Valeo Thermo G 300 Instruction manual

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

Thermo G Content
1
1 Introduction 101
1.1 Content and purpose 101
1.2 Meaning of warnings and highlighted content 101
1.3 Further documentation to be used 101
1.4 Safety information and regulations 101
1.4.1 General safety regulations 101
1.4.2 Other safety information 102
1.5 Suggestions for Improvement and change 102
2 Technical data 201
2.1 Heater 201
2.1.1 Altitude capability 201
2.2 Gas pressure regulator 202
2.3 Fuel 202
2.4 Circulating pump 202
3 Description of assemblies and components 301
3.1 Burner head 302
3.1.1 Combustion air fan 302
3.1.2 Control device 302
3.1.3 Mixing chamber 302
3.1.4 Heat protection cover 303
3.1.5 ZF Module with electronic ignition unit and ionization electrode 303
3.1.6 Flame tube 303
3.2 Combustion chamber 303
3.3 Heat exchanger 303
3.4 Temperature sensors with water temperature 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 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
5 Troubleshooting 501
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

Thermo G Content
2
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 symptoms "Temperature sensor / overheating protection defective" 509
5.4.6 Error symptom "Solenoid valve 1 or 2 defective" 509
5.4.7 Error symptom "Overheat protection has triggered" 510
5.5 Individual component tests 511
5.5.1 General visual inspection 511
5.5.2 Heat exchanger visual inspection 511
5.5.3 Visual inspection of exhaust outlet and exhaust line 511
5.5.4 Combustion chamber visual inspection 511
5.5.5 Resistance check of the temperature sensor with integrated overheat protection 511
5.5.6 Fan and combustion air intake line visual inspection 512
5.5.7 Burner motor inspection 512
5.5.8 ZF module inspection 512
5.5.9 Ignition electrode inspection 513
5.5.10 Heat protection cover inspection 514
5.5.11 Gas pressure regulator inspection 514
6 Wiring diagrams 601
6.1 General 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 Measurement of the exhaust CO2 content 702
7.6.2 Adjustment of the exhaust CO2 content 702
8 Removal and installation of components and of the heater 801
8.1 General 801
8.2 Removal and installation of the temperature sensor with integrated overheating protection 801
8.3 Hood removal and installation 802
8.4 Burner head Removal and installation 802
8.5 Separating the fan housing from the mixing chamber 803
8.6 Control device removal and Installation 804
8.7 Fan wheel removal and installation 804
8.8 Fan motor removal and installation 804
8.9 ZF module removal and installation 804
8.10 Combustion chamber removal and installation 806
8.11 Heat exchanger removal and installation 806
8.12 Heater removal and installation 807
8.13 Gas pressure regulator removal and installation 807
8.14 Start-up after installation of burner head, heater or heat exchanger 807
8.14.1 Bleeding of the coolant circuit 807
9 Modifications and retrofits 901

Thermo G Content
3
10 Packing / storage and shipping 1001
10.1 General 1001
Appendix
Scheduled heater maintenance A-1

101
Thermo G 1 Introduction
1Introduction
1.1 Content and purpose
This workshop manual is intended for the maintenance
and repair of the water heaters (hereinafter heaters)
Thermo G300 on the gas low pressure side.
Work on the heater must only be carried out by
trained and / or by Valeo-trained personnel.
Any work on the gas supply line, for example when
removing or installing the gas regulator, may only be
carried out by persons with the appropriate official
authorization.
1.2 Meaning of warnings and highlighted
content
Throughout this manual the emphasized words Warning!,
Caution!, ATTENTION: and NOTE: used as follows:
This caption is used to indicate possible severe inju-
ries or fatal accidents if instructions or procedures
are carried out incorrectly or entirely disregarded.
This caption is used to indicate possible minor inju-
ries if instructions or 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
feature.
1.3 Further documentation to be used
In the Thermo G Operating and Service Instructions
you will find all the necessary information as well as useful
hints relating to the safe operation of the heater.
The Thermo G Installation Instructions contain all
required information as well as useful 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 Technical Information
(TI) for operation, maintenance or repair of the heater.
The Heater Accessories Catalog contains useful acces-
sories for your heater installation.
All mentioned documents you will find on the Valeo
website www.valeo-thermalbus.com/eu_de/Service.
1.4 Safety information and regulations
Basically, general accident pevention provisions and the
valid industrial safety directions must be adhered to.
"General Safety Regulations" which exceed the frame-
work of these provisions are listed below. The specific
safety regulations which affect the present manual are
issued in the individual sections or procedures with
headings in capital letters.
1.4.1 General safety regulations
Read the Thermo G Operating and Service Instruc-
tions before operating the heater for first time.
Familiarize yourself with the Thermo G Installation
Instructions before you make any modifications to the
existing heater installation.
NOTE:
The Thermo G Operating and Service Instructions contain
safety instructions and regulations to be followed for safe
operation of the heater.
The Thermo G Installation Instructions contain the
statutory regulations and other safety hints and regula-
tions for the proper installation of the heater.
Danger to life and health!
Warning!
Danger to life and health!
Warning!
Hazardous to health!
Caution!
Danger to life and health!
Warning!

