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Water Heater
Status: 12/2011
Ident.-no. 11114913B
Workshop Manual
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400
with Control Unit 1586

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Summary of Contents for Spheros Thermo S 160

  • Page 1 Water Heater Workshop Manual Thermo S 160 Thermo S 230 Thermo S 300 Thermo S 350 Thermo S 400 with Control Unit 1586 Status: 12/2011 Ident.-no. 11114913B...
  • Page 3: Table Of Contents

    Thermo S 160/230/300/350/400 1 Introduction Introduction Content and purpose Workshop manual validity Meaning of highlighted content Additional applicable documentation Installation and safety regulations 1.5.1 Legal installation regulations 1.5.2 Installation regulations for railway vehicles 1.5.3 General safety regulations 1.5.4 Combustion air supply 1.5.5...
  • Page 4 1 Introduction Thermo S 160/230/300/350/400 General error symptoms Malfunction code output via flash code Error symptoms during functional tests with malfunction code output or diagnosis 5.4.1 Error symptom "No start within safety period" 5.4.2 Error symptom "Flame interruption" 5.4.3 Error symptom "Low voltage"...
  • Page 5 Thermo S 160/230/300/350/400 1 Introduction Modifications and retrofits 10 Packing / storage and shipping 10.1 General 1001 Appendix A 1 Periodic heater maintenance...
  • Page 6 1 Introduction Thermo S 160/230/300/350/400...
  • Page 7: Content And Purpose

    R10 (EMC): No. 03 5266 and maintenance and repair of water heaters Thermo R122 (Heater) No. 00 0208 for Thermo S 160 S 160, S 230, S 300, S 350 and S 400. No. 00 0226 for Thermo S 230 No.
  • Page 8: Installation Regulations For Railway Vehicles

    The Spheros. The same applies if repairs are carried out installation box must be sufficiently vented from the incorrectly or with the use of parts other than genuine...
  • Page 9 Thermo S 160/230/300/350/400 1 Introduction CAUTION If the temperature within the installation box exceeds the If operated without coolant (overheating!), the heaters permissible ambient temperature of the heater, the outer enclosure may reach the ignition temperature of venting opening must be increased after consultation with diesel fuel during operation! Spheros.
  • Page 10 1 Introduction Thermo S 160/230/300/350/400 Water heating circulation system - wall heater and roof channel heater Wall heater with fan Heat exchanger at the entrance Heater Circulation pump Roof heat exchanger Vehicle engine Shut-off valve Driver seat heater Control element...
  • Page 11: Combustion Air Supply

    Thermo S 160/230/300/350/400 1 Introduction 1.5.4 Combustion air supply 1.5.6 Adapter wiring harness The combustion air intake opening may not point into ATTENTION driving direction. It should be arranged to effectively avoid Do not put strain on the adapter wiring harness or adapter contaminations as well as snow plastering and splash plugs installed for testing purposes.
  • Page 12 1 Introduction Thermo S 160/230/300/350/400...
  • Page 13: Electrical Components

    * 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 of Spheros circulation pumps for highest efficiency and reliability. In order to reduce starting currents the circulating pump can be synchronized by the control unit for a short time period during activation.
  • Page 14 2 Technical data Thermo S 160/230/300/350/400 ATTENTION The listed temperature ranges, hence minimum permissible temperatures strongly depend on the respective fuel quality. In case of bad-quality fuel the use limitations may deviate, e.g. in case of too high water content.
  • Page 15 (cyclic operation). The control unit controls heater activation and The Spheros Thermo S 160, S 230, S 300, S 350 and deactivation based on the temperature sensor signals. S 400 water heater systems are used in conjunction with...
  • Page 16: Combustion Air Fan

    3 Assemblies and components Thermo S 160/230/300/350/400 Burner 3.1.2 Fuel pump The fuel pump is responsible for fuel supply. The burner consists of components The pump is driven by the burner motor via a coupling. Fuel is compressed in the fuel pump to approx. 10 bar and •...
  • Page 17: Control Unit

