Spheros Thermo 230 Workshop Manual
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Spheros Thermo 230 Workshop Manual

Spheros Thermo 230 Workshop Manual

With control unit 1572d
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See also: Workshop Manual , Manual and Warranty
Water Heaters
Revision 12/2011
Doc. P/N: 9003656D
Workshop Manual
Thermo 230
Thermo 300
Thermo 350
with control unit 1572D

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Summary of Contents for Spheros Thermo 230

  • Page 1 Workshop Manual Water Heaters Thermo 230 Thermo 300 Thermo 350 with control unit 1572D Revision 12/2011 Doc. P/N: 9003656D...

  • Page 2: Table Of Contents

    Thermo Series Coolant Heaters Table of Contents List of Contents 1. Introduction Scope and Purpose....................7 Applicability of Manual .
  • Page 3 Thermo Series Coolant Heaters Table of Contents Components Testing..................33 6.3.1 Temperature Sensor Resistance Check .
  • Page 4 Thermo Series Coolant Heaters Table of Contents c i r...
  • Page 5 Thermo Series Coolant Heaters Table of Contents...

  • Page 6: Introduction

    This repair shop manual is intended to support familiarized personnel in the repair of water heaters "General Safety Regulations" beyond the scope of these Thermo 230, 300 and 350. regulations are detailed in the following. The water heater may only be operated with the fuel...

  • Page 7: Legal Provisions For Installation

    Directives 72/245/EEC (EMC) and 2001/56EC (Heating vent cap or any other type of ventilation (vent Systems) were granted for the heaters Thermo 230 / line). Thermo 300 / Thermo 350 with the following EC Type...

  • Page 8: Corrections And Improvements

    Thermo Series Coolant Heaters Introduction Corrections and Improvements Deficiencies, improvements, or proposals for correction of this workshop manual are to be mailed to: Spheros North America, Inc. 5536 Research Drive Canton MI. 48188 Telephone: 1-734-218-7350 Fax: 1-734-487-1569 website: www.spheros.us / info@spheros.us...
  • Page 9 Thermo Series Coolant Heaters Introduction...

  • Page 10: General Description

    Thermo Series Coolant Heaters General Description General Description The heaters Thermo 230, 300 and 350 basically consist of – the combustion air fan The water heaters Spheros Thermo 230, 300 and 350 are – the fuel pump with nozzle block and nozzle used in combination with the vehicle’s own heating...

  • Page 11: Combustion Air Fan

    Thermo Series Coolant Heaters General Description Combustion Air Fan 2.2.1 Nozzle block pre-heater NOTE The combustion air fan supplies the air required for combustion from the combustion air inlet to the For operation with PME (Biodiesel) the installation of a combustion chamber.

  • Page 12: Control Unit

    Thermo Series Coolant Heaters General Description Control Unit The control unit 1572D is the central component to ensure controlled operation and monitoring of Igniter electrodes combustion. Ignition coil (green connector cover; mechanically coded) only in combination with control unit 1572D Control unit 1572D Temperature Sensor Flame Sensor...

  • Page 13: Overheat Thermostat For Burner (Thermo Heaters Operated In Vertical Position Only)

    Thermo Series Coolant Heaters General Description 2.10 Overheat Thermostat for burner (Thermo heaters operated in vertical position only) Aquavent 6000C (U 4855) The overheat thermostat is screwed onto the disk and electrically connected to the solenoid valve of the fuel pump.

  • Page 14: Heated Fuel Filter (For Pme Biodiesel Use)

    Thermo Series Coolant Heaters General Description Overload protection After completion of the soft start an overload protection is activated to limit the power consumption and keep the speed at 5550 rpm. That means that the motor is not damaged in case of circulating pump hydraulic overpressure.
  • Page 15 Thermo Series Coolant Heaters General Description...

  • Page 16: Functional Description

    Thermo Series Coolant Heaters Functional Description Functional Description and the nozzle sprays fuel into the combustion chamber to be ignited by the igniter spark. A photo control circuit deactivates the electronic ignition coil after flame-up. Activation and deactivation is by means of a switch Heating Operation timer...

  • Page 17: Power Save

    Thermo Series Coolant Heaters Functional Description Power Save Heater Lockout (heaters with control unit 1572D) With power save on the control temperatures of the heating circuit are kept low. Combustion performance is After the heater has performed eight consecutive start not reduced.

  • Page 18: Switch-Off Upon Failure (Heaters With Control Unit 1572D)

    Thermo Series Coolant Heaters Functional Description Operating indicator light Heater cartridge M2 Circulating pump Igniter box M1 Combustion air fan Solenoid valve Flame sensor Switch on Start Flame-up, combustion operation Temperature sensor – upper switching threshold Flame sensor – dark Control idle Temperature sensor –...

