Spheros Thermo S 160 Installation Instructions Manual
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Spheros Thermo S 160 Installation Instructions Manual

Spheros Thermo S 160 Installation Instructions Manual

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Water Heaters
Stand: 02/2012
Ident Nr. XXXXXX
Installation Instructions
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400

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Summary of Contents for Spheros Thermo S 160

  • Page 1 Water Heaters Installation Instructions Thermo S 160 Thermo S 230 Thermo S 300 Thermo S 350 Thermo S 400 Stand: 02/2012 Ident Nr. XXXXXX...
  • Page 2 NEVER try to install or repair Spheros heating or cooling systems if you have not completed a Spheros 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: Table Of Contents

    Thermo S 160/230/300/350/400 Table of Contents Statutory regulations governing installation l l a l l a l l a Connection to the vehicle cooling system i r t...

  • Page 4: Statutory Regulations Governing Installation

    R10 (EMC): No. 03 5266 and comply with the requirements of paragraph 5.3. R122 (Heater) No. 00 0208 for Thermo S 160 5.3.2 Positioning of combustion heater No. 00 0226 for Thermo S 230 No. 00 0227 for Thermo S 300 5.3.2.1 Body sections and any other components in the vicinity of the...
  • Page 5 IMPORTANT: Failure to follow the installation instructions and the notes contai- ned therein will lead to all liability being refused by Spheros. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts. This will result in the invali- dation of the type approval for the heater and therefore of its ECE Type Approval.
  • Page 6 2.2. Versions The water heaters are used in connection with the vehicle’s own heating system Thermo S 160 – 24V – to heat the passenger cabin, Water heater for “diesel“ – to defrost the vehicle windows and with 16 kW (55,000Btu/h) heat current –...
  • Page 7 3.1.1. Installation Location in Rail Vehicles must always be submitted to Spheros for approval. In rail vehicles the heater is to be installed either in the engine room (e.g. If this approval is not obtained, all warranty and liability claims locomotive) or in a special mounting box.
  • Page 8 440 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 S 160/230/300/350/400 heater...
  • Page 9 o S 160/230/300/350/400 3.2. Installation of a Thermo S heater The heater may be secured either with four M8 screws or with four bolts and nuts (see Figure 3) . 0° - 15° 0° - 15° 0° - 5° 0° - 5° Fig.
  • Page 10 3.3. Model plate 3.4. Additional Plate The model plate must be protected from damage and must be clearly le- Heaters approved for use in rail vehicles are additionally identi ed by the gible when the heater is installed (otherwise a duplicate model plate type plate illustrated below: must be used).

  • Page 11: Installation Example

    Installation example Thermo S 160/230/300/350/400 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 12 The pump ports and connection lines from the water intake and wa- ter outlet must be flush (no stress). IMPORTANT: The heater should be installed preferably with Spheros circulating pumps. If the pump is not controlled by the heater, its operation is to be en- sured by all means during whole heater operation (initial cycle, heating operation and purge cycle).
  • Page 13 Installation of the circulat 5.1. U 4814 (Aquavent 5000) circulating pump Fig. 8: Hole pattern for the stand for U 4814 circulating pump Delivery rate (with water at 20°C) Fig. 7: U 4814 circulating pump installation position Flow resistance ∆ (with the pump stopped) Fig.
  • Page 14 lation of the circulating pump 5.2. U 4854 (Aquavent 5000S) circulating pump 99,5 131,5 0-90° 0-85° Fig. 11: Hole pattern for the stand for U 4854 circulating pump min. 5° Delivery rate (with water at 68°F/20°C) Fig. 10: U 4854 circulating pump installation position Flow resistance 24 V...
  • Page 15 Installation of the circulat 5.3. U 4855 (Aquavent 6000C) circulating pump ±2 52,8 30,8 0-85° Fig. 14: Hole pattern for the stand for U 4855 circulating pump min. 5° 0-90° Delivery rate (with water at 68°F/20°C) Fig. 13: U 4855 circulating pump installation position Flow resistance 24 V...

  • Page 16: E S E V

    lation of the circulating pump 5.4. U 4856 (Aquavent 6000SC) circulating pump ±2 Ø 0-85° 0-90° Fig. 17: Hole pattern for the stand for U 4856 circulating pump min. 5° Delivery rate (with water at 68°F/20°C) Fig. 16: U 4856 circulating pump installation position Flow resistance 24 V...
  • Page 17 Installation of the circulat 5.5. Motor for circulating pump model U 4855 (Aquavent 6000C) 5.5.5. Sleep-Mode and U 4856 (Aquavent 6000SC) In the sleep mode the internal consumers of the motor electronics are These circulating pumps are equipped with a brushless motor. switched o .

  • Page 18: Connection To The Vehicle Cooling System

    2 minutes. Basically the water hoses supplied by Spheros should be used. If this is not the case, the hoses must comply with DIN 73411 requirements as a minimum.