102
Thermo G 1 Introduction
1.4.2 Other safety information
1.4.2.1 Temperature sensor
ATTENTION:
The temperature sensor cable may not be mechani-
cally stressed (pull on the cable, carry the heater at
the cable etc.).
1.5 Suggestions for Improvement and
change
Please direct any complaints, improvement or modifica-
tion suggestions regarding this manual to:
service-va[email protected]om
STOP!

201
Thermo G 2 Technical data
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.
2.1 Heater
2.1.1 Altitude capability
The heater is adjusted in the factory, and without change
of the CO2adjustment unlimited usable up to an altitude
of 1500 m above MSL, above an altitude of 1500 m up to
2000 m an application with splash guard or combustion air
intake line must be used.
Table 201 Technical data heater
Heater
ECE type approval number E1 122R-00 0447 / E1 10R-04 7263
Kind of design Low-pressure gas burner
Heat output 30 kW ±10%
Fuel CNG (natural 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 consumption without circulating pump 110 W
Current in standby mode < 1 mA
Max. current at the circulating pump output 12A
Used gas pressure regulator M96-E-SP
Max. ambient temperature for the heater and control device Storage temperature -40 ... +120°C
Operating temperature -40 ... +100°C
Permissible sucked in combustion air temp. (permanent) -40 ... +60°C
Permissible operating overpressure 2.0 bar
Capacity of the heat exchanger 1.8 l
Minimum capacity of the water system 25.00 l
Minimum water flow 2400 l/h
CO2in exhaust gas at rated voltage 8.0 ... 9.0 Vol.-%
Switch thresholds switches off at 82°C ±1K
switches on at 72°C ±1K
Heater dimensions
(tolerance ±3 mm)
L 585 mm
W 247 mm
H 226 mm
Heater weight 19 kg

202
Thermo G 2 Technical data
2.2 Gas pressure regulator
Table 202 Technical data gas pressure regulator
2.3 Fuel
ATTENTION:
The heater may only be operated using natural gas
(CNG).
As fuel natural gas (CNG) with a minimum methane
content of 95 % is used.
If natural gas with a less methane content is used (natural
gas of class L), the CO2level must be adjusted according
to section 7.6.2 in chapter 7.
The max. oil content of the gas is 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 R110, R10.04
Kind of gas Natural gas (CNG) class H/L
Permissible oil content in gas < 10 mg/m³
Input pressure 5 ... 220 bar
Output pressure -0.25 ... -2.5 mbar
Pressure 1st stage 1.8 ... 3.5 bar
Pressure 2nd stage 0.65 ... 0.75 bar
Operating temperature -40 ... +120°C
Sorage temperature -40 ... +100°C
Rated voltage 24 V
Nominal coil power at rated voltage (2x) 24 W
Operating voltage range 20 ... 30 V
Dimensions
(tolerance ±3 mm)
L 150 mm
W 130 mm
H 170 mm
Weight 1.7 kg

301
Thermo G 3 Description of assemblies and components
3 Description of assemblies and
components
The water heater Thermo G 300 operates in conjunction
with the on-board heating system
– to heat the passenger compartment
– to defrost the windscreen, and
– to pre-heat the water-cooled engines
in busses.
The water heater operates independently of the vehicle’s
engine and is connected to the cooling system, the gas
system and the electrical system of the vehicle. It is
screw-mounted to the chassis of the vehicle or an addi-
tional crossmember.
The heat is generated by the combustion of the gas. Via
the heat exchanger 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 of the
signals of a temperature sensor the on and off switching
of the burner.
The heater Thermo G basically consists of:
– the burner head
– the combustion chamber
– the heat exchanger
– temperature sensor system
In addition, a circulating pump and a gas pressure regu-
lator for the gas supply to the heater are installed in the
vehicle.
1 Combustion air, intake
2 Hood
3 Fan housing
4 Coolant, inlet
5 Temperature sensor with integrated
overheat protection
6 Coolant, outlet
7 Heat exchanger
8 Plug, sensor system
9 Exhaust outlet
10 Control device
11 Gas port
12 Mesh
13 Protective grid
1
2
3
45
6
8
9
7
10
11
12
13

302
Thermo G 3 Description of assemblies and components
3.1 Burner head
The burner head consists of the components
• combustion air fan
• control device
• mixing chamber
• heat protection cover
• ZF module with electronic ignition unit and ionization
electrode
•flametube
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.
By the air fan in addition, the required amount of gas is
sucked in through the gas pressure regulator.
The air fan consists of the combustion air motor and the
fan wheel. Air is sucked in through a protective grid in the
hood and mixed 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
and monitors the burner operation.
3.1.3 Mixing chamber
In the mixing chamber, the gas is mixed with the combus-
tion air and then guided into the flame tube.
Across the surface of the mixing chamber evenly small
bulges are distributed. On the one hand they generate
turbulence for mixing of gas and combustion air and on
the other hand they increase the flow-around surface of
the mixing chamber. So it is cooled more effectively.
Circlip
Fan wheel
Motor
Control device 1588
Socket P
customer
connector
Socket P
Socket T
diagnostic system
Socket D
Socket V
solenoid valves
and electrical circulating pump
temperature sensor system
regulator heating