Valeo Thermo plus 160 Workshop Manual
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Valeo Thermo plus 160 Workshop Manual

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HEATING SYSTEMS
Thermo plus 160
Thermo plus 230
Thermo plus 300
Thermo plus 350
Thermo plus Rail
Workshop Manual
Rev. 06/2021
Id.No. DOK50060-001

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Summary of Contents for Valeo Thermo plus 160

  • Page 1 HEATING SYSTEMS Thermo plus 160 Thermo plus 230 Thermo plus 300 Thermo plus 350 Thermo plus Rail Workshop Manual Rev. 06/2021 Id.No. DOK50060-001...
  • Page 2 Thermo plus 160/230/300/350 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 General safety regulations 1.6.2 Other safety information Suggestions for improvement and change...
  • Page 3 Thermo plus 160/230/300/350 Content 5.5.3 Error symptom "Low voltage" 5.5.4 Error symptom "Extraneous light detected prior to ignition or during purge cycle" 5.5.5 Error symptom "Flameguard defective" 5.5.6 Error symptoms "Temperature sensor / overheating protection defective" and "Overheating" 5.5.7 Error symptom "Circulating pump defective"...
  • Page 4 Thermo plus 160/230/300/350 Content 10 Packing/storage/shipping 10.1 General 1001 Attachment Periodic heater maintenance Link list Keyword Link page Pumps http://www.valeo-thermalbus.com/eu_en/Service/Downloads/Pumps Spare parts and accessories http://www.valeo-thermalbus.com/eu_en/Service/Spare-Parts-Accessories/ Heating-systems/Thermo-Plus 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 plus 160, plus 230, plus 300 and plus 350. Further documentation to be used ATTENTION: Work on the heater may only be performed by briefed and/or trained by Valeo personnel.
  • Page 6 Thermo plus 160/230/300/350 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.). STOP! Suggestions for improvement and change...

  • Page 7: Technical Data

    Only the on the model plate of the heater spe- voltage. The burner motor supply voltage is controlled by cified fuel must be used. the control device. The following table lists the by Valeo approved fuels and their specifications. NOTE: Circulating pumps must be assigned to the heaters accor- ding to the flow resistance in the coolant circulation system.
  • Page 8 TI Fuels Further information on approved fuels contains the TI (Technical Information) Fuels. It can be found on the Valeo website under Service/ Technical Updates/Heating systems. In case of air temperatures below 0°C a commercially available winter Diesel fuel, at temperatures below -18°C a Diesel for arctic climate conditions must be used.
  • Page 9 The heaters Valeo Thermo plus 230, plus 300 and Heat is generated by combustion of liquid fuels. Via the plus 350 are used in conjunction with the vehicle heating...

  • Page 10: Control Device

    Thermo plus 160/230/300/350 3 Assemblies and components 3.1.2 Control device The heaters of the Thermo plus series basically consist of the main components: The control device (Fig. 303) ensures the operating • burner head sequence and burner operation monitoring. It constitutes •...
  • Page 11 Thermo plus 160/230/300/350 3 Assemblies and components 3.1.2.2 Flameguard The flameguard (see Fig. 304) is integrated in the control during heater operation. device. The flame guard is a photo transistor that changes its resi- The flameguard monitors the combustion flame condition stance depending on the incident light.

  • Page 12: Fuel Pump

    Thermo plus 160/230/300/350 3 Assemblies and components Disc Flameguard Sight window Fig. 304 Flameguard 3.1.3 Fuel pump atomized by the atomiser nozzle. The solenoid valve installed at the fuel pump opens and closes the fuel supply to the atomizer nozzle.

  • Page 13: Nozzle Block Preheater

    Thermo plus 160/230/300/350 3 Assemblies and components The fuel pump can be used in dual-line operation only atomizer nozzle. (fuel supply and return line). The control unit defines the preheating time of the heating If the heater is operated with element, which depends on the water temperature, before –...
  • Page 14 Thermo plus 160/230/300/350 3 Assemblies and components Retaining clamp Thermostat Heating element NOTE: The disc is displayed transparently. Burner head Fig. 307 Nozzle block preheater Water temperature sensor with integrated overheat protection Fig. 308 Temperature sensors...

