Valeo Thermo H 160 Instruction manual

Rev. 03/2019
Id.No. 11123930B
Thermo H 160
Thermo H 230
Thermo H 300
Thermo H 350
Workshop Manual
HEATING SYSTEMS

1
Thermo H Content
1 Introduction
1.1 Content and purpose 101
1.2 Effectivity of the workshop manual 101
1.3 Meaning of highlighted content 101
1.4 Symbols 101
1.5 Further documentation to be used 101
1.6 Safety information and regulations 101
1.6.1 Required qualifications 102
1.6.2 Emergency stop / de-energizing 102
1.6.3 Work at the heater 102
1.7 Suggestions for improvement and change 102
2 Technical data
2.1 Fuel 202
3 Description of assemblies and components
3.1 HV control head 302
3.1.1 Small distribution board 302
3.2 Heat exchanger 303
3.2.1 Combustion chamber 303
3.2.2 Heating cartridges 303
3.3 Diesel burner head 304
4 Functions of the heater
4.1 General functional description of the heater 401
4.2 HV heater 401
4.2.1 Switching on 401
4.2.2 Heating operation 401
4.2.3 Switching off 401
4.3 D heater 402
4.3.1 Switching on and start 403
4.3.2 Heating operation 403
4.3.3 Switching off 404
4.3.4 Diagnosis interface and DTT diagnosis 405
4.3.5 Test plug 405
4.3.6 Malfunction interlock and heater interlock 405
4.3.7 Error output 408
5 Troubleshooting and error correction
5.1 General 501
5.2 HV heater troubleshooting 501
5.3 D heater troubleshooting 502
6 Wiring diagrams
6.1 General 601
6.2 HV heater 601
6.3 D heater 611

2
Thermo H Content
7 Servicing
7.1 General 701
7.1.1 Heater servicing 701
7.2 HV heater servicing 701
7.3 D heater servicing 701
8 Components and heater removal and installation
8.1 General 801
8.2 HV control head 802
8.2.1 Temperature guards (temperature limiter, control thermostat) removal/installation. 802
8.2.2 Hood removal/installation 803
8.2.3 Housing removal/installation (incl. cable connections) 803
8.2.4 Small distribution board removal/installation 803
8.2.5 Heating cartrides/screw plugs removal/installation 804
8.2.6 HV DC wiring harness removal/installation 806
8.2.7 HV AC wiring harness removal/installation 807
8.2.8 LV DC control wiring harness removal/installation 807
8.2.9 Pump harness harness removal/installation 808
8.3 Diesel burner head 809
8.3.1 Burner removal/installation 809
8.3.2 Removal/installation of the temperature sensor with integrated overheating protection 810
8.3.3 Hood removal/installation 810
8.3.4 Combustion air fan removal/installation 811
8.4 Heat exchanger removal/installation 812
8.5 Heater removal/installation 812
8.6 Start-up after burner or heater installation 814
8.6.1 Bleeding the fuel system 814
8.6.2 Bleeding of the coolant circuit 814
9 Modifications and retrofits
9.1 General 901
10 Packing/storage/shipping
10.1 General 1001

101
Thermo H 1 Introduction
1Introduction
1.1 Content and purpose
This workshop manual is used during maintenance and
repair of water heaters (further referred to as heaters)
Thermo H.
Electrical work may only be performed by persons,
which have the required qualification (see 1.6.1).
ATTENTION:
Work on the heater may only be performed by briefed
and/or trained by Valeo personnel.
1.2 Effectivity of the workshop manual
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 effectife version is binding. This
version can be found on the Valeo homepage under
www.valeo-thermalbus.com/eu_en/Service/Downloads/
Heating-systems/Thermo-H.
1.3 Meaning of 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.
1.4 Symbols
1.5 Further documentation to be used
The use of additional service literature is required.
References are provided in the workshop manual at
appropriate locations.
Use the following documents during operation and main-
tenance of the heaters:
• Installation and operating instructions
• Spare parts list
• Technical Information (TI)
• Workshop Manual Thermo S
This service literature is also available at www.valeo-ther-
malbus.com/eu_en/Service/Downloads/Heating-systems
for download.
1.6 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 highlighted in the individual sections or
procedures.
Danger to life and health!
Warning!
Danger to life and health!
Warning!
Hazardous to health!
Caution!
Symbol tightening torque value:
Identifies in graphics parts (eg nuts, bolts)
that are to be mounted with a specific tigh-
tening torque. The torque values are
shown at the symbol and are binding.
Orientation help - next wor-
king step (s) on the HV
control head.
Orientation help - next wor-
king step (s) on the heat
exchanger.
Orientation help - next wor-
king step (s) on the Diesel
burner head.