  • Page 19: Fuel Supply

    When using fuel hoses, basically the hoses supplied or o ered by Spheros are to be used. If this is not the case, the fuel hoses must, as a a) With a separate bleeding device according to the prescribed for minimum, comply with the requirem ents of DIN 73379.
  • Page 20 500 mbar not exceeds. 7.2. Fuel Filter A fuel lter supplied or approved by Spheros must be used (consider the ow direction). To avoid malfunctions the lter or lter insert is to be re- placed annually before the cold weather season starts.

  • Page 21: Combustion Air Supply

    4.5 in2 (30 cm2) 6.0 in2 (40 cm2) If the temperature in the installation housing exceeds the permissible ambient temperature of the heater (see Technical Data), the ventilation opening must be enlarged subject to prior consultation with Spheros.

  • Page 22: Exhaust Pipe

    Exhaust pipe The discharge opening of the exhaust pipe must not point in the direc- tion of travel. The exhaust pipe discharge opening must be so located that any clog- ging caused by snow or mud is not to be expected. Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm, or exible tubes of alloyed steel are to be used.

  • Page 23: Electrical Connections

    Route the electrical cables so their insulation will not be damaged (i.e. wedging, temperature exposure, kinks, chafing) 10.2. Connection of the heater controls The heater can be switched on and o using the following Spheros heater controls: – Switch, see system wiring diagram Fig. 19 –...
  • Page 24 Thermo S 160/230/300/350/ (UP) (HG) Heater cable harness 2,5mm UP - UP 1 UP + 2,5mm Terminal 31 2.5mm Terminal 30 (1) 2,5mm 2,5mm rt/ws Terminal 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Terminal 61 (D+) 0,75mm rt/ws 0,75mm K-Line or CAN-H...
  • Page 25 Electrical connections Thermo S 160/230/300/350/400 75(15) (UP) (HG) Heater cable harness UP 1 2,5mm UP - UP + 2,5mm Terminal 31 2.5mm 2,5mm Terminal 30 (1) 2,5mm rt/ws Terminal 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Terminal 61 (D+) 0,75mm...
  • Page 26 Thermo S 160/230/300/350/ Item Designation To vehicle (power) Fuel solenoid valve Light, operation mode max. 5W T. 31 (ground) Fuel solenoid valve + T. 30 („+“) 25A Fuel solenoid valve – Motor, combustion air fan Combustion control Nozzle preheater T. 30 („+“) 25A Vehicle fuse 25A acc.
  • Page 27 i t i Initial start-up NOTE: The safety precautions given in the operating and maintenance instructions must be considered. It is mandatory to read through the operating and maintenance instructions before starting the heater. After you have installed the heater, bleed the water system and the fuel supply system carefully.
  • Page 28 Maintenance Periodic maintenance is to be performed in accordance with Chapter 7 and Appendix A of the Workshop Manual. When the heater is operated in rail vehicles, maintenance chart / test certi cate item no. 90 087 22 is to be used.

  • Page 29: O M B U T S O I N

    Malfunctions The control device detects the following malfunctions and generates respective ash codes: * Consec. Description of malfunction Flash code o i t y t l No start within the safety time Flame interruption, restart failed Low voltage Overvoltage Extrinsic light ( ame guard „bright“ before starting) i r t g i l a l f...
  • Page 30 Consec. Description of malfunction Flash code Electronic ignition unit short circuit after terminal 31 Electronic ignition unit fails or short circuit after terminal 30 Heater fault lock-out - deactivation necessary (caused by several malfunctions or ame interruptions) Nozzle preheater sensor short circuit after terminal 31 Nozzle preheater sensor fails or short circuit after terminal 30 r t r c r i...

  • Page 31: Technical Data

    rmo S 160/230/300/350/400 Technical data nozzle preheater and heated fuel lter Except where limit values are speci ed, these technical data refer to the usual heater tolerances of ±10 % at an ambient temperature of +20 °C IMPORTANT: and at the rated voltage. The above mentioned temperature ranges, that means the mini- NOTE: mum permissible temperatures are determined strongly by the...

  • Page 32: O R N M E T

    * without circulating pump Max. continuous current of the circulating pump 10 A, maximum peak current for 0.5 s duration = 90 A - We recommend the use o f Spheros circulation pumps for highest efficiency and reliability. In order to reduce starting currents the circulating pump can be synchronized by the control unit f or a short time period during activation.
  • Page 33 rmo S 160/230/300/350/400 irculating pump data c r i Aquavent 5000 Aquavent 6000C 5200 5200 6000 6000 US Gal/m 26.4 26.4 12 ... 24 10 ...14/20 ... 28 Nominal power consumption Watts Length 229 (9) Length 249 (9.8) Length 224 (8.8) Length 229 (9) mm (in.) Width 100 (3.9)
  • Page 34 Thermo S 160/230/300/ 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 prob lems. In the process the materials...

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