Spheros NGW 300 Workshop Manual
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Spheros NGW 300 Workshop Manual

Spheros NGW 300 Workshop Manual

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Water heaters
02/2006
Identification no. 27 101 03B
Workshop manual
NGW 300
LGW 300
GBW 300
NGW 300 / LGW 300 model

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Summary of Contents for Spheros NGW 300

  • Page 1 Water heaters Workshop manual NGW 300 LGW 300 GBW 300 NGW 300 / LGW 300 model 02/2006 Identification no. 27 101 03B...

  • Page 2: Table Of Contents

    NGW 300 / LGW 300 / GBW 300 Table of contents Table of contents Introduction Content and purpose ....................101 Meaning of the headings in capitals ...............101 Additional documentation to be used ..............101 Safety information and regulations .................101 1.4.1 General safety regulations ................101 Legal installation regulations .................102...
  • Page 3 Table of contents NGW 300 / LGW 300 / GBW 300 Troubleshooting and elimination of faults General information ....................501 General fault symptoms ..................501 Functional tests General information ....................601 Combustion test ......................601 6.2.1 Test of the CO content ................601 Tests of individual parts ..................602 6.3.1...
  • Page 4 NGW 300 / LGW 300 / GBW 300 Table of contents Repair General information ....................901 9.1.1 Measures for components when the system is disassembled ....901 9.1.2 Implementation of modifications ...............901 Disasssembly and reassembly ................905 9.2.1 Replacing the temperature limiter ............905 9.2.2...
  • Page 5 Testing the CNG (NGW 300) gas pressure regulator...........604 Testing the LPG (LGW 300) gas pressure regulator ............604 Basic wiring for the NGW 300 / LGW 300 / GBW 300 with switch .......702 Basic wiring for the NGW 300 / LGW 300 / GBW 300 with timer .........703 System wiring for the GBW 300 - MAN ................704...

  • Page 6: Content And Purpose

    Motor Vehicles and Drivers] for the NGW 300, LGW 300 This workshop manual serves as support for trained staff and GBW 300 water heaters in the area governed by the in the repair of the NGW 300, LGW 300 und GBW 300 StVZO [Road Traffic Licensing Regulation]: water heaters.
  • Page 7 1 Introduction NGW 300 / LGW 300 / GBW 300 ATTENTION under the floor of the vehicle, into the vicinity of the side The gas pressure regulator must be replaced after boundary of the driver’s cab or of the vehicle. Exhaust 4 years of operation, for safety reasons.

  • Page 8: General Description

    GBW 300 ting system as well as a thermostat valve for heating the NGW 300 version for the CNG type of gas (natural gas) gas pressure regulator. The NGW 300 also has a time- LGW 300 version for the LPG type of gas (propane) delayed solenoid installed in the heater’s gas suction hose.

  • Page 9: General Description 2.1 Combustion Air Fan

    2 General description NGW 300 / LGW 300 / GBW 300 Combustion air fan The combustion air fan forces the air necessary for com- bustion from the combustion air inlet into the combustion chamber. In addition, the necessary amount of gas is aspi- rated from the fan by means of the gas pressure regulator.

  • Page 10: Heat Exchanger

    The control unit guarantees the function sequence and monitoring of the firing operation. The SG 1578 control unit for the NGW 300 and LGW 300 heaters is no longer available and is being replaced by the modified SG 1585 control unit.

  • Page 11: Ignition Spark Generator With Ignition Electrodes

    2 General description NGW 300 / LGW 300 / GBW 300 Ignition spark generator with ignition Gas inlet nozzles electrodes The amount of gas required for combustion is determined by the gas inlet nozzles on the burner. ImIn the ignition spark generator, high voltage is produced to ignite the gas-air mixture.

  • Page 12: Regulating Thermostat

    NGW 300 / LGW 300 / GBW 300 2 General description 2.10 Regulating thermostat U 4814 The regulating thermostat (bimetal) measures the coolant temperature at the water outlet of the heat exchanger. The signal is conducted to the control unit and is processed there.
  • Page 13 2 General description NGW 300 / LGW 300 / GBW 300 Overload protection Overload protection is activated after completion of the soft start. In this way, the consumption of current is restric- ted and the speed is regulated to 5,550 rpm. This means that the motor will not be damaged, by the hydraulic com- pression of the circulating pump.