102
Thermo H 1 Introduction
1.6.1 Required qualifications
Electrical work may only be performed by a qualified
electrician for HV systems in motor vehicles, crafts-
man, activity with repetitive character. Training acc.
to DGUV 200-005 (previously BGI 8686)
NOTE:
The provisions of these Regulations are binding within the
territory governed by DGUV Regulations and should
similarly be observed in countries without specific regula-
tions.
Even before the start of non-electrical work, the
voltage- freeness must be determined by a skilled
electrician.
1.6.2 Emergency stop / de-energizing
The Thermo H heater itself does not have an emergency
stop system. It‘s control and power supply is integrated
into the vehicle's electrical system.
It is therefore the responsibility of the user to inform
himself before the commisioning of the heater in the
vehicle how the heater can be successfully de-energized
if necessary (maintenance, service work, abnormal beha-
vior etc.).
1.6.3 Work at the heater
Installation, maintenance and repairs may only be
carried out when the vehicle's engine is not running
and the high voltage supply (AC/DC) / power supply is
switched off.
Before starting the work at the heater, it is to make
voltageless acc. to DIN VDE 0105-100 and this state
must be ensured for the duration of the work.
The following safety precautions must be observed:
– switch off the power supply to the heater
– ensure it cannot be switched on again
– verify system is voltage-free, all poles
– ground and short circuit (the de-energized circuit)
– cover or block neighbouring parts under voltage
Electrical cables and operating elements of the heater
must be arranged in the vehicle in such a way that
their functioning is faultless under normal operating
conditions and cannot be hampered.
Work at electrical equipment may only be started if
protective measures against electric shock, short
circuits and arcing faults have been carried out.
Familiarize yourself with the Thermo H Installation
Instructions before you make any modifications to the
existing heater installation.
NOTE:
The Installation and operating instructions contain the
statutory regulations and other safety hints and regula-
tions for the proper installation of the heater.
Further they contain safety instructions and regulations to
be followed for safe operation of the heater.
1.7 Suggestions for improvement and
change
Please direct any complaints, improvement or modifica-
tion suggestions regarding this manual to:
service-valeo[email protected]
High voltage!
Danger to life!
Warning!
High voltage!
Danger to life!
Warning!
High voltage!
Danger to life!
Warning!
Danger to life and health!
Warning!

201
Thermo H 2 Technical data
2 Technical data
Except where limit values are specified, these technical
data refer to the usual heater tolerances of ±10% at an
ambient temperature of +20°C and at the rated voltage.
Technical data:
Heater (general)
Kind of design Hybrid heater
Ambient temperature during operation °C -40 up to +85
Storage temperature °C -40 up to +85
Operating overpressure max. bar 2.0
Dimensions (tolerance +/- 3 mm) mm Lenth: 828
Width: 274
Height: 350
Weight kg 32
Capacity of the heat exchanger l 7
Minimum water flow l/h >1500 *
Minimum capacity of the water system l 35
Antifreeze ratio in the cooling system % 30 up to 60
* Depending on the heat flow taken by the vehicle, a minimum burner operation
of 120 seconds should be achieved.
Electrical part (high voltage)
Device version AC070 AC090 AC140 AC200 DC070 DC070 DC200 DC140
Nominal heating flow max. kW 7 9 14 20 7 7 20 2x 7
Rated voltage V 400 690 600 690 600
Rated control voltage V 24
Control voltage min. V 20.4 16
Control voltage max. V 26.4 32
Power consumption kW 7 9 14 20 7 7 20 2x 7
Frequency Hz 50-60 --
Rated current A 9.9 13.5 19,75 29.6 9.9 11.8 29.6 2x 11.8
Electrical protection A 16 16 25 32 16 16 35 2x 18

202
Thermo H 2 Technical data
Optional Fuel Filter Heater NOTE:
Circulating pumps must be assigned to the heaters accor-
ding to the flow resistance in the coolant circulation sys-
tem.
2.1 Fuel
Suitable fuel is the diesel fuel specified by the vehicle ma-
nufacturer. Only the on the model plate of the heater
specified fuel must be used.
The following table lists the by Valeo approved fuels and
their specifications.
*Further information on approved by Valeo fuels con-
tains the TI (Technical Information) Fuels.
It can be found on the Valeo homepage under Service/
Technical Updates (TI)/Heating systems.
In case of air temperatures below 0°C a commercial avail-
able winter Diesel fuel must be used.
The usage of flow improvers respectively additives is per-
mitted. There are no negative influences due to additives
known.
ATTENTION:
While using the fuels, their operating limits must be
considered and if necessary, suitable measures
(nozzle preheating, electrical heated filter) should be
applied.
If fuel is supplied from the vehicle tank, follow the
vehicle manufacturer’s instructions on additives.
Diesel part
Thermo H 160 230 300 350
Heating flow (at ambient
temperature of 20°C )
kW
kcal/h
16
13800
23
20000
30
26000
35
30000
Fuel Diesel
Fuel consumption kg/h 1.62.53.03.6
Rated voltage V 24
Operation voltage range V 20 - 30
Electrical power consumption at 24V W 50 65 90 120
Max. permitted temperature of sucked
combustion air
°C +85
CO2in exhaust gas at rated voltage Vol % 9.5 + 1.5
Filter heater
Rated power consumption W 240
Rated voltage V 24
Switch-on point C° 0.5 ± 2.5
Switch-off point C° 5.5 ± 2.5
Fuel Requirements
acc.
Summer diesel DIN EN 590
Winter diesel DIN EN 590
Arctic diesel and Diesel for a strong
winter climate
DIN EN 590
Bio diesel (FAME)*DIN EN 12214
Paraffinic diesel fuel from synthesis
or hydrogenation (HVO)*DIN EN 15940