    Thermo S 160/230/300/350/400 3 Assemblies and components The fuel pump can be used in dual-line operation (fuel 3.1.4 Control unit supply and return line). The control unit 1586 ensures the operating sequence If the heater is operated with and burner operation monitoring.
  • Page 18: Temperature Sensors With Water Temperature Sensor And Integrated Overheating Protection

    3 Assemblies and components Thermo S 160/230/300/350/400 3.1.6 Temperature sensors with water Electronic ignition unit temperature sensor and integrated Disc overheating protection The water temperature sensor captures the coolant temperature at the heat exchanger outlet as electrical resistance. This signal is transmitted to the control unit, where it is processed.
  • Page 19: Heat Exchanger

    Thermo S 160/230/300/350/400 3 Assemblies and components Heat exchanger The heat exchanger transfers the heat generated by combustion to the coolant circulation system. Depending on the system integration a heat exchanger with or without thread in the coolant inlet socket can be installed.
  • Page 20: Combustion Chamber

    Thermo S series. Deviating from the standard combustion chamber variant for Thermo S 230, S 300 and S 350, the Thermo S 160 is equipped with a combustion chamber with a sheet metal swirler and the Thermo S 400 is equipped with a burner pipe with increased wall thickness (1.5 mm).
  • Page 21: Circulating Pump

    Thermo S 160/230/300/350/400 3 Assemblies and components Circulating pump The externally arranged circulating pump ensures coolant transport within the vehicle and/or heater circulation system. Aquavent 5000 Depending on the application, the circulating pump is (U4814) switched on via the control unit or directly via the vehicle electrical system and operated during the entire heater operation duration.
  • Page 22: Aquavent 6000C (U4855) And Aquavent 6000Sc (U4856) Circulating Pumps

    3 Assemblies and components Thermo S 160/230/300/350/400 3.4.2 Aquavent 6000C (U4855) and Aquavent Inverse-polarity protection 6000SC (U4856) circulating pumps The circulating pump motor is not equipped with an internal inverse-polarity protection. The Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps are Fuel filter equipped with a brushless motor.
  • Page 23: General Heater Functionality Description

    -content is determined during For overheating protection of the heater the switching first calibration at Spheros and is stored in the control unit. thresholds are modified by the control unit, if specified In a maintenance event the workshop can adjust the CO temperature gradients are exceeded.
  • Page 24: Operational Heater Sequence

    4 Heater functions Thermo S 160/230/300/350/400 Operational heater sequence Signals Main switch Terminal 61 off (parking heating) on (auxiliary heating) off (parking heating) Coolant temperature T > T_min T < T_min T >= T_max T < T_min T >= T_max T <...
  • Page 25: Switching Off

    Thermo S 160/230/300/350/400 4 Heater functions Once the temperature falls short of the lower switching 4.2.2.3 Gradient evaluation threshold, the heater restarts burner operation. It runs through the same sequence as the switching-on In case of low coolant flow or poor coolant circuit venting sequence.
  • Page 26 4 Heater functions Thermo S 160/230/300/350/400 If a malfunction occurs during run-down (e.g. flame detection), the run-down may be shorter than 120 seconds. During run-down it is permitted to switch the heater back on. The burner will restart after a run-down time...
  • Page 27: Diagnosis Interface And Stt-Diagnosis

    For protection against moisture and contamination ensure that the diagnosis interface is sealed using protective caps, if not in use. The latest SST diagnosis software can be found in the Internet on the Spheros homepage under Service / Technical Documents.
  • Page 28: Malfunction Interlock And Heater Interlock

    4 Heater functions Thermo S 160/230/300/350/400 Malfunction interlock and heater Malfunction criteria: • Short circuit and/or interruption of electrical interlock components: – Burner motor (stops immediately) Malfunction interlocks and heater interlocks are – Circulating pump distinguished. – Electronic ignition unit Each malfunction interlock and heater interlock is stored –...
  • Page 29: Malfunctions During Run-Down

