Valeo Thermo E+ 120 Workshop Manual
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Valeo Thermo E+ 120 Workshop Manual

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HEATING SYSTEMS
Thermo E+ 120
Thermo E+ 200
Thermo E+ 320
12/24V
Workshop manual
Rev. 03/2020
Id.No. DOK50059-
001

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Summary of Contents for Valeo Thermo E+ 120

  • Page 1 HEATING SYSTEMS Thermo E+ 120 Thermo E+ 200 Thermo E+ 320 12/24V Workshop manual Rev. 03/2020 Id.No. DOK50059-...
  • Page 2 Thermo E+ 120/200/320 Table of contents 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 General safety regulations 1.6.2 Other safety information Suggestions for improvement and change...
  • Page 3 Thermo E+ 120/200/320 Table of contents 5.5.6 Error symptoms "Temperature sensor / overheating protection defective" and "Overheating" Individual component tests 5.6.1 General visual inspection 5.6.2 Heat exchanger visual inspection 5.6.3 Combustion chamber visual inspection 5.6.4 Resistance check of the temperature sensor with integrated overheating protection 5.6.5...
  • Page 4 Thermo E+ 120/200/320 Table of contents Link list Keyword Link Page Technical-Updates-TI https://www.valeo-thermalbus.com/eu_en/Service/Technical-Updates-TI/ Heating-systems Pumps http://www.valeo-thermalbus.com/eu_en/Products/Pumps Technical-Updates-TI http://www.valeo-thermalbus.com/eu_en/Service/Technical-Updates-TI/ Heating-systems Download http://www.valeo-thermalbus.com/eu_en/Service/Downloads/ Heating-systems/Diagnostic-Preheater-Fuel-Filter-Software...
  • Page 5 The torque values are shown repair of water heaters (further referred to as heaters) at the symbol and are binding. Thermo E+ 120, E+ 200 and E+320 in the 12V and 24V version, as well as in single-pipe and two-pipe version. NOTE:...

  • Page 6: Other Safety Information

    Thermo E+ 120/200/320 1 Introduction NOTE: The Thermo E+ Operating and Service Instructions contain safety instructions and regulations to be followed for safe operation of the heater. The Thermo E+ Installation Instructions contain the statu- tory regulations and other safety hints and regulations for the proper installation of the heater.

  • Page 7: Technical Data

    Thermo E+ 120/200/320 2 Technical Data 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...
  • Page 8 Fuel Suitable fuel is the diesel fuel specified by the vehicle manufacturer. 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. Requirements Remarks Fuel acc.
  • Page 9 The control device controls on the basis of the signals of a temperature sensor the on and off switching of the The heaters Valeo Thermo E+ 120, E+ 200 and E+ 320 burner. are used in conjunction with the vehicle heating system –...

  • Page 10: Combustion Air Fan

    Thermo E+ 120/200/320 3 Assemblies and components Burner The burner consists of the components The combustion air fan consists of the burner motor and the fan wheel. Air is drawn in through the air intake • combustion air fan opening in the hood. This air intake opening is equipped •...

  • Page 11: Control Device

    Thermo E+ 120/200/320 3 Assemblies and components 3.1.2 Control device The control device SG1590 ensures the operating sequence and burner operation monitoring. In the control device the flameguard is integrated. Port „P“ circulating pump ATTENTION: Danger of confusion! Port „C“...
  • Page 12 Thermo E+ 120/200/320 3 Assemblies and components 3.1.2.1 Flame guard The flameguard monitors the combustion flame condition the dust protection tube into the opening in the housing of during heater operation. the control device (see also Fig. 304) and thus to the The flame guard is a photo transistor in the control device photo transistor.

  • Page 13: Fuel Nozzle

    Thermo E+ 120/200/320 3 Assemblies and components 3.1.3 Fuel pump with solenoid valve ting voltage, different fuel pumps are installed in the heaters. The fuel pump is responsible for fuel supply. 3.1.4 Fuel nozzle The pump is driven by the burner motor via a coupling.
  • Page 14 Thermo E+ 120/200/320 3 Assemblies and components 3.1.5 Electronic ignition unit In the electronic ignition unit the high voltage required for - use 11121236_ with the electronic control unit ignition of the fuel-air mixture is induced. 11121234_ (12V) only For this it receives voltage pulses in a certain frequency - use 11121237_ with the electronic control unit from the control device.

