Spheros Thermo s 350 User manual

Water Heaters Installation Instructions
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400
Stand: 02/2012
Ident Nr. XXXXXX

Thermo S 160/230/300/350/400
1
Improper installation or repair of Spheros heating and cooling systems can cause fire or the leakage of deadly
carbon monoxide leading to serious injury or death.
To install and repair Spheros heating and cooling systerns you need to have completed a Spheros training course
and have the appropriate technical documentation, special tools and special equipment.
NEVER try to install or repair Spheros heating or cooling systems if you have not completed a Spheros training
course, you do not have the necessary technical skills and you do not have the technical documentation, tools and
equiprnent available to ensure that you can complete the installation and repair work properly.
ALWAYS carefully follow Spheros installation and repair instructions and heed all WARNINGS.
Spheros rejects any liability for problems and damage caused by the system being installed by untrained personnel.

2
Thermo S 160/230/300/350/400
Table of Contents
1 Statutory regulations governing installation 3
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6 Connection to the vehicle cooling system 16
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Thermo S 160/230/300/350/400 Statutory regulations governing installation
3
1 Statutory regulations governing installation
1.1. Statutory regulations governing installation
For the heaters exist type approvals according to the ECE Regulations
R10 (EMC): No. 03 5266 and
R122 (Heater) No. 00 0208 for Thermo S 160
No. 00 0226 for Thermo S 230
No. 00 0227 for Thermo S 300
No. 00 0228 for Thermo S 350
No. 00 0225 for Thermo S 400
Installation is governed above by the provisions in Annex 7 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 7)
4. The heater must have a manufacturer’s label showing the manufac-
turer’s name, the model number and type together with its rated output
in kilowatts. The fuel type must also be stated and, where relevant, the
operating voltage and gas pressure.
7.1. A clearly visible tell-tale in the operator’s eld of view shall inform
when the combustion heater is switched on or o.
(Extract from ECE Regulation R122, Part I)
5.3 Vehicle Installation Requirements for Combustion Heaters
5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2., combustion heaters shall be in-
stalled according to the requirements of paragraph 5.3.
5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to
comply with the requirements of paragraph 5.3.
5.3.2 Positioning of combustion heater
5.3.2.1 Body sections and any other components in the vicinity of the
heater must be protected from excessive heat and the possibility of fuel
or oil contamination.
5.3.2.2 The combustion heater shall not constitute a risk of re, even in
the case of overheating. This requirement shall be deemed to be met if
the installation ensures an adequate distance to all parts and suitable
ventilation, by the use of re resi stant materials or by the use of heat
shields.
5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must
not be positioned in the passenger compartment. However, an installa-
tion in an eectively sealed envelope which also complies with the con-
ditions in paragraph 5.3.2.2. may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 1.4., or a duplicate,
must be positioned so that it can be easily read when the heater is in-
stalled in the vehicle.
5.3.2.5 Every reasonable precaution should be taken in positioning the
heater to minimize the risk of injury and damage to personal property.
5.3.3 Fuel supply
5.3.3.1 The fuel ller must not be situated in the passenger compart-
ment and must be provided with an eective cap to prevent fuel spillage.
5.3.3.2 In the case of liquid fuel heaters, where a supply separate from
that of the vehicle is provided, the type of fuel and its ller point must be
clearly labelled.
5.3.3.3 A notice, indicating that the heater must be shut down before re-
fuelling, must be axed to the fuelling point. In addition a suitable in-
struction must be included in the manufacturer’s operating manual.

