Workshop Manual

Water Heaters

Thermo 230
Thermo 300
Thermo 350
with control unit 1572D

Revision 12/2011
Doc. P/N: 9003656D

Thermo Series Coolant Heaters Table of Contents

List of Contents

1. Introduction 7
1.1 Scope and Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Applicability of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Meaning of Warnings, Cautions and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4 Additional Documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.5 Safety Information and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.5.1 General Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.6 Legal Provisions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Corrections and Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. General Description 11
2.1 Combustion Air Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Nozzle block pre-heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Electronic Ignition Coil with Igniter Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Overheat Thermostat for burner (Thermo heaters operated in vertical position only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.11 Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.12 Heated Fuel Filter (for PME Biodiesel use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Functional Description 17
3.1 Switch On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Heating Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Switch Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Power Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.5 Auxiliary Heating Operation (heaters with control unit 1572D only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.6 Heater Lockout (heaters with control unit 1572D only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.7 Switch-off upon Failure (heaters with control unit 1572D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Error Code Output (heaters with control unit 1572D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4. Technical Data 22
4.1 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Propellant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5. Troubleshooting 24
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2 General Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.3 Fault Symptoms during Functional Checkouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.3.2 Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6. Functional Checkouts 32
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.2.1 Adjustment of CO2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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Table of Contents Thermo Series Coolant Heaters

6.3 Components Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.1 Temperature Sensor Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.2 Flame Sensor Resistance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.3 Igniter Electrodes Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.4 Electronic Ignition Coil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.3.5 Fuel Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.3.6 Drive Motor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.7 Solenoid Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.8 Nozzle Block Pre-heater Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7. Circuit Diagrams 36
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
8. Servicing 42
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.2 Heater Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3 Vehicle Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.4 Heater Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.5.1 Inspection and Attachment of the Exhaust Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.5.2 Burner Head Opening and Closing or Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.6 Visual Inspections and Regulations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.6.1 Connection to Vehicle Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.6.2 Connection to Vehicle Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.6.3 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.6.4 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.7 Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.7.2 Temperature Limiter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.7.3 Temperature Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.7.4 Burner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.7.5 Electronic Ignition Coil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.7.6 Flame Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.7.7 Combustion Chamber, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.8 First Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.8.1 Water Circuit, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.8.2 Fuel Supply System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9. Repair 50
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.1.1 Work on Components after Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
9.1.2 Incorporation of Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
9.2 Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.1 Temperature Limiter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.2 Temperature Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.3 Burner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.4 Combustion Air Fan and motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2.5 Control Unit, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2.6 Fuel Pump, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2.7 Electronic Ignition Coil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2.8 Flame Sensor, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2.9 Heat Exchanger, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.2.10 Combustion Chamber, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Spheros North America, Inc. 4 www.spheros.com

Thermo Series Coolant Heaters Table of Contents Annex A.spheros. .us 5 Spheros North America. Inc. Scheduled Maintenance 65 www. Heater.

com .spheros. Inc. 6 www.Table of Contents Thermo Series Coolant Heaters Spheros North America.

in enclosed areas such as garages or This workshop manual contains all information and workshops not equipped with an exhaust venting procedures necessary for the repair of heaters Thermo facility.g.spheros. 1. There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum NOTE temperature of 185 °F (85° C)in the installation box. The heater may only be fitted in vehicles or in WARNING independent heating systems with a minimum coolant capacity of 2. Excessive temperatures may cause malfunctions. Cautions and Notes For heaters designed for installation in rail vehicles.64 Gal (10 liters). Inc. The use of the heater in to 2. 1.4 Additional Documentation to be used heater must not be operated. vehicles not subject to the EU Directive 70/156/EEC (e.2 Applicability of Manual 1. Cautions. Should the heater This heading is used to highlight that non-compliance nevertheless be installed in such a compartment. 300 and 350. designated type of electrical connection.7). not even with timed operation.5 Safety Information and Regulations 1. Operating instructions and installation instructions may be used as complementary information as necessary. 230.1 General Safety Notes This manual is applicable only for heaters identified on The year of first operation must be permanently marked the title page. regulations are detailed in the following. In combination with control unit 1572D additionally a The heaters are cleared for heating the vehicle engine different type of electronic ignition coil is installed (refer and the passenger cabin. 300 and 350.5. This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or The heater may only be installed in motor vehicles or in lethal accidents to personnal. ships) is partly governed by regional regulations. type approval has been granted (not for vertical models) by WARNINGS.3 Meaning of Warnings. The use of additional documentation is normally not At filling stations and fuel depots the heater must be necessary. and Notes.us 7 Spheros North America. The water heater may only be operated with the fuel The specific safety regulations applicable to this manual specified on the model plate and the relevant are highlighted in the individual chapters by Warnings. the with instructions or procedures may cause damage installation box must be sealed tight against the vehicle to equipment. on the identification label by removing the relevant number of the year. switched off to prevent explosions. independent heating systems with a minimum coolant capacity of 1. www. .1 Scope and Purpose The general safety regulations for the prevention of accidents and the relevant operating safety instructions This repair shop manual is intended to support have to be observed at all times. interior. This heading is used to highlight and draw specific attention to information. The heater must not be installed in the passenger or CAUTION driver compartments of vehicles. familiarized personnel in the repair of water heaters "General Safety Regulations" beyond the scope of these Thermo 230. CAUTIONS. and NOTES in this manual have the Federal Railway Authority with the type approval the following meaning: number: EBAAZ3/0141/04.Thermo Series Coolant Heaters Introduction 1 Introduction 1. WARNING Due to the danger of poisoning and suffocation the 1.58 Gal (6 liters).

i. e1*2001/56*0009*-. installation of the heater in vehicles. etc.e. Type Approvals pursuant to EC t fuel containers must either be equipped with a 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).spheros.6 Legal Provisions for Installation passengers’ or driver’s compartment of any vehicle. t the fuel filler neck must not be located in the 1. applicable to separate heating circuits). the acceptance by the relevant the territory governed by EU Directive 70/156/EEC and authority is required as applicable.1.g.15 bar) overpressure. Installation is governed above all by the provisions in t The operational state of the heater. cereal depots. Installation Instructions for Spheros fuel tanks for the fuel supply of water heaters in vehicles: The opening pressure in the vehicle cooling system - normally indicated on the radiator filler cap . coal. 8 www. installation instructions. The same applies if repairs are accordance with the vehicle manufacturer’s carried out incorrectly or with the use of parts other instructions.for Thermo 350 All fuel containers offered in the Spheros Accessories Catalogue are subjected during manufacture to Up to 4/03. WARNING A violation of this temperature limit may cause Failure to follow the installation instructions and the permanent damage to the electronics.g. For heaters in vehicles not ruled by the EU Directive but The provisions of these Directives are binding within other regulations.18 psi (0. plastics and rubber and must leave no deposits. NOTE The heater must not be operated near flammable For further notes and provisions relating to the materials such as dry grass and leaves. The water in the heating circuit of the than genuine service parts.us . Inc. Thermo 300 / Thermo 350 with the following EC Type Approval Numbers: Only vent caps in accordance with DIN 73400 may be used. cardboard boxes.35 psi (0. should similarly be observed in countries without specific regulations. installations) the heater must be switched off to prevent explosions.Introduction Thermo Series Coolant Heaters CAUTION Where flammable fumes or dust may build up (e.0 bar above operating pressure (also permitted in. t the passengers’ or driver’s compartment. Additives in the heating circuit must not affect metals. This will result in the heater must contain a minimum of 20% of a quality invalidation of the type approval for the heater and brand anti-freeze.for Thermo 300 pressure of 2. A clearly visible indicator within the user's field of the vicinity of fuel. With effect from 4/03.3 bar) these heaters. wood. In the vicinity of the water heater a temperature of 110° C (230 °F) storage temperature must not be exceeded under any circumstances (e. therefore of its homologation / EC type licence. or similar vision must show when the heater is switched on or off.4 and 2. General Design Certifications existed for individual pressure testing with at least 4. during body paint work). an indication "on" or "off" must be easily and NOTE clearly visible. in 1. e1*72/245*95/54*1010*-- All fuel containers offered in the Spheros Accessories e1*2001/56*0007*-.for Thermo 230 Catalogue are suitable for a maximum operating e1*2001/56*0008*-. refer to the paper. notes contained therein will lead to all liability being When checking the cooling water level proceed in refused by Spheros. overpressure. at least Annex VII of Directive 2001/56/EC.7. (Extract from Directive 2001/56/EC Annex VII) Spheros North America.must be t in buses and trains the installation is not between 0.

Thermo Series Coolant Heaters Introduction 1.us 9 Spheros North America.spheros.us www.us / info@spheros. 5536 Research Drive Canton MI.spheros. Inc.7 Corrections and Improvements Deficiencies. Inc. 48188 Telephone: 1-734-218-7350 Fax: 1-734-487-1569 website: www. improvements. . or proposals for correction of this workshop manual are to be mailed to: Spheros North America.

10 www. Inc.com .Introduction Thermo Series Coolant Heaters Spheros North America.spheros.

300 and 350 are – the fuel pump with nozzle block and nozzle used in combination with the vehicle’s own heating installation to – the heat exchanger – heat the passenger compartment – the combustion chamber – defrost the windscreen – the electronic ignition coil with igniter electrodes – preheat water-cooled engines For control and monitoring the heater includes The water heater operates independent from the vehicle – a control unit engine and is connected to the vehicle cooling system. Inc.us 11 Spheros North America. – a temperature sensor The heater designed to the heat exchanging principle – a temperature limiter (automatic reset) operates intermittently controlled by the temperature sensor.spheros. or. 1 Burner 4 2 Coolant inlet 3 3 Temperature limiter 4 Temperature sensor 5 Coolant outlet 6 Heat exchanger 2 7 Exhaust outlet 8 Fuel return 9 Combustion air inlet 5 10 Fuel delivery 11 Splash protection cover (instead of screen) 1 6 11 7 8 10 9 www. in case of compact units. 300 and 350 basically consist of – the combustion air fan The water heaters Spheros Thermo 230.Thermo Series Coolant Heaters General Description 2 General Description The heaters Thermo 230. . – a flame sensor the fuel system and the electrical system. directly at the heater. An external circulating pump is installed inside the vehicle.

Heat exchanger Solenoid valve Nozzle block preheater (optional) Combustion chamber O-ring Fuel pump Spheros North America. The fan consists of a drive motor with fan rotor. 2. nozzle block pre-heater is mandatory. Air is taken in through a splash protection cover or a screen and the cap.2 Fuel Pump for combustion to heat the heat exchanger.spheros. Preheating is deactivated when the thermostat ambient temperature is 46 °F (+8 °C).General Description Thermo Series Coolant Heaters 2. At extremely low temperatures malfunctions may occur Drive motor without a nozzle block pre-heater.4 Combustion Chamber The fuel/air mix is dispersed in the combustion chamber 2.2. At a temperature of < 32 °F (0 °C)a thermostat activates Splash protection cover the heater cartridge in the nozzle block. A screwed on solenoid valve controls the fuel flow to the nozzle. If the heater is not equipped with a nozzle block pre- Fan rotor heater a retrofit is possible. 2.com .1 Nozzle block pre-heater The combustion air fan supplies the air required for NOTE combustion from the combustion air inlet to the For operation with PME (Biodiesel) the installation of a combustion chamber.3 Heat Exchanger Cap Grille The heat exchanger transfers the heat generated by combustion to the coolant circuit. The fuel pump delivers the fuel and is driven by the drive motor via a clutch.1 Combustion Air Fan 2. Inc. The heating period depends on the heat reflected within the combustion chamber. The fuel is pressurized in the pump to approximately 10 bar (145 psi) and diffused by a high pressure nozzle. 12 www.