  • Page 19: Error Code Output (Heaters With Control Unit 1572D)

    Thermo Series Coolant Heaters Functional Description Error Code Output (heaters with control Malfunctions by overheating: unit 1572D) Overheating results in deactivation of the heater by the temperature limiter. Dependent on heater When equipped with a standard timer an error code configuration: readout appears on the display of the timer after a the reset button on the temperature limiter must be...
  • Page 20 Thermo Series Coolant Heaters Functional Description...

  • Page 21: Technical Data

    Thermo Series Coolant Heaters Technical Data Technical Data Where no threshold values are specified technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 68°F ( + 20 °C) and at nominal voltage. Electrical components Control unit, fan and circulating pump motors, solenoid valve, electronic ignition coil, heater cartridge, nozzle...
  • Page 22 Thermo Series Coolant Heaters Technical Data Heater data - - * - - * - - * Btu/h 80,000 104,000 120,000 ) . x 0.79 1.05 1.14 US Gal/hr l/hr 4.35 Kg/h . . . Nominal power consumption Watts (without circulating pump) Permissible operating ambient F °...

  • Page 23: Troubleshooting

    Troubleshooting is normally limited to the isolation of defective components. This section describes troubleshooting procedures for The following possible causes for trouble have not been the heaters Thermo 230, 300, and 350. taken into consideration and must always be excluded CAUTION as a possible cause for malfunction:...
  • Page 24 Thermo Series Coolant Heaters Troubleshooting Heater operation stops because heat exchangers connected do not Rate of flow too low, because dissipate enough heat. air in heater, in heat exchangers or system sections. valves (flow regulators) throttled, contaminated or closed. contamination in system, e.g. in areas of restricted flow. circulating pump rate of delivery insufficient (air in pump housing).

  • Page 25: Fault Symptoms During Functional Checkouts

    1572D) may be tested in the vehicle. readout is available after a malfunction on the display of the timer. For details refer to operating instructions for "Spheros When the heater is operated by means of a switch a Thermo Test PC based Heater Diagnosis".
  • Page 26 Thermo Series Coolant Heaters Troubleshooting 5.3.2 Fault Symptoms and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the 5.3.2.1 Fault Symptom "No Start" heater on and disconnection of the heater power supply NOTE during run-down.
  • Page 27 Thermo Series Coolant Heaters Troubleshooting 5.3.2.2 Fault Symptom "Flame-out" and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. NOTE The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply Heaters with control unit 1572D: during run-down.
  • Page 28 Thermo Series Coolant Heaters Troubleshooting 5.3.2.4 Fault Symptom "Unexpected Light Detection during Run-up or Run-down" Has heater been in long time operation Flame sensor defective, replace. shortly before? Control unit defective, replace. Allow heater to cool down and restart (approx. 2 min.). Clean combustion tube.
  • Page 29 Thermo Series Coolant Heaters Troubleshooting 5.3.2.7 Fault Symptom "Solenoid Valve Defective" Is solenoid valve supplied Make electrical connections. with electrical power? Replace solenoid valve. Is components test with diagnostic computer o.k. Control unit defective, replace. (audible click of solenoid valve)? Does fuel leak from nozzle in run-down? Replace solenoid valve.
  • Page 30 Thermo Series Coolant Heaters Troubleshooting 5.3.2.8 Fault Symptom "Temperature Limiter Defective" Is electrical power supply Make electrical connections. to components o.k.? Control unit defective, replace. Has temperature limiter responded (reset limiter)? Determine why temperature limiter has responded, e.g.: ck shut-off elements, ck water circulation in system is free from bubbles, ck circulation pump sense of rotation,...

  • Page 31: Functional Checkouts

    Thermo Series Coolant Heaters Functional Checkouts Functional Checkouts General This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities.

  • Page 32: Components Testing

    Thermo Series Coolant Heaters Functional Checkouts Components Testing 6.3.3 Igniter Electrodes Check NOTE 6.3.1 Temperature Sensor Resistance Check The insulator of the igniter electrodes must show no When checking the temperature sensor with a digital damage. Igniter electrodes not working properly must multimeter the values of the following diagram must be be replaced.

  • Page 33: Electronic Ignition Coil Check

    (with a range from 0 to 15 bar 0r 200 psi) can be High voltage; 20,000 volts arcing across the igniter procured from your authorized Spheros dealer. electrodes. The fuel pump and fuel hoses must be replaced every 5 CAUTION years.

  • Page 34: Drive Motor Check

    In this On heaters with control unit 1572D the fuel pump may case fuel keeps dripping through the fuel nozzle. only be checked by means of the Spheros Thermo Test PC heater diagnosis. Short smoke emissions are normal caused by clearing the area between solenoid valve and nozzle bore.