  • Page 15: Nozzle Block Preheater

    Thermo E+ 120/200/320 3 Assemblies and components 3.1.6 Nozzle block preheater In case of very low temperatures fuel may exhibit severely 8°C the thermostat switches off. modified viscosity. Due to insufficient fuel atomization functional heater malfunctions may occur. The use of the nozzle block preheater is optional. The retrofitting can be done without control device modifica- Depending on the fuel used, these temperatures vary.
  • Page 16 The cable between the plug and the temperature sensors The overheating protection integrated into the tempera- is shorter with the Thermo E+ 120 than with the Thermo ture sensor is responsible for temperature limitation. As E+ 200/320.

  • Page 17: Combustion Chamber

    They differ in length and the swirl plates (see figure below). The heat exchanger of the Thermo E+ 120 is shorter than The combustion chamber of the Thermo E + 120 has addi- that of the Thermo E+ 200/320.

  • Page 18: Circulating Pump

    Thermo E+ Installa- tion Instructions. All service information regarding your Valeo circulating pump(s) can be found on the Valeo website under Pumps. Heated fuel filter The integrated filter heating is switched on at a fuel tem- perature of ≤...
  • Page 19 • or climate control. The first CO adjustment was made at Valeo. For adaption to different applications (extension of com- During heating operation the burner is automatically swit- bustion air intake or exhaust line) and after any main- ched on and off. For control a temperature sensor is...

  • Page 20: Heating Operation

    Thermo E+ 120/200/320 4 Heater functions Operational heater sequence Processes Signals Main switch UPFA Coolant temperature T > T_US T < T_US T >= T_OS T < T_US T >= T_OS T < T_US Actuators Operating display Combustion air motor...

  • Page 21: Switching Off

    120 seconds, the lower switching The operating instructions are also available for value is lowered by 1K for the following combustion Download from the Internet on the Valeo website. process. The upper switching threshold remains as is.

  • Page 22: Fault Lock-Out

    Control device malfunction In a heater lock-out safety-related components are affected by the failure or malfunction. It may only be released by Valeo trained personnel after eliminating the 4.4.1.2 Malfunctions during heater operation cause. Each fault lock-out and heater lock-out is stored in the NOTE: control device.

  • Page 23: Error Output

    6. Heater is ready for service and starts, if necessary Prior to restarting the heater troubleshooting must be turn it off. performed by personnel trained by Valeo in order to iden- tify the root cause. NOTE: After that the heater interlock can be released (see If the main switch remains in the on position when discon- 4.4.2.1).

  • Page 24: Troubleshooting

    Disconnecting the heater from the This section describes troubleshooting and error correc- vehicle electrical system tion for Thermo E+ 120, E+ 200 and E+ 320 heaters. In case of doubt functional connections can be obtained in Some troubleshooting procedures require to disconnect chapters 3 and 4.
  • Page 25 Thermo E+ 120/200/320 5 Troubleshooting Table 501 General error symptoms Error symptom Possible cause Error in the water system Circulating pump does not operate (Aquavent 6000S and • Error mode activated. Aquavent 6000SC only). In case of malfunctions the motor is switched off via the error mode.
  • Page 26 Thermo E+ 120/200/320 5 Troubleshooting Table 501 General error symptoms Error symptom Possible cause Error in the fuel supply No fuel delivery to the heater. • Fuel tank empty. • Bent, closed, clogged or leaking lines. • Paraffin deposits or frozen water entrapments in fuel filter or lines •...
  • Page 27 Thermo E+ 120/200/320 5 Troubleshooting Table 502 Flash code No. of Error Error description impulses Control device error Control device error No start within safety period No start within safety period Flame interruption in burner operation, repeated Flame interruption start unsuccessful High voltage (>...
  • Page 28 Thermo E+ 120/200/320 5 Troubleshooting Error symptoms during functional 5.5.2 Error symptom "Flame interruption" tests with malfunction code output If due to a malfunction flame interruption occurs during heating operation five times in a row, the heater will be 5.5.1 Error symptom "No start within safety locked-out.
  • Page 29 Thermo E+ 120/200/320 5 Troubleshooting Table 503 Error symptom "No start within safety period“ and “Flame interruption“ Kind of check / Medium Possible cause Fault elemination error symptom Check fuel filter and filter Fuel filter contaminated, clog- head for damage, is it soiled,...
  • Page 30 Thermo E+ 120/200/320 5 Troubleshooting Table 503 Error symptom "No start within safety period“ and “Flame interruption“ Kind of check / Medium Possible cause Fault elemination error symptom Electronic ignition unit is not Electronic ignition unit defec- Check electronic ignition unit...
  • Page 31 Thermo E+ 120/200/320 5 Troubleshooting 5.5.3 Error symptom "Low voltage" A value is stored in the control unit as smallest "permis- sible 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 32 Thermo E+ 120/200/320 5 Troubleshooting 5.5.4 Error symptom "Extraneous light detected prior to ignition or during purge cycle" Correct overheating cause. Did overheating occur? Is the burner properly screwed onto the Properly screw burner onto the heat heat exchanger? exchanger.
  • Page 33 Thermo E+ 120/200/320 5 Troubleshooting 5.5.5 Error symptom "Flame guard defective" The flameguard cannot be replaced. If necessary the control device is to be replaced. 5.5.6 Error symptoms "Temperature sensor / overheating protection defective" and "Overheating" Is the temperature sensor plug,...
  • Page 34 20mm (E+ 120) are permissible. • Inspect plugs and cables for corrosion, contact and crimp errors and repair as needed. Combustion chamber Thermo E+ 120 only: • The insulation of the combustion chamber must be • Check plug contacts for corrosion and tight fit. Repair checked for condition, damage and correct seating.
  • Page 35 Thermo E+ 120/200/320 5 Troubleshooting 5.6.4 Resistance check of the temperature Resistance vs. temperature charts sensor with integrated overheating protection Water temperature sensor (Pin 1 and 3) 2850 Caution! Risk of scalds! 2650 2450 Observe the risk of injuries due to increased coolant temperature.
  • Page 36 Thermo E+ 120/200/320 5 Troubleshooting 5.6.5 Fan, hood and combustion air intake line • If the speed is not as required: • Remove hood (see 8.4). visual inspection • Check whether the proper motor is installed (heating capacity class, operating voltage of the •...
  • Page 37 Thermo E+ 120/200/320 5 Troubleshooting 5.6.7 Electronic ignition unit inspection • Nominal condition: Ignition sparks jump over at the ignition electrodes. For electronic ignition unit description, see 3.1.5. NOTES: – How can it be determined whether the control device or the electronic ignition unit (EIU) is defec-...
  • Page 38 Thermo E+ 120/200/320 5 Troubleshooting 5.6.8 Flame guard inspection 5.6.7.1 Ignition electrodes inspection For ignition electrodes description, see 3.1.5. For flame guard description, see 3.1.2. Inspection Visual inspection • Remove burner (see 8.2) • Check correct arrangement of dust protection tube ATTENTION: and spring between control device and disc.