Temperature sensor 2. The temperature limiter responds at 257 °F (125 °C) to switch off the heater. The flame sensor continuously monitors the flame This signal is supplied to the control unit for processing.spheros.us 13 Spheros North America. mechanically coded) only in combination with control unit 1572D Control unit 1572D 2. Thermo Series Coolant Heaters General Description 2. The temperature limiter (bimetal) protects the heater against undue high operating temperatures. The signals are supplied to the control unit for processing.8 Temperature Sensor 2. .6 Flame Sensor The temperature sensor senses the coolant temperature at the heat exchanger outlet as an electrical resistance.9 Temperature Limiter flame intensity. condition during operation. Igniter electrodes Ignition coil (green connector cover. The flame sensor is a photo transistor changing its resistance depending on the 2.7 Electronic Ignition Coil with Igniter Electrodes Temperature The electronic ignition coil generates the high voltage limiter for igniting the fuel/air mix by a high voltage ignition spark across the electrodes.5 Control Unit The control unit 1572D is the central component to ensure controlled operation and monitoring of combustion. www. Inc. The temperature limiter can be reset Flame sensor manually or has an automatic reset.

Aquavent 5000S (U4854). Aquavent 5000 (U 4814) Soft start Motor run-up is slow with no stress for the material. the operation can be continuted. dry running is detected. It takes 5 seconds to reach maximum speed. Dry run protection (only U4855 and U4856) Protection against dry running is integrated into the circulation pump motor. The heaters may be operated with circulating pump Aquavent 5000 2. The pump is activated by the control unit to operate as long as the heater is in operation.1 Circulating Pump (U4814). Spheros North America. Aquavent 6000C (U4855). After approx. 2 minutes and circulating pump motor reactivation. the motor is switched off by means of the failure mode.General Description Thermo Series Coolant Heaters 2. Inc. Aquavent 6000SC (U4856). 14 www. The circulating pump motor is switched off. Aquavent 6000 SC (U 4856) Overheat Thermostat 2. The circulating pump Aquavent 6000C (U4855) and Aqua vent 6000SC (U4856) are equipped with a brushless motor. 45 minutes significantly less current. Aquavent 5000S (U 4854) Blocking protection When operating speed drops below 571 rpm the motor is switched off after approx. When the burner overheats the thermostat causes an error lockout.spheros.11 Circulating Pump The externally mounted circulating pump ensures proper coolant circulation in the vehicle and heater circuit. 1 second by means of the failure mode.11.us . If no complete revolution is achieved within 1 second with the motor powered. If the circulating pump motor consumes within a time period of approx.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.

www.5 °C (42 ± 4. After power re-connection the motor will again run up with a soft start. the temperature switch will turn the filter heater on at a fuel temperature of 0. When the integrated filter heater is connected.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.12 Heated Fuel Filter (for PME Biodiesel use) A fuel filter can be fitted that may be heated if desired. Failure mode The failure mode stops the motor in case of malfunctions. Motor reactivation The motor can be reactivated out of the sleep mode by disconnection of the power supply for approx. In combination with a wiring harness and a 25 A fuse the motor is protected against reverse poling. 2 minutes.5 °F).5 ± 2. Inc.5 ± 2. . The power consumption in this mode then amounts to < 2 mA. 2. Reverse pole protection The motor is not equipped with an internal reverse pole protection. Sleep mode In the sleep mode the internal consumers of the motor electronics are switched off. After approx.spheros.5 °F) and turn it off at 5.us 15 Spheros North America.5 °C (33 ± 4. 5 seconds the failure mode switches the motor to the power saving sleep mode.

16 www.spheros. Inc.General Description Thermo Series Coolant Heaters Spheros North America.com .

If Heaters with control unit 1572D gradient evaluation is available. fuel pump and circulating pump start operation. The flame extinguishes. Approximately 1 second later the solenoid valve in the fuel pump opens www. The operating indicator light goes out and run-down 3. upper operating point is exceeded. and deactivation of the burner in order to maintain a For monitoring operation. temperature in the heating mode rises too quickly. economy The circulating pump remains in operation during the Upper operating point 158 °F (70 °C) control idle period. the control unit is able to detect any undue temperature rise and can When connecting terminal +61 the heaters may operate automatically shift the upper operating point to a lower in the auxiliary heating mode of operation.2 Heating Operation t timer t air conditioning After reaching operating temperature the control unit takes over to provide controlled operation by activation dependent on the type of installation. Switch off begins a run-down procedure (see "Switch The heating operation is terminated as soon as the off"). normal pump however continue their operation.3 Switch Off Gradient evaluation YES Hysteresis adaptation YES Switching off the heater stops combustion. (coolant). consumption (see circuit diagram) Heaters with control unit 1572D t equipped or retrofitted with a nozzle block pre-heater Gradient evaluation for extreme low temperatures (required for operation With a low coolant flow rate or poor venting. 63482F (Bus) Control idle period Auxiliary heating A rise in temperature above the upper operating point Upper operating point 185 °F (85 °C) makes the solenoid valve in the fuel pump shut off the Lower operating point 172 °F (78 °C) fuel supply initiating the run-down. No.Thermo Series Coolant Heaters Functional Description 3 Functional Description and the nozzle sprays fuel into the combustion chamber to be ignited by the igniter spark. The combustion air fan and circulating pump are deactivated after approximately 120 seconds Upon switch on the operating indicator light goes on. an operating nearly constant temperature of the heat exchanger indicator light must be provided. Any tripping of the temperature limiter due to Operating Thresholds residual heat after the combustion operation has been terminated can thus be prevented. The heater now starts the control idle period. the combustion air fan and the circulating Parking heating. permitted. After Upper operating point 185 °F (78 °C) approximately 120 seconds (for heaters with control unit 1572D) run-down is completed with deactivation Lower operating point 158 °F (70 °C) of the combustion air fan. A photo control circuit Activation and deactivation is by means of a deactivates the electronic ignition coil after flame-up. value. Inc. Lower operating point 131 °F ( 55 °C) 3.us 17 Spheros North America. . t switch 3. at a minimum. (If fitted and temperature is < 0 °C (32 °F) Reactivation of the heater during run-down is nozzle block pre-heater is also activated). the with PME or biodiesel).1 Switch On commences. The burner immediately resumes operation After approximately 12 seconds (run-up time) the high after the run-up time. voltage igniter spark is available. Heater The heaters may be operation is resumed when the temperature drops t operated with power save for reduced fuel below the lower operating point. The operating indicator light remains on.spheros. Control Unit Ident. for heater with control unit 1572D. Parking heating. Combustion air fan.

spheros. This lockout is superior to limited heating performance is required (e. If combustion lasts more than 120 seconds.Charge Indicator) is connected and active. The length of combustion time until the upper operating point is exceeded should be 120 seconds. the lower operating point is 172 °F (78 °C).Functional Description Thermo Series Coolant Heaters 3. Spheros North America. 80 °C. the lower operating point is increased by 1 Kelvin. in heat the normal error lockout. 18 www. the lower operating point is lowered by 1 Kelvin. starting the heater and disconnection of the main power supply of the heater during error run-down. The lower temperature threshold for restarting the burner after the control idle period is completed is raised above that for parking mode operation and is automatically shifted up or down dependent on the combustion time of the heater (hysteresis adaptation). up to max. down to minimally 158 °F (70 °C). Combustion operation is started when the temperature falls below this threshold.6 Heater Lockout (heaters with control unit 1572D) With power save on the control temperatures of the heating circuit are kept low. Inc. attempts due to a malfunction or after five consecutive subsequent flame-outs the heater enters a lockout and This results in a reduced heat radiation loss when start attempts are suspended.us .g. If combustion time is less than 120 seconds. Hysteresis adaptation (example) After the first control idle period. Combustion performance is After the heater has performed eight consecutive start not reduced. Unlocking is performed by hold operation) cutting down fuel consumption.5 Auxiliary Heating Operation (heaters with control unit 1572D) If terminal +61 (ALT. 3.4 Power Save 3.the heater will be operating in the auxiliary heating mode.

– solenoid valve – solenoid valve short or open circuit. circulating pump is automatically stopped and may Flash pulses are output via the operating indicator light. max. – short/open circuit or dry run (if programmed) of The heater switches off automatically when detecting circulating pump. max.Functional Description Thermo Series Coolant Heaters A H1 Operating indicator light B E1 Heater cartridge C M2 Circulating pump 7 D U1 Igniter box E M1 Combustion air fan 3 5 3 F Y1 Solenoid valve 1 2 6 8 2 9 6 10 G B1 Flame sensor A C 1 Switch on 2 Start D 3 Flame-up.spheros. only be reactivated after approximately 2 minutes The combustion air fan and the circulating pump are should coolant be missing or the pump wheel be switched off after approx.7 Switch-off upon Failure (heaters with – no flame detected after approximately 25 seconds control unit 1572D) after heater start. When using the circulating pump Aquavent 5000 Several subsequent switch-offs due to a malfunction approximately 15 seconds after switch-on the will cause the heater to enter an error lockout condition. Malfunctions during switch-on: Malfunctions during heating operation: Short or open circuit of – low voltage threshold of approximately 21V violated for a duration of 20 seconds. Inc. 12 14 max. 19 www. seized. max. following 90 seconds. – temperature sensor – no combustion for more than 10 seconds. Spheros North America. 9 Switch off 12s 1s 1s 12s 30s 12s 1s 1s 12s 30s 10 Heater – off 12 14 max. 12 Start-up 13 15 120s 13 15 120s 13 Foreign light check 16 16 14 Pre-ignition 15 Safety period 16 Run-down Figure 1: Functional Sequence (heaters with control unit 1572D) 3. – flame sensor – temperature sensor short or open circuit.us . 120 seconds. combustion operation E 5 Temperature sensor – upper switching threshold F 6 Flame sensor – dark 7 Control idle G 8 Temperature sensor – lower switching threshold max. one of the following malfunctions. – electronic ignition coil Malfunctions during run-down: Malfunctions during start-up: Detection of a flame after more than 30 seconds after – short or open circuit of electronic ignition coil start of run-down with the circulating pump and – flame detected by photo control circuit prior to high combustion air fan only maintaining operation for the voltage igniter spark. – burner motor – flame sensor short or open circuit.

www. overheat thermostat will be stored in the control unit as a flame- out (F 02) in the case of vertically installed heaters (MCI). overheat thermostat to initiate an error F 01 no start lockout at 302 °F (150 °C). After five Malfunction by overheating of the burner in vertical short signals the long flash pulses are counted. type of error is output during heater run-down via a flash code of the operating indicator light.spheros.8 Error Code Output (heaters with control Overheating results in deactivation of the heater by the unit 1572D) temperature limiter. An auto-reset occurs after F 03 low voltage cool-down of the thermostat. An error reset for a new start standby is achieved by When the heater is operated by means of a switch the switching the heater off and on again. The flash installations (MCI): pulses correspond to the error number in the following table: Overheating of the burner head causes the burner protection. F 04 foreign light detected during run-up and run- down F 05 flame sensor defective F 06 temperature sensor defective F 07 solenoid valve defective F 08 drive motor defective F 09 circulating pump defective F 10 temperature limiter defective / overheating Overheat Thermostat - F 11 electronic ignition coil defective Burner head protection F 12 error lockout due to repeated malfunction or repeated flame failure (8x no start-up or 5x flame failure * A response of the burner protection.us 20 Spheros North America. the fuel supply is cut off and a run-down is initiated. reset manually except where the limiter is of the auto- NOTE reset type. Inc. . Dependent on heater configuration: When equipped with a standard timer an error code readout appears on the display of the timer after a the reset button on the temperature limiter must be malfunction. F 02 flame-out * The fuel solenoid valve closes.Thermo Series Coolant Heaters Functional Description Malfunctions by overheating: 3.

