Valeo thermo plus 230 Instruction manual

HEATING SYSTEMS
Rev. 07/2017
Id.No. 11121156A
Thermo plus 230
Thermo plus 300
Thermo plus 350
Workshop Manual

1
Thermo plus 230/300/350 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 General safety regulations 101
1.6.2 Other safety information 102
1.7 Suggestions for improvement and change 102
2 Technical Data
2.1 Elektrical components 201
2.2 Fuel 201
3 Description of assemblies and components
3.1 Burner head 302
3.1.1 Combustion air fan 302
3.1.2 Control device 302
3.1.3 Fuel pump 304
3.1.4 Electronic ignition unit with ignition electrodes 305
3.1.5 Nozzle block preheater 305
3.1.6 Temperature sensors with water temperature sensor and integrated overheating protection 305
3.2 Heat exchanger 307
3.3 Combustion chamber 307
3.4 Circulating pump 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 Diagnosis interface and (Spheros Thermo Test) STT diagnosis 403
4.4 Fault lock-out and heater lock-out 404
4.5 Fault lock-out 404
4.5.1 Malfunctions during switching-on and start procedure 404
4.5.2 Malfunctions during heater operation 404
4.5.3 Malfunctions during purge cycle 404
4.5.4 Fault lock-out release and error clearance 405
4.6 Heater lock-out 405
4.6.1 Heater lock-out release 405
5 Troubleshooting
5.1 General 501
5.2 Disconnecting the heater from the vehicle electrical system 501
5.3 General error symptoms 501
5.4 Malfunction output via flash code 504
5.5 Error symptoms during functional tests with malfunction code output or diagnosis 505
5.5.1 Error symptom "No start within safety period" 505
5.5.2 Error symptom "Flame interruption" 505

2
Thermo plus 230/300/350 Content
5.5.3 Error symptom "Low voltage" 507
5.5.4 Error symptom "Extraneous light detected prior to ignition or during purge cycle" 508
5.5.5 Error symptom "Flameguard defective" 509
5.5.6 Error symptoms "Temperature sensor / overheating protection defective" and "Overheating" 509
5.5.7 Error symptom "Circulating pump defective" 509
5.6 Individual component tests 510
5.6.1 General visual inspection 510
5.6.2 Heat exchanger visual inspection 510
5.6.3 Combustion chamber visual inspection 510
5.6.4 Resistance check of the temperature sensor with integrated overheating protection 510
5.6.5 Fan and combustion air intake line visual inspection 512
5.6.6 Burner motor inspection 512
5.6.7 Electronic ignition unit inspection 513
5.6.8 Ignition electrode inspection 514
5.6.9 Flameguard inspection 514
5.6.10 Fuel pump inspection 515
5.6.11 Solenoid valve inspection 516
5.6.12 Nozzle block preheater inspection 517
5.6.13 Circulating pump inspection 518
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 Periodic heater maintenance 701
7.2.2 CO2 content adjustment 701
8 Burner head, components and heater removal and installation
8.1 General 801
8.2 Burner head 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 Fan wheel removal and installation 803
8.6 Electronic ignition unit and ignition electrode removal and installation 804
8.7 Control device removal and installation 805
8.8 Fuel pump removal and installation 805
8.9 Solenoid valve removal and installation 807
8.10 Nozzle block preheater removal and installation 808
8.11 Fuel nozzle removal and installation 809
8.12 Combustion chamber removal and installation 809
8.13 Heat exchanger removal and installation 810
8.14 Heater removal and installation 810
8.15 Start-up after burner head or heater installation 811
8.15.1 Bleeding the fuel system 811
8.15.2 Bleeding of the coolant circuit 811
9 Modifications and retrofits
9.1 General 901

3
Thermo plus 230/300/350 Content
10 Packing/storage/shipping
10.1 General 1001
Appendix
Periodic heater maintenance A-1

101
Thermo plus 230/300/350 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 plus 230, plus 300 and plus 350.
ATTENTION:
Work on the heater may only be performed by briefed
and/or trained by Spheros 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 Spheros homepage under
Service/Downloads/Heating systems.
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:
• Operating and Service Instructions
• Installation Instructions
• Technical Information (TI)
• Spare Parts List
• Operating Instructions for the Spheros Thermo Test,
further referred to as STT Diagnosis
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 proce-
dures.
1.6.1 General safety regulations
Read the Thermo plus Operating and Service Instruc-
tions before operating the heater for first time.
Familiarize yourself with the Thermo plus Installation
Instructions before you make any modifications to the
existing heater installation.
NOTE:
The Thermo plus Operating and Service Instructions
contain safety instructions and regulations to be followed
for safe operation of the heater.
The Thermo plus 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!
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.
Danger to life and health!
Warning!

102
Thermo plus 230/300/350 1 Introduction
1.6.2 Other safety information
1.6.2.1 Temperature sensors
ATTENTION:
The temperature sensors cable may not be mechani-
cally stressed (pull on the cable, carry the heater at
the cable etc.).
1.7 Suggestions for improvement and
change
Please direct any complaints, improvement or modifica-
tion suggestions regarding this manual to:
[e-mail]
STOP!

