Spheros Thermo S 160 Workshop Manual
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Spheros Thermo S 160 Workshop Manual

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Water Heater
Status: 01/2012
Ident.-no. 11114913B
Workshop Manual
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400
with Control Unit 1586

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Summary of Contents for Spheros Thermo S 160

  • Page 1 Workshop Manual Water Heater Thermo S 160 Thermo S 230 Thermo S 300 Thermo S 350 Thermo S 400 with Control Unit 1586 Status: 01/2012 Ident.-no. 11114913B...

  • Page 3: Table Of Contents

    Introduction Content and purpose d i l y t i g i l i l p o i t l l a l l a l l a l c i Technical data Electrical components Fuel Assemblies and components descriptions Burner 3.1.1 Combustion air fan...
  • Page 4 1 Introduction Thermo S 160/230/300/350/400 General error symptoms Malfunction code output via flash code Error symptoms during functional tests with malfunction code output or diagnosis 5.4.1 Error symptom "No start within safety period" 5.4.2 Error symptom "Flame interruption" 5.4.3 Error symptom "Low voltage"...
  • Page 5 Thermo S 160/230/300/350/400 1 Introduction Modifications and retrofits 10 Packing / storage and shipping 10.1 General 1001 Appendix A 1 Periodic heater maintenance...
  • Page 6 1 Introduction Thermo S 160/230/300/350/400...

  • Page 7: Content And Purpose

    R10 (EMC): No. 03 5266 and maintenance and repair of water heaters Thermo R122 (Heater) No. 00 0208 for Thermo S 160 S 160, S 230, S 300, S 350 and S 400. No. 00 0226 for Thermo S 230 No.
  • Page 8 This in particular applies for the circulating Spheros. pump, which does not automatically draw. CAUTION After coolant replacement sufficient purging of the cooling system must be ensured.
  • Page 9 160/230/300/350/400 Water heating circulation system - wall heater and roof channel heater Wall heater with fan Heat exchanger at the entrance Heater Circulation pump Roof heat exchanger Vehicle engine Shut-off valve Driver seat heater Control element Supply Return Fig. 101 Heater installation example in a bus Coolant level verification and cooling system purging must be performed acco rding to the vehicle If a shut-off fitting is installed in the return line, an...
  • Page 10 Suggestions for Improvement and change Please direct any complaints, improvement or modification suggestions regarding this manual to: Spheros North America, Inc. 5536 Research Drive Canton MI. 48188 Telephone: 1-734-218-7350 Fax: 1-734-487-1569 website: www.spheros.us / info@spheros.us...
  • Page 11 160/230/300/350/400...

  • Page 12: Electrical Components

    * without circulating pump Max. continuous current of the circulating pump 10 A, maximum peak current for 0.5 s duration = 90 A - We recommend the use o f Spheros circulation pumps for highest efficiency and reliability. In order to reduce starting currents the circulating pump can be synchronized by the control unit f or a short time period during activation.
  • Page 13 S 160/230/300/350/400 CAUTION The listed temperature ranges, hence minimum permissible temperatures strongly depend on the respective fuel quality. In case of bad-quality fuel the use limitations may deviate, e.g. in case of too high water content. At temperatures below 32°F (0°C ) commercially available winter diesel should be used.

  • Page 14: Burner

    (cyclic operation). The control unit controls heater activation and The Spheros Thermo S 160, S 230, S 300, S 350 and deactivation based on the te mperature sensor signals. S 400 water heater systems are used in conjunction with...

  • Page 15: Combustion Air Fan

    3 Assemblies and components Thermo S 160/230/300/350/400 3.1.2 Fuel pump Burner The fuel pump is responsible for fuel supply. The burner consists of components The pump is driven by the burner motor via a coupling. Fuel is compressed in the fuel pump to approx. 10 bar and Burner motor atomised via the atomiser nozzle.

  • Page 16: Control Unit

    Thermo S 160/230/300/350/400 3 Assemblies and components 3.1.4 Control unit The fuel pump can be used in dual-line operation (fuel supply and return line). The control unit 1586 ensures the operating sequence If the heater is operated with and burner operation monitoring.