Functional Description Thermo Series Coolant Heaters Spheros North America. 21 www.spheros.com . Inc.

solenoid valve. 4. 4. When using fuel from the vehicle tank the information about additives of the vehicle manufacturer must be observed.2 Fuel The suitable propellant is the Diesel fuel specified by the vehicle manufacturer. A bad influence caused by additives is not known.us 22 Spheros North America. Inc.spheros. flame sensor. heater cartridge.Thermo Series Coolant Heaters Technical Data 4 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. When using fuel from a separate fuel tank and at temperatures below 32°F (0 °C). winter Diesel fuel must be used or a winter petroleum additive or flow improvers added to the Diesel fuel observing the relevant mixing ratios recommended by the manufacturer of the additive. . Also Diesel fuel with an addition of 5 to 20% PME (vegetable oil methyl ester). NOTE The allocation of circulating pumps to heater units must be in accordance with coolant resistances. fan and circulating pump motors. Temperature limiter. electronic ignition coil. www.1 Electrical components Control unit. Only the type of fuel indicated on the identification plate may be used. class EL fuel oils (not fuel oil L) may be used if their quality is in accordance with the German standard. nozzle block pre-heater and timer are 24V components. temperature sensor and switches are voltage independent components.

.B20 max.685) mm (in.000 120.5 ±2.) Width 246 (9.1) 4.6 .000 Kw 23 30 35 Fuel Diesel / Diesel PME Mix (Biodiesel B5 .56 CO2 in exhaust at nominal voltage Vol.7 Nominal voltage Volts 24 Operating voltage Volts 20 .) Length 610 (24.05 1.8 (2.0 PSI 5.4) 5. 28 Nominal power consumption Watts 65 110 140 (without circulating pump) Permissible operating ambient temperature range °F (°C ) -40 ..Technical Data Thermo Series Coolant Heaters Heater data Heater Thermo 230 Thermo 300 Thermo 350 Mark of conformity up to 04/03 ~ S230 ~ S229 ~ S228 EC type approval number e1*2001/56* 0007*-.1) Height 105 (4.5) Optional fuel filter heater Nominal voltage Volts 24 Nominal power consumption Watts 240 Switch-on point °C (°F) 0.4 Nominal voltage Volts 12 . (2.3 3.spheros.3 (2.. 29 Heat exchanger coolant capacity Litre 1.5 (42 ±4.) Width 100 (3.35 Kg/h 2. 28 Nominal power consumption Watts 104 104 210 210 Dimensions mm (in. +85) (heater..5 ±2.4 26.) Height 220 (8.-% 10 ±0.5) mm (in.8) Length 229 (9) mm (in.) 19 (41. 24 Operating voltage Volts 10 .5 (33 ±4.5 to 500 m (1640 ft.8 .4 .9) Circulating pump data Circulating pump Aquavent 5000 Aquavent 5000 S Aquavent 6000C Aquavent 6000 SC Volume of flow l/h 5200 5200 6000 6000 US Gal/m 23 23 26. (+110 max) Permissible operating overpressure bar 0.5 3..us .. 2..9) Width 115 (4..) Fuel consumption US Gal/hr 0.0 4. +185 (-40 .... 0009*-- Heater principle High pressure atomizer Heating flow Btu/h 80. 0008*-. 23 www.14 l/hr 3.5) Switch-off point °C (°F) 5. Inc.) Height 105 (4. control unit.0 4.79 1.14/20 .8 US Quart 1.8) Length 224 (8.9 Minimum capacity of coolant circuit Litre 10 US Quart 10..5) Spheros North America. circulating pump) Permissible storage temperature °F (°C) +230max.5 (2.) Length 229 (9) Length 249 (9.015) mm (in..9) Width 100 (3.3) Height 110 (4..) above sea level Dimensions of heater mm (in.661) Weight of heater kg (lb.3) Weight 4.1) Height 110 (4..2) 5.000 104..5) Width 115 (4.

. the heaters Thermo 230. The motor can be reactivated out of the sleep mode by disconnection of the power supply for approx. Fuse F2 blows Short circuit in circulating pump or in wiring to heater. After power re-connection the motor will again run up with a soft start. 3 and Fig. In the sleep mode the internal power consumers of the motor electronics are switched off. The power consumption in this mode then amounts to < 2 mA. After any fault correction a functional checkout in the vehicle has to be performed. Fuse F3 blows Short circuit in wiring to heater/motor/nozzle block pre-heater (if installed) Normal heater operation.1 General Troubleshooting is normally limited to the isolation of This section describes troubleshooting procedures for defective components. Operating indicator light defective or wiring to light open or shorted. After approximately 5 sec. 5. Fault in water system Circulation pump not operating t Failure mode activated The failure mode switches the motor off in case of malfunctions. 4) lists possible fault symptoms of a general nature.Thermo Series Coolant Heaters Troubleshooting 5 Troubleshooting CAUTION 5. Symptom Probable Cause Fault in electrical system Operating indicator light is not on. the failure mode switches the motor to the power saving sleep mode.2 General Fault Symptoms The following tables (Fig. The following possible causes for trouble have not been taken into consideration and must always be excluded CAUTION as a possible cause for malfunction: Troubleshooting requires profound knowledge about corrosion on connector components and their theory of operation and may only loose contact on connector be performed by trained personnel. t no power supply t fuses t wiring to terminals of connector A of control unit.spheros. Inc. no heater operation. 2 minutes. Figure 3: General Fault Symptoms (Sheet 1 of 2) www.us 24 Spheros North America. operating indicator light is out. and 350. 300. wrong crimping on connector corrosion on wiring and fuses In case of doubt functional interrelations may be derived corrosion on battery terminals from Sections 2 and 3.

Troubleshooting Thermo Series Coolant Heaters

Symptom Probable Cause
Heater operation stops because heat exchangers connected do not Rate of flow too low, because
dissipate enough heat. t air in heater, in heat exchangers or system sections.
t valves (flow regulators) throttled, contaminated or closed.
t contamination in system, e.g. in areas of restricted flow.
t circulating pump rate of delivery insufficient (air in pump housing).
wrong sense of rotation – check wiring colors (black + / brown –).
t not enough anti-freeze - slushing.
t excessive system resistance (especially high when cold).
t circulation pump defective.

Heat exchanger does not dissipate enough heat, because
t air in heat exchangers or in system sections.
t contaminated heat exchanger surfaces (external).
t insufficient air intake or exit.
t fan: rate of delivery low / wrong sense of rotation / resistance too
high.
t incorrect anti-freeze concentration - too high.
t heat exchanger of too low capacity.
Rough calculation of rate of flow
heat flow [kW] according to ident. label
Rate of flow in [l/h] = x 860
temperature difference Δt in [K] or [°C]
measured between heater water inlet and outlet
(e.g. with contact thermometer)

Fault in fuel supply

No fuel delivery to heater t fuel tank empty.
t kinked, closed, contaminated or leaking lines.
t paraffin deposits or water captured in fuel filter or fuel lines.
t vent in tank clogged.
t fuel lines interchanged.
t fuel filter contaminated.
t fuel screen in pump contaminated.
Wrong combustion

CO2 value cannot be set to rated value, combustion irregular. t air bubbles in suction line (suction line leaking).
t fuel filter contaminated or leaking.
t fuel system integration leak (suction height, low pressure in tank);
observe installation instructions.
t fuel pump defective (pump pressure).
t return line throttled.
t filter screen in pump contaminated.
t O-ring sealing on fuel pump no longer effective (ageing)
t nozzle jet defective.
t combustion air or exhaust lines throttled or closed.
t drive motor speed too low.

Figure 4: General Fault Symptoms (Sheet 2 of 2)

Spheros North America, Inc. 25 www.spheros.com

Thermo Series Coolant Heaters Troubleshooting

5.3 Fault Symptoms during Functional Components Tester
Checkouts
Using the components tester several types of faults and
Error Code Output or Tests with Diagnostic Computer, component malfunctions may be analyzed in the
Components Tester or PC Heater Diagnosis vehicle. The test of the individual components with the
components tester is not intended. Faults like short or
5.3.1 General open circuits may be detected with the components
tester but cannot be localized.
Error Code Output
For details refer to operating instructions for
NOTE "Components Tester".
Only heaters with a control unit 1572D provide an error
Spheros Thermo Test PC based Heater Diagnosis
code output.
When equipped with a standard timer an error code By use of the PC heater diagnosis heaters (with control
readout is available after a malfunction on the display of unit 1572D) may be tested in the vehicle.
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".
coded flashing of the operating indicator light during
run-down of the heater or until switch-off indicates the
type of error (see section 3.9).

Diagnostic Computer

By use of the diagnostic computer heaters may be
checked in the vehicle. The following tests are available:
t indication of measured values: water temperature,
control unit supply voltage, flame sensor bright/dark.
t indication and erasure of faults stored in the control
unit.
Operation of the diagnostic computer is menu
controlled by means of four push button switches.
For details refer to operating instructions for "Diagnostic
Computer".

www.spheros.us 26 Spheros North America, Inc.

Troubleshooting Thermo Series Coolant Heaters

5.3.2 Fault Symptoms and stops any further attempts to start. This error
lockout is superior to the normal error lockout condition.
5.3.2.1 Fault Symptom "No Start" The error lockout reset is achieved by switching the
heater on and disconnection of the heater power supply
NOTE during run-down.
Heaters with control unit 1572D:
If the heater performs 8 subsequent attempts to start
due to a malfunction, the heater enters an error lockout

NO

Switch on heater. Motor and fan wheel Is fan wheel caught Is voltage present on Check fuses F1/F2/F3
Is combustion air fan free to move? in cap? plug contact A3? and relais K1, K2 and
operating? replace as required
(control unit 1572
only).
Does trouble persist?

Check motor electrics Replace cap Is voltage too low? Check electrical
YES and replace as and fan wheel. Rated value >20,5 volts wiring and
required. (± 0,5 volts) connections.
Does trouble persist?

Low voltage switch Control unit defective,
off during start-up. replace.
Check battery.

Is fuel free of bubbles Is fuel filter Fuel suction line Fuel lines empty? Are O-rings in fuel
in supply and return? contaminated? leak? pump?
Is pump mounted
securely?

Replace fuel filter. Retighten line Repeat start (several Fuel pump defective,
connections, times if necessary) replace.
replace lines as until lines are filled.
required.

Is solenoid valve Connect solenoid
connected to valve.
electrics?

Is gap between igniter Check gap between
electrodes ok? igniter electrodes.

Is nozzle free of foreign Replace nozzle.
matter and deposits
and properly secured?

Is viewing glass of Clean window and
flame sensor viewing glass.
contaminated?