201
Thermo plus 230/300/350 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.
Table 201 Technical Data
2.1 Elektrical components
Control unit, circulating pump, solenoid valve, electronic
ignition and the digital timer are designed for 24V nominal
voltage. The burner motor supply voltage is controlled by
the control device.
NOTE:
Circulating pumps must be assigned to the heaters
according to the flow resistance in the coolant circulation
system.
2.2 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 Spheros approved fuels
and their specifications.
Heater Thermo plus 230 Thermo plus 300 Thermo plus 350
ECE Type Approval Number E1 122R 00 0466 0467 0468
Kind of construction High pressure atomizer
Heating flow (at ambient temperature of
20°C)
kW
(kcal/h)
23
(20 000)
30
(26 000)
35
(30 000)
Fuel Diesel / Heating oil
Fuel consumption kg/h 2.5 3.0 3.6
Rated voltage V = 24
Operating voltage range V = 20.5 ... 30
Rated power consumption at 24V * W 60 90 120
Max. permitted temperature of sucked
combustion air at < 85°C ambient tem-
perature
°C
85
Max. permitted temperature of sucked
combustion air at > 85°C ambient tem-
perature
°C
60
Permitted ambient temperature during ope-
ration
°C -40...+ 85 (100**)
Permitted storage temperature °C -40...+ 110
Permitted operating overpressure bar max. 2.0
Capacity of the heat exchanger l 1.8
Minimum water flow *** l/h 1900 2400 2700
Minimum capacity of the water system l 25
CO2in exhaust gas at rated voltage Vol % 9.0 +1.5 9.5 +1.5 9.5 +1.5
Heater dimensions (tolerance ±3 mm) mm Length 540 / Width 250 / Height 222
Weight kg 16.8
* without circulating pump
** When operating in ambient temperatures >85°C a special Spheros wiring harness is to be used.
** Minimum water flow at coolant temperatures above 50°C
Below 50°C a lower water flow is permitted, if the occurence of vapor bubbles due to local overheating safely can be excluded.

202
Thermo plus 230/300/350 2 Technical Data
*Further information on approved fuels contains the TI
(Technical Information) Fuels.
It can be found on the Spheros homepage under Ser-
vice/Technical Updates/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.
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 plus 230/300/350 3 Assemblies and components
3 Description of assemblies and
components
The heaters Spheros Thermo plus 230, plus 300 and
plus 350 are used in conjunction with the vehicle heating
system
– to heat the passenger compartment
– to defrost the windows
– 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
down to the vehicle chassis or is secured using an addi-
tional cross beam.
Heat is generated by combustion of liquid fuels. 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 (intermittend
mode).
The control device controls on the basis of the signals of
a temperature sensor the on and off switching of the
burner.
Fig. 301 Heater overview
1
2
4
5
6
7
8
9
10
1 Burner head
2 Coolant, intake
3 Temperature sensors
4 Coolant, outlet
5 Heat exchanger
6 Exhaust outlet
7 Fuel, return
8 Combustion air, intake
Version for
additional sensor
11
9 Fuel, supply
10 Splashguard
(grid alternative)
11 Grid
12 Intake air elbow
incl. adapter
(grid alternative)
12
3

302
Thermo plus 230/300/350 3 Assemblies and components
The heaters of the Thermo plus series basically consist of
the main components:
• burner head
• combustion chamber
• heat exchanger
External in the vehicle a circulation pump is installed or in
case of compact device directly on the heater.
3.1 Burner head
The burner head consists of the components
• combustion air fan
• control device with burner motor and flame guard
• fuel pump with solenoid valve and atomizer nozzle
• electronic ignition unit with ignition electrodes
• nozzle preheater (optional)
• disc with sight window
3.1.1 Combustion air fan
The combustion air fan (Fig. 302) transports the air
required for combustion from the combustion air intake to
the combustion chamber.
The combustion air fan consists of the burner motor at the
control device and the fan wheel. Air is drawn in through
the air intake opening in the hood.
This air intake opening is equipped with a splashguard, a
protective grid or an intake air elbow (see Fig. 301).
3.1.2 Control device
The control device (Fig. 303) ensures the operating
sequence and burner operation monitoring. It constitutes
a unit with the burner motor.
The control device is mounted onto the front of the burner
housing, under the hood. It protrudes with four external
electric ports out the heater:
• Port C - power/control,
• Port P - circulating pump,
• Port T - temperature sensors and
• Port G - diagnosis interface
Internally the control device provides the ports
• connector V - nozzle preheater,
• connector M - solenoid valve, and
• connector Z - electronic ignition unit.
3.1.2.1 Burner motor
The control device constitutes a unit with the brushless
EC burner motor which is installed at the burner housing.
This arangement allows its direct power supply via the
control device board. The speed measurement is done by
a Hall sensor module.
The shaft of the external rotor motor protrudes through the
control device. To the forward end the fan wheel is instal-
led and on the backside of the control device via a coup-
ling the fuel pump is driven.
The speed of the burner motor is controlled depending on
the operating status by the control device.
Fig. 302 Combustion air fan
Fan wheel
Burner motor
(displayed transparently)