  • Page 15: Heat Exchanger

    Thermo plus 160/230/300/350 3 Assemblies and components Heat exchanger NOTE: In the heaters are used different combustion chambers depending on the heating capacity class. The heat exchanger (Fig. 309) transfers the heat genera- ted by combustion to the coolant circulation system.

  • Page 16: Fuel Filter

    Thermo plus 160/230/300/350 3 Assemblies and components All service information regarding your Valeo circulating pump(s) can be found on the Valeo website under pumps. Fuel filter As an option a heated fuel filter is available (see spare parts and accessories on the Valeo-website).
  • Page 17 The speed required for the CO content is determined The heater is switched on, when the temperature falls during first calibration at Valeo and is stored in the control short of a lower temperature threshold, and is switched unit. off, if the upper temperature threshold is reached (see...

  • Page 18: Heating Operation

    Thermo plus 160/230/300/350 4 Heater functions 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 19: Switching Off

    Thermo plus 160/230/300/350 4 Heater functions The purge cycle ends approx. after 120 seconds. The always achieved. combustion air fan is switched off. In order to achieve the minimum combustion period, the The heater is in a controlled break. lower switching threshold is variably adjusted by the The operation indicator is on.

  • Page 20: Fault Lock-Out

    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 4.5.2 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 21 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 22: Troubleshooting

    Disconnecting the heater from the This section describes troubleshooting and error correc- vehicle electrical system tion for Thermo plus 160, plus 230, plus 300 and plus 350 heaters. Some troubleshooting procedures require to disconnect the heater from the vehicle electrical system.
  • Page 23 • System resistance too high (especially high in the cold) • Circulating pump defective • Adapter wiring harness “Valeo“ for variants > 85°C defective Heat exchanger provides not enough heat, because • Air in the heat exchangers and/or system sections •...
  • Page 24 Thermo plus 160/230/300/350 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 lines or lines •...

  • Page 25: Error Indication

    Thermo plus 160/230/300/350 5 Troubleshooting Error indication and ground of connector C via the wiring harness (see Fig. 601). After five short signals, the long flashing pulses are Depending on the equipment, the error indication can be counted. The number of long flashing pulses corresponds done by means of an error code or error code text.
  • Page 26 Thermo plus 160/230/300/350 5 Troubleshooting Table 502 Error code No. of Error Error causes impulses/ Error code Flame interruption counter threshold exceeded Heater lock-out Heater lock-out - release required Malfunction counter threshold exceeded not used not used Fuel pump defective...
  • Page 27 Thermo plus 160/230/300/350 5 Troubleshooting 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 28 Thermo plus 160/230/300/350 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 29 Thermo plus 160/230/300/350 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 30 Thermo plus 160/230/300/350 5 Troubleshooting 5.5.5 Error symptom "Flameguard defective" The flameguard cannot be replaced. It can only be tested using STT diagnosis. In case of damage or if the target value cannot be reached, the control device must be replaced as needed.
  • Page 31 Thermo plus 160/230/300/350 5 Troubleshooting Individual component tests is absolutely necessary. 5.6.3 Combustion chamber visual inspection Individual components can basically be tested using visual inspection or manual electrical testing. • Remove combustion chamber (see 8.12). In addition, the electrical components burner motor, circu- •...
  • Page 32 Thermo plus 160/230/300/350 5 Troubleshooting 5.6.4 Check of the temperature sensor with Resistance vs. temperature charts integrated overheating protection Diagramm Widerstand über Temperatur Water temperature sensor (pin 1 and 3) Caution! Risk of scalds! 2850 2650 Prior to removing the temperature sensors, the over-...
  • Page 33 Thermo plus 160/230/300/350 5 Troubleshooting 5.6.5 Fan and combustion air intake line visual inspection • Inspect a possibly available combustion air intake line for contamination, condition and deposits. • Remove hood (see 8.4). • Inspect fan channels for contamination and deposits.
  • Page 34 Thermo plus 160/230/300/350 5 Troubleshooting 5.6.7 Electronic ignition unit inspection • Install burner head (see 8.2). NOTE: Manual functional test when disassembled: It is possible to manually test the functionality of the electronic ignition unit, and using the Component Test •...

