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. 02/2021
Id.No. DOK50065-
001

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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. 02/2021 Id.No. DOK50065-...

  • Page 2: Table Of Contents

    Thermo H plus 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 1.6.4 Cleaning Suggestions for improvement and change...
  • Page 3 Thermo H plus Content HV heater D heater 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.

  • Page 4: Introduction

    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 Orientation help - next wor- www.valeo-thermalbus.com/eu_en/Service/Downloads/ king step (s) on the Diesel Heating-systems/Thermo-H plus.

  • Page 5: Required Qualifications 102

    Installation, maintenance and repairs may only be Please direct any complaints, improvement or modifica- carried out when the vehicle's engine is not running tion suggestions regarding this manual to: and the high voltage supply (AC/DC) / power supply is switched off. service-valeobus@valeo.com...

  • Page 6: Technical Data

    Thermo H plus 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...

  • Page 7: Fuel 202

    Only the on the model plate of the heater spe- ins the TI (Technical Information) Fuels. cified 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 plus 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 plus 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 plus 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 plus 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 plus series heaters.

  • Page 12: Functions Of The Heater

    Thermo H plus 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 plus hybrid heater integrates two different ATTENTION: and 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 ched on and off. For control a temperature sensor is during first calibration at Valeo and is stored in the control installed in the coolant outlet of the heat exchanger. unit.

  • Page 14: Switching On And Start 403

    Thermo H plus 4 Functions of the heater Operational heater sequence Signals Main switch UPFA Econ. mode Terminal 61 off (parking heating) on (aux. heating) Coolant temperature T > T_min T < T_min T >= T_max T >= T_max Actuators Operation indicator Flame indicator Comb.

  • Page 15: Switching Off 404

    Instructions which are supplied with the device. 4.3.2.4 Minimum combustion period The Operation Instructions are also available for down- load on the Valeo website. NOTE: Frequent burning time under 120 seconds may result in NOTE: soot build and increased smoke formation.

  • Page 16: Fault Lock-Out And Heater Lock-Out 405

    In a heater lock-out safety-related components are no fault lock-out). affected by the failure or malfunction. It may only be released by Valeo trained personnel after eliminating the 4.6.2 Malfunctions during heater operation cause. Each fault lock-out and heater lock-out is stored in the In case of malfunctions during heater operation, a 120 control device.

  • Page 17: Fault Lock-Out Release And Error Clearance 406

    5. Repeat steps 2. and 3. Prior to restarting the heater troubleshooting must be 6. Heater is ready for service and starts, if necessary performed by personnel trained by Valeo in order to iden- turn it off. tify the root cause.

  • Page 18: Troubleshooting And Error Correction

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

  • Page 19: D Heater Troubleshooting 502

    Thermo H plus 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 •...