    If the heater interlock is active, neither start nor run-down are executed after switching the heater back on. Prior to restarting the heater troubleshooting must be performed by personnel trained by Spheros in order to identify the root cause. After that the heater interlock can be released (see 4.6.1).
  • Page 30: Error Output

    4 Heater functions Thermo S 160/230/300/350/400 4.6.1.1 Release of a heater interlock triggered by the 4.6.1.2 Release of a heater interlock triggered by temperature sensors other malfunctions using SST diagnosis If the heater interlock was triggered less than 1. Switch interlocked heater off.
  • Page 31: General

    Corrosion on battery terminals • Cable insulation damage This section describes troubleshooting and error correction for Thermo S 160, S 230, S 300, S 350 and S 400 heaters. ATTENTION Prior to replacing a fuse troubleshooting needs to be ATTENTION performed.
  • Page 32 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Table 501: General error symptoms Error symptom Possible cause Error in the water system Circulating pump not operating (Aquavent 6000S and • Error mode activated. Aquavent 6000SC only). In case of malfunctions the motor is switched off via the error mode.
  • Page 33: Malfunction Code Output Via Flash Code

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 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. •...
  • Page 34 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Table 502 Error and flash codes Error description Flash code Control unit error (e.g. incorrect checksum, no EOL programming) No start within safety period Flame interruption in burner operation, repeated starts unsuccessful Low voltage Extraneous light (flame detector "Bright"...
  • Page 35: Error Symptoms During Functional Tests With Malfunction Code Output Or Diagnosis

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Error symptoms during functional tests with malfunction code output or diagnosis 5.4.1 Error symptom "No start within safety period" If due to a malfunction the heater unsuccessfully attempted to start eight times in a row, it will be interlocked.
  • Page 36 5 Troubleshooting and error correction Thermo S 160/230/300/350/400 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 37: Error Symptom "Low Voltage

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.4.3 Error symptom "Low voltage" A value is stored in the control unit as smallest "permissible 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 38: Error Symptom "Extraneous Light Detected Prior To Ignition Or During Run-Down

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.4.4 Error symptom "Extraneous light detected prior to ignition or during run-down" Correct overheating cause. Did overheating occur? Is the burner properly screwed onto the Properly screw burner onto the heat heat exchanger? exchanger.
  • Page 39: Error Symptom "Flame Detector Defective

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.4.5 Error symptom "Flame detector defective" The flame detector cannot be replaced. It can only be tested using SST diagnosis. In case of damage or if the target value cannot be reached, the control unit must be replaced as needed.
  • Page 40: Individual Component Tests

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Individual component tests 5.5.1 General visual inspection • Inspect components for damages (cracks, deformation, Individual components can basically be tested using leaks, discolourations, etc.) and replace as needed. visual inspection or manual electrical testing.
  • Page 41: Resistance Check Of The Temperature Sensor With Integrated Overheating Protection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Pin 3 & 4 Water temperature sensor Pin 1 & 2 Overheating protection Fig. 503 5.5.4 Resistance check of the temperature sensor with integrated overheating protection Fig. 504 CAUTION Prior to removing the temperature sensor, the overpressure in the cooling system must be released by Resistance vs.
  • Page 42: Adapter Wiring Harness Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.5.5 Adapter wiring harness inspection • Check circlip for proper fit. • Install hood (see 8.4). Inspection • Inspect adapter wiring harness for tight fit and damage of the rubber grommet and the plug.
  • Page 43: Electronic Ignition Unit Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction Inspection using SST diagnosis 5.5.8 Electronic ignition unit inspection • Disconnect the heater from the vehicle electrical system. NOTE It is possible to manually test the functionality of the • Disconnect the temperature sensor plug and connect electronic ignition unit, and using the Component Test the test plug to the adapter wiring harness.
  • Page 44: Ignition Electrode Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 Inspection using SST diagnosis CAUTION • Remove burner (see 8.2). High voltage: The voltage received by the ignition electrode is >13.000 Volt. • Connect the test plug to the adapter wiring harness.
  • Page 45: Flame Detector Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.5.10 Flame detector inspection Electronic ignition unit Disc NOTE In case of contamination the glass body of the flame detector and the inspection glass in the disc (see Fig. 513) must be cleaned.
  • Page 46: Fuel Pump Inspection