  • Page 14: Switching Off

    Interruption of the circulating pump (when regulator (after another second, the delayed-action programmed) solenoid in the gas hose for the NGW 300 opens, if – Short circuit /interruption of the flame monitor mode available) and the gas-air mixture is conveyed into the –...
  • Page 15 3 Description of function NGW 300 / LGW 300 / GBW 300 Operating indicator Circulating pump Ignition spark generator Combustion air fan Solenoid Vacuum switch Flame monitor CONTROL Control pause 1 Main switch “ON” A Temperature monitoring Start B Supply...

  • Page 16: Ngw 300 / Lgw 300 / Gbw 300

    NGW 300 / LGW 300 / GBW 300 Description of function 3.4.7 Faults due to overheating /interruption of the temperature limiter If the heater overheats there is a fault lock-out by means of the temperature limiter and the heater becomes locked after the error after-run.
  • Page 17 3 Description of function NGW 300 / LGW 300 / GBW 300 Blank page for notes...

  • Page 18: Technical Data

    PLEASE NOTE PLEASE NOTE The NGW 300 version of the heaters is set for CNG-Gas The allocation of circulating pumps to heaters must be with a methane content of more than 95% by volume done in accordance with the cold water side resistors.
  • Page 19 4 Technical data NGW 300 / LGW 300 / GBW 300 Blank page for notes...

  • Page 20: Troubleshooting And Elimination Of Faults 5.1 General Information

    General information this reason should be excluded: This section describes the troubleshooting and the elimi- Corrosion of connectors nation of faults in NGW 300 / LGW 300 and GBW 300 A loose connection on a plug heaters. Crimping faults on connectors...
  • Page 21 5 Troubleshooting and elimination of faults NGW 300 / LGW 300 / GBW 300 Fault symptom possible cause • Circulating pump defect Heat exchangers (water/air) supply has too little heat, because • there is air in the heat exchangers or in the system sections •...

  • Page 22: Combustion Test

    300 heater – when retrofitting NGW 300 and LGW 300 heaters with an adjustable nozzle – for the operation of the NGW 300 heater with CNG Setting screw (natural gas) whose methane content is below 95 % by volume –...

  • Page 23: Test Of The Regulating Thermostat

    6 Functional tests NGW 300 / LGW 300 / GBW 300 Tests of individual components 6.3.4 Test of the flame monitor electrode PLEASE NOTE 6.3.1 Test of the regulating thermostat The insulating material of the ignition electrodes must not show any sign of damage or cracks. If a flame monitor PLEASE NOTE electrode is not working perfectly, it should be replaced.

  • Page 24: Test Of The Burner Motor

    (in the Testing of the combustion air motor is conducted when it NGW 300) must still be controlled Combustion must stop is installed. If the target values are not achieved, the motor immediately.
  • Page 25 In the event that solid particulate matter is found in the oil/ condensate, the gas pressure regulator must be replaced. After the test, the drain plug for the CNG (NGW 300) gas pressure regulator must be screwed in with a tightening torque of 8 ±1 Nm.

  • Page 26: Wiring Diagrams 7.1 General Information

    NGW 300 / LGW 300 / GBW 300 7 Wiring diagrams Wiring diagrams General information Figures. 701 to 709 show the system wiring diagrams of the heaters with switches and/or timers and vehicle-spe- cific circuits.

  • Page 27: Wiring Diagrams

    Combustion air fan ON/OFF switch Heater 1-pin plug connection Flame semsor ON/OFF switch Remote-controlled circulating pump 2-pin plug connection Circulating pump Vacuum switch Fig. 701 Basic wiring for the NGW 300 / LGW 300 / GBW 300 with a timer...
  • Page 28 1-pin plug connection Vacuum switch Motor Combustion air fan 1-pin plug connection Combustion air fan Timer 1-pin plug connection Flame semsor ON/OFF switch Remote-controlled circulating pump Vacuum switch Abb. 702 Basisschaltung für NGW 300 / LGW 300 / GBW 300 mit Vorwahluhr...

  • Page 29: System Wiring For The Gbw 300 - Man

    7 Wiring diagrams NGW 300 / LGW 300 / GBW 300 Reglator control outlet W-Bus diagnosis Item Designation Comment Item Designation Comment Heater GBW 300 Ignition electrode Conrol unit Flame monitor electrode Temperature limiter 2-pin plug connection A2 control unit...

