Valeo THERMO PLUS 160 Installation Instructions Manual
Valeo THERMO PLUS 160 Installation Instructions Manual

Valeo THERMO PLUS 160 Installation Instructions Manual

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HEATING SYSTEMS
THERMO PLUS 160/230/300/350
Installation instructions
Rev. 03/2021
Id.No. 11121149C

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Summary of Contents for Valeo THERMO PLUS 160

  • Page 1 HEATING SYSTEMS THERMO PLUS 160/230/300/350 Installation instructions Rev. 03/2021 Id.No. 11121149C...
  • Page 2 NEVER try to install or repair Valeo heating or cooling systems if you have not completed a Valeo training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equiprnent available to ensure that you can complete the installation and repair work properly.
  • Page 3 Thermo plus 160/230/300/350 Highlighted words like Warning!, Caution!, ATTENTION and NOTE in these Installation instructions signify the following precautions: This caption is used to indicate pos- sible severe injuries or fatal acci- Warning! dents if instructions or procedures are carried out incorrectly or entirely disregarded.
  • Page 4: Table Of Contents

    Thermo plus 160/230/300/350 Table of content Statutory regulations governing installation Use / version Installation Installation example Installation of the circulating pump Connection to the vehicle cooling system Fuel supply Combustion air supply Exhaust pipe Electrical connections Initial start-up Maintenance Malfunctions...
  • Page 5: Statutory Regulations Governing Installation

    Thermo plus 160/230/300/350 Statutory regulations governing installation Statutory regulations governing installation 1.1. Statutory regulations governing installation Extract from ECE Regulation R122, Part I: For the heaters exist type approvals according to the ECE Regulations “ ... R10 (EMC): No. 05 7559 and 5.3 Vehicle Installation Requirements for Combustion Heaters...
  • Page 6 Failure to follow the installation instructions and the notes contai- 5.3.3.1 The fuel filler must not be situated in the passenger compart- ned therein will lead to all liability being refused by Valeo. The ment and must be provided with an effective cap to prevent fuel spillage.
  • Page 7: Use / Version

    Annex 9 of the UN/ECE Regulation R122. – be shut down and the fuse shall be removed in the event of ex- tensive smoke development, unusual combustion noises or fuel odors. The heater must not be used again until personnel trained by Valeo have examined it.
  • Page 8 Use / version Thermo plus 160/230/300/350 2.2. Versions Thermo plus 160 – 24V Water heater for „diesel“ with 16 kW (13800 kcal/h) heat current Thermo plus 230 – 24V Water heater for „diesel“ with 23 kW (20000 kcal/h) heat current Thermo plus 300 –...
  • Page 9: Installation

    (see Figures 1 and 5) when report must always be submitted to Valeo for approval. If this installing the heater. approval is not obtained, all warranty and liability claims will be void.
  • Page 10 Installation Thermo plus 160/230/300/350 302,5 ca. 350 Combustion air intake Exhaust outlet Fuel intake Fuel discharge Coolant intake Coolant outlet Temperature sensor Space required to remove the burner chamber Fig. 1: Dimensions of the Thermo plus 230/300/350 heater (horizontal installation)
  • Page 11 Thermo plus 160/230/300/350 Installation 3.2. Installation of a Thermo plus heater NOTE: The heaters are only licensed for horizontal installation (see Fig. 2). The heater may be secured either with four M8 screws or with four screws and nuts (see Figure 3) .
  • Page 12 Installation Thermo plus 160/230/300/350 3.3. Model plate The model plate must be protected from damage and must be clearly le- gible when the heater is installed (otherwise a duplicate model plate must be used). Thermo plus 300 2020 2021 2022 Fig.
  • Page 13: Installation Example

    Thermo plus 160/230/300/350 Installation example Installation example Water heating circuit – wall heater and roof duct heating system Wall heater with blower Heat exchanger at entry point Heater Circulating pump Roof heat exchanger Vehicle engine Driver’s position heating system Control element...
  • Page 14: Installation Of The Circulating Pump

    Installation of the circulating pump Thermo plus 160/230/300/350 Installation of the circulating pump ATTENTION: The heater should be equipped with a Valeo circulating pump. Pumps of other manufacturers must be approved by Valeo. The following pumps are available: – U4814 (Aquavent 5000) –...
  • Page 15: Connection To The Vehicle Cooling System

    2 minutes. the Valeo website. ATTENTION: Basically the water hoses supplied by Valeo should be used. If this is not Before commissioning the heating system, the heating hoses, the the case, the hoses must comply at least with DIN 73411 requirements.
  • Page 16: Fuel Supply

    The operation with a closed return line will cause damage to the Valeo are to be used. If this is not the case, the fuel hoses must at least fuel pump or fuel line. Fuel can leak out - fire hazard! comply with the requirements of DIN 73379.
  • Page 17 Deviations are to be approved by Valeo. 7.2. Fuel Filter A fuel filter supplied or approved by Valeo must be used (consider the flow direction). To avoid malfunctions the filter or filter insert is to be re- placed annually before the cold weather season starts.
  • Page 18: Combustion Air Supply