    A pressure test unit with a display range from 0 to 15 bar • Follow the instructions provided by SST diagnosis. is required (Fig. 514). The pressure test unit can be obtained from a Spheros • After the test is completed, exit SST diagnosis as Service Center or a distribution partner.
  • Page 47: Solenoid Valve Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction • Select and start the solenoid valve in the Component Test menu. • The solenoid valve must audibly open. • After the test is completed, exit SST diagnosis as needed. • Disconnect the heater from the vehicle electrical system.
  • Page 48: Nozzle Block Preheater Inspection

    5 Troubleshooting and error correction Thermo S 160/230/300/350/400 5.5.13 Nozzle block preheater inspection Manual inspection • Remove burner (see 8.2). CAUTION • Disconnect the nozzle block preheater plug from the The heating element of the nozzle block preheater can control unit.
  • Page 49: Circulating Pump Inspection

    Thermo S 160/230/300/350/400 5 Troubleshooting and error correction 5.5.14 Circulating pump inspection ATTENTION The safety device of the circulating pump may never be pulled, while the pump is running. Inspection using SST diagnosis • Disconnect the heater from the vehicle electrical system.
  • Page 50 5 Troubleshooting and error correction Thermo S 160/230/300/350/400...
  • Page 51: General

    Thermo S 160/230/300/350/400 6 Schematic diagrams Schematic diagrams General The following figures represent customer-dependent heater connection options to the vehicle electrical system. The heater wiring harness cables as well as the cables of the vehicle electrical system are shown. ATTENTION In case of vehicle cable lengths up to 7.5 m the cable...
  • Page 52: Schematic Diagrams

