
switched off via the error mode. After approx. 5 seconds
the error mode switches the circulating pump motor into
energy-saving sleep mode.
Sleep mode
In sleep mode internal electronics consumers of the circu-
lating pump motor are switched off.
Reactivation of the circulating pump motor
It is possible to reactivate the circulating pump motor from
sleep mode. For this purpose the power supply is discon-
nected for > 2 min. After the power supply is reconnected,
the circulating pump motor restarts in soft-start mode.
Inverse-polarity protection
ATTENTION
The circulating pump motor is not equipped with an
internal inverse-polarity protection.
3.5 Fuel filter
A heatable fuel filter is available as an option.
The integrated filter heating is switched on below of a fuel
temperature of 0.5°C and off at a temperature of 5.5°C.
When the heater is operated at temperatures below of
-30°C the usage of this heatable fuel filter is absolutely
necessary.

3 Description of assemblies and components Thermo E 200 / 320
308