  • Page 35: Ignition Electrode Inspection

    Thermo plus 160/230/300/350 5 Troubleshooting 5.6.8 Ignition electrode inspection 5.6.9 Flameguard inspection NOTE: NOTE: The ignition electrode insulation may not be damaged. In case of contamination the flameguard lens and the Ignition electrodes not functioning properly must be inspection glass in the disc (see Fig.

  • Page 36: Fuel Pump Inspection

    (Fig. 511). Close the bleed port and read the present pressure at The pressure test gauge can be obtained from a Valeo the gauge. Service Center or a distribution partner. •...

  • Page 37: Solenoid Valve Inspection

    Thermo plus 160/230/300/350 5 Troubleshooting 5.6.11 Solenoid valve inspection • Install ignition electrode (see 8.6). • Install burner head (see 8.2). Caution! Risk of burns! The coil of the solenoid valve can heat up in switched- on condition. The solenoid valve must only be completely replaced.
  • Page 38 Thermo plus 160/230/300/350 5 Troubleshooting Manual inspection The power consumption of the heating element at 24V is • Remove burner head (see 8.2). approx. 80W. Inspection using the STT diagnosis • Disconnect the solenoid valve plug from the control device.
  • Page 39 Thermo plus 160/230/300/350 5 Troubleshooting Thermostat Holding clamp Heating element Fig. 513 Nozzle block preheater 5.6.13 Circulating pump inspection ATTENTION: The circulating pump fuse may never be pulled, while the pump is running. Inspection using the STT diagnosis • Check electrical connections as well as the leak-tight- ness of the cooling system.

  • Page 40: Wiring Diagrams

    Thermo plus 160/230/300/350 6 Wiring diagrams Wiring diagrams General The following figures represent heater connection options to the vehicle electrical system. The minimum cable cross-sections indicated in the table must be applied. Cable length <7.5m Cable length 7.5 - 15m 0.75 mm²...
  • Page 41 Thermo plus 160/230/300/350 6 Wiring diagrams Terminal 58 Terminal 15 Terminal 30 (permanent plus) Terminal 31 (ground) Terminal 61 (D+) T. 30, UP, DVW 2.5mm T. 31, UP, DVW 2.5mm 1 - 4 must be all connected T. 30 2.5mm T.
  • Page 42 Thermo plus 160/230/300/350 6 Wiring diagrams Position Designation Operation indicator max. 1x5W or 2x2W Flame indicator 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 43 Thermo plus 160/230/300/350 6 Wiring diagrams Ansicht von vorn / front view Ansicht von vorn / front view 1 3 5 7 Ansicht von vorn / front view Wiring harness Fig. 603 Wiring harness 11123331_ - connector and pin assignment Wiring harness Fig.
  • Page 44 Thermo plus 160/230/300/350 6 Wiring diagrams Wiring harness Fig. 605 Wiring harness 11123530_ - connector and pin assignment X2 21pos G 4pos Wiring harness Fig. 606 Wiring harness 11141003_ - connector and pin assignment...
  • Page 45 Thermo plus 160/230/300/350 6 Wiring diagrams X001J 2pos P 10pos X326J 2pos X164J 6pos C 10pos 4pos X003J X003P 4pos X003P Wiring harness X003J Fig. 607 Wiring harness 11125777_ - connector and pin assignment...
  • Page 46 Thermo plus 160/230/300/350 7 Servicing Servicing The STT diagnosis sequence defines the CO content adjustment procedure. General Within the scope of the adjustment, the motor speed must be changed in such a way, that the required CO content in the exhaust gas is established (ref. to Table in 2 Technical Data).
  • Page 47 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 48 Thermo plus 160/230/300/350 8 Repairs Burner head removal and installation Burner head removal Burner head installation 1. Disconnect the heater from the vehicle electrical 1. Bring burner head (1, Fig. 801) in assembly position system (Observe and ensure center alignment and correct fit.

  • Page 49: Hood Removal And Installation

    Thermo plus 160/230/300/350 8 Repairs Removal and installation of the Hood removal and installation temperature sensor with integrated overheating protection Removal 1. Disconnect the heater from the vehicle electrical system (Observe 2. Loosen screws (2, Fig. 803). 3. Remove hood (1).

