Spheros Thermo S 230 Installation guide

Water Heaters
Water Pumps
Revision 05/2016
Doc. P/N: 100 000 32B
Warranty Manual
Thermo 230
Thermo 300
Thermo 350
DBW 230
DBW 300
DBW 350
GBW 300
LGW 300
NGW 300
U4814 Aquavent 5000
U4855 Aquavent 6000C
U4856 Aquavent 6000SC

List of Contents
Spheros North America Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purpose of this Warranty Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items that ARE COVERED under this warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items that ARE NOT COVERED under this warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Owner Responsibilities . . .. . . . .. . . .. . .. . . .. . . .. . . .. . . . . .. . .. . . .. . . .. . . .. . . .. . . .. . . 4
Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PerformingWarranty Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Return Material Authorization (RMA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Claim Reimbursement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flat Rate Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Repair Procedure and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flat RateLabor Guide - Thermo Series / DBW Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Submitting aWarranty Claim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refused Claims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heater Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Spheros Warranty Claim Form………….. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . 9
www.spheros.us 2 Spheros North America, Inc.

SPHEROS NORTH AMERICA
LIMITED NON-TRANSFERABLE WARRANTY
Spheros North America, Inc. (hereinafter referred to as Spheros) warrants their products against defects in material and
workmanship for twenty four
(24) months effective on the date of vehicle registration for Original equipment installation
(OE). This warranty period may not exceed twenty seven (27) months from the original date of sale by Spheros. This
warranty period may
be superseded byacontractual agreement.
Replacement parts are covered for six (6) months or the remainder of the original warranty period, whichever is longer.
Replacement heaters are considered a “Replacement Part”.
The intent of the Spheros warranty is to protect the original end-user of Spheros products from such defects and provide
free repair and replacement of defective parts in the manner provided herein. During the warranty period the exclusive
remedy will be for Spheros, at their discretion, to repair or replace those parts which are demonstrated to be defective in
material or workmanship.
Information concerning all warranties may be obtained by calling [phone] ext 103 or 112. Toll free (888) 960-
4849.
Owner’s Responsibilities:
Service heater at the start of each season. While such maintenance may be performed by any company, improper or
incorrectly performed maintenance or repair
voids this warranty. Service parts including fuel nozzles, filters and overheat
fuses are not covered under warranty.
Warranty Limitations:
Spherosspecifically excludes and limits from warranty the following:
–Normal wear of
service parts:(fuel nozzles, filters and overheat fuses are not covered).
–
Removal and replacement of heater.
–
Damage to product in transit. All claims must be filed with carrier.
–Improper installation, which isnot in
accordance with valid,supplied installation instructions or approved OEM
applications.
–Deterioration dueto normal wear,
corrosion, improper storage or operating conditions.
–
Use of non-genuine parts or repair byunauthorized personnel.
–
Economic loss for expenses related to travel, vehicle disability, personal injury or other incidental or consequential
damages arising from any breach of this expressed warranty.
THIS WARRANTY SHALL NOT APPLY IF PRODUCT: (a) IS MODIFIED OR TAMPERED WITH; (b) IS DAMAGED BY NEGLIGENCE,
ACCIDENT, UNREASONABLE USE, OR BY OTHER CAUSES UNRELATED TO DEFECTIVE MATERIALS OR WORKMANSHIP; OR (c)
HAS HAD THE SERIAL NUMBER ALTERED, DEFACED OR REMOVED.
THE WARRANTY DOES NOT APPLY TO LOSS OF THE VEHICLE OR EQUIPMENT, LOSS OF TIMES, TOWING, TELEPHONE, TRAVEL
LODGING, LOSS OF REVENUES, OR COST OF A REPLACEMENT VEHICLE.
THIS WARRANTY IS NON-TRANSFERABLE.
ANY APPLICABLE IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED ABOVE. IN NO EVENT SHALL
SPHEROS BE LIABLE FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES RESULTING FROM THE BREACH OF ANY IMPLIED OR
EXPRESS WARRANTIES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LAST OR
EXCLUSION OF CONSEQUENTIAL OR INCIDENTAL DAMAGES, SOTHEABOVE LIMITATIONS MAY NOT APPLY TO YOU.
This warranty gives you specific legal rights. You may also have other rights which varyfrom state to state or province to
province. This warranty isonly valid in the United States andCanada.
Spheros North America, Inc. reserves the right to change this documentation anytime without notification.
S p h e r o s N o r t h America, Inc. 3 www . s p h e r o s . c o m