Statutory regulations governing installation Thermo S 160/230/300/350/400
4
5.3.4 Exhaust system
5.3.4.1 The exhaust outlet must be located so as to prevent emissions
from entering the vehicle through ventil ators, heated air inlets or opening
windows.
5.3.5 Combustion air inlet
5.3.5.1 The air for the combustion chamber of the heater must not be
drawn from the passenger compartment of the vehicle.
5.3.5.2 The air inlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.6 Heating air inlet
not applicable
5.3.7 Heating air outlet
not applicable
5.3.8 Automatic control of the heating system
5.3.8.1 The heating system must be switched o automatically and the
supply of fuel must be stopped within ve seconds when the vehicle’s
engine stops running. If a manual device is already activated, the hea-
ting system can stay in operation.
IMPORTANT:
Failure to follow the installation instructions and the notes contai-
ned therein will lead to all liability being refused by Spheros. 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 invali-
dation of the type approval for the heater and therefore of its ECE
Type Approval.
CAUTION:
At petrol stations and other fuel filling facilities the heater must be
switched off due to the explosion hazard. To advice to this require-
ment the self-adhesive label with the text ’’Switch off heater before
refueling!“, delivered with each heater, is to be affixed next to the
filler neck.
1.2. Provisions relating to the installation in rail vehicles
For heater models Thermo S 230 / 300 / 350 / 400 Rail a design certi-
cation acc. to § 33 EBO (= Federal Railway Authority) has been issued
with the following approval number: EBA 32AZ3/0006/10.
Particular attention must be given to incidental provision 1.6 of the
design certication:
Should the manufacturer, operator or service technician gain knowledge
of any accidents and damage (caused by re, explosion, escape of
Diesel fuel or heating oil EL) that may have occurred despite proper use
of the heater, he is required to immediately notify the certifying body
thereof.

Thermo S 160/230/300/ noisrev/esU004/053
5
2 Use / version
2.1. Use of the water heaters
The water heaters are used in connection with the vehicle’s own heating
system
– to heat the passenger cabin,
– to defrost the vehicle windows and
– to preheat water-cooled engines.
NOTE:
If the heater is used mostly in altitudes > 1500m above NN, the CO2
value is to be readjusted by means of the diagnostic tool.
The water heater operates independently of the engine and is connec-
ted to the cooling system, the fuel system and the electrical system of
the vehicle.
IMPORTANT:
The heater is approved for heating the passenger cabin or the
driver’s cab, but not for use in vehicles subjected to the Directive
94/55/EC (ADR, TRS).
NOTE:
The heaters are only licenced for horizontal installation.
(see Figure 2)
2.2. Versions
Thermo S 160 – 24V
Water heater for “diesel“
with 16 kW (55,000Btu/h) heat current
Thermo S 230 – 24V
Water heater for “diesel“
with 23 kW (80,000Btu/h) heat current
Thermo S 300 – 24V
Water heater for “diesel“
with 30 kW (104,000Btu/h) heat current
Thermo S 350 – 24V
Water heater for “diesel“
with 35 kW (120,000Btu/h) heat current
Thermo S 400 – 24V
Water heater for “diesel“
with 40 kW (137,000Btu/h) heat current
Depending on request and on the requirements of conguration, the
heater may be equipped with a nozzle preheating system.

mrehTnoitallatsnI o S 160/230/300/350/400
6
3 Installation
IMPORTANT:
– The statutory regulations governing installation on pages 3
and 4 must be adhered to.
– If the water heater is to be operated in a separately installed hea-
ting system, prior to installation an installation planning report
must always be submitted to Spheros for approval.
If this approval is not obtained, all warranty and liability claims
will be void. The water heater has been designed, tested and
approved for specific bus requirements.
– To the temperature sensor cable no mechanical load must be
applied (e.g. carry the heater with it).
– Heater and circulating pump shall be always installed in such a
way that a negative impact by road dirt, splashing water, ex-
haust gases or other harmful influences is excluded.
NOTE:
Consider the installation situation of the relevant vehicle type.
3.1. Installation location
The heater and circulating pump are to be integrated into the cooling
system (or in a separate heating system).
The heater must be installed in as low a position as possible to allow the
heater and circulating pump to be bled automatically. This is particularly
important as the circulati ng pump is not self-priming.
If it is not possible to install the heater and the circulating pump in the
vehicle’s engine bay it may be installed in a box. The installation box
must have sucient external ventilation to ensure that a maximum
temperature of 60 °C is not exceeded in the box.
Bear in mind the space required for servicing accessibility (for example
for removing the combustion chamber) (see Figure 1) when installing
the heater.
3.1.1. Installation Location in Rail Vehicles
In rail vehicles the heater is to be installed either in the engine room (e.g.
locomotive) or in a special mounting box. Other installation locations
require Spheros's approval in writing.
NOTE:
No metallic antivibration mounts must be used for securing the heater in
rail vehicles.