  • Page 39: Fuel Pump Inspection

    Thermo E+ 120/200/320 5 Troubleshooting 5.6.9 Fuel pump inspection ATTENTION: Plug the temperature sensor screwed into the heat exchanger into the control device again. For fuel pump description, see 3.1.3. NOTE: The replacement interval of the fuel pump depends on the fuel used and must be observed, see Maintenance Schedule Thermo E +.

  • Page 40: Solenoid Valve Inspection

    Thermo E+ 120/200/320 5 Troubleshooting 5.6.10 Solenoid valve inspection Inspection using the DTT diagnosis • Remove burner (see 8.2). • Connect the DTT diagnosis to the heater using the Caution! Risk of burns! adapter wiring harness (ref. to Operating Instructions for the DTT diagnosis).
  • Page 41 Thermo E+ 120/200/320 5 Troubleshooting • Reconnect the heater with the vehicle electrical system. Caution! Risk of burns! • Start DTT diagnosis, establish connection to the The heating element of the nozzle block preheater can heater and open the Component Test menu.
  • Page 42 Thermo E+ 120/200/320 5 Troubleshooting Manual inspection • Remove burner (see 8.2). • Unplug the nozzle block preheater connector from the control device. • Remove the nozzle block preheater as required. • Measure the resistance with an ohmmeter on the...

  • Page 43: Wiring Diagrams

    Thermo E+ 120/200/320 6 Wiring diagrams Wiring diagrams General The following figures show the connection options of the heater to the vehicle electrical system. ATTENTION: The repair or replacement of cables and / or plugs must be carried out in accordance with the instruc- tions in the Thermo E + Installation instructions.
  • Page 44 S-Bus 0,75mm², YE NOTE: Applies to pre-selection timers of Valeo Thermal Com- mercial Vehicles Germany GmbH. For other pre-selec- tion timers, the pinning may differ. Fig. 602 Pin assignment of connector C if pre-selection timer 1531 is used, legend see page 603...
  • Page 45 Thermo E+ 120/200/320 6 Wiring diagrams Item Description Car flat-type fuse 30A at 12V / 25A at 24V acc. to DIN 72581 part 3 or ISO 8820-3 Car flat-type fuse 5A acc. to DIN 72581 part 3 or ISO 8820-3 Operation indicator max.
  • Page 46 Thermo E+ 120/200/320 7 Servicing Servicing General A factory set combustion air amount change is permitted an can be achieved by rotation of the adjustment ring. The measurement of the CO content in the exhaust gas and the adjustment of the combustion air amount is to be...
  • Page 47 Thermo E+ 120/200/320 7 Servicing If the CO value cannot be adjusted to target value pro- • Measure the burner motor speed and compare with ceed as follows: the values in table in 5.6.6, replace if necessary. • Check the fuel filter for contamination and replace if •...
  • Page 48 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. Symbol tightening torque: Features in graphics parts (e.g. nuts, bolts) that are to be mounted with a specific tigh- tening torque.