  • Page 17: Temperature Sensors With Water Temperature Sensor And Integrated Overheating Protection

    3 Assemblies and components Thermo S 160/230/300/350/400 3.1.6 Temperature sensors with water temperature sensor and integrated Electronic ignition unit Disc overheating protection The water temperature sensor captures the coolant temperature at the heat exchanger outlet as electrical resistance. This signal is transmitted to the control unit, where it is processed.

  • Page 18: Heat Exchanger

    Thermo S 160/230/300/350/400 3 Assemblies and components Heat exchanger The heat exchanger transfers the heat generated by combustion to the coolant circulation system. Depending on the system integration a heat exchanger with or without thread in the coolant inlet socket can be installed.

  • Page 19: Combustion Chamber

    Thermo S series. Deviating from the standard combustion chamber variant for Thermo S 230, S 300 and S 350, the Thermo S 160 is equipped with a combustion chamber with a sheet metal swirler and the Thermo S 400 is equipped with a burner pipe with increased wall thickness (1.5 mm).

  • Page 20: Circulating Pump

    Thermo S 160/230/300/350/400 3 Assemblies and components Circulating pump Aquavent 5000 (U4814) Aquavent 5000S (U4854) c r i Aquavent 5000 Aquavent 6000C 5200 5200 6000 6000 US Gal/m 26.4 26.4 12 ... 24 10 ...14/20 ... 28 Nominal power consumption...

  • Page 21: Aquavent 6000C (U4855 ) And Aquavent 6000Sc (U4856) Circulating Pumps

    3 Assemblies and components Thermo S 160/230/300/350/400 3.4.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps Inverse-polarity protection The circulating pump motor is not equipped with an internal inverse-polarity protection. The Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps are Fuel filter equipped with a brushless motor.
  • Page 22 The speed required for the CO 2 -content is determined during For overheating protection of the heater the switching first calibration at Spheros and is stored in the control unit. thresholds are modified by the control unit, if specified In a maintenance event the workshop can adjust the CO 2 - temperature gradients are exceeded.

  • Page 23: Switching On And Start

    o S 160/230/300/350/400 Operational heater sequence Signals Main switch Terminal 61 a i l > < > < > < Actuators Operating display Flame display Combustion air motor Circulating pump Electronic ignition unit Solenoid valve Nozzle block preheater Time in s 0..108 12 0..15 0..108 12...

  • Page 24: Switching Off

    4.2.2.3 Gradient evaluation Once the temperature falls short of the lower switching threshold, the heater restarts burner operation. It runs through the same sequence as the switching-on In case of low coolant flow or poor coolant circuit venting sequence. the temperature quickly increases in heating operation. Different switching thresholds are defined for different The control unit recognises the quick temperature heater operating modes.
  • Page 25 o S 160/230/300/350/400 If a malfunction occurs during run-down (e.g. flame detection), the run-down may be shorter than 120 seconds. During run-down it is permitted to switch the heater back on. The burner will restart after a run-down time of 30 seconds and subsequent initial cycle time.

  • Page 26: Test Plug

    For protection against moisture and contamination ensure that the diagnosis interface is sealed using protective caps, if not in use. The latest SST diagnosis software can be found in the Internet on the Spheros homepage under Service / Technical Documents.

  • Page 27: Malfunction Interlock

    o S 160/230/300/350/400 Malfunction interlock and heater Malfunction criteria: Short circuit and/or interruption of electrical interlock components: – Burner motor (stops immediately) Malfunction interlocks and heater interlocks are – Circulating pump distinguished. – Electronic ignition unit Each malfunction interlock and heater interlock is stored –...

  • Page 28: Heater Interlock

    If the heater interlock is active, neither start nor run-down are executed after switching the heater back on. Prior to restarting the heater troubleshooting must be performed by personnel trained by Spheros in order to identify the root cause. After that the heater interlock can be released (see 4.6.1).

  • Page 29: Error Output

    o S 160/230/300/350/400 4.6.1.1 Release of a heater interlock triggered by the 4.6.1.2 Release of a heater interlock triggered by temperature sensors other malfunctions using SST diagnosis If the heater interlock was triggered less than 1. Switch interlocked heater off. 120 seconds ago: 2.