www.spheros.us Spheros North America, Inc.
Purpose of this Warranty Manual
The purpose of this manual is to provide the customer with specific “how to proceed” instructions for product defects
within the products limited warranty
period. This manual provides the policies and procedures to follow for a product
warranty claim andreimbursement.
Itemsthat ARE COVERED under this warranty
Spheros covers the following items and procedures:
•
Testing & Diagnosis asdescribed in the flat rate labor time guide on page 8.
•
External items and accessories suppliedby Spheros including:
Timers, Electrical Harness,Thermostats, Temperature Limiters, Relays, Control Switches, FuelLineConnection Fittings and
Fasteners, Ignition Coils (DBW and Thermo),Coolant Pumps.
•Internal items including:
Burner Head, Intermediate Housing, Air Adjustment Ring,Drive Motor, Motor Support Plate, FanRotor, Coupling (Clutch),
Fuel Pump, Fuel Solenoid, Fuel Pressure Control Valve,Safety Thermostat, Nozzle Preheating Assembly,Electronic Ignition
Unit, Ignition Electrodes,Electronic Control Unit, Electrical Harnesses,Strain Reliefs, Flame Detection Photocell, Photo
Disk,Combustion Chamber, Heat Exchanger, Shaftor Bearing Assembly (DBW Series), miscellaneous hardware where
required for the
replacement of parts covered under warranty.
Itemsthat ARE NOT COVERED under this warranty
• Heater,replacement parts and accessories nolonger within the warranty period.
•Normal wear of
service parts.
•
Removal and replacement of heater.
•
Damage to product in transit. All claims must be filed with carrier.
•Improper installation, not in
accordance with, suppliedinstallation instructions or approved OEM applications.
•Deterioration dueto normal wear,
corrosion, abuse, damage, accident, improper storage or operation.
•Modification of product byalteration,
use of non-genuine parts or repaired byunauthorized service center or personnel.
•
Diagnosis time for heater inter-lock / lock-out modereset.
•
Filters, Fuel Nozzles, Fuel Lines, Fuel line couplers, Clamps (Fuel / Coolant), Coolant hoses, Illumination Bulbs, Overheat
Fuses, Intake and Exhaust tubing, Coolant (Including additives)
•
Opened or altered electricalparts (not sealed in original box).
•
Damage to electrical parts caused bywrong voltageor reversed polarity.
•
Damage caused byimproper fuel. Please reference the product related installation manual for properfuel usage.
OwnerResponsibilities
The intent of the Spheros warranty is to protect the original product owner from product defectsand provide free repairand
replacement of defectiveparts in the manner provided herein. During the warranty period the exclusiveremedy will be for
Spheros, at their discretion,to repair or replace thoseparts which are demonstrated to be defectivein material or
workmanship.
1. Service heater at the start of each season. While such maintenance may be performed byany company, improper or
incorrectlyperformed maintenanceorrepair
voids the warranty. Parts including fuel nozzles, filters andoverheat fuses
are not covered under warranty.
2. A product serial number isrequired for all warranty claims for heaters, pumps andaccessories.
This warranty gives the product owner specific legal rights andmay also have other rights which vary by State or Province.
Warranty Registration
The Spheros North America, Inc. warranty is effective on the date of vehicle registration for Original equipment installation
(OE).This warranty periodmaynot exceed twenty seven (27) months from the original date of sale bySpheros.
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Spheros North America, Inc.
PerformingWarranty Work
While such maintenance may be performed byany company, improper or incorrectly performed maintenance or repair
voids the warranty. The facility must provide their technicians with all the necessary tools andtraining required to properly
diagnose and repair equipment functions.
Technical publications such as technical manuals, parts manuals, and service bulletins areavailable viathe Spheros web site
(http://www.spheros.us). Informational newsletters
and important product update notifications areperiodically sent to our
network of
Spheros customers to providethem with the latest information and changes required for quality servicing of
Spherosproducts. Product specific tools andtesting equipment are available andrequired for most equipment warranty
claims . Forquestions, contact Spheros North America, Inc. for further assistance.[phone] ext. 265 or 223.
Once the product andinstallation has been examined, the cause of malfunction determined and the defective part
replaced, apost-repair operational test must be performed to ensure properfunctionality. In the case of the Thermo series
heaters, anyremaining error codes held in the electroniccontrol unit memoryshould be cleared using the diagnostics link
and SpherosThermo Test software installed on acomputer.
Any part replaced under warranty must be returned to Spheros North America, Inc. to be tested to confirm that it is
defectiveandfor
purposes of ongoing product improvement.
Return Material Authorization (RMA)
A Return Material Authorization (RMA) isrequired from Spheros prior toreturning anyproduct. Spheros will provide the
customerwith an RMA number and shipping instructions. Depending on the reason for return, there may be a 20% re-
stocking fee. TheRMA number must be prominently displayed on the shipping container and referenced on all
correspondence pertaining to the returned product. Torequest a RMA number, call Spheros at: [phone] ext. 265 or
223.Please have the following information available prior tocalling for anRMA:
1. Reference P.O no., VIN no. , part no., date of registration, the serial number from the product for which the
warranty claim pertains to.
2. The reason of RMA request.
IMPORTANT NOTICE: When any product is returned without an RMA,there will be a $50.00 administration fee charge
applied to the customeraccount. Also, this further delay processing of the claim and reject cost of shipping.
Claim Reimbursement
Labor Times - Recovery is based onthe applicable labor time guide starting on page 7.
Labor Rate - Recovery is based onthe standardcustomerrate, which isapublished / verifiable rate.
Parts - Recovery is based oncomponent cost plus markup for shipping andhandling.
Flat Rate Labor Guide
Maximum allowable labor isacombination of testing and diagnosis and oneof the following operations:
1. ExteriorComponentRepair.
2.Easily Accessible ComponentRepair.
3. Complete Dismantling Repair andReassemble.
Repair Procedure andPerformance
1. A check of connectors, fuse, wiring, fuel supply, and battery integrity should be performed prior to conducting any
diagnostic test procedure.
2. Usingthe appropriate service andrepair manual, the technician should proceed to test and diagnose to isolate
defective
components on the heater model in question.
3. Proceed with component removaland installation.
4. Perform post-repair operational testing.
Replacement and removal of equipment, as a means of repair, isnot covered.