Spheros North America, Inc. 27 www.spheros.com

2.? connections. Is battery properly charged? Control unit defective. NOTE The error lockout reset is achieved by switching the Heaters with control unit 1572D: heater on and disconnection of the heater power supply If the heater performs 5 subsequent attempts to start during run-down. This error lockout is superior to the normal error lockout condition. www.k. Electrical power Replace defective Is combustion air supply. components.k. electrical fan operating? fuses. 0. motor and YES in supply and return? or jellied? move? fan wheel. plug contacts.3.? Replace motor.3 Fault Symptom "Low Voltage" NO Is voltage present on plug contact A3? Is electrical wiring Make electrical o. Control unit defective.2 Fault Symptom "Flame-out" and stops any further attempts to start. contaminated? Is nozzle free of Replace nozzle.3. relays o.2. YES replace.k.? line.5 volts less than on battery? Is electrical power supply line Replace power supply to heater o. replace. temperature rating. Is viewing glass of Clean window and flame sensor viewing glass. Inc. foreign matter and deposits? 5.k.? Is fuel free of bubbles Is fuel filter contaminated Is fan wheel free to Check cap.Thermo Series Coolant Heaters Troubleshooting 5. Replace filter and check fuel low Is motor o. the heater enters an error lockout NO Switch on heater. Disconnect heater from battery supply.us 28 Spheros North America.spheros. replace. Is voltage between plug contacts A3 and A6 approx. . due to a malfunction. Control unit defective. Connect heater.

replace control unit. YES WARNING: Water may escape! If replacement of temperature sensor does not cure the problem.k. YES 5. Allow heater to cool down and restart (approx. replace. 2 min. Clean combustion tube. replace. replace control unit. replace.6 Fault Symptom "Temperature Sensor Defective" NO Are electrical lines and contacts to and on Make contacts or replace component. Does same symptom show again? Remove coke deposits. replace.2. replace.2. YES Control unit defective.).? WARNING: loss of water! Temperature sensor defective. temperature sensor o. shortly before? Control unit defective.com .3.4 Fault Symptom "Unexpected Light Detection during Run-up or Run-down" NO Has heater been in long time operation Flame sensor defective.5 Fault Symptom "Flame Sensor Defective" NO Flame sensor defective.Troubleshooting Thermo Series Coolant Heaters 5. Spheros North America. 29 www. Inc.2. If replacement of flame sensor does not cure the problem.3.3. 5.spheros.

k. (audible click of solenoid valve)? Does fuel leak from nozzle in run-down? Replace solenoid valve. replace. YES Is components test with diagnostic computer o.7 Fault Symptom "Solenoid Valve Defective" NO Is solenoid valve supplied Make electrical connections.spheros. . Control unit defective. www.Thermo Series Coolant Heaters Troubleshooting 5.us 30 Spheros North America.3. Inc. with electrical power? Replace solenoid valve.2.

Spheros North America.k. e. to components o. (reset limiter)? YES Determine why temperature limiter has responded.3. replace.2.com . ‡FKHck water circulation in system is free from bubbles.spheros.g.Troubleshooting Thermo Series Coolant Heaters 5. ‡FKHck circulation pump sense of rotation. Can no fault be detected? Replace temperature limiter.: ‡FKHck shut-off elements. ‡FKHck coolant low temperature resistance.? Has temperature limiter responded Control unit defective. replace. If symptom shows again after testing: control unit defective.8 Fault Symptom "Temperature Limiter Defective" NO Is electrical power supply Make electrical connections. 31 www. Inc.

fuel pump NOTE (complete or partial rebuild) CO2 setting depends on fuel (viscosity) and on geodetic – irregularities in combustion altitude (0. .spheros. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities. – repairs on the burner head – nozzle replacement. – tighten fastening screw with 1.5 Nm and apply Adjustments may be necessary in the following cases: screw seal varnish.1 General This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. To prevent fires do not switch heater on with burner swung open.-% 8 7 6 18 20 22 24 26 28 30 32 Voltage CO2 .2.1% per 100 m). 6. Inc. air shutter. – functional checkouts If proper setting cannot be obtained or when exceeding Setting procedure smoke spot number.2 Adjustments Fastening screw 6.us 32 Spheros North America. above) and adjustment is not suggested unless the burner head has reposition setting ring with fastening screw until been rebuilt or its components have been replace rated value is obtained. The heater comes from the factory preset and – loosen fastening screw (refer to Fig.1 Adjustment of CO2 Contents It is generally not necessary to change the factory setting for combustion air quantity during routine maintenance procedures.Thermo Series Coolant Heaters Functional Checkouts 6 Functional Checkouts 6. required – measure CO2 contents and smoke spot number and – check fuel pump pressure and replace pump if compare with relevant diagram required – check fuel filter and strainer in fuel pump for contamination and replace if required 14 – adjust fuel pump pressure 13 – replace fuel nozzle 12 – measure burner motor speed 11 10 9 CO2 (Vol.0 +0. proceed as follows: – measure control unit power supply voltage – check burner head air side for damage and replace if – operate heater for approximately 5 min.setting at 500 m www.

Inc.3 Components Testing 6. Check – cover flame sensor glass bulb – check resistance (rated value: < 20 kOhm) – uncover flame sensor glass bulb and expose to light of strong lamp.2 Flame Sensor Resistance Check NOTE The glass bulb of the flame sensor and the viewing glass of the window are to be cleaned if contaminated. 33 www.3.1 Temperature Sensor Resistance Check The insulator of the igniter electrodes must show no When checking the temperature sensor with a digital damage.. In case of damage or not abtaining the rated value replace flame sensor.spheros. 4892 1000 100 °C # 319 .3 Igniter Electrodes Check NOTE 6.... Igniter electrodes not working properly must multimeter the values of the following diagram must be be replaced..Functional Checkouts Thermo Series Coolant Heaters 6. Resistance checking is preferably performed at ambient temperatures between 68° F (20° C) and Check approximately 212° F (20° C) (immerse sensor in water). 348 T/°C 10 50 100 Water temperature °C 6. – check resistance (rated value: < 400 Ohm) Viewing glass Glass bulb Spheros North America.3. Resistance (Ohm) 5000 20 °C # 4419 .. – inspect insulators of igniter electrodes for damage R/y CAUTION 10000 In order not to disturb the fuel atomization do not touch nozzle bore when inspecting electrodes...com .3. obtained.

– screw in nozzle and torque to 20 Nm +2 Nm. Such a High voltage.3.2. Inc.Thermo Series Coolant Heaters Functional Checkouts 6.5 unit 1572D. – apply 24V as shown on figure – normal condition: spark between electrodes. Thermo 350 9 Thermo 300 8. NOTE WARNING A test gauge is required for performing the test.000 volts arcing across the igniter gauge (with a range from 0 to 15 bar 0r 200 psi) can be electrodes. Electronic ignition coil (green connector cover) in – Fuel does accumulate in pressure gage as a result combination with control of the pressure test.000 V – Do not operate heater without electrodes installed in coil. – Install electronic ignition coil (refer to 9. unit 1572D. The fuel pump and fuel hoses must be replaced every 5 CAUTION years. CAUTION Check Do not damage nozzle bore.3. . NOTE Igniter electrodes 20.7.5.5 Fuel Pump Check NOTE 6. Use caution when removing gage as the fuel may still be pressured.spheros.5 (new style housing) in 10 combination with control 9.3.5 Thermo 230 8 2500 3000 4000 5000 6000 7000 8000 8500 Speed (rpm) Pump pressure in relation to speed www.2).000 V 11 Pump pressure (bar) Electronic ignition coil 10.4 Electronic Ignition Coil Check 6. procured from your authorized Spheros dealer. 20. 5 10 0 15 bar NOTE Igniter electrodes 20.1 Fuel Pump Check on Heaters with Control The electronic ignition coil may also be tested using Unit 1572D the PC heater diagnosis (component test). Do not apply voltage to electronic ignition coil without electrodes.us 34 Spheros North America.

The drive motor check is performed with the burner installed. PC heater diagnosis.6 Drive Motor Check CAUTION NOTE Disconnect solenoid valve connector from control unit to avoid damage to the control unit.3.42 Amps – measure speed and compare with the diagram NOTE below Thermo 230 4400 ±350 24 Volt With all variant of the control unit.spheros. If normal conditions are not obtained the – Check electrics for the following values: drive motor must be replaced.3. years. 28.. 18 20 22 24 26 28 30 32 Voltage Spheros North America. 5500 Thermo 230 Power consumption is 130 ±13 Watts at 24 Volt.Functional Checkouts Thermo Series Coolant Heaters 6. Pre-heating is deactivated when the 6000 thermostat ambient temperature is 46 °F ( +8 °C).. Check 6. 6.8 Volts – check drive motor bearing condition (binding) t power consumption at – measure heater power supply voltage nominal voltage and 20 °C 10 Watts – switch on heater t nominal current 0.8 Nozzle Block Pre-heater Check 8000 Thermo 350 NOTE 7500 At a temperature of 32 °F ( 0 °C) the heater cartridge 7000 in the nozzle block is activated. The heating period depends on the heat reflected within the combustion 6500 Thermo 300 chamber.3. 35 www.5.0 Volts Check t operating voltage 19. Short smoke emissions are normal caused by clearing The fuel pump and fuel hoses must be replaced every 5 the area between solenoid valve and nozzle bore.2 . In this only be checked by means of the Spheros Thermo Test case fuel keeps dripping through the fuel nozzle.3. 4. Inc.com . 5000 Check 4500 – swing burner head open or remove 4000 – disconnect electrical connector from nozzle Speed (rpm) 3500 – connect ohmmeter to connector 3000 – using cooling spray cool down thermostat or bridge 2500 – resistance (max.2 Fuel Pump Check on Heaters with Control 6. t break voltage 17.7 Solenoid Valve Check Unit 1572D NOTE NOTE A solenoid valve with a leaking valve seat is indicated by On heaters with control unit 1572D the fuel pump may rather long smoke emissions during run-down.5 Ohm). the solenoid valve Thermo 300 5200 ±420 24 Volt may also be checked by means of the PC heater Thermo 230 6200 ±500 24 Volt diagnosis (component test).

300 and 350 with control unit 1572D and with – switch – standard timer 1531 www. 6) show possible heater circuits for Thermo 230.Thermo Series Coolant Heaters Circuit Diagrams 7 Circuit Diagrams 7.1 General The circuit diagrams (Fig. .spheros.us 36 Spheros North America. 5 and Fig. Inc.

spheros.75 mm2 (16 Gauge) 1. Instrument Panel Lamps 58 Ignition / Run 75 (15) Alt.5 .5 mm 2 (12 Gauge) 4.15 m (24 .5 mm2 (14 Gauge) 2. Inc.5 m (24 ft) 7. 31 Wire gauges (Vehicle side of connectors) Length < 7.50 ft) 0.com Thermo Series Coolant Heaters .0 mm2 (10 Gauge) www. Charge Indicator 61 BAT + 30 A 6 1 F1 F2 F3 5 2 4 3 W2 X4 A Circuit Diagrams Red C B Black Spheros North America. C Brown D X2 1 A Orange S3 2 B Blue 1 2 C Red w/ White Trace 34 D 2 1 H2 F F 1 2 2 1 D 3 2 1 4 W1 A X1 A 5 Black B Orange 1 X1 C Red w/ White Trace 3 S1 37 X3 Red 4 A C B A S2 3 B Black 2 X3 C Brown 6 D Blue D C B A H1 X5 C X2 A2 A B 2 M2 M M1 U1 B3/B5 B2 B4 B3 1 J D C + SE - U1 M B5 J X4 X5 E1 M1 Y1 J B2 B1 1 U2 Figure 5: Automatic Control Circuit with Switch A1 A B 2 A2 B 1 Y 1 E1 A1 C BAT .