  • Page 30: General

    Corrosion on cable and fuses Corrosion on battery terminals Cable insulation damage This section describes troubleshooting and error correction for Thermo S 160, S 230, S 300, S 350 and S 400 heaters. CAUTION Prior to replacing a fuse troubleshooting needs to be performed.
  • Page 31 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Table 501: General error symptoms Error in the water system Circulating pump not operating (Aquavent 6000S and Error mode activated. Aquavent 6000SC only). In case of malfunctions the motor is switched off via the error mode.

  • Page 32: Malfunction Code Output Via Flash Code

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Table 501: General error symptoms Error in the fuel supply i l e . y t Bent, closed, clogged or leaking lines. Paraffin deposits or frozen water entrapments in fuel lines or lines.
  • Page 33 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Table 502 Error and flash codes Error description Flash code No start within safety period s t r Low voltage Extraneous light (flame detector "Bright" prior to ignition) or (flame detector "Bright" in run-down 2)

  • Page 34: Error Symptoms During Functional Tests With Malfunction Code Output Or Diagnosis

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Error symptoms during functional tests with malfunction code output or diagnosis 5.4.1 Error symptom "No start within safety period" If due to a malfunction the heater unsuccessfully attempted to start eight times in a row, it will be interlocked.
  • Page 35 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Clean and securely mount the combustion air intake Are the combustion air intake opening and line and the opening and line and the exhaust line. exhaust line clean and securely mounted? Secure fresh air supply. Prevent Is sufficient fresh air intake ensured and are no exhaust fumes exhaust intake.

  • Page 36: Error Symptom "Low Voltage

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.4.3 Error symptom "Low voltage" A value is stored in the control unit as smallest "permissible low voltage". It must be noted that the voltage may be lowered during heater start, and that the "low voltage" threshold may be violated.

  • Page 37: Error Symptom "Extraneous Light Detected Prior To Ignition Or During Run-Down

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.4.4 Error symptom "Extraneous light detected prior to ignition or during run-down" Correct overheating cause. Did overheating occur? Is the burner properly screwed onto the Properly screw burner onto the heat heat exchanger? exchanger.

  • Page 38: Error Symptom "Flame Detector Defective

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.4.5 Error symptom "Flame detector defective" The flame detector cannot be replaced. It can only be tested using SST diagnosis. In case of damage or if the target value cannot be reached, the control unit must be replaced as needed.

  • Page 39: Individual Component Tests

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.5.1 General visual inspection Individual component tests Inspect componen ts for damages (cracks, deformation, Individual components can basically be tested using leaks, discolourations, etc.) and replace as needed. visual inspection or manual electrical testing.

  • Page 40: Resistance Check Of The Temperature Sensor With Integrated Overheating Protection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Pin 3 & 4 Water temperature sensor Pin 1 & 2 Overheating protection Fig. 503 5.5.4 Resistance check of the temperature sensor with integrated overheating protection Fig. 504 WARNING Prior to removing the temperature sensor, the Resistance vs.

  • Page 41: Adapter Wiring Harness Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.5.5 Adapter wiring harness inspection Check circlip for proper fit. Install hood (see 8.4). Inspection Inspect adapter wiring harness for tight fit and damage of the rubber grommet and the plug. Hood Remove hood (see 8.4).

  • Page 42: Electronic Ignition Unit Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Inspection using SST diagnosis 5.5.8 Electronic ignition unit inspection Disconnect the heater from the vehicle electrical system. NOTE Disconnect the temperature sensor plug and connect It is possible to manually te st the functionality of the the test plug to the adapter wiring harness.

  • Page 43: Ignition Electrode Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Inspection using SST diagnosis WARNING Remove burner (see 8.2). High voltage: The voltage received by the ignition electrode is >13.000 Volt. Connect the test plug to the adapter wiring harness. During operation or testing the ignition electrode may not be contacted by persons or items.

  • Page 44: Flame Detector Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.5.10 Flame detector inspection Electronic ignition unit NOTE Disc In case of contamination the glass body of the flame detector and the inspection glass in the disc (see Fig. 513) must be cleaned.

  • Page 45: Fuel Pump Inspection

    A pressure test unit with a display range from 0 to 15 bar is required (Fig. 514). After the test is completed, exit SST diagnosis as The pressure test unit can be obtained from a Spheros needed. Service Center or a distribution partner.