  • Page 35: Circuit Diagrams

    Thermo Series Coolant Heaters Circuit Diagrams Circuit Diagrams General The circuit diagrams (Fig. 5 and Fig. 6) show possible heater circuits for Thermo 230, 300 and 350 with control unit 1572D and with – switch – standard timer 1531 c i r...
  • Page 36 Thermo Series Coolant Heaters Circuit Diagrams Figure 5: Automatic Control Circuit with Switch...
  • Page 37 Thermo Series Coolant Heaters Circuit Diagrams Legend for Fig. 5 (previous page) Optional - flame indication light Optional - power save (pre-heating) signal Optional - water pump run input (no heat) Item Nomenclature Remark Item Nomenclature Remark Heater pump Control unit SG 1572D Flame sensor observe polarity...
  • Page 38 Thermo Series Coolant Heaters Circuit Diagrams Figure 6: Automatic Control Circuit with Standard Timer 1531...
  • Page 39 Thermo Series Coolant Heaters Circuit Diagrams Legend for Fig. 6 (previous page) Optional - flame indication light Optional - power save (pre-heating) signal Optional - water pump run input (no heat) Optional - connection to instrument panel lighting Timer: with plus to connection 10 = continuous operating during immediate heating terminal 10 not connected = duration of heating programmable (10 min.
  • Page 40 Thermo Series Coolant Heaters Circuit Diagrams Page empty for notes...

  • Page 41: Servicing

    General the heater should be checked in regular intervals by a This section describes the servicing procedures allowed Spheros service agent or properly trained technician, on the heater when installed. the latest before the beginning of the heating season (refer to Annex A "Scheduled Maintenance").
  • Page 42 4. If the exhaust muffler has been lost it may be secure muffler with a sheet metal screw B 3.9 x 25 (see ordered free of charge from Spheros (P/N 20691C). figure). Fasten muffler according to NOTE. Slot or drill exhaust pipe and refit.

  • Page 43: Burner Head Opening And Closing Or Removal And Installation

    Thermo Series Coolant Heaters Servicing 8.5.2 Burner Head Opening and Closing or Opening or removal Removal and Installation 1. Disconnect electrical connections to temperature limiter and temperature sensor. WARNING 2. Loosen nuts (2, Fig. 7) enough to release hinge bolts The electronic ignition coil operates with high voltage.

  • Page 44: Visual Inspections And Regulations For Installation

    Should fuel hoses be installed, always use the hoses It is a basic requirement to use the coolant hoses supplied or offered by Spheros. If other hoses are used supplied by Spheros, otherwise the hoses must at least they must at least meet the specifications of DIN 73379- meet the specifications of DIN 73411.
  • Page 45 Water heating circuit – Sidewall radiators and roof duct heating Supply Return Sidewall heat exchanger with fan Stepwell heat exchanger with fan Spheros Heating unit Circulating pump Heat exchanger, roof Vehicle engine Water valves Driver area heat exchanger / defroster...

  • Page 46: Combustion Air Supply

    Observe official regulations concerning the installation (see 1.6). A fuel filter supplied as deliverable item or cleared for use by Spheros is to be fitted. The exhaust pipe outlet opening must not point in the Installation position possibly vertical with horizontal direction of motion.

  • Page 47: Removal And Installation

    6. Connect electrical connectors of cable harness in – max. bend: 270° vehicle and to circulating pump. As an alternative an exhaust deflector must be installed 7. Bleed fuel supply system. cleared by Spheros. 8. Bleed coolant circuit. Removal and Installation 8.7.2 Temperature Limiter, Replacement...

  • Page 48: Electronic Ignition Coil, Replacement

    Thermo Series Coolant Heaters Servicing 8.7.5 Electronic Ignition Coil, Replacement lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply within 120 sec. during run-down. The replacement procedure for the electronic ignition coil is identical with the heater installed or removed.

  • Page 49: Repair

    Repair General This section describes the repairs that may be performed on the heaters Thermo 230, 300 and 350 when removed. Any further disassembly will void the warranty. For re-assembly, only components of the proper service part kits are to be used.

  • Page 50: Work On Components After Disassembly

    Thermo Series Coolant Heaters Repair 9.1.1 Work on Components after Disassembly 9.1.2 Incorporation of Modifications NOTE CAUTION Continuous enhancement of heater design is for All gaskets located between disassembled components optimizing performance and avoiding failures and must always be replaced and old gaskets discarded. malfunctions.
  • Page 51 Thermo Series Coolant Heaters Repair 9.1.2.1 Installation of Control Unit 1572D as Procedure Substitute for Control Unit 1572 CAUTION General Control unit 1572D may only be used in combination with the electronic ignition coil delivered (green Due to the progress in the development of processors connector cover).
  • Page 52 Thermo Series Coolant Heaters Repair NOTE 9.1.2.2 Installation of Circulating Pump Aquavent 5000/ 5000s or 6000 as substitute The circulating pump is not self-venting of any for Circulating Pump U 4816 accumulating air. Therefore the pump has to be installed at the lowest point of the water circuit General observing the permitted pump orientation (see Fig.).
  • Page 53 Thermo Series Coolant Heaters Repair Procedure, circulating pump Aquavent 5000S (U 4854) Prior to first operation of the circulating pump, the Aquavent 6000SC (u 4856) vehicle cooling system and the pump body must be bled. CAUTION The Aquavent 6000 SC pump head includes no parts subject to wear.