  • Page 30: System Wiring For The Gbw 300 - Usa

    NGW 300 / LGW 300 / GBW 300 7 Wiring diagrams W-Bus diagnosis Item Designation Comment Item Designation Comment Heater GBW 300 Ignition electrode Control unit Flame monitor electrode Temperature limiter 2-pin plug connection A2 control unit Regulating thermostat 4-pin plug connection...
  • Page 31 7 Wiring diagrams NGW 300 / LGW 300 / GBW 300 UP control signal W-Bus diagnosis Item Designation Comment Item Designation Comment Heater GBW 300 Flame monitor electrode Control unit 2-pin plug connection A2 control unit Temperature limiter 4-pin plug connection...

  • Page 32: System Wiring For The Ngw Iveco

    NGW 300 / LGW 300 / GBW 300 7 Wiring diagrams Item Designation Comment Item Designation Comment Heater NGW 300 Flame monitor electrode Control unit 2-pin plug connection A2 control unit Temperature limiter 4-pin plug connection A2 control unit Regulating thermostat...
  • Page 33 Vacuum switch 2-pin plug connection Vehicle interface Ignition spark generator 4-pin plug connection Vehicle interface Ignition electrode 6-pin plug connection Vehicle interface Ignition spark generator 8-pin plug connection Heater Fig. 707 System wiring for the LGW / NGW 300 Standard...

  • Page 34: System Wiring For The Ngw 300 Evobus Citaro

    Heater Device Flame monitor electrode 1-pin plug connection Vehicle interface 2-pin plug connection A2 control unit 5-pin plug connection with SPST relay 4-pin plug connection A2 control unit Preessure regulator Fig. 708 System wiring for the NGW 300 EvoBus Citaro...

  • Page 35: System Wiring For The Ngw 300 Man

    Remote control circulating pump 2-pin plug connector Circulating pump Vacuum switch 8-pin plug connector Vehicle interface Ignition spark generator 5-pin plug connector Vehicle interface Ignition electrode 8-pin plug connector Heater Pressure regulator Fig. 709 System wiring for the NGW 300 MAN...

  • Page 36: Maintenance Work

    NGW 300 / LGW 300 / GBW 300 Servicing work Servicing work – Every three months accumulated oil and condensate must be drained in accordance with 6.3.8.5 at the gas pressure regulator’s oil drain plug. General information PLEASE NOTE If no oil/condensate accumulation is visible, the draining This section describes the workwhich is permitted to be interval can be lengthened.

  • Page 37: Connection To The Vehicle's Cooling System

    8 Servicing work NGW 300 / LGW 300 / GBW 300 8.5.1 Disassembling and mounting the burner head PLEASE NOTE Ensure that the temperature limiter’s and the regulating thermostat’s electrical connections are wired, using the CAUTION proper colours. The ignition spark generator is operated at high voltage.

  • Page 38: Connection To The Vehicle's Gas System

    8.6.2 Connection to the vehicle’s gas system 8.6.4 Exhaust gas line For the NGW 300 version, gas must be withdrawn from the tank or from the immediate vicinity of the tank. The exhaust pipe opening may not point in the direction in Withdrawing gas from the filler line and at places where oil which the bus is traveling.
  • Page 39 8 Control element 9 Gas tanks 10 Gas pressure regulator 11 Thermostat valve 12 Air vent slots (at the highest point for the NGW 300 and at the lowest point for the LGW 300) Fig. 802 Installation example for a bus heater...

  • Page 40: Disassembly And Installation

    NGW 300 / LGW 300 / GBW 300 Servicing work Disassembly and installation 8.7.2 Replacing the temperature limiter PLEASE NOTE ATTENTION The same procedure is followed when replacing the In its installed state, only the following disassembly and temperature limiter whether the heater is installed or not.

  • Page 41: Start-Up

    8 Servicing work NGW 300 / LGW 300 / GBW 300 Start-up Insufficient coolant must be replenished. Switch on the heater and the vehicle’s own heating fan, if After the heater is installed, the coolant circuit must be the engine is shut down. After a certain cooling period, the carefully bled.