  • Page 46: Solenoid Valve Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Select and start the solenoid valve in the Component Test menu. The solenoid valve must audibly open. After the test is completed, exit SST diagnosis as needed. Disconnect the heater from the vehicle electrical system.

  • Page 47: Nozzle Block Preheater Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Manual inspection 5.5.13 Nozzle block preheater inspection Remove burner (see 8.2). CAUTION Disconnect the nozzle block preheater plug from the The heating element of the nozzle block preheater can control unit. heat up during inspection.

  • Page 48: Circulating Pump Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.5.14 Circulating pump inspection CAUTION The safety device of the circulating pump may never be pulled, while the pump is running. Inspection using SST diagnosis Disconnect the heater from the vehicle electrical system.
  • Page 49 5 Troubleshooting and error correction Thermo S 160/230/300/350/400...

  • Page 50: General

    Thermo S 160/230/300/350 Schematic diagrams General The following figures represent customer-dependent heater connection options to the vehicle electrical system. The heater wiring harness cables as well as the cables of the vehicle electrical system are shown. CAUTION In case of vehicle cable lengths up to 7.5 m the cable...
  • Page 51 mo S 160/230/300/350/400 (HG) (UP) Heater wiring harness UP - 2,5mm UP 1 UP + 2,5mm Terminal 31 2.5mm 2,5mm Terminal 30 (1) 2,5mm rd/wt Terminal 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Terminal 61 (D+) 0,75mm rd/wt 0,75mm K-line or CAN-H 0,75mm L-line or CAN-L Saving mode 1...
  • Page 52 Thermo S 160/230/300/350 75(15) (UP) (HG) Heater wiring harness UP 1 2,5mm UP - UP + 2,5mm Terminal 31 2.5mm Terminal 30 (1) 2,5mm 2,5mm rd/wt Terminal 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Terminal 61 (D+) 0,75mm rd/wt 0,75mm...
  • Page 53 mo S 160/230/300/350/400 (UP) (HG) Terminal 31 2,5mm br Terminal 30(1) 2,5mm rd Terminal 30(2) 2,5mm rt/wt 0,75mm bl 0,75mm bl L-line 0,75mm rd K-line UP - 2,5mm br UP - 2,5mm br UP 1 UP + 2,5mm bl UP monitoring 0,75mm bl UPFA 0,75mm or...
  • Page 54 mo S 160/230/300/350/400 (UP) (HG) Terminal 31 2,5mm br Terminal 30(1) 2,5mm rd Terminal 30(2) 2,5mm rd/wt 0,75mm bl UP - 2,5mm br UP - 2,5mm br UP 1 UP + 2,5mm bl UP monitoring 0,75mm bl UPFA 0,75mm or BA + 0,75mm bl Terminal...
  • Page 55 mo S 160/230/300/350/400...

  • Page 56: Heater Servicing

    If bio diesel or FAME is used, the fuel pump and fuel lines by a Spheros Service Center. must be replaced according to the latest technical information. You can find the latest overview on the Spheros homepage under Service / Technical Documents.
  • Page 57 160/230/300/350/400 Obtain the next steps from SST diagnosis. Adjust the 7.2.1 CO 2 content adjustment burner motor speed using SST diagnosis to achieve the target value for the CO 2 content. A modification of the factory-adjusted burner motor speed A speed increase results in a reduction of the CO 2 and thus of the exhaust CO 2 content is permitted.

  • Page 58: General

    NOTE If components are disassembled to a degree not covered in this workshop manual, any warranty claim shall be voided. Only genuine Spheros spare parts should be used. Removing the burner provides access to the following components: Atomizer nozzle Fuel pump and solenoid valve...

  • Page 59: Burner Removal And Installation

    Burner installation Burner removal and installation 1. Bring burner (1, Fig. 801) in assembly position and ensure centre alignment and correct fit. Burner removal 2. Place nuts (2) and alternately tighten them slightly. 1. Disconnect the heater from the vehicle electrical 3.

  • Page 60: Removal And Installation Of The Temperature Sensor With Integrated Overheating Protection

    Removal and installation of Hood removal and installation the temperature sensor with integrated overheating protection Removing the hood provides access to the following components for maintenance, inspection and repair WARNING purposes: Risk of injuries if coolant temperature is increased. Burner motor Motor cross member Removal Control unit...