noitallatsnI004/053/003/032/061SomrehT
7
Fig. 1: Dimensions of the Thermo S 160/230/300/350/400 heater
386
ca. 440
8243 50
5
6
7
600
303
1
2
247
022.ac
190
011
232
38
70 43
1 Combustion air intake
2 Exhaust outlet
3 Fuel intake
4 Fuel discharge
5 Coolant intake
6 Coolant outlet
7 Temperature sensor
8 Space required to remove the burner chamber

mrehTnoitallatsnI o S 160/230/300/350/400
8
3.2. Installation of a Thermo S heater
The heater may be secured either with four M8 screws or with four bolts
and nuts (see Figure 3) .
Fig. 2: Installation position
Fig. 3: Hole pattern
0° - 5°
320 150
136
0° - 15° 0° - 15°
0° - 5°
Welded nut
M8 Din 929 D = ø 4,5 if M4 screws are
used
D = ø 2,9 if sheet metal
screws B 3.9 are used
Attachment variant 1
Attachment variant 2
4x screw M8
4x screw M8
4x nut M8
D
320
82
150
25
180
011
ø75
ø88

noitallatsnI004/053/003/032/061SomrehT
9
3.3. Model plate
The model plate must be protected from damage and must be clearly le-
gible when the heater is installed (otherwise a duplicate model plate
must be used).
NOTE:
The year of the initial operation must be durably marked by remo-
ving the year numbers that are not applicable.
3.4. Additional Plate
Heatersapproved for use in rail vehicles are additionally identied by the
type plate illustrated below:
Fig. 4: Model plate
2008 2009 2010
Thermo S 300
30kW / 102000 BTU/h
24V / 90W
2710210A
0208
5266
Fig. 5: Additional plate
Made in Germany
Eisenbahn-Bundesamt
BauartzulassungsNr.
EBA 32AZ3/0006/10

Installation example Thermo S 160/230/300/350/400
10
4 Installation example
Fig. 6: Installation example for the heater
1 Wall heater with blower
2 Heat exchanger at entry point
3 Heater
4 Circulating pump
5 Roof heat exchanger
6 Vehicle engine
7 Driver’s position heating system
8 Control element
Supply
Return
Water heating circuit – wall heater and roof duct heating system

latsnI004/053/003/032/061SomrehT lation of the circulating pump
11
5 Installation of the circulating pump
The circulating pump must be installed as shown in Figure 7, 10, 13 or
16. Note the installation position!
NOTE:
The pump ports and connection lines from the water intake and wa-
ter outlet must be flush (no stress).
IMPORTANT:
The heater should be installed preferably with Spheros circulating
pumps.
If the pump is not controlled by the heater, its operation is to be en-
sured by all means during whole heater operation (initial cycle,
heating operation and purge cycle).

Installation of the circulat 004/053/003/032/061SomrehTpmupgni
12
5.1. U 4814 (Aquavent 5000) circulating pump
Fig. 7: U 4814 circulating pump
installation position
Sw+Br-
Fig. 8: Hole pattern for the stand for U 4814 circulating pump
Fig. 9: Delivery rate and flow resistance
U 4814 circulating pump
∆
Delivery rate
(with water at 20°C)
Flow resistance
(with the pump stopped)

latsnI004/053/003/032/061SomrehT lation of the circulating pump
13
5.2. U 4854 (Aquavent 5000S) circulating pump
NOTE:
When connecting the circulating pump it must be ensured that the
volume flow does not drop below 2500 l/h for longer than a brief
period only! Continuous operation at less than 2500 l/h will result
in undue wear of the wearing disc of the impeller!
Fig. 10: U 4854 circulating pump
installation position
5°min.
0-90°
249
53
31
011
83
522
32
60
99,5
83
32
131,5
Sw+Br-
0-85°
Fig. 11: Hole pattern for the stand for U 4854 circulating pump
Fig. 12: Delivery rate and flow resistance
U 4854 circulating pump
1,1
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
Q
10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)
P
bar
24 V
Delivery rate
(with water at 68°F/20°C)
Flow resistance
(with the pump stopped)