    4 mm is to be made at its lowest point. Only by Valeo approved combustion air intake lines may be used. When the heater is installed in the vicinity of the vehicle tank in a com-...
  • Page 19: Exhaust Pipe

    – The total length of both, the air intake pipe and the exhaust pipe must not exceed 5 m Deviations only after approval by Valeo. NOTE: If there is a risk of contact with the exhaust pipe during intended use, it...
  • Page 20: Electrical Connections

    10.2. Connecting the controls High Voltage! Warning! The heater can be switched on and off using the following Valeo Danger to Life! controls: – Switch, see system wiring diagram Figure 7 Disconnect first the electrical connection to the vehicle and then to –...
  • Page 21 Thermo plus 160/230/300/350 Electrical connections 10.6. Water temperature control thresholds (standard values): Heater Aux. heating Parking heating Econ. setting (Terminal 61) Off (CI) Off (CI) Off (CI) Thermo plus 160 Thermo plus 230 Thermo plus 300 Thermo plus 350 control idle...
  • Page 22 Electrical connections Thermo plus 160/230/300/350 10.7. Wiring diagrams 10.7.1. Legend for wiring diagrams: Description Position Designation Connector Operation indicator 3W (max. 5W) To vehicle (Power) Flame indicator 3W (max. 5W) Terminal 30 (+), UP (DVW) Circulation pump Terminal 31 (–), UP (DVW)
  • Page 23 10.7.2. Connectors Connector “G“ (STT Diagnosis) If a circulating pump is connected to the heater, a Valeo cable harness is to be used. To connect the Spheros Thermo Test diagnosis or the blind plug: The crimping for the connectors must be carried out according to the Blind plug Valeo ID: 11119375_...
  • Page 24 Electrical connections Thermo plus 160/230/300/350 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. 31 2.5mm...
  • Page 25 Thermo plus 160/230/300/350 Electrical connections 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. 31 2.5mm 0.75mm UPFA 0.75mm...
  • Page 26: Initial Start-Up

    After heater installation, bleed the water system and the fuel supply sy- stem carefully. In this process it is mandatory to fill the suction line and the fuel filter of the heater completely. Valeo recommends the usage of a separate bleeding unit. Follow the appropriate instructions provided by the vehicle manufacturer.
  • Page 27: Maintenance

    Thermo plus 160/230/300/350 Maintenance Maintenance Periodic service activities have to be performed in accordance with the Workshop Manual.
  • Page 28: Malfunctions

    If a heater lock-out has occurred, the heater must be maintained and re- – Is a sufficient amount of fuel in the tank? leased by Valeo trained personnel. – Are the fuses ok? – Are the electrical connections and cables in order? 13.1.
  • Page 29 Thermo plus 160/230/300/350 Malfunctions Table: Flash code No. of long Description of malfunction pulses not used No start within the safety time Flame interruption, restart failed Low voltage / overvoltage Extrinsic light before starting or within the purge cycle not used...
  • Page 30: Technical Data

    In case of air temperatures below 0°C a commercially available winter Diesel fuel, at temperatures below -18°C a Diesel for arctic climate con- The following table lists the by Valeo approved fuels and their specifica- ditions must be used. tions.
  • Page 31 Thermo plus 160/230/300/350 Technical data Heater Thermo plus 160 Thermo plus 230 Thermo plus 300 Thermo plus 350 0580 ECE Type Approval Number E1 122R 00 0466 0467 0468 Kind of construction High pressure atomizer Heating flow (at ambient temperature of 20°C)
  • Page 32 Technical data Thermo plus 160/230/300/350 Circulating pump U 4814 U 4854 U 4855 U4856 SPump 260 Aquavent 5000 Aquavent 5000S Aquavent 6000C Aquavent 6000SC Delivery rate 5000 (against 0.2 5000 (against 0.2 6000 (against 0.4 6000 (against 0.4 6000 (against 0.5...
  • Page 33: Environment

    Thermo plus 160/230/300/350 Environment Environment Recycling of heater parts The correct disposal of the heater components determined by material groups for old appliances, damaged or defective parts and packaging material can be realized without problems. In the process the materials...
  • Page 34: Annex

    Annex Annex Circulating pumps installation position 99,5 131,5 0-90° 0-85° Brown - Brown - Black + Black + min. 5° U 4814 Installation position U 4854 Installation position...
  • Page 35 Annex ±2 ±2 52,8 30,8 Ø 0-85° 0-85° 0-90° min. 5° min. 5° 0-90° U 4855 Installation position U 4856 Installation position...
  • Page 36 Annex 212 ±2 92.5 29.3 90° 90° Preferred installation position / bevorzugte Einbauposition Permitted installation position / zulässige Einbauposition SPump Installation position Hole pattern for stand...
  • Page 37 memos...
  • Page 38: Heating Systems

    HEATING SYSTEMS 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 plus 230Thermo plus 300Thermo plus 350

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