  • Page 49: Burner Removal And Installation

    Thermo E+ 120/200/320 8 Repairs Burner removal and installation NOTE: Do not bent any lines when placing the burner down. Burner removal Back to 1. Disconnect the heater from the vehicle electrical sys- 8.7. - Disc and dust protection tube removal tem (Observe 8.9.

  • Page 50: Hood Removal And Installation

    Thermo E+ 120/200/320 8 Repairs 4. If applicable, bolt fuel lines down using a banjo bolt and new gaskets, or slide on fuel lines and secure with hose clamps. 5. If applicable, secure the combustion air intake line to the heater.
  • Page 51 Thermo E+ 120/200/320 8 Repairs Burner motor removal and installation 2. Position motor (5) onto the fuel pump (9). NOTE: Removal The coupling part on the motor shaft must engage in 1. Remove disc with dust protection tube (see 8.7).
  • Page 52 Thermo E+ 120/200/320 8 Repairs Hood Screws, hood (2) Shaft circlip Fan wheel Burner motor Screws, motor (3) Motor connector Coupling (two-part) Fuel pump 10 Control device 5 ±0.5 Nm 2 +0.5 Nm Fig. 804 Component removal and installation (1)
  • Page 53 Thermo E+ 120/200/320 8 Repairs Control device removal and dust protection tube (11) is thereby pushed onto the lens of the flame guard in the control device installation (10, Fig. 804). Hold disc in position. 4. Install circlip (2, Fig.
  • Page 54 Thermo E+ 120/200/320 8 Repairs Installation ATTENTION: 1. Put new gasket ring (19, Fig. 805) onto the sleeve with There are 2 versions of the nozzle block hexagon (16) and screw sleeve with hexagon into the preheater heating element (see 3.1.6).
  • Page 55 Thermo E+ 120/200/320 8 Repairs 1.5 Nm ±10% 5 Nm ±10% 2 +0.5 Nm ATTENTION: There are 2 versions of the nozzle block preheater heating element (see 3.1.6). 20 ±2 Nm 2 +0.5 Nm 1 +0.2 / -0.3 Nm Fuel nozzle...
  • Page 56 Thermo E+ 120/200/320 8 Repairs 7. Position control device (10, Fig. 804) onto the fuel 9. Install burner motor (see 8.5). pump (9). In process of that, after installing the circlip (2, Fig. 8. Plug all internal connectors (nozzle block preheating if...

  • Page 57: Heat Exchanger Removal And Installation

    Thermo E+ 120/200/320 8 Repairs NOTE: 9. If necessary remove temperature sensors (see 8.3). – The combustion chamber should be inserted into the 10. Remove heat exchanger from vehicle. heat exchanger in such a way that its welding seam is...

  • Page 58: Bleeding The Fuel System

    Once the cooler thermostat opens, switch the vehicle Valeo recommends the usage ofa separate bleeding unit. engine off and check the coolant level. Refill coolant as Follow the appropriate instructions provided by the needed.
  • Page 59 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. Information can be found on the Valeo homepage under Service.
  • Page 60 Thermo E+ 120/200/320 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 61: Maintenance Plan

    Thermo, Thermo E, Thermo S, Thermo plus and Thermo E+ in buses und railway vehicles Periodic heater maintenance adhered. If there no such regulations, Valeo prescribes the here shown maintenance intervals for common The heater should be inspected in periodic time intervals, applications.
  • Page 62 Technical Information d) Replace fuel screen with gasket in the pump. Biodiesel / FAME www.valeo- thermalbus.com 4. Burner head a) Inspect combustion air intake opening for clear passage. Replace damaged b) Inspect hood for damage.
  • Page 63 Maintenance plan for heaters of type Thermo, Thermo E, Thermo S, Thermo plus and Thermo E+ in buses und railway vehicles 6. Water system a) If available, inspect, clean as needed or replace water filter insert. 7. Functional check a) If available, open shut-off valve of the fuel return line and water line.
  • Page 64 memos...
  • Page 65 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 e+ 200Thermo e+ 320

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