301
Thermo H 3 Description of assemblies and components
3 Description of assemblies and components
The water heater, hereafter referred to as heater, is used
in conjunction with the vehicle’s own heating system
– to heat the passenger compartment,
– to defrost the vehicle windows and
– for pre-heating
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
down to the vehicle chassis or is secured using an addi-
tional cross beam.
The hybrid function of the heater includes the generation
of heat
a) by burning liquid fuel, and
b) by electric current.
The diesel burner head (see Fig. 301) is responsible for
heat generation by combustion - the control head AC / DC
with the connected heating cartridges for the generation of
heat by electric current.
Both systems for heat generation operate independently
of one another and can be operated simultaneously or
individually.
The heat is transferred to the coolant circuit of the vehicle
via the heat exchanger of the heater. The adaptation to
the changing heat demand is done by intermittent opera-
tion (intermittent mode).
Fig. 301 Heater - Overview
Heat exchanger
Diesel burner head
HV Control head

302
Thermo H 3 Description of assemblies and components
3.1 HV control head
The AC/DC control head (see Fig. 302) consists of an
aluminum die-cast ring as housing (4) and the hood (1).
Inside is a small distribution board (3) behind a stabilizer
(2). The housing (4) is screwed to the heat exchanger (8) .
3.1.1 Small distribution board
The small distribution board (3, Fig. 302) includes the
components required for the electrical part of the heater
which are mounted on a 35mm top hat rail.
The top hat rail is attached to the heat exchanger (8) via
stud bolts.
Fig. 302 HV control head / Small distributor board
1 Hood
2 Stabilizer
3 Small distribution board
4 Housing with cable glands
5 Control thermostat
6 Temperature limiter
7 Heating cartridges
8 Heat exchanger
1
2
3
4
7
8
5
6

303
Thermo H 3 Description of assemblies and components
3.2 Heat exchanger
In the heat exchanger (1, Fig. 303) the water flowing
through is heated directly by heating cartridges (7) arran-
ged in a ring shape.
The water is also heated via the inner wall (15) of the heat
exchanger when the diesel burner head is in operation.
The hot exhaust gases resulting from the combustion are
conducted on the inner wall via lamellas (5) and thus give
off heat to them.
The cylindrically welded construction has a water inlet (3)
and a water outlet (11). The heater is integrated into the
cooling water circuit via these two connection ports.
In the water inlet is the control thermostat (12) for the
electrical part of the heater installed.
The temperature limiter (13) for the electrical part and the
control thermostat (14) for the control of the diesel burner
head are located in the wall of the heat exchanger. The
plate at the front has receiving openings with threads for
the heating cartridges. At the rear, the Diesel burner head
is fixed.
3.2.1 Combustion chamber
The combustion chamber (8, Fig. 303) is located inside
the heat exchanger. In it the combustion of the diesel-air
mixture produced by the diesel burner head takes place.
After exiting the combustion chamber, the hot exhaust
gases are deflected and passed through fins (5) which are
located on the inner wall of the water-conducting part of
the heat exchanger.
3.2.2 Heating cartridges
At the end of the rod-shaped, water-proof heating cart-
ridges (6, Fig. 302 and 7, Fig. 303) there is an external
thread with a hexagon for screwing in and the electrical
cables are led out.
Fig. 303 Heat exchanger
1 Heat exchanger outer wall
2 Bleed screw
3 Water inlet
4 Device attachment
5 Lamellae
6 Exhaust gas outlet
7 Heating cartridge (6x)
8 Combustion chamber
9 water-carrying area
10 Blind plugs (3x)
11 Water outlet
12 Control thermostat (HV control
head)
13 Temperature limiter (HV control
head)
14 Control thermostat (Diesel
burner head)
15 Heat exchanger inner wall
1
2
3
5
4
6
7
8
9
10
7
11
12
13
14
15