    6 Schematic diagrams Thermo S 160/230/300/350/400 (HG) (UP) Heizgeräte- Kabelbaum 2,5mm UP - UP 1 UP + 2,5mm Klemme 31 2.5mm Klemme 30 (1) 2,5mm 2,5mm rt/ws Klemme 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Klemme 61 (D+) 0,75mm rt/ws 0,75mm K-Line od.
  • Page 53 Thermo S 160/230/300/350/400 6 Schematic diagrams 75(15) (HG) (UP) Heizgeräte- Kabelbaum UP 1 2,5mm UP - UP + 2,5mm Klemme 31 2.5mm 2,5mm Klemme 30 (1) 2,5mm rt/ws Klemme 30(2) 0,75mm BA + 0,75mm UPFA 0,75mm Klemme 61 (D+) 0,75mm...
  • Page 54 6 Schematic diagrams Thermo S 160/230/300/350/400 (UP) (HG) Klemme 31 2,5mm br Klemme 30(1) 2,5mm rt Klemme 30(2) 2,5mm rt/ws 0,75mm sw 0,75mm sw L-Line 0,75mm rt K-Line UP - 2,5mm br UP - 2,5mm br UP 1 UP + 2,5mm sw UP Überwachung...
  • Page 55 Thermo S 160/230/300/350/400 6 Schematic diagrams (HG) (UP) X1 10pol. Klemme 31 2,5mm br Klemme 30(1) 2,5mm rt Klemme 30(2) 2,5mm rt/ws 0,75mm sw 2,5mm sw UPFA 0,75mm or BA + 0,75mm bl X2 8pol. Klemme 31 2,5mm br Klemme 61 (D+)
  • Page 56 6 Schematic diagrams Thermo S 160/230/300/350/400 Markierungspunkt grün (UP) (UP2) (HG) 2,5mm br UP - UP 1 2,5mm sw UP + Markierungspunkt gelb UP - 2,5mm br UP 2 UP + 2,5mm sw Wasserpumpe 2 + 2,5mm sw 2,5mm br...
  • Page 57 Thermo S 160/230/300/350/400 6 Schematic diagrams (UP) (HG) Heizgeräte- Kabelbaum X1 2 pol. 2,5mm br UP - UP 1 UP + 2,5mm sw X2 6 pol. 2.5mm br Klemme 31 2,5mm rt Klemme 30(1) 2,5mm rt/ws Klemme 30(2) 0,75mm bl...
  • Page 58 6 Schematic diagrams Thermo S 160/230/300/350/400 (HG) (UP) Klemme 31 2,5mm br Klemme 30(1) 2,5mm rt Klemme 30(2) 2,5mm rt/ws 0,75mm sw UP - 2,5mm br UP - 2,5mm br UP 1 UP + 2,5mm sw UP Überwachung 0,75mm sw...
  • Page 59 Thermo S 160/230/300/350/400 6 Schematic diagrams (UP) (HG) Heizgeräte- Kabelbaum X1 2pol. 2,5mm br UP - UP 1 UP + 2,5mm sw X2 12pol. Klemme 31 2.5mm br Klemme 30(1) 2,5mm rt 2,5mm rt/ws Klemme 30(2) 0,75mm bl BA +...
  • Page 60 6 Schematic diagrams Thermo S 160/230/300/350/400 (UP) (HG) Heizgeräte- Kabelbaum 2,5mm br UP - UP 1 UP + 2,5mm sw Klemme 31 2.5mm br 2,5mm rt Klemme 30(1) 2,5mm rt/ws Klemme 30(2) 0,75mm bl BA + 0,75mm or UPFA 0,75mm sw...
  • Page 61 Thermo S 160/230/300/350/400 6 Schematic diagrams X1 2pol. (UP) (HG) UP - 2,5mm br UP 1 2,5mm sw UP + Temperaturschalter 0,75mm br 0,75mm rt X2 16pol. 0,75mm rt Temperaturwächter 2,5mm sw UP + 2,5mm sw 0,75mm br Klemme 31 2.5mm br...
  • Page 62 6 Schematic diagrams Thermo S 160/230/300/350/400...
  • Page 63: Heater Servicing

    If bio diesel or FAME is used, the fuel pump and fuel lines by a Spheros Service Center. must be replaced according to the latest technical information. You can find the latest overview on the Spheros homepage under Service / Technical Documents.
  • Page 64 7 Servicing Thermo S 160/230/300/350/400 7.2.1 CO content adjustment • Obtain the next steps from SST diagnosis. Adjust the burner motor speed using SST diagnosis to achieve the target value for the CO content. A modification of the factory-adjusted burner motor speed...
  • Page 65: Removal And Installation

    NOTE If components are disassembled to a degree not covered in this workshop manual, any warranty claim shall be voided. Only genuine Spheros spare parts should be used. Removing the burner provides access to the following components: • Atomizer nozzle •...
  • Page 66: Burner Removal And Installation

    8 Repair Thermo S 160/230/300/350/400 Burner removal and installation Burner installation 1. Bring burner (1, Fig. 801) in assembly position and ensure centre alignment and correct fit. Burner removal 2. Place nuts (2) and alternately tighten them slightly. 1. Disconnect the heater from the vehicle electrical 3.
  • Page 67: Removal And Installation Of The Temperature Sensor With Integrated Overheating Protection

    Thermo S 160/230/300/350/400 8 Repair Removal and installation of Hood removal and installation the temperature sensor with integrated overheating protection Removing the hood provides access to the following components for maintenance, inspection and repair purposes: CAUTION Risk of injuries if coolant temperature is •...
  • Page 68: Combustion Air Fan Removal And Installation