  • Page 54: Disassembly And Assembly

    Thermo Series Coolant Heaters Repair Disassembly and Assembly opening the coolant circuit pressure cap. If required, also allow heater to cool down and have collector vessel ready to collect escaping coolant. 9.2.1 Temperature Limiter, Replacement 2. Unscrew temperature sensor (2, Fig. 9) and remove. 9.2.1.1 Removal 9.2.2.2 Installation 1.
  • Page 55 Thermo Series Coolant Heaters Repair Temperature limiter Temperature sensor Rubber cap Connector Temperature Coolant outlet limiter Cotter pin Nut (2) Retaining clip Hinge bolt (2) Burner NOTE Depending on the burner head direction of swing, the cotter pin may be located on the opposite side. Figure 9: Temperature Limiter, Temperature Sensor and Burner, Replacement c i r...

  • Page 56: Combustion Air Fan And Motor Replacement

    Thermo Series Coolant Heaters Repair 9.2.4 Combustion Air Fan and motor 9.2.4.2 Installation Replacement NOTE NOTE Drive motor (7, Fig. 10) to be aligned with control unit (recess in mounting flange) and with clutch (by rotating For replacement of the combustion air fan and motor, drive shaft).
  • Page 57 Thermo Series Coolant Heaters Repair Splash protection cover Screw (2) Fan wheel Slide lock Screw (3) Drive motor Clutch Electrical connector Figure 10: Combustion Air Fan, Replacement c i r...

  • Page 58: Control Unit, Replacement

    Thermo Series Coolant Heaters Repair 9.2.5 Control Unit, Replacement 6. Withdraw fuel pump (10) together with solenoid valve (7) and set aside. NOTE 7. Remove and discard O-rings (12) and filter screen For replacement of the control unit the burner head (11).
  • Page 59 Thermo Series Coolant Heaters Repair Electronic ignition coil Overheat (new style housing) in thermostat combination with control (Vertical only) unit 1572D and 1572. Control unit 1572D Electronic ignition coil (black connector cover) in combination with control unit 1572 only. Control unit 1572 Electronic ignition coil 15 Flame sensor...

  • Page 60: Electronic Ignition Coil, Replacement

    Thermo Series Coolant Heaters Repair 9.2.8 Electronic Ignition Coil, Replacement 9.2.9 Flame Sensor, Replacement 9.2.8.1 Removal 9.2.9.1 Removal 1. Remove burner if required (refer to 9.2.3.1). 1. Remove burner if required (refer to 9.2.3.1). 2. Using screw driver lever off igniter electrodes 2.
  • Page 61 Thermo Series Coolant Heaters Repair Electronic ignition coil Overheat (new style housing) in thermostat combination with control (Vertical only) unit 1572D and 1572. Control unit 1572D Electronic ignition coil (black connector cover) in combination with control unit 1572 only. Control unit 1572 Electronic ignition coil 15 Flame sensor...

  • Page 62: 9.2.10 Heat Exchanger, Replacement

    Thermo Series Coolant Heaters Repair 9.2.10 Heat Exchanger, Replacement 9.2.11 Combustion Chamber, Replacement 9.2.10.1 Removal 9.2.11.1 Removal 1. Remove temperature limiter (refer to 9.2.1.1). 1. Disconnect electrical connections to temperature limiter and temperature sensor. 2. Remove temperature sensor (refer to 9.2.2.1). 2.
  • Page 63 Thermo Series Coolant Heaters Annex A Heater, Scheduled Maintenance time when weather conditions cause increased use of heater). The heater should be checked in regular intervals at The maintenance intervals indicated below apply to least at the beginning of the heating season (point of applications and requirements typical of buses.I Maintenance / Repair o.k.
  • Page 64 Thermo Series Coolant Heaters Annex A...
  • Page 66 Doc. P/N: 9003656D Edited for North America - 12/2011 Subject to modification © Spheros North America, Inc. 2011 Spheros North America, Inc. 5536 Research Drive, Canton MI 48188 Tel. 1-734-218-7350 · Fax 1-734-487-1569 www.spheros.us · info@spheros.us...

This manual is also suitable for:

Thermo 300Thermo 350

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