www.spheros.us Spheros North America, Inc.
Testing andDiagnosis
A functional test isrequired to isolate defectivecomponents.
The Spheros Thermo Test Kit for PC’s running Windows operating system can be obtained to perform diagnosticsand
functional tests onall SpherosThermo seriesheaters except the DBW series (160,230,300, 350 and
470).
A separate tester can be obtained for DBW series heaters.
SpherosThermo Test and Adapter
NOTE:
The allowabletime for testing and diagnosis includes post repairoperational testing. Claims with labor times
exceeding the times listed in this manual without approval, in writing, will beadjusted accordingly.
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Spheros North America, Inc.
Flat Rate Labor Guide - Thermo Series / DBW Series
Part Description Operation Time Allowance(Minutes)
A. Testing & Diagnosis 30
B. ExteriorComponentRepair
Timers Replace
30
Electrical Harnesses Replace 30
Thermostats/Temperature Sensors Replace
15 DBW / 30Thermo
Temperature Limiters Replace 1 5
Relays Replace
1 5
Control Switches Replace
30
Fuel LineConnection Fittings Replace 1 5
Ignition
Coils (DBW) Replace 30
Coolant Pumps Replace 30
C.Easily Assessable ComponentRepair
Fan Rotor Replace 1 5
DriveMotor
Replace 1 5
Coupling(Clutch) Replace
1 5
Air Adjustment Ring Replace
1 5
Fuel Pump Replace 1 5
Fuel Solenoid Replace 1 5
Fuel Pressure Control Valve Replace 30
Safety Thermostat Replace 1 5
NozzlePreheating Assembly Replace 1 5
Ignition Electrodes Replace
1 5
Electronic Ignition Unit Replace 1 5
Internal
Electrical Harnesses Replace 1 5
Flame Detection Photocell/Photo
Disc Replace
1 5
Electronic ControlUnit Replace 30
Combustion Chamber Replace 1 5
Burner Head Replace 1 5
D.Complete Dismantling Repair and Reassemble
Intermediate Housings Replace
60
HeatExchangers Replace
60
Shaftor
Bearing Assembles (DBW) Replace 60
NOTE:
The allowabletime for testing and diagnosis includes post repairoperational testing. Claims with labor times
exceeding the times listed in this manual without approval, in writing, will beadjusted accordingl

