Spheros thermo 230 Workshop Manual
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Spheros thermo 230 Workshop Manual

Spheros thermo 230 Workshop Manual

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See also: Manual and Warranty , Instruction and Installation Manual
Water Heaters
12/2012
Ident Nr. 9003656C II
Workshop Manual
Thermo 230
Thermo 300
Thermo 350
with control unit 1572
model .30 and up
Thermo 230
Thermo 300
Thermo 350
with control unit 1572D
model .030 and up
Thermo 231
Thermo 301
model .01 and up
Thermo Rail

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Summary of Contents for Spheros thermo 230

  • Page 1 Water Heaters Workshop Manual Thermo 230 Thermo 300 Thermo 350 with control unit 1572 model .30 and up Thermo 230 Thermo 300 Thermo 350 with control unit 1572D model .030 and up Thermo 231 Thermo 301 model .01 and up...

  • Page 3: Table Of Contents

    Thermo 230 / 231 / 300 / 301 / 350 List of Contents List of Contents Introduction Scope and Purpose ..........................101 Applicability of Manual ........................... 101 Meaning of Warnings, Cautions and Notes ................... 101 Additional Documentation to be used ....................101 Safety Information and Regulations.......................
  • Page 4 List of Contents Thermo 230 / 231 / 300 / 301 / 350 Troubleshooting General ..............................501 General Fault Symptoms ........................501 Fault Symptoms during Functional Checkouts and Error Code Output or Tests with Diagnostic Computer, Components Tester or PC Heater Diagