Valeo Thermo H 160 Workshop Manual
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Valeo Thermo H 160 Workshop Manual

Valeo Thermo H 160 Workshop Manual

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

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Summary of Contents for Valeo Thermo H 160

  • Page 1 HEATING SYSTEMS Thermo H 160 Thermo H 230 Thermo H 300 Thermo H 350 Workshop Manual Rev. 03/2019 Id.No. 11123930B...

  • Page 2: Table Of Contents

    Thermo H Content Introduction Content and purpose Effectivity of the workshop manual Meaning of highlighted content Symbols Further documentation to be used Safety information and regulations 1.6.1 Required qualifications 1.6.2 Emergency stop / de-energizing 1.6.3 Work at the heater Suggestions for improvement and change Technical data Fuel Description of assemblies and components...
  • Page 3 Thermo H Content Servicing General 7.1.1 Heater servicing HV heater servicing D heater servicing Components and heater removal and installation General HV control head 8.2.1 Temperature guards (temperature limiter, control thermostat) removal/installation. 8.2.2 Hood removal/installation 8.2.3 Housing removal/installation (incl. cable connections) 8.2.4 Small distribution board removal/installation 8.2.5...

  • Page 4: Introduction

    It may be subjected to modifications and amendments. The respectively currently effectife version is binding. This Orientation help - next wor- version can be found on the Valeo homepage under king step (s) on the Diesel www.valeo-thermalbus.com/eu_en/Service/Downloads/ burner head.

  • Page 5: Required Qualifications 102

    (maintenance, service work, abnormal beha- service-valeobus@valeo.com vior etc.). 1.6.3 Work at the heater High voltage!

  • Page 6: Technical Data

    Thermo H 2 Technical data 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...

  • Page 7: Fuel 202

    Only the on the model plate of the heater tains the TI (Technical Information) Fuels. specified fuel must be used. It can be found on the Valeo homepage under Service/ Technical Updates (TI)/Heating systems. The following table lists the by Valeo approved fuels and their specifications.

  • Page 8: Description Of Assemblies And Components

    Thermo H 3 Description of assemblies and components Description of assemblies and components The water heater, hereafter referred to as heater, is used a) by burning liquid fuel, and in conjunction with the vehicle’s own heating system b) by electric current. –...

  • Page 9: Hv Control Head 302

    Thermo H 3 Description of assemblies and components HV control head 3.1.1 Small distribution board The small distribution board (3, Fig. 302) includes the The AC/DC control head (see Fig. 302) consists of an components required for the electrical part of the heater aluminum die-cast ring as housing (4) and the hood (1).

  • Page 10: Heat Exchanger 303

    Thermo H 3 Description of assemblies and components Heat exchanger the heating cartridges. At the rear, the Diesel burner head is fixed. In the heat exchanger (1, Fig. 303) the water flowing 3.2.1 Combustion chamber through is heated directly by heating cartridges (7) arran- ged in a ring shape.

  • Page 11: Diesel Burner Head 304

    Thermo H 3 Description of assemblies and components Diesel burner head The diesel burner head is used to generate the diesel-air mixture, which is burned in the combustion chamber. Components for the control of the combustion process are integrated. Further information can be found in Chapter 3 of the Workshop Manual for the Thermo S series heaters.

  • Page 12: Functions Of The Heater

    Thermo H 4 Functions of the heater Functions of the heater General functional description of the is regulated. The overheat protection opens its contact at 125°C and heater must be mechanically reset by service personnel. The Thermo H hybrid heater integrates two different and ATTENTION: independent each other coolant heating systems: After the overheating protection has been triggered,...

  • Page 13: D Heater 402

    The speed required for the CO -content is determined during first calibration at Valeo and is stored in the control unit. For overheating protection of the heater the switching In a maintenance event the workshop can adjust the CO thresholds are modified by the control unit, if specified setting using the DTT diagnosis (Diagnose Thermo Test).

  • Page 14: Switching On And Start 403

    Thermo H 4 Functions of the heater Operational heater sequence Signals Main switch Terminal 61 off (parking heating) on (auxiliary heating) off (parking heating) Coolant temperature T > T_min T < T_min T >= T_max T < T_min T >= T_max T <...

  • Page 15: Heating Operation 403

    Thermo H 4 Functions of the heater sequence. The control unit recognises the quick temperature Different switching thresholds are defined for different increase and automatically sets the upper switching heater operating modes. threshold to a lower value. The switching thresholds are selected depending on the The quicker the temperature increases, the lower the present condition and the selected heating operation.

  • Page 16: Diagnosis Interface And Dtt Diagnosis 405

    Each malfunction interlock and heater interlock is stored The latest DTT diagnosis software can be found in the in the control unit. Internet on the Valeo homepage under Service/ Downloads/Heating Systems/Diagnostic-Preheater-Fuel- The heater should be protected against thermal loads. Filter-Software.
  • Page 17 Thermo H 4 Functions of the heater Thermal loads can be triggered by: • Voltage exceeding the high voltage threshold of approx. 30 V at motor start or within a duration of 6 seconds (run- • Coolant flow too low down only, no malfunction interlock).
  • Page 18 NOTE: Prior to restarting the heater troubleshooting must be The heater starts after reconnection to the vehicle electri- performed by personnel trained by Valeo in order to cal system automatically. identify and remedy the cause. The heater can be switched off during initial cycle.

  • Page 19: Error Output 408

    Thermo H 4 Functions of the heater ATTENTION: It is not allowed to disconnect the heater from the vehicle mains by pulling the heater connector under power. 1. Read out the heater error memory using the DTT diagnosis. 2. Disconnect the switched-on and interlocked heater from the vehicle electrical system for >...

  • Page 20: Troubleshooting And Error Correction

    5 Troubleshooting Troubleshooting and error correction General This section describes troubleshooting and error correc- tion for Thermo H 160, H 230, H 300 and H 350 heaters. Warning! Danger to life and health! The safety information and regulations (see 1.6) must be observed.

  • Page 21: D Heater Troubleshooting 502

    Thermo H 5 Troubleshooting Table 501: Error symptoms and possible causes Error symptom Possible cause No HVIL (Interloop) signal (if existent) • SC600 respective the control unit does not transmit a HVIL signal • HVIL contact is not established • Hood not (correctly) mounted •...

  • Page 22: Wiring Diagrams

    Electrical work may only be performed by persons, which have the required qualification (see 1.6.1). NOTE: Consider also the information on the electrical installation given in the Thermo H Installation and operating instruc- tion. The document is available for download at www.valeo-thermalbus.com/eu_en/Service/Downloads/ Heating-systems/Thermo-H.
  • Page 23 Thermo H 6 Wiring diagrams HV heater Contactor / Schütz AC 600V DC Contactor / Schütz DC End connector / Endverbinder X - not connected X - Anschluss nicht belegt End connector / Endverbinder Fig. 601 Housing removal for devices Thermo H AC/DC 9,3/7,0 kW (heater ident. no. acc to model plate 11121208A)
  • Page 24 Thermo H 6 Wiring diagrams HV heater Fig. 602 Housing removal for devices Thermo H AC/DC 9,3/7,0 kW (heater ident. no. acc to model plate 11121208B)
  • Page 25 Thermo H 6 Wiring diagrams HV heater Fig. 603 Housing removal for devices Thermo H DC/DC 7,0/7,0 kW (heater ident. no. acc to model plate 11124146 and 11124147)
  • Page 26 Thermo H 6 Wiring diagrams HV heater End connector / Endverbinder Contactor / Schütz AC X - not connected X - Anschluss nicht belegt Fig. 604 Housing removal for devices Thermo H AC 14,0 kW (heater ident. no. acc to model plate 11123469B, 11124196B and 11124197A)
  • Page 27 Thermo H 6 Wiring diagrams HV heater End connector / Endverbinder End connector / Endverbinder X - not connected X - Anschluss nicht belegt Contactor / Schütz DC Fig. 605 Housing removal for devices Thermo H DC 7,0 kW (heater ident. no. acc to model plate 11121604A)
  • Page 28 Thermo H 6 Wiring diagrams D heater Fig. 606 Housing removal for devices Thermo H DC 7,0 kW (heater ident. no. acc to model plate 11121604B)
  • Page 29 Thermo H 6 Wiring diagrams D heater X - not connected X - Anschluss nicht belegt 11121073A Contactor / Schütz AC Contactor / Schütz DC Connecting HLP / Anschluss HLP Connecting HLP / Anschluss HLP orange cable white cable orange cable blue cable (oranges (weißes...
  • Page 30 Thermo H 6 Wiring diagrams Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) DC12 DC22 DC23 DC24 DC20 DC17 DC14 Fig. 609 Small distribution board removal for devices Thermo H DC/DC 7,0/7,0 kW (heater ident. no. acc to model plate 11124146 und 11124147) X - not connected 11123481_ X - Anschluss nicht belegt...
  • Page 31 Thermo H 6 Wiring diagrams X - not connected X - Anschluss nicht belegt 11122854_ Contactor / Schütz DC Connecting HLP / Anschluss HLP orange cable white cable (oranges (weißes Kabel) Kabel) DC11 DC12 DC16 DC15 DC13 DC17 Fig. 611 Small distribution board removal for devices Thermo H DC 7,0 kW (heater ident. no. acc to model plate 11121604A) 11137637A Connecting HLP / Anschluss HLP...
  • Page 32 Thermo H 6 Wiring diagrams D heater The minimum cable cross-sections indicated in the table must be applied. Cable length <7.5m Cable length 7.5 - 15m 0.75 mm² 1.5 mm² 2.5 mm² 4.0 mm² * * The cable cross-section is to be reduced to 2.5 mm² in front of the heater...
  • Page 33 Fig. 613 System wiring diagram for the D heater of the Thermo H, legend see page 613 75(15) (HG) (UP) Heater cable harness UP 1 2,5mm UP - UP + 2,5mm Valeo Terminal 31 2.5mm Spheros Terminal 30 (1) 2,5mm Pre-selection 2,5mm rt/ws Terminal 30(2) 0,75mm...
  • Page 34 Thermo H 6 Wiring diagrams Position Designation Operation indicator max. 5W Combustion air motor Nozzle block preheater Car flat-type fuse 25A acc. to DIN 72581 part 3 Car flat-type fuse 25A acc. to DIN 72581 part 3 Car flat-type fuse 5A acc. to DIN 72581 part 3 Flame indicator max.

  • Page 35: Servicing

    HV heater servicing The necessary service work can be found in the main- tenance plan for the Thermo AC/DC heater series. This can be downloaded from the Valeo homepage in the Service/Downloads/Heating Systems/Thermo AC DC section. D heater servicing...

  • Page 36: Components And Heater Removal And Installation

    If components are disassembled to a degree not covered in this workshop manual, any warranty claim shall be voided. Only genuine Valeo spare parts should be used. In the figures of the procedures following icon is used: Symbol tightening torque: Features in graphics parts (e.g.

  • Page 37: Hv Control Head 802

    Thermo H 8 Repairs HV control head 8.2.1 Temperature guards (temperature limiter, Installation 1. Screw the control thermostat (7, Fig. 801) by hand into control thermostat) removal/installation. the coolant inlet. 2. Install protection cap (6). 3. Slide rubber cap (4) of the temperature limiter (2) back until it can be put in its installation position.

  • Page 38: Hood Removal/Installation 803

    Thermo H 8 Repairs 8.2.2 Hood removal/installation 8. Remove housing (12) from heater. Installation Removing the hood provides access to the following 1. Position housing (12) over the small distribution board components for maintenance, inspection and repair onto the heater and then secure it using screws (24, purposes: Fig.

  • Page 39: Heating Cartrides/Screw Plugs Removal/Installation 804

    Thermo H 8 Repairs NOTE: For connections to be established, refer to wiring diagrams in Chapter 6, depending on the heater version. Actuation tool Compare the heater ident. number under the wiring diagram with that on the model plate of your heater. Wire 5.
  • Page 40 Thermo H 8 Repairs 1.5 -0.3 Nm 8 -1 Nm 15 -1 Nm 16 +1 Nm 9 10 5 +1 Nm 10 +1 Nm 8 +1 Nm 10 -1 Nm 2 +0.5 Nm 30 ±1 Nm 30 ±1 Nm 10 +1 Nm Fig.

  • Page 41: Hv Dc Wiring Harness Removal/Installation 806

    Thermo H 8 Repairs 4. Using a wrench loosen the heating cartridges (20, Fig. 5. If necessary disconnect connectors from the HVIL 805) or the screw plugs (21), screw them out and socket (Fig. 808). remove them from heat exchanger. Discard gasket 6.

  • Page 42: Hv Ac Wiring Harness Removal/Installation 807

    Thermo H 8 Repairs 5. Check the wiring again using the wiring diagram. socket (Fig. 808). 6. Bundle single wires using cable ties. 6. Remove ties wich bundle disconnected wires. 7. Install hood (see 8.2.2). 7. Separate single wires at the end connectors (see 8.

  • Page 43: Pump Harness Harness Removal/Installation 808

    Thermo H 8 Repairs 6. Bundle single wires using cable ties. 7. Install hood (see 8.2.2). 8. Connect all supply cables to the vehicle electrical sys- tem, fix them if required. 9. Perform a function check. 8.2.9 Pump harness harness removal/ installation Removal 1.

  • Page 44: Diesel Burner Head 809

    Thermo H 8 Repairs Diesel burner head 8.3.1 Burner removal/installation Removal 1. Establish voltage-free state of the heater and secure it for duration of the work (Observe 1.6.3 2. If necessary, disconnect the combustion air intake line from the heater. Removing the Diesel burner head, in the following 3.

  • Page 45: Hood Removal/Installation 810

    The two combination nuts M8, connecting the burner and the heat exchanger, must be tightened to 7.5 +1 Nm each and additional are to be secured using thread lock (Valeo ident. no.: 154245Z). 17 ±1 Nm 8.3.2 Removal/installation of the temperature sensor with integrated...

  • Page 46: Combustion Air Fan Removal/Installation 811

    Thermo H 8 Repairs 8.3.4 Combustion air fan removal/installation b) the position of cut-outs in the combustion chamber head. Removal NOTE: 1. Remove burner (see 8.3.1). – The combustion chamber should be inserted into the 2. Withdraw combustion chamber (1, Fig.

  • Page 47: Heat Exchanger Removal/Installation 812

    Thermo H 8 Repairs Heat exchanger removal/installation 6. Install screws (24, Fig. 805) with washers (15). 7. Install temperature sensor (D heater), refer to 8.3.2. 8. Install temperature guards (HV heater), refer to 8.2.1. Removal 9. Install threaded pins (9, Fig.
  • Page 48 Thermo H 8 Repairs 3. Close coolant hoses (7, Fig. 811) using suitable pinch- 5. If necessary, install the extension/deflection onto the off pliers. exhaust outlet (3, Fig. 811) using a hose clamp . 4. Loosen hose clamps (8) and pull the coolant hoses (7) 6.

  • Page 49: Start-Up After Burner Or Heater Installation 814

    Thermo H 8 Repairs Start-up after burner or heater While the vehicle engine is switched off, switch on the heater with the circulating pump and the vehicle heating fan. installation After the engine motor cooled down, the heater must automatically start and stop as soon as the upper swit- The coolant circuit and the fuel system must be bleeded ching threshold is reached.

  • Page 50: Modifications And Retrofits

    Thermo H 9 Modifications and retrofits Modifications and retrofits General 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 51: 10 Packing/Storage/Shipping

    Thermo H 10 Packing/storage/shipping Packing/storage/shipping 10.1 General The heater or its components, which are sent to Valeo for inspection or repair, must be cleaned and packaged to ensure that handling, transport and storage will not damage them. ATTENTION: If a complete heater is sent back, it must be comple- tely drained.
  • Page 52 memos...
  • Page 53 Valeo Thermal Commercial Vehicles Germany GmbH Friedrichshafener Str. 7 - 82205 Gilching - Germany - Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889 www.valeo-thermalbus.com - service-valeobus@valeo.com...

This manual is also suitable for:

Thermo h 230Thermo h 300Thermo h 350

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