  • Page 42: General Information

    Installation of the SG 1585 control unit as a replace- • Examine plugs for corrosion and connectors to make ment for the SG 1578 control unit for the NGW 300 sure that they are firmly attached and repair, if neces- and LGW 300 (see 9.1.2.1) sary •...
  • Page 43 General information 6. Disconnect the connector plug between the control The SG 1578 control unit for the NGW 300 and LGW 300 unit and the heater. heaters is no longer available and was replaced by the SG 1585 control unit.
  • Page 44 NGW 300 / LGW 300 / GBW 300 9 Repair 9.1.2.2 Installation of the U 4851 or Aquavent 6000 S Implementation - U 4851 circulating pump circulating pump as a replacement for the U ATTENTION 4814 and U 4816 circulation pumps When installing the U 4851 circulating pump, the following directions must be followed without fail.
  • Page 45 9 Repair NGW 300 / LGW 300 / GBW 300 Implementation: Aquavent 6000 S circulating pump clamps to prevent them from slipping. • No solenoids or other shut-off valves which could be ATTENTION closed during the operation of the pump, must be instal- When installing the Aquavent 6000 S circulating pump, led on the water infeed side of the circulating pump.
  • Page 46 NGW 300 / LGW 300 / GBW 300 9 Repair Disassembly and reassembly PLEASE NOTE The rubber cap must be fitted in such a way that its cable sleeve runs in the direction of the heater’s centre line. Af- 9.2.1 Replacement of the temperature limiter ter the rubber cap has been fitted, the cable in the sleeve must be adjusted without tension.

  • Page 47: Replacing The Sg 1585 Control Unit

    9 Repair NGW 300 / LGW 300 / GBW 300 9.2.3 Replacing the SG 1585 control unit 9.2.4 Replacing the ignition spark generator ATTENTION PLEASE NOTE Replacement of the control unit must be done in an unen- The ignition spark generator must be replaced complete ergised state.

  • Page 48: Replacing The Ignition Electrodes, The Flame Monitor Electrode And The Burner

    NGW 300 / LGW 300 / GBW 300 9 Repair 9.2.5 Replacing ignition electrodes 9.2.5.2 Installation 1. Position the ignition electrodes (3, fig. 907) with a new 9.2.5.1 Disassembly gasket (2) at the installation space, create electrical connections to the ignition electrodes (3) and push the 1.

  • Page 49: Replacing The Flame Monitor Electrode

    9 Repair NGW 300 / LGW 300 / GBW 300 9.2.6 Replacing the flame monitor electrode 9.2.7 Replacing the burner 9.2.6.1 Disassembly 9.2.7.1 Disassembly 1. Dismantle the burner head (see 8.5.1.1). 1. Dismantle the burner head (see 8.5.1.1). ATTENTION ATTENTION...
  • Page 50 NGW 300 / LGW 300 / GBW 300 9 Repair 14. Detach the coupling (9) and remove. 9.2.8.2 Reassembly 15. Remove the gasket (11). 16. Remove the screws (8) and lock washers (7). 1. Press the bearing (15, fig. 908) onto the shaft (14) until 17.
  • Page 51 9 Repair NGW 300 / LGW 300 / GBW 300 9. Coat the sealing surfaces between the motor bracket 17. Tighten the screws (5) with 5.5 Nm. (16) and the fan casing (25) with a sealant (e.g. Loctite 18. Attach the vacuum switch (3) to the bracket with two 396003).

  • Page 52: Replacing The Heat Exchanger And The Combustion Chamber

    NGW 300 / LGW 300 / GBW 300 9 Repair 9.2.9 Replacing the heat exchanger 9.2.10 Replacing the combustion chamber 9.2.9.1 Dismantling 9.2.10.1 Disassembly 1. Dismount the heater (see 8.7.1.1). 1. Dismount the burner head (see 8.5.1.1). 2. Dismount the burner head (see 8.5.1.1).

  • Page 53: Replacing The Gas Pressure Regulator

    1. Disconnect the delayed-action solenoid from the electricity supply. PLEASE NOTE 2. Loosen the gas hose on both sides and remove. Replacement gas pressure regulators for the NGW 300 in 3. Unscrew the delayed-action solenoid and remove it compliance with ECE-R 110: from the bracket.

  • Page 54: Packaging/Storage/Shipping 10.1 General Information

    Packaging/Storage/Shipping 10.1 General information The heater or its components, which are shipped to Spheros GmbH for checking or repair, must be cleaned and packed in such a way that they are protected from damage during handling, trasnportation and storage. A description of the defect must be enclosed.
  • Page 55 10 Packaging/Storage/Shipping NGW 300 / LGW 300 Blank page for notes 1002...

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