  • Page 61: Combustion Air Fan Removal And Installation

    Installation Combustion air fan removal 1. If necessary, reconnect the burner motor (3, Fig. 803) and installation to the motor cross member (5). For this purpose align the burner motor with the motor cross member. NOTE Observe the motor cross memb er installation position. For replacement of the combustion air fan the burner does Screw the countersunk screws (7) into the dedicated not need to be removed.
  • Page 62 Shaft circlip Burner motor Motor plug Motor cross member Screws (3) Countersunk screws (3) Hood Screws (2) 10 Coupling with magnets 11 Burner housing Fig. 803 Combustion air fan removal and installation...
  • Page 63 Installation Electronic igniti on unit and ignition 1. Bring electronic ignition unit (1, Fig. 804) into electrode removal and installation installation position, attach ready for connection and secure with screws (4). Removal 2. Tighten screws (4) with 5 Nm +1 Nm. 1.
  • Page 64 Electronic ignition unit Screw (2) Ignition electrode Atomizer nozzle Disc Solenoid valve Nozzle block preheater, optional Support Fuel pump 10 O-rings (2) 11 Filter insert 12 Screws (3) 13 Burner housing 14 Control unit 15 Heater wiring harness 16 Adapter wiring harness 17 Coupling with magnets Fig.

  • Page 65: Control Unit Removal And Installation

    Control unit removal and installation 6. Pull fuel pump (9) with the solenoid valve (6) off and remove it. 7. Remove and scrap O-rings (10) and filter insert (11). Removal 8. If applicable, remove the nozzle block preheater (7). 1. Remove burner (see 8.2). For this purpose, remove support (8) from the nozzle 2.
  • Page 66 Electronic ignition unit Screw (2) Ignition electrode Atomizer nozzle Disc Solenoid valve Nozzle block preheater, optional Support Fuel pump 10 O-rings (2) 11 Filter insert 12 Screws (3) 13 Burner housing 14 Control unit 15 Heater wiring harness 16 Adapter wiring harness 17 Coupling with magnets Fig.

  • Page 67: Solenoid Valve Removal And Installation

    Solenoid valve removal and installation 3. Using suitable tools, tighten hexagon, wrench size 16 (6, Fig. 807) of th e solenoid valve with NOTE 5 Nm ± 0.5 Nm. The solenoid valve must be completely replaced and 4. Connect the solenoid valve plug (6, Fig. 806) to the may not be further dismantled! In case of replacement control unit (14, Fig.

  • Page 68: Combustion Chamber Removal And Installation

    8.11 Combustion chamber removal and 8.12 Heat exchanger removal and installation installation Removal Removal 1. Remove burner (see 8.2). 1. Remove burner (see 8.2). 2. Pull combustion chamber (1, Fig. 808) out of the heat 2. If necessary, remove temperature sensor (see 8.3). exchanger (2).

  • Page 69: Start-Up After Burner Or Heater Installation

    8.14.2 Bleeding of the water circuit 8.14 Start-up after burner or heater installation NOTE The fuel system must be bleeded after burner installation. The water circuit must be principally bleeded The coolant circuit and the fuel system must be bleeded according to manufacturer specification.
  • Page 70 Thermo S 160/230/300/350/400 9 Modifications and retrofits Modifications and retrofits For further optimization the heaters are continuously improved. Units in the field can usually be upgraded or retrofitted. For this purpose respective modification kits will be available.
  • Page 71 9 Modifications and retrofits Thermo S 160/230/300/350/400...
  • Page 72 10 Packing / storage / shipping Packing / storage and shipping 10.1 General The heater or its components, which are sent to Spheros for inspection or repair, must be cleaned and packaged to ensure that handling, transport and storage will not damage them.
  • Page 73 10 Packing / storage / shipping Thermo S 160/230/300/350/400 Empty page for notes 1002...
  • Page 74 Appendix A Periodic maintenance...
  • Page 75 (time of applications, the maintenance intervals may be shortened increased heater usage due to present weather or extended. In such cases please cont act your dedicated Spheros conditions). partner for further information. Measured values...

This manual is also suitable for:

Thermo s 400Thermo s 230Thermo s 300Thermo s 350

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