    8 Repair Thermo S 160/230/300/350/400 Combustion air fan removal Installation 1. If necessary, reconnect the burner motor (3, Fig. 803) and installation to the motor cross member (5). For this purpose align the burner motor with the motor cross member.
  • Page 69 Thermo S 160/230/300/350/400 8 Repair Shaft circlip Burner motor Motor plug Motor cross member Screws (3) Countersunk screws (3) Hood Screws (2) 10 Coupling with magnets 11 Burner housing Fig. 803 Combustion air fan removal and installation...
  • Page 70: Electronic Ignition Unit And Ignition Electrode Removal And Installation

    8 Repair Thermo S 160/230/300/350/400 Electronic ignition unit and ignition Installation 1. Bring electronic ignition unit (1, Fig. 804) into electrode removal and installation installation position, attach ready for connection and secure with screws (4). Removal 2. Tighten screws (4) with 5 Nm +1 Nm.
  • Page 71 Thermo S 160/230/300/350/400 8 Repair Electronic ignition unit Screw (2) Ignition electrode Atomizer nozzle Disc Solenoid valve Nozzle block preheater, optional Support Fuel pump 10 O-rings (2) 11 Filter insert 12 Screws (3) 13 Burner housing 14 Control unit 15 Heater wiring harness...
  • Page 72: Control Unit Removal And Installation

    8 Repair Thermo S 160/230/300/350/400 Control unit removal and installation 6. Pull fuel pump (9) with the solenoid valve (6) off and remove it. 7. Remove and scrap O-rings (10) and filter insert (11). Removal 8. If applicable, remove the nozzle block preheater (7).
  • Page 73 Thermo S 160/230/300/350/400 8 Repair Electronic ignition unit Screw (2) Ignition electrode Atomizer nozzle Disc Solenoid valve Nozzle block preheater, optional Support Fuel pump 10 O-rings (2) 11 Filter insert 12 Screws (3) 13 Burner housing 14 Control unit 15 Heater wiring harness...
  • Page 74: Solenoid Valve Removal And Installation

    8 Repair Thermo S 160/230/300/350/400 Solenoid valve removal and installation 3. Using suitable tools, tighten hexagon, wrench size 16 (6, Fig. 807) of the solenoid valve with NOTE 5 Nm ± 0.5 Nm. The solenoid valve must be completely replaced and 4.
  • Page 75: Combustion Chamber Removal And Installation

    Thermo S 160/230/300/350/400 8 Repair 8.11 Combustion chamber removal and 8.12 Heat exchanger removal and installation installation Removal Removal 1. Remove burner (see 8.2). 1. Remove burner (see 8.2). 2. Pull combustion chamber (1, Fig. 808) out of the heat 2.
  • Page 76: Start-Up After Burner Or Heater Installation

    8 Repair Thermo S 160/230/300/350/400 8.14 Start-up after burner or heater 8.14.2 Bleeding of the water circuit installation NOTE The water circuit must be principally bleeded The fuel system must be bleeded after burner installation. according to manufacturer specification. The coolant circuit and the fuel system must be bleeded after heater installation.
  • Page 77 Thermo S 160/230/300/350/400 9 Modifications and retrofits 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.
  • Page 78 9 Modifications and retrofits Thermo S 160/230/300/350/400...
  • Page 79 10 Packing / storage / shipping Packing / storage and shipping 10.1 General The heater or its components, which are sent to Spheros for inspection or repair, must be cleaned and packaged to ensure that handling, transport and storage will not damage them.
  • Page 80 10 Packing / storage / shipping Thermo S 160/230/300/350/400 Empty page for notes 1002...
  • Page 81 Thermo S 160/230/300/350/400 A Appendix Appendix A Periodic maintenance...
  • Page 82 (time of applications, the maintenance intervals may be shortened increased heater usage due to present weather or extended. conditions). In such cases please contact your dedicated Spheros partner for further information. Inspection / maintenance activities Important information Inspection...

This manual is also suitable for:

Thermo s 400Thermo s 230Thermo s 300Thermo s 350

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