Installation of the circulat 004/053/003/032/061SomrehTpmupgni
14
5.3. U 4855 (Aquavent 6000C) circulating pump
Fig. 13: U 4855 circulating pump
installation position
30,8
52,8
98
115
60
0-90°
0-85°
min. 5°
32
23
224±2
Ø
38
Ø
38
Fig. 14: Hole pattern for the stand for U 4855 circulating pump
Fig. 15: Delivery rate and flow resistance
U 4855 circulating pump
1,1
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
Q
10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)
P
bar
24 V
Delivery rate
(with water at 68°F/20°C)
Flow resistance
(with the pump stopped)

latsnI004/053/003/032/061SomrehT lation of the circulating pump
15
5.4. U 4856 (Aquavent 6000SC) circulating pump
NOTE:
When connecting the circulating pump it must be ensured that the
volume flow does not drop below 2500 l/h for longer than a brief pe-
riod only! Continuous operation at less than 2500 l/h will result in
undue wear of the wearing disc of the impeller!
Fig. 16: U 4856 circulating pump
installation position
Ø
38
Ø
38
31
53 126
229
±2
23
32
60
115
0-90° 0-85°
min. 5°
Fig. 17: Hole pattern for the stand for U 4856 circulating pump
Fig. 18: Delivery rate and flow resistance
U 4856 circulating pump
1,1
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
Q
10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)
P
bar
24 V
Delivery rate
(with water at 68°F/20°C)
Flow resistance
(with the pump stopped)

Installation of the circulat 004/053/003/032/061SomrehTpmupgni
16
5.5. Motor for circulating pump model U 4855 (Aquavent 6000C)
and U 4856 (Aquavent 6000SC)
These circulating pumps are equipped with a brushless motor.
5.5.1. Soft Start
The motor starts up slowly and in a way that is gentle to the material.
It takes approx. 5 sec. until maximum speed is reached.
5.5.2. Run-dry protection (only U 4855 and U 4856)
In the event of a dry running motor the slide ring gasket may be dama-
ged. A dry running motor has a very high speed while the current con-
sumption is slow.
The dry running protection is activated if the current consumption (eec-
tive) is 0,5 A > I < 4 A, the motor isn’t just in the start phase,
n > 3300 1/min and the waiting period is exceeded.
Waiting period: M3G074CF44-17: 8 - 10 s
M3G074CF44-16: 40 - 45 min
Waiting periods depend on power supply level. The device will be swit-
ched into the sleep mode 10 s after the waiting period is passed.
5.5.3. Blocking protection
Ifthespeed dropsbelow57 1/min, the motor is switched oafterapprox.
1 second by the error mode. If the motor does not complete a whole rev-
olution within 1 second despite the medium ow, it will also be shut down
by the error mode.
5.5.4. Error mode
The error mode switches o the motor in the event of faults. The motor
is switched to power-saving sleep mode by the error mode after approx.
5 seconds.
5.5.5. Sleep-Mode
In the sleep mode the internal consumers of the motor electronics are
switched o. The current consumption in this mode is then < 2 mA.
5.5.6. Motor reactivation
The motor can be reactivated from sleep mode. This is done by discon-
necting it from the power supply approx. 2 minutes. When the voltage
supply is reconnected the motor will restart in soft start mode.
5.5.7. Polarity reversal protection
The motor does not feature an internal polarity reversal protection. The
motor is protected against polarity reversal through the wiring harness
and a 25 A fuse.