  • Page 50: Installation

    Thermo plus 160/230/300/350 8 Repairs Hood Screws (2)(not removable) Circlip Fan wheel Burner motor 2 Nm +0.5 Nm Fig. 803 Fan wheel removal and installation Electronic ignition unit and ignition electrode removal and installation Removal Installation 1. Remove burner head (see 8.2).
  • Page 51 Thermo plus 160/230/300/350 8 Repairs Electronic ignition unit Ignition electrode Disc Screws (2) Light window Flame guard 5 Nm +1 Nm Fig. 804 Electronic ignition unit / ignition electrode removal and installation Control device removal and 4. Install the fan wheel (see 8.5).
  • Page 52 Thermo plus 160/230/300/350 8 Repairs Electronic ignition unit 5 +1 Nm Combination screw (2) Ignition electrode Fuel nozzle Disc 20 ±2 Nm Solenoid valve Nozzle block preheater (optional) Retaining clamp Fuel pump 10 O-rings (2) 11 Screen insert 12 Screws (3)
  • Page 53 Thermo plus 160/230/300/350 8 Repairs Installation assembly and disassembly a new gasket ring must be 1. If necessary, install solenoid valve (6, Fig. 805) onto used. the fuel pump (9) (siehe 8.9). It is not absolutely necessary to remove the fuel pump for 2.
  • Page 54 Thermo plus 160/230/300/350 8 Repairs 2. Using a suitable tool, tighten hexagon, wrench size 16 nic ignition unit by twisting a screwdriver sideways Fig. 806) of the solenoid valve. (see Fig. 804) and remove it. 3. Connect the solenoid valve plug (6, Fig.
  • Page 55 Thermo plus 160/230/300/350 8 Repairs 8.11 Fuel nozzle removal and installation Installation 1. Screw in the fuel nozzle (4, Fig. 805) and tighten. It is necessary to counteract with a tool at the hexagon of Removal the nozzle block of the fuel pump (9).

  • Page 56: Heat Exchanger Removal And Installation

    Thermo plus 160/230/300/350 8 Repairs Installation 7. Remove screws and washers of the heat exchanger stand (4). ATTENTION: 8. Pull combustion chamber (1) out of the heat exchan- ger (2). When replacing the combustion chamber, ensure that 9. If necessary remove temperature sensor (see 8.3).

  • Page 57: Bleeding The Fuel System

    Thermo plus 160/230/300/350 8 Repairs 8.15 Start-up after burner head or heater While the vehicle engine is switched off, switch on the heater with circulation pump and ensure that the heat is installation transferred into the vehicle. After the engine motor cooled down, the heater must auto- The fuel system must be bleeded after burner installation.
  • Page 58 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 59 – spring (2) and – disc (3) 5. Pre-assemble new disc (3), tube (1) and spring (2). are included in the dust protection kit Valeo ID 6. Place new disc (3), tube (1) and spring (1) into position: – 11136327_...
  • Page 60 Thermo plus 160/230/300/350 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 and Thermo plus 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 Thermo 10 ±0.5 Thermo E 200 9.5 ±0.5 Thermo E 300 10.0 ±0.5 Thermo S 9.5 +1.5 Thermo plus 160 9.5 +1.0 Thermo plus 230 9.0 +1.5 Thermo plus 300/350 9.5 +1.5 (ppm) at 19V Rail versions _ < 1000 Smoke spot number acc.
  • Page 63 Maintenance plan for heaters of type Thermo, Thermo E, Thermo S and Thermo plus in buses und railway vehicles 7. Functional check a) If available, open shut-off valve of the fuel return line and water line. b) Check fault memory, clear it as needed using the diagnostic tool (STT).
  • Page 64 memos...
  • Page 65 Valeo Thermal Commercial Vehicles Germany GmbH Friedrichshafener Str. 7 - 82205 Gilching - Germany - Tel. +49 8105 7721-0 - www.valeo-thermalbus.com...

This manual is also suitable for:

Thermo plus 230Thermo plus 300Thermo plus 350Thermo plus rail

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