5 (previous page) M Optional . 1-pole at control unit E1 Heating cartridge for nozzle preheating D Plug connections.spheros.us 38 Spheros North America. 2-pole at control unit F2 Fuse 25A flat fuse SAE J 1284 X1 Plug connections. 2-pole water circulating pump M2 Motor circulating pump Y1 Solenoid valve S1 Switch on / off www.water pump run input (no heat) Item Nomenclature Remark Item Nomenclature Remark A1 Heater S2 Switch external trigger circulating pump A2 Control unit SG 1572D S3 Switch power save operation B1 Flame sensor observe polarity U1 Electronic Ignition Coil B2 Temperature sensor polarity optional U2 Igniter electrodes B3 Temperature limiter W1 Wiring Harness (1) B4 Thermostat for nozzle preheating W2 Wiring harness (2) B5 Thermostat alternative to B3 A Plug connections. 4-pole H2 Light flame indicator X4 Plug connections. . 3-pole main power / ground F3 Fuse 25A flat fuse SAE J 1284 X2 Plug connections. 6-pole at control unit B6 Thermostat for vertical installation (MV Y1) C Plug connections. Inc.power save (pre-heating) signal O Optional . 4-pole H1 Light operation indicator light X3 Plug connections.Thermo Series Coolant Heaters Circuit Diagrams Legend for Fig. 3-pole diagnostic connection M1 Motor combustion air fan X5 Plug connections. 4-pole at control unit F1 Fuse 5A flat fuse SAE J 1284 F Plug connections.flame indication light N Optional .

Charge Indicator 61 6 1 BAT + 30 5 2 4 3 4 5 F1 F2 F3 C S3 W2 X4 A Red D Circuit Diagrams 1 10 11 B Black C Spheros North America.0 mm2 (10 Gauge) www.50 ft) 0.com Thermo Series Coolant Heaters .5 . Inc. Instrument Panel Lamps 58 A Ignition / Run 75 (15) Alt.5 m (24 ft) 7. 10 Figure 6: Automatic Control Circuit with Standard Timer 1531 31 Wire gauges (Vehicle side of connectors) Length < 7. Brown P 1 2 2 H2 X2 34 1 A Orange 2 B F H3 Blue H1 8 1 C Red w/ White Trace 2 D 2 1 12 7 4 X6 F X1 2 1 D 3 2 1 4 W1 A X1 A 5 Black B Orange 1 C B A C Red w/ White Trace 3 X3 X3 Red 4 39 A D C B A S2 3 B Black 2 C Brown 6 X2 D A B Blue D C X5 C A2 2 X4 X5 1 M2 M M1 U1 B3/B5 B2 B4 B3 1 J A B 2 + SE - U1 M B5 J E1 M1 Y1 B2 B1 C J U2 A1 3 21 X6 A2 B 1 Y 1 E1 A1 4 7 BAT .5 mm 2 (12 Gauge) 4.5 mm2 (14 Gauge) 2.75 mm2 (16 Gauge) 1.spheros.15 m (24 .

water pump run input (no heat) P Optional . 2-pole water circulating pump M2 Motor circulating pump X6 Plug connections.) Item Nomenclature Remark Item Nomenclature Remark A1 Heater S1 Switch on / off A2 Control unit SG 1572D S2 Switch external trigger circulating B1 Flame sensor observe polarity pump B2 Temperature sensor polarity optional S3 Switch power save operation B3 Temperature limiter U1 Electronic Ignition Coil B4 Thermostat for nozzle preheating U2 Igniter electrodes B5 Thermostat alternative to B3 W1 Wiring Harness (1) B6 Thermostat for vertical installation (MV Y1) W2 Wiring harness (2) E1 Heating cartridge for nozzle preheating A Plug connections.flame indication light N Optional .Thermo Series Coolant Heaters Circuit Diagrams Legend for Fig. 4-pole at control unit F3 Fuse 25A flat fuse SAE J 1284 F Plug connections. .us 40 Spheros North America.power save (pre-heating) signal O Optional . 6 (previous page) M Optional . 1-pole at control unit F2 Fuse 25A flat fuse SAE J 1284 D Plug connections. 3-pole main power / ground H2 Light flame indicator X2 Plug connections.spheros. 2-pole at control unit H1 Light operation indicator light X1 Plug connections. 3-pole diagnostic connection M1 Motor combustion air fan X5 Plug connections. to 120 min. 4-pole H3 Symbol for “Heating” in symbol lighting (in item P) X3 Plug connections.connection to instrument panel lighting Q Timer: with plus to connection 10 = continuous operating during immediate heating terminal 10 not connected = duration of heating programmable (10 min. 12-pole Standard Timer 1531 P Standard Timer (1531) for timed operation Y1 Solenoid valve www. 6-pole at control unit F1 Fuse 5A flat fuse SAE J 1284 C Plug connections. 4-pole Display X4 Plug connections. Inc.

Inc.spheros. 41 www.Circuit Diagrams Thermo Series Coolant Heaters Page empty for notes Spheros North America.com .

) After working on the heating circuit replenish with a NOTE coolant mix prepared with water and anti-freeze and bleed circuit afterwards according to vehicle If the exhaust muffler is already secured with a sheet manufacturer’s instructions. 8.) To ensure functional reliability of the heater the following maintenance must be performed: t check combustion air inlet and exhaust outlet for contamination and clean as required. Therefore an inspection for proper 8. the following procedure need not be performed... www. This avoids future difficulties when starting-up.. in enclosed areas like garages or workshops not Heaters manufactured equipped with exhaust ventilation facilities.. . calendar 8.) (for year or date of °C) must under no circumstances be exceeded (e. 3G..1 Inspection and Attachment of the Exhaust overheat protection. t at least once a year..5 Maintenance label week 36. t the heater should be checked in regular intervals by a This section describes the servicing procedures allowed Spheros service agent or properly trained technician.g. in the case of contaminated fuel more often. not even with the timer.. 90 087 As long as the heater is in operation or in run-down the 22B is to be used.3 Vehicle Servicing General CAUTION The exhaust muffler of heaters manufactured from the beginning of 1996 up to a manufacturing date of 1998 In the vicinity of the heater a temperature of 230°F (110 (calendar week 36. t at least once a year the heat exchanger must be Exhaust muffler cleaned inside. the latest before the beginning of the heating season (refer to Annex A "Scheduled Maintenance").5..Thermo Series Coolant Heaters Servicing 8 Servicing t in case of leakage the fuel pump and the fuel lines must be replaced immediately.... t outside the heating season the heater should be operated with the vehicle engine cold approximately every four weeks for 10 minutes setting the heating system to "warm".2 Heater Servicing When the heater is installed in rail vehicles.. battery main power supply must not be disconnected to prevent the heater from overheating by response of the 8. metal screw. maintenance chart / test certificate item no. production date 1998.. the fuel filter or filter cartridge as well as the filter screen of the fuel pump must be replaced to avoid malfunctions. on the heater when installed.spheros. The heater must not be operated. 3G.4 Heater Test Run attachment of the muffler should be performed. calendar week 36. from beginning of 1996 Identification up to 1998.. otherwise every 5 8. Muffler When performing major repairs on the heater its (Only heaters from year of production 1996 and up to removal is appropriate. production refer to identification label) the exhaust during paint work on the vehicle)..1 General years. 8. muffler may get loose or lost under certain circumstances. Inc.us 42 Spheros North America. 3G..

43 www.9 x 25 B 3.9 x 25 Hole 2. Exhaust end pipe Exhaust Sheet metal Sheet metal screw end pipe screw B 3. figure).5 mm Ø (3/16” Ø) Exhaust deflector P/N 84970A Heater without exhaust pipe Exhaust pipe Heater with exhaust pipe Spheros North America. fasten 2. For checking remove exhaust end pipe as required. Slot or drill 1.5 mm Ø Hole (3/16” Ø) 2. (2.5 mm) into the exhaust end pipe and muffler and 4. If no muffler is found in exhaust end pipe check if muffler is upstream in exhaust pipe. Inc. Drill a hole with a diameter of 3/16 in and refit. Slot or drill exhaust end (P/N 84970A) must be additionally fitted. If heater is operated without exhaust pipe. If the exhaust muffler has been lost it may be secure muffler with a sheet metal screw B 3. Check exhaust end pipe for presence of muffler. Slot or drill exhaust pipe sheet metal screw.Servicing Thermo Series Coolant Heaters Inspection and Attachment 3. secure muffler as The exhaust muffler must always be secured with a described in NOTE above.com .spheros.9 x 25 (see ordered free of charge from Spheros (P/N 20691C). An exhaust deflector described in NOTE above. Fasten muffler according to NOTE.5 mm Ø (3/16” Ø) Exhaust muffler P/N 20691C Exhaust muffler P/N 20691C Hole 2. If muffler is NOTE dislocated in the exhaust pipe. exhaust pipe and refit. If muffler is found in exhaust end pipe fasten as muffler according to NOTE. 5. pipe and refit.

4. the cotter pin may be located on the opposite side. In order to obtain a convenient burner head opening angle it is required to disconnect the electrical connection(s) to the temperature limiter and temperature sensor. Closing or installation NOTE 1.us 44 Spheros North America.spheros. – igniter electrodes 5. 1 Burner head 2 Screw (2) 3 Nut (2) 4 Cotter pin 4 3 NOTE 2 1 Depending on the burner head direction of swing. 7) enough to release hinge bolts Prior to opening the burner head the connectors of the (1). prevent lethal injuries. – combustion chamber NOTE – nozzle block pre-heater (if installed) When making electrical connections observe wiring color codes. head. Swing hinge bolts (1)out.5 Nm + 1 Nm. . – fuel pump and fuel nozzle 3. As required for installation.2 Burner Head Opening and Closing or Opening or removal Removal and Installation 1. Figure 7: Swinging Burner Head open www.5. Swing hinge bolts (2) into lock position and secure – solenoid valve with nuts (3). Disconnect electrical connections to temperature WARNING limiter and temperature sensor. Swing burner head (4) closed and locate for assembly. cable harness in the vehicle have to be disconnected to 3. Torque nuts (3) to 7. – electronic ignition coil 4. reconnect 5. 2. The electronic ignition coil operates with high voltage. After closing and securing burner head. Inc. Reconnect electrical connections to the – flame sensor temperature limiter and temperature sensor.Thermo Series Coolant Heaters Servicing 8. Fig. fasten burner head (4. By swinging the Fig. Maintenance on the heater is easy. Remove cotter pin (1) as required to remove burner connectors in the vehicle. 801) in position using cotter pin (1) burner head open the following components become accessible: 2. Loosen nuts (2. Swing burner head (3) open.