  • Page 20: Wiring Diagrams

    Thermo H plus 6 Wiring diagrams Wiring diagrams General The following figures show wiring diagrams/connecting schematics applicable for the Thermo H plus heater. Wiring diagrams/connecting schematics concerning the electrically operated part of the heater are designated with HV heater - such concerning the Diesel operated part are designated with D heater.
  • Page 21 Thermo H plus 6 Wiring diagrams HV heater Fig. 601 Housing removal for devices Thermo H plus DC/DC 7.0/7.0 kW (heater ident no. acc. to model plate 11143458A and 11143457A)
  • Page 22 Thermo H plus 6 Wiring diagrams HV heater Fig. 602 Housing removal for devices Thermo H plus AC 20.0 kW (heater ident no. acc. to model plate 11139571A and 11143481A)
  • Page 23 Thermo H plus 6 Wiring diagrams HV heater HV Cable Id. no. Heater Id. no. 11124288 11139574A 11139490 11142595A Fig. 603 Housing removal for devices Thermo H plus DC 20.0 kW (heater ident no. acc. to model plate 11139574A and 11142595A)
  • Page 24 Thermo H plus 6 Wiring diagrams HV heater Fig. 604 Housing removal for devices Thermo H plus AC 20.0 kW (heater ident no. acc. to model plate 11142671A)
  • Page 25 Thermo H plus 6 Wiring diagrams HV heater Fig. 605 Housing removal for devices Thermo H plus AC 7.0 kW (heater ident no. acc. to model plate 11142686A)
  • Page 26 Thermo H plus 6 Wiring diagrams HV heater Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) DC12 DC22 DC23 DC24 DC20 DC17 DC14 Fig. 606 Small distribution board removal for devices Thermo H plus DC/DC 7.0/7.0 kW (heater ident no.
  • Page 27 Thermo H plus 6 Wiring diagrams HV heater Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) DC16 DC14 DC13 DC12 DC11 DC10 DC19 DC20 DC17 Fig. 608 Small distribution board removal for devices Thermo H plus DC 20.0 kW (heater ident no.
  • Page 28 Thermo H 6 Wiring diagrams D heater D heater The minimum cable cross-sections indicated in the table must be applied. * Note for F2: The max. possible for the design value is shown. The fuse is to be adapt under circumstances acc. to Cable length <7.5m Cable length 7.5 - 15m the smaller cable cross section of the connected...
  • Page 29 T. 30 2.5mm T. 31 2.5mm 0.75mm UPFA ZFG+ 0.75mm UPFA econ. setting econ. setting 0.75mm ZFG SE T. 61 T. 61 Valeo 0.75mm Pre-selection Valeo ZFG- Vorwahluhr timer SG 1589 0.75mm 0.75mm UP + Coolant temperature UP - sensor...
  • Page 30 Thermo H 6 Wiring diagrams D heater Position Designation Operation indicator 3W (max. 5W) Flame indicator 3W (max. 5W) Circulation pump Spheros Thermo Test (diagnostic tool) F1, F2* Car flat-type fuse 25A acc. to DIN 72581 part 3 or ISO 8820-3 F3 - F7 Car flat-type fuse 5A acc.

  • Page 31: 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 32: 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 33: Hv Control Head 802

    Thermo H plus 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 34: Hood Removal/Installation 803

    Thermo H plus 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 35: Heating Cartrides/Screw Plugs Removal/Installation 804

    Thermo H plus 8 Repairs 8.2.5 Heating cartrides/screw plugs removal/ installation Actuation tool Removal 1. Establish voltage-free state of the heater and secure Wire it for duration of the work (Observe 1.6.3 NOTE: To ensure the safe removal and installation of the heating cartridges, the heat exchanger is to be removed and placed in a vertical mounting position.
  • Page 36 Thermo H plus 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 37: Hv Dc Wiring Harness Removal/Installation 806

    Thermo H plus 8 Repairs NOTE: The groove of the gasket ring must in installed position Installation rest on the heat exchanger. NOTE: 3. Apply thread sealant according to the manufacturer‘s During the next step pay attention that the cables are not instructions onto the thread, see Fig.

  • Page 38: Dc Control Wiring Harness Removal/Installation 807

    Thermo H plus 8 Repairs 3. Remove hood (see 8.2.2). 4. Remove housing (see 8.2.3). 5. Remove ties wich bundle disconnected wires. NOTE: During the next step pay attention that the cables are not jammed or are still connected. “Danger of damage“. 6.

  • Page 39: Diesel Burner Head 808

    Thermo H plus 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 40: Hood Removal/Installation 809

    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...

  • Page 41: Combustion Air Fan Removal/Installation 810

    Thermo H plus 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 42: Heat Exchanger Removal/Installation 811

    Thermo H plus 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 43 Thermo H plus 8 Repairs 3. Reconnect the fuel lines for fuel supply and fuel return 3. Close coolant hoses (7, Fig. 811) using suitable pinch- to the heater, using for each a hollow screw and two off pliers. gasket rings. 4.

  • Page 44: Start-Up After Burner Or Heater Installation 813

    Thermo H plus 8 Repairs Start-up after burner or heater installation The fuel system must be bleeded after burner installation. As soon as it is confirmed that the vehicle engine is filled The coolant circuit and the fuel system must be bleeded with coolant, run vehicle engine with increased idle speed.

  • Page 45: Modifications And Retrofits

    Thermo H plus 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 46: 10 Packing/Storage/Shipping

    Thermo H plus 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 47 memos...
  • Page 48 Valeo Thermal Commercial Vehicles Germany GmbH Friedrichshafener Str. 7 - 82205 Gilching - Germany - Tel. +49 8105 7721-0 - Fax +49 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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