Thermo S 160/230/300/350/400 Connection to the vehicle cooling system
17
6 Connection to the vehicle cooling system
The heater is to be connected to the vehicle cooling system in
accordance with Figures 1 and 6. The system must contain at least 10
litres of coolant. A minimum of 20 % of a good quality antifreeze should
be maintened in the heating circuit of the heater at all times.
Basically the water hoses supplied by Spheros should be used. If this is
not the case, the hoses must comply with DIN 73411 requirements as a
minimum. The hoses are to be routed without any kinks and - for proper
venting of the heater - in an upward pi tch, if possible. Hose connections
must be secured against slipping o by means of hose clamps.
NOTE:
The specified tightening torques of the hose clamps used must be
adhered.
In the vehicle cooling system, or in a separate heating circuit, only pres-
sure control valves with an opening pressure of min. 0.4 bar and max.
2.0 bar may be used.
Before the heater is started up for the rst time, or after the coolant has
been replaced, it must be ensured that the cooling system is properly
bled. Heater and piping should be installed in such a way that static
bleeding of the system is ensured.
Proper bleeding action can be recognised by the nearly silent operation
of the circulating pump. Insucient bleeding can result in tripping of the
resettable temperature limiter when the heater is operating.
In the case of circulating pump U 4855 / Aquavent 6000C the circulating
pump will be automatically deactivated approx. 15 seconds after its ac-
tivation if coolant is lacking or a blockage of the pump impeller has oc-
curred, and can then be restarted after approx. 2 minutes.
If the circulating pump U 4856 / Aquavent 6000SC is used, it will be
automatically deactivated approx. 45 seconds after its activation if cool-
ant is lacking or a blockage of the pump impeller has occurred, and can
then be restarted after approx. 2 minutes.

004/053/003/032/061SomrehTylppuSleuF
18
7 Fuel Supply
Fuel is extracted from the vehicle's fuel tank or from a separate fuel tank.
Thereby also during vehicle operation a continuous fuel supply must be
ensured.
7.1. Fuel Lines
To prevent air inclusions from forming in the fuel, the fuel lines should be
routed in an upward pitch, if possible. Connections within the fuel lines
must be secured by means of hose clamps unless mechanical screwed
connections are used.
When using fuel hoses, basically the hoses supplied or oered by
Spheros are to be used. If this is not the case, the fuel hoses must, as a
minimum, comply with the requirem ents of DIN 73379. Fuel hoses must
neither be kinked nor twisted and must be secured by clamps spaced
approx. 25 cm apart.
Materials commonly used in the constr uction of vehicles may be also
used for fuel hoses taking into account a suitable connection system in
each case. The selection should be done considering the ambient tem-
perature range.
IMPORTANT:
If the heater is operated without coolant, the outer shell of the heat-
er may reach a temperature equalling the ignition temperature of
diesel fuel!
– The lines must be protected from stone damage
– Any dripping or evaporating fuel must neither collect nor be ig-
nited by hot components or electrical equipment. Therefore if
necessary a drip pan with defined drain holes is to be installed
in the area below the interface burner housing/fuel line connec-
tors/heat exchanger.
Note:
The fuel pump is delivered in series for a two-pipe system (with return
line).
The fuel pump can be ordered option ally for an appropriate heating
system or burner head also in a single-pipe version. In a single-pipe
system (without return line) accord ing to the delivered application the
return line port at the housing is closed with a screw plug and a gasket
ring.
Bleeding is particularly in a single-pipe system mandatory:
a) With a separate bleeding device according to the prescribed for
this device procedure!
b) While the fan motor is running (initial cycle/pur ge cycle), loosen
the screw plug, ident. no. 149314Z, and hold open until the fuel co-
mes out nearly free of air bubbles (collect fuel with a container).
Then close screw plug, torque to 16 +/-1 Nm.
Refer also to the workshop Manual for further notes on fuel system
bleeding!
IMPORTANT:
The operation with a closed return line will cause damage to the
fuel pump, fuel can leak out - fire hazard!
Unsupported fuel lines must be secured to prevent them from sag-
ging.
The installation of an additional fuel pump is not permitted.
For legal provisions refer to pages 33 and 34.

Thermo S 160/230/300/ ylppuSleuF004/053
19
7.1.1. Permissible dimensions of the fuel lines
– Inside diameter for suction and return lines: 6 mm (other diameters
on request).
– Max. permissible length of each suction and return line: 15 m
– Max. permissible suction height: 2 m
– Max. permissible admission pressure: 0.3 bar.
– For a differing fuel supply system ensure that the negative pres-
sure in the suction line directly before the heater 500 mbar not
exceeds.
7.2. Fuel Filter
A fuel lter supplied or approved by Spheros must be used (consider the
ow direction). To avoid malfunctions the lter or lter insert is to be re-
placed annually before the cold weather season starts.