g.6.Servicing Thermo Series Coolant Heaters 8. The cooling system coolant capacity must be at least 10 liters.2. 45 www. After 2 minutes Installation the pump may be reactivated.g. U4856 t Dripping or evaporating fuel may neither the circulating pump automatically switches off accumulate nor ignite on hot components or approx. The hoses have to 1C. In overheat condition the heater outer shell may reach Proper venting may be identified by a circulating pump Diesel fuel inflammation temperature! almost noiseless in operation.4 bar and of max. Mecanyl RWTL) may also be used according to DIN 73378 observing the applicable Prior to the heater’s first operation or after replacement jointing instructions. always use the hoses It is a basic requirement to use the coolant hoses supplied or offered by Spheros. 2. t Protect lines from stone strike. If other hoses are used supplied by Spheros. Fuel hoses must not be kinked or twisted and be installed free of kinks and for proper venting in an must be secured with clamps every 1 in (25 mm). lines made of unhardened. This applies in particular for the 8. 8. Spheros North America. they should only be installed with an incline. 15 seconds after switch-on should coolant be electrical equippment.6. e. inclination. The heater is to be connected to the vehicle cooling 8. Inc. attention must be paid to carefully bleed the cooling system. The fuel line joints are to be secured against disconnection with The vehicle cooling system or the separate heating hose clamps should no screwed mechanical unions be in circuit must use only pressure relief valves with an use.0 bar. of the coolant.6. In order to avoid air from being captured in fuel lines. Should fuel hoses be installed. Heater and lines must be installed Basic rules for the routing of fuel lines are: so that static venting is guaranteed. copper or plastic Hose clamps must be torqued with 1.5 Nm. Fuel lines consisting of materials standard in the NOTE manufacturing of vehicles. low as possible to ensure self-venting of the heater and circulating pump.2 Connection to Vehicle Fuel System circulating pump because it is not self-priming. In combination with control unit 1572D (Thermo label 8. opening pressure of at least 0. steel. light and temperature stabilized PA11 or PA12 (e.1 Fuel Lines system according to Fig. t Protect against undue temperatures.spheros. type 3. The installation of the heater should be in a location as the heater also switches off when coolant is missing. Improper venting may cause malfunctions by WARNING overheating in equipment operation. Hose connections must be secured against slippage with hose clamps.5 Nm+0. When using the circulating pump U4855.com .1 Connection to Vehicle Cooling System colored) and with programmed circulating pump check. otherwise the hoses must at least they must at least meet the specifications of DIN 73379- meet the specifications of DIN 73411. Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel tank.6 Visual Inspections and Regulations for missing or the pump wheel be seized.

roof 6 Vehicle engine 7 Water valves 8 Driver area heat exchanger / defroster 9 Control device (Timer and/or Switch) Figure 8: Example of a Heater Installation in a Transit Bus www.spheros.Thermo Series Coolant Heaters Servicing Water heating circuit – Sidewall radiators and roof duct heating 5 6 3 4 7 1 1 1 2 1 9 8 Supply Return 1 Sidewall heat exchanger with fan 2 Stepwell heat exchanger with fan 3 Spheros Heating unit 4 Circulating pump 5 Heat exchanger. . Inc.us 46 Spheros North America.

CAUTION Observe official regulations concerning the installation The heater must be electrically disabled by (see 1. Fuel may escape. t Max. It must be located so that no clogging by contamination.6).3 bar for suction 8. Danger of fire. combustion air must be taken in from and the exhaust routed to the exterior. permissible length for each suction and return line: 33 ft ( 10 m) If the temperature in the installation box exceeds the t Max. installation compartment. 47 www.5 in2 (30 cm2) Thermo 350 5.6.5 ft (2 m). To avoid operating malfunctions Spheros North America. upwards to the heater.6). CAUTION 8. disconnection of the main power supply whenever the return line is blocked! Combustion air must under no circumstances be extracted from rooms with persons.2.spheros. impact of snow.5 ft (5m) t max. Thermo 230 and 300 4. The exhaust pipe outlet opening must not point in the Installation position possibly vertical with horizontal direction of motion. bend: 270° The combustion air inlet must be located so that no Example of Information Label exhaust fumes can enter. The combustion air inlet must not point towards the forward direction of motion.6.Servicing Thermo Series Coolant Heaters When installing a shut-off device in the return line a replace filter or filter cartridge once a year or more often clearly visible information label must be provided. The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle. direction of flow.us . NOTE Loose fuel lines must be secured in order to avoid If the combustion air intake line cannot be routed sagging. a water drain hole Ø 1/8 in (4 mm. Inc.6. suction height) consulting Spheros. use by Spheros is to be fitted. permitted ambient temperature of the heater (see (installation of a bottom valve is recommended for Technical Data).4 in2 (35 cm2) t max.2 Fuel Filter Observe official regulations concerning the installation A fuel filter supplied as deliverable item or cleared for (see 1.) is to be provided at the lowest point. a vent t inner diameter for suction and return line: port is required: t 1/4 in (6 mm) (other diameters upon request). if fuel is contaminated. permissible suction height: 6.3 Combustion Air Supply Operation with the return line shut off causes damage to the fuel pump. CAUTION 8. length: 16. or intake of splash water is to be expected. Fuel lines permissible dimensions: If the heater is located in a closed installation box. The feed-throughs must be sealed against splash water. Permissible dimensions of combustion air intake line: t inner diameter: 2-3/16 in (55mm) t max. permissible priming pressure: 0. The installation of an additional fuel pump is not If the heater is located near the fuel tank in a common allowed. the vent port must be enlarged max.4 Exhaust Line and return line.

2. – replacement of combustion chamber WARNING 8. Rigid pipes made of unalloyed or alloyed steel with a 2. Perform replacement in accordance with 9. Loosen hose clamps on coolant hoses. not to expect clogging by snow or mud. – max.1. Slide on coolant hoses and fasten with hose used as exhaust line or flexible pipes made of alloyed clamps. Disconnect combustion air intake on heater if 8. As an alternative an exhaust deflector must be installed 7. 8. The replacement procedure for the burner is identical disconnect and fit dummy plugs.2 Temperature Limiter. Removal and Installation Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by 8. 4. – replacement of flame sensor Perform replacement in accordance with 9.1.2. Loosen fuel supply and return line connections.7. The combustion air intake and exhaust outlet is to be 8.g. NOTE 3.1 Heater. If required. – replacement of temperature limiter – replacement of temperature sensor 8. Bleed coolant circuit.2. 8. screws and washers or 4 screws and washers.75 in (70mm) 5. Replacement CAUTION NOTE In installed condition only the following disassembly or The replacement procedure for the temperature limiter removal procedures are permitted should enough space is identical with the heater installed or removed. Torque clamps to 1. 2. Connect electrical connectors of cable harness in vehicle and to circulating pump.4 Burner. The exhaust pipe is secured to the air heater e. Inc.2. steel only.5 Nm. Replacement required. for removal allow such action: Perform replacement in accordance with 9. connectors of cable harness in vehicle to avoid lethal accidents. with a clamp. The electronic ignition coil operates on high voltage.1 Removal opening the cooling circuit sealing element. cleared by Spheros. bend: 270° 6. Disconnect connectors of cable harness in vehicle collector vessel ready to collect escaping coolant.2 Installation located so that no air pressure difference builds up in 1. with the heater installed or removed. also allow heater to cool down and have 1. www. Close water cocks as applicable.7.1.5 ft (5m) without exhaust extension applicable.7. Remove heater.Thermo Series Coolant Heaters Servicing The exhaust pipe outlet opening must be located so as 7. Bleed fuel supply system. Secure combustion air inlet line on heater as – max. Loosen clamp on exhaust outlet.7. – inner diameter: 2. 5.us 48 Spheros North America.7 Removal and Installation 8. Remove 3 screws and washers or 4 screws and Prior to replacement of burner disconnect electrical washers. disconnect WARNING hoses and fit dummy plugs. Locate heater for installation and secure with 3 any operating condition of the vehicle. and of circulating pump. .3. 4. Secure line on exhaust outlet using clamp.3 Temperature Sensor. length: 16. minimum wall thickness of 1/32 in (1 mm) have to be 3. Replacement – replacement of combustion air fan NOTE – replacement of burner The replacement procedure for the temperature sensor – replacement of electronic ignition coil is identical with the heater installed or removed. Connect fuel supply and return lines and tighten connections or screw tight with banjo bolt and new Permissible exhaust line dimensions: copper gaskets. Open water cocks. 6.spheros.7.7.

electrical connectors of cable harness in vehicle to avoid lethal accidents. WARNING Operate engine at increased idle until radiator The electronic ignition coil operates on high voltage. In this case. During test runs all Should no combustion be achieved with the first start coolant and fuel line connections have to be checked for attempt. avoid lethal accidents. In case NOTE of no restart attempt the temperature limiter on the heater has responded because the heater has not been The replacement procedure for the combustion cham bled properly.2 Fuel Supply System. Bleeding After heater installation the coolant circuit and the fuel When switching the heater on. Replacement glycol based anti-freeze (protection against corrosion). button on temperature limiter and repeat complete Perform replacement in accordance with 9. NOTE When using pure water there will be no protection against corrosion and due to the lower boiling point of The replacement procedure for the flame sensor is the water when overheating.2.8. Prior to resetting temperature limiter.7. Replacement must automatically switch on and control to off. Inc. the fuel pump draws fuel supply system must be thoroughly bled observing the to prime the complete fuel supply system.6 Flame Sensor. Switch on heater and vehicle heating fan with engine shut down.Servicing Thermo Series Coolant Heaters 8. NOTE Heaters with control unit 1572D: If the heater performs 8 subsequent attempts to start due to a malfunction.com . coil is identical with the heater installed or removed. during run-down. 49 www. Reset temperature limiter by pushing ber is identical with the heater installed or removed. Additives in Perform replacement in accordance with 9. NOTE WARNING The heater may be equipped with an automatically The heater operates on high voltage.7. Replacement lockout is superior to the normal error lockout condition. check coolant Prior to replacement of flame sensor disconnect level and replenish as required.11.7. The manual reset is not replacement of combustion chamber disconnect necessary. with manufacturer’s instructions. bleeding procedure. thermostat opens.2. Should the heater in operation enter a fault condition. Perform replacement in accordance with 9. switch the heater off and on again. This error Spheros North America.2.9. plastics or rubber and leave no deposits. 8. For bleeding. allow time for heater to cool electrical connectors of cable harness in vehicle to down and limiter to self-reset. perform troubleshooting (refer to Section 5). the Prior to replacement of electronic ignition coil circulating pump must not be switched on.8.7 Combustion Chamber. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply The replacement procedure for the electronic ignition within 120 sec. Set vehicles own heating system to "warm" and replenish coolant which must consist of at least 20% 8. loss of cooling water may identical with the heater installed or removed. Shut down engine. the coolant must not affect metals. Bleeding NOTE WARNING Bleeding must always be performed in accordance The electronic ignition coil operates on high voltage. security and no leakage. 8. the heater enters an error lockout and stops any further attempts to start. disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.5 Electronic Ignition Coil.8 First Operation 8. After a certain cool-down period the heater 8.1 Water Circuit.spheros. result requiring continuous replenishment. vehicle manufacturer’s instructions.8.

The following components may also be replaced with the heater installed unless restricted space prevents access: – temperature limiter – temperature sensor – combustion air fan – burner – electronic ignition coil – flame sensor – combustion chamber Prior to replacement disconnect connectors of cable harness in vehicle to avoid lethal accidents. WARNING The electronic ignition coil operates on high voltage. For re-assembly. 300 and 350 when removed. Any further disassembly will void the warranty. If required.1 General This section describes the repairs that may be performed on the heaters Thermo 230. Before replacing the temperature sensor also release pressure from cooling system by opening coolant system pressure cap. also allow heater to cool down. . Inc. www.spheros.us 50 Spheros North America. WARNING Hot coolant may escape during the replacement of the temperature sensor.Thermo Series Coolant Heaters Repair 9 Repair 9. only components of the proper service part kits are to be used.

deposits.1) t Check terminals for corrosion and contacts for installation of circulating pump U 4855 or U4856 security.1. 9.2. – Check welding seem for cracks. etc.1. Spheros North America. as substitute for circulating pump U4816. NOTE Longitudinal cracks up to 3 in (80mm) are allowed.1.1 Work on Components after Disassembly 9. – Inspect combustion chamber for oxidizing and coke deposits and remove as required. – Inspect heat exchanger for exterior damage. NOTE Deposits are to be removed with water jet and brush. loose contacts.2) 9.com .spheros.2 Incorporation of Modifications CAUTION NOTE All gaskets located between disassembled components Continuous enhancement of heater design is for must always be replaced and old gaskets discarded. The following modifications may be incorporated during repair procedures: t Examine connectors and wiring for corrosion.) and replace as necessary. damage and corrosion. 9. 9. Repair as required.Repair Thermo Series Coolant Heaters 9. deformation.1. Visual Inspection – Inspect exhaust ducting in heat exchanger for sooting.1.1. and repair as installation of control unit 1572D as substitute for necessary.2 Combustion Chamber.1. (see 9. remove carbon deposits in heat exchanger using a suitable tool. wear. CAUTION When replacing the combustion chamber on heaters installed vertically.1. – Check slide lock for proper seating. General Normally equipment in use may be retrofitted using available modification kits t Examine all components for damages (cracks. wrong crimping. control unit 1572 (see 9.1. deformation.2. Inc. optimizing performance and avoiding failures and malfunctions. NOTE Heavy deformation may cause restricted flow of coolant.1. Visual Inspection – Check swirl ring for security.1.4 Combustion Air Fan Rotor. etc.1.3 Heat Exchanger.1 Visual Inspection. – Check cover plate for security. 51 www. Visual Inspection – Check fan rotor for contamination and cracks. etc.

us 52 Spheros North America.2. .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 Due to the progress in the development of processors with the electronic ignition coil delivered (green control unit 1572 can no longer be supplied.2.5.1 The modification kit consists of: and discard.2. – control unit 1572D 3. Install new control unit according to 9. Apply new thermo label onto existing label to indicate retrofit.5.2. Inc. connector cover). – thermo identification label 4.spheros.2. Install new electronic ignition coil according to – electronic ignition coil 9. Remove control unit according to 9.1.1 and to the following procedure: discard. 2. The electrical connector is coded.8. Previous electronic ignition unit Thermo label New electronic ignition unit Control unit 1572 Control unit 1572D www. The retrofit of control unit 1572D is performed according 1. Remove electronic ignition coil according to 9.Thermo Series Coolant Heaters Repair 9. 5.2.8.

the following: vehicle cooling system and the pump body must be bled. allowing closure during pump operation.1. the new mount must be attached so that there is a clearance of 2-3/8 in (60 mm) to the wall (reference line: circulating pump centerline). CAUTION Procedure.). The circulating pumps U 4816 may be substituted t The hoses must be installed routed upwards free of by circulating pump Aquavent 6000C (U 4855) kinks. Hose connections must be secured against Aquavent 6000CS (U 4856). U 4814 Water inlet port Spheros North America. The tightening torque specification of the clamps used must be complied When exchanging circulating pump U 4816 the with. the exchange procedure is difficult and must be checked if practicable. t If the circulating pump is mounted into a compact Permitted installation position unit. t On the water inlet side of the pump no solenoid used. slippage with hose clamps. the new mount must be relocated in relation to the old mount.spheros. 53 www.com .2 Installation of Circulating Pump Aquavent NOTE 5000/ 5000s or 6000 as substitute t The circulating pump is not self-venting of any for Circulating Pump U 4816 accumulating air. circulating pump Aquavent 5000 (U 4814) Aquavent 6000C (U 4855) Improper bleeding or a dry run of the pump causes damage to the slip ring seal. t The existing mount and hose clamp must be removed and discarded.2. The same applies for filters which may clog. Inc.Repair Thermo Series Coolant Heaters 9. Installation must be performed using a new mount and hose clamp. If required. Therefore the pump has to be installed at the lowest point of the water circuit General observing the permitted pump orientation (see Fig. attachment parts (mount and hose clamp) may be re. t Hose connections must be adapted. When exchanging circulating pump U 4814 observe the t Prior to first operation of the circulating pump. t When mounting the circulating pump near to a wall. The same applies for compact units. Proper bleeding may be CAUTION verified by almost noiseless operation of the pump. valves or other shut-off devices must be installed An adaptation of the water connection is not necessary. When installing circulating pump U 4814 and U4855 the following information must be strictly observed to avoid loss of warranty.

the following information must be strictly observed to A motor replacement. Inc. The same applies for filters which may clog. NOTE t Different to the U 4814. the U4854 and U 4856 can be installed in the vertical position so that the pump head is located above the motor.spheros. A dry run of the Aquavent 6000 SC circulating pump is permitted up to 15 minutes. in some cases. without removal of the pump head from the circulation system. the Aquavent 6000SC (u 4856) vehicle cooling system and the pump body must be bled. subject to wear. circulating pump Aquavent 5000S (U 4854) t Prior to first operation of the circulating pump. CAUTION t The Aquavent 6000 SC pump head includes no parts When installing circulating pump U 4854 and U 4856. is possible avoid loss of warranty.us 54 Spheros North America. Hose connections must be secured against slippage with hose clamps. Proper bleeding may be t On the water inlet side of the pump no solenoid verified by almost noiseless operation of the pump. valves or other shut-off devices must be installed allowing closure during pump operation. The tightening torque CAUTION specification of the clamps used must be complied with. t The circulating pump is not self-venting of any accumulating air.). Therefore the pump has to be installed at the lowest point of the water circuit observing the permitted pump orientation (see Fig.Thermo Series Coolant Heaters Repair Procedure. Aquavent 5000S Water inlet port www. t The hoses must be installed routed upwards free of Permitted installation position kinks. .

(1. relieve coolant pressure in cooling system by Spheros North America.1 Removal 1. Make electrical connections. the cable must be aligned in the cable sleeve. Using screw driver lever off coolant outlet (4). installation.5 Nm + 1 Nm.1). Remove burner (8). 4. 3. Swing hinge bolts (7) open and remove cotter pin 3. After the rubber cap has been placed in position.com . 9.2.3.1 Removal 5. Only then will the temperature limiter be in proper contact 2. Tighten nuts (6) to 7.Repair Thermo Series Coolant Heaters 9. Slide rubber cap of temperature limiter (1.1. 9.2. Fig. Restore electrical connections.1 Removal NOTE 1. 4. (5).3. Perform procedures on components after from strain. free 5. 9) and remove. 1.2. Fig. also allow heater to cool down and have 9. Unscrew temperature sensor (2.2 Installation NOTE 1. audibly (twice) at the collar of the locating socket. Restore electrical connections.2. screws (6). 2.2.1. Connect fuel lines.2 Temperature Sensor. 2. Disconnect electrical connection to temperature 9. Replacement 3.2. Withdraw rubber cap. 9. Loosen nuts (6. 55 www. 9) Observe electrical wiring color coding when making back until temperature limiter can be located for connections to temperature sensor. Replacement push in retaining clip.2 Installation limiter. Disconnect electrical connections on burner and The retaining spring must be located in the groove of loosen fuel supply and return line connections. Position burner (8. swing Observe electrical wiring color coding when making hinge bolts closed and secure temporarily using connections to temperature limiter.2 Installation NOTE 1. Disconnect electrical connection to temperature NOTE sensor. condition. 9). If required. with the heat exchanger jacket. Torque temperature sensor to 20 Nm +5 Nm.1. 9) into 2. Fig. Inc. Replacement collector vessel ready to collect escaping coolant. 9.2. Manually screw temperature sensor (2.2.3 Burner. Observe electrical wiring color coding when making WARNING connections to temperature limiter and temperature Prior to replacement of temperature sensor in installed sensor.2. Fit rubber cap. Fig.1 Temperature Limiter. Fig. Insert cotter pin (5) according to the intended opening swing direction.2.spheros.2 Disassembly and Assembly opening the coolant circuit pressure cap. Fig. 3. 1. disassembly (refer to 9.2. 4. 9) until hinge bolts are free. retaining spring and remove temperature limiter 2. Connection cables must not be routed over reset button. 9) for installation. 2. Position temperature limiter (1) in connector (3) and 9. the housing and must be latched both perceptibly and disconnect and fit dummy plugs. 9. 9.

Replacement www. Temperature Sensor and Burner. Figure 9: Temperature Limiter.spheros.us 56 Spheros North America. Inc. the cotter pin may be located on the opposite side. .Thermo Series Coolant Heaters Repair 1 Temperature limiter 2 Temperature sensor Rubber cap 3 Connector 4 Coolant outlet Temperature 5 Cotter pin limiter 6 Nut (2) 7 Hinge bolt (2) Retaining clip 8 Burner 3 2 4 1 5 6 8 7 NOTE Depending on the burner head direction of swing.

8. 4. (recess in mounting flange) and with clutch (by rotating the burner may be left installed. Perform procedures on components after disassembly (refer to 9. 7. 1/8” pin punch) open slide 5. Tighten screws to 5 Nm + 1 Nm. 1/8” pin punch or pliers) close slide lock 4.spheros.1 Removal washers. Disconnect electrical connector (9). Align drive motor (7) and position for installation.1). Bring slide lock (5) on fan rotor in installation lock (5) until fan rotor can be pulled off. 2. Inc. drive shaft). 57 www. In removed condition ensure that igniter electrodes are 1.5 Nm. position. Connect electrical connector (9). Attach drive motor using screws (6) and lock 9. 2. Locate cap (2) and secure with screws (3).1.2.2. Loosen screws (3. Tighten screws to 2 Nm + 0. 10) and withdraw cap (2) from burner. 10) to be aligned with control unit For replacement of the combustion air fan and motor. Fig.g. 6.4. Fig. not bent and nozzle is not damaged. 5.Repair Thermo Series Coolant Heaters 9.2 Installation Replacement NOTE NOTE Drive motor (7.com .g. Opening slide lock Closing slide lock Spheros North America.4 Combustion Air Fan and motor 9. Using suitable tool (e. 1. 3.2. Remove screws (6) with lock washers and withdraw until fan rotor is locked. 3.4. drive motor (7). Slide fan rotor onto drive shaft and using suitable tool (e.

us 58 Spheros North America. Replacement www. Inc.Thermo Series Coolant Heaters Repair 6 5 8 4 2 9 7 1 3 1 Splash protection cover 2 Cap 3 Screw (2) 4 Fan wheel 5 Slide lock 6 Screw (3) 7 Drive motor 8 Clutch 9 Electrical connector Figure 10: Combustion Air Fan.spheros. .

While holding the nozzle holder with an 18 mm 9.9. Replacement wrench. Fig. Fig. 1. direction from burner head (17) and remove. Swing burner head open (refer to 8.2.2. If a control unit 1572 is substituted with a control unit 1572D.2.4. nozzle preheat (24).1. 3. Install solenoid valve (7. Remove disk (6. 12) from electronic ignition coil (2) and remove.1 Removal NOTE 1. Fig.6. 9.3. perform procedure according to 9.1). (3. 11) on fuel pump (10) 9. Carefully withdraw control unit (23) in axial position. Remove burner (refer to 9. Fig.4. screw in nozzle (4) and tighten with a 16 4. and. Plug in igniter electrodes (3. Make all electrical connections on control unit (23). 11) and nozzle pre-heating cartridge (if installed) from pump (10). disassembly (refer to 9.2).1. 4. 8. Fig. Only touch the nozzle by its hexagon surface. Remove disk (6.2). 11) with nozzle pre-heating During the following step ensure that escaping fuel is thermostat (if installed) into position on pump (10). In removed condition ensure that igniter electrodes are 9. 11). Remove and discard O-rings (12) and filter screen For replacement of the control unit the burner head (11).2).2. 11). remove. Perform procedures on components after 8.2. 6. Replacement 1. Remove flame sensor (refer to 9. Fig.2. 11). immediately neutralized and properly disposed of.2. Withdraw fuel pump (10) together with solenoid valve (7) and set aside. Using screwdriver. 4. 9. Plug in igniter electrodes (3. While holding the nozzle holder with an 18 mm wrench. Tighten screws to 5 Nm + 1 Nm.Repair Thermo Series Coolant Heaters 9. Fig.1). Replacement 6. nozzle preheat (24).7. Fig. Carefully install control unit (23. lever off igniter electrodes 3.2 Installation 9.2. 9.2. may be left installed and must only be swung open for disconnection of electrical connector (8. Using screwdriver.5.3. if equipped.2 Installation 1. Connect electrical connector (8) of fuel solenoid.2. Connect electrical connector (8) of fuel solenoid 3.1). Fit new O-rings (12) and filter screen (11) on fuel unit (23. 1.7. 9.3. pump (10). Fig. thermostat (if installed) from pump (10). Install burner (refer to 9. Perform procedures on components after not bent and nozzle is not damaged.com . 3. 5.2. Remove solenoid valve (7) from fuel pump (10) if required.1). Disconnect electrical connector (8) of fuel solenoid. Remove screws (9) with lock washers.2. Position fuel pump (10) for installation and secure disconnect electrical connector (8) of fuel solenoid with screws (9) and lock washers. 11) from electronic ignition coil (1) and 4.5. Remove combustion air fan (refer to 9. Install combustion air fan (refer to 9.1).2). Install flame sensor (refer to 9. 5.2.3.1.2. Tighten nozzle to 20 Nm. 6. 2. if equipped. (1. Place disk (6. 11) with nozzle pre-heating and. 5. Fig. Remove burner (refer to 9.2. remove nozzle (4) with a 16 mm wrench or socket. 7.2) and 3.5 Control Unit. 4.7 High Pressure Nozzle. Install heating cartridge and place disk (6) into 5. 11) in axial 9.1). lever off igniter electrodes nozzle.2 Installation 3. 2. Inc. 1. Disconnect all electrical connections from control 2. 4.2.1 Removal direction into burner head (17) until fully seated. NOTE 2. Install burner (refer to 9. 2.2.6. NOTE 7. Fig. 11). Ensure cleanliness is maintained when installing the 2.spheros.1.6 Fuel Pump.2. mm wrench or socket. disassembly (refer to 9. Spheros North America.5.9.1 Removal if required. 59 www.

Inc.spheros. 5 6 25 10 11 12 24 13 Control unit 1572 14 15 16 17 18 23 1 Electronic ignition coil 15 Flame sensor 2 Screw (2) 16 Screw 19 3 Igniter electrodes 17 Burner housing 4 High pressure nozzle 18 Strain relief clamp (2) 22 20 5 Viewing glass 19 Screw (2) 21 6 Disk 20 Base plate for relays 7 Solenoid valve 21 Relay 8 Electrical connector 22 Relay 9 Screw (3) 23 Control unit 10 Fuel pump 24 Heating cartridge with 11 Filter screen thermostat 12 O-ring (2) 25 Clip 13 Combustion air ring 26 Overheat thermostat 14 Screw (Vertical only) Figure 11: Control Unit and Fuel Pump.us 60 Spheros North America. (Vertical only) Control unit 1572D 26 5 6 2 3 7 1 8 4 Electronic ignition coil 9 (black connector cover) in combination with control unit 1572 only. Replacement www. .Thermo Series Coolant Heaters Repair Electronic ignition coil 1 23 Overheat (new style housing) in combination with control thermostat unit 1572D and 1572.

1. Tighten screw (14) to 5 Nm + 1 Nm. Remove burner if required (refer to 9. 2. 6. 12) from (Fig.2 Installation 1. 4.8 Electronic Ignition Coil.2. 2.2.1). Replacement 9.1. 4.1). Remove disk (6).2. 6.2.2. plug in making correct electrical 1. Install burner (refer to 9.2. electronic ignition coil using screw driver and 3. Tighten screws (2) to 5 Nm + 1 Nm. Install burner (refer to 9.3. Using screw driver lever off igniter electrodes 2. Locate electronic ignition coil (1.2. disassembly (refer to 9. 2.3.1). Remove burner if required (refer to 9.2). Replacement (Sheet 1 of 2) Spheros North America.3. 3. 3.9.com . lever off igniter electrodes (Fig. 61 www. Electronic Ignition coil Igniter electrodes Removal and installation of igniter electrodes Flame sensor Figure 12: Electronic Ignition Coil and Flame Sensor. 12) from electronic ignition coil and remove.8. 1.spheros. Replacement 9. Remove screws (2) with lock washers.9 Flame Sensor. Position disk (6) and align. Fig. 3.2). Inc. 4. Remove screw (14) and lock washer. Withdraw electronic ignition coil (1) and remove. Perform procedures on components after disassembly (refer to 9. secure with screw (14) and lock washer. Plug in igniter electrodes (3). 4.9. remove.3. Fig.2.8. Position disk (6) and align. 13) for installation. Position flame sensor (15. Perform procedures on components after 5. 13) for installation. 5. 5.1 Removal 9.1 Removal 1.2. connections and secure with screws (2) and lock plug in to make correct electrical connections and washers.1). If required.Repair Thermo Series Coolant Heaters 9. Remove disk (6). Plug in igniter electrodes (3). Withdraw flame sensor (15) and remove. 5.2.2 Installation 9. 9.

(Vertical only) Control unit 1572D 26 5 6 2 3 7 1 8 4 Electronic ignition coil 9 (black connector cover) in combination with control unit 1572 only. Replacement (Sheet 2 of 2) www. Inc.us 62 Spheros North America. 5 6 25 10 11 12 24 13 Control unit 1572 14 15 16 17 18 23 1 Electronic ignition coil 15 Flame sensor 2 Screw (2) 16 Screw 19 3 Igniter electrodes 17 Burner housing 4 High pressure nozzle 18 Strain relief clamp (2) 22 20 5 Viewing glass 19 Screw (2) 21 6 Disk 20 Base plate for relays 7 Solenoid valve 21 Relay 8 Electrical connector 22 Relay 9 Screw (3) 23 Control unit 10 Fuel pump 24 Heating cartridge with 11 Filter screen thermostat 12 O-ring (2) 25 Clip 13 Combustion air ring 26 Overheat thermostat 14 Screw (Vertical only) Figure 13: Electronic Ignition Coil and Flame Sensor. .Thermo Series Coolant Heaters Repair Electronic ignition coil 1 23 Overheat (new style housing) in combination with control thermostat unit 1572D and 1572.spheros.

Fig.2.1). 2. 4.11.2 Installation 9.1). Install temperature sensor (refer to 9.2).2. 2 1 1 Combustion chamber 2 Heat exchanger Figure 14: Heat Exchanger and Combustion Chamber.10. Remove burner (refer to 9.11 Combustion Chamber. 14) from heat exchanger (2).10 Heat Exchanger. 1.1). Replacement Spheros North America. heat exchanger (2) and remove.Repair Thermo Series Coolant Heaters 9. Swing burner closed (refer to 8. Fig.com . Slide combustion chamber (1. 2.3.2. 2.1.2.2).2).11.1. 5.2Installation 1. Inc. Remove heat exchanger (2).2). Withdraw combustion chamber (1.1. 63 www. 3.2.10.2.1 Removal 1. Remove temperature limiter (refer to 9. Install temperature limiter (refer to 9. Swing burner open (refer to 8. 14) fully into heat exchanger (2) against stop.5. Disconnect electrical connections to temperature 2.1. Fig. 14) fully into heat exchanger (2) against stop.2.2.spheros. 9.3.2.2. 3. Perform procedures on components after disassembly (refer to 9. Replacement 9. Perform procedures on components after disassembly (refer to 9. Make electrical connections to temperature limiter and to temperature sensor. Fig.2). Replacement 9.2.5. 4.1 Removal 9.1). Install burner (refer to 9.2.1).2. connections. Observe electrical wiring color coding when making 4.2. limiter and temperature sensor. 14) from 3. Slide combustion chamber (1. Remove temperature sensor (refer to 9. NOTE 3. Withdraw combustion chamber (1. 6. 1.

Check for secure connection to heat exchanger. water circuit). 101322).us 64 Spheros North America. Replace bent electrodes. Exhaust system a) Check exhaust line for contamination and clean as required. clean water filter. b) Inspect fuses for oxidation and/or check transition resistances. e. open water shut-off cocks. connections in fuel supply and return! c) If existing. spray. f) Replace nozzle. reason for overheating (e. d) Fuel pump and fuel lines.k. Fuel system a) Check fuel lines and connections for leaks.g. e) Check igniter electrodes for condition. www. (order no. Swing burner head open: b) Check cover for damage Replace damaged cover c) Check housing interior for accumulation of fuel caused by leaks. Scheduled Maintenance time when weather conditions cause increased use of heater). Water system a) If installed. Inc.g. Check temperature c) Clean heater exterior and interior. 6. b) Check heater function. 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. c) Check for smoke emissions in run-down. spray and reconnect after performing contact spray step 5. after at least 10 min. open shut-off cock in return line. inspect both components for damage and contamination and clean or replace as required. b) Remove combustion chamber from heat exchanger. Electrical connections Use suitable contact a) Disconnect electrical connectors to cable harness.I Check / Maintenance Important Notes Check Result Measured Values. 1. 5.k. not performed o. 2. 4. b) If installed. Heat exchanger If necessary investigate a) Inspect paint for dark stains of burn (local overheating). replace nozzle if required. . Replace pump and lines every 5 years. special inspect for oxidation. open fuel shut-off cocks. Functional checks a) If installed.Thermo Series Coolant Heaters Annex A Heater. d) Clean viewing glass of flame sensor. d) Restore electrical connections. c) Insert combustion chamber and mount burner head. b) Check for signs of leakage. 3.spheros. of heating operation. Retighten joints and hose clamps. e) Replace fuel filter screen with gaskets in pump. When coked reduce replacement interval for fuel filter. Burner head a) Check combustion air inlet for contamination. Maintenance / Repair o. Check for tight b) Replace fuel filter cartridge with gasket. limiter. 7.

spheros. Inc.Annex A Thermo Series Coolant Heaters Spheros North America. 65 www.com .

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Inc.spheros. Inc. 2011 Spheros North America. 5536 Research Drive. 1-734-218-7350· Fax 1-734-487-1569 www. Canton MI 48188 Tel.12/2011 Subject to modification © Spheros North America. Doc.us . P/N: 9003656D Edited for North America .us · info@spheros.