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Spheros North America, Inc
While warranty isprovided to the “original end-user”, it is to beadministered and serviced in accordance with the
Spheros warranty policy or contractual agreement between Spheros anda second party.
NOTE: If the connection to the heater using the diagnostics tool is not possible due to afailedcontrolunit, thismust be noted
onthe warranty claim form.
1. Warranty claims must be submitted within 6 months from the date of service.
2.Submitted claims containing incomplete shaded fields will be refused. Please ensure that all fault codes discovered
during the
diagnosis process as well as the associated test procedures performed are noted in the problem description
field.
3.Approved claims will be reimbursedthrough ac redit memo or customer preferred payment.
4. Spheros will processapproved claims within one (1) month of receipt.
5.Defective parts must be identified with the Spheros issued RMA number and returned to Spheros before a warranty
claim can be approved for reimbursement.
IMPORTANT NOTICE: Spheros must receive the warranty claim within 6months of the servicerepair. Claims submitted
more than 6 months out will berefused.
Refused Claims
In the event that aclaim is refused or adjusted, Warranty claim form will be updated and a copy will be issued to the
customer outlining the
reason for adjustment or refusal. Replacement and removalof equipment, as a means of repair, is
not covered.
Note:Maintenance components including: fuel nozzles, filters and overheat fuses are not covered. For afull list of non-
covered components refer to page 4.
Made in G e rmany
HEATER MODEL
VOLTAGE / EL. POWER
HEAT FLOW RATE
FUEL
MAX.
OPERATING PRESSURE
THERMO 230
24 / 65 W
23,3 kW / 80345 BTU/h
DIESEL NO.1/NO.2 AND
ARCTIC
2 BAR / 29 PSI
Heater Model
Identification Plate
Location
Artikel Nr. 12345A Ausf. 036 Fabr. Nr. XXXXXXXX
Product S e rial Number
Inbetriebnahmejahr 09 10 11

Spheros Warranty Claim Form
Spheros North America, Inc.
9
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WARRANTY CLAIM FORM
Please return defective part/s identified with an RMA no. to Spheros North America, Inc.
Warranty isaccepted according to the Warranty Policy Terms and Condition. Fill up shaded field.
Incomplete form will notbe processed. Credit memo will be issued once warranty isaccepted.
Send completed form through e-mail: [e-mail] or fax at [phone].
Note: The product serial no. will be the claim no. for this warranty claim.
For hatch claims, Spheros North America, Inc. will provide the claim no.
Product Category: ☐Heater ☐A/C ☐Hatch ☐Others, Please specify
__________________
Please cross box provided
Product Serial No. / Unit Model
File Date
P.O Reference:
RMA No.
Vehicle Identification No. (VIN):
Make/Model:
Model Year:
Date of Registration/Purchase:
Dealer Name:
Address:
Contact Details:
Contact Person:
Phone: ( )
Customer Name
Address:
Contact Details:
Contact Person:
Phone: ( )
Defect/Complaint Description : (Attach error report from Thermo test tool is claim is under heater category)
Product condition: ☐New/Zero-Mile ☐Used; Mileage_____________ (Only for heater. Readable via thermo test tool)
This section shall be filled up by Spheros or accredited service provider
Evaluation Result: ( State briefly)
Service Technician:
Disposition
☐Accepted. (Fill up repair detail section) ☐Refused (Inform customer on the rejection by sending the warranty claim form if necessary. Fill up repair detail section if
customer request to repair of unit )
Customer disposition if warranty is void
☐Return ☐Repair/Invoiced ☐Scrap on Site
Authorized by:
Name below signature
Date
____________
Repair Details
P.O no. ( P.O support customer authorization to repair the unit.)
Quantity
Part No.
Description
Price
Sub total
Labor rate/hr (
If applicable
)
Repair Time (hr) (
As per Spheros Labor Time Guide
)
Labor
To be filled up by Spheros North America, Inc.
Handling
Warranty Cost Disposition:
☐Approved ☐Disapproved , Adjusted Amount ($)
__________________
Approved by: ____________________
Name below signature TOTAL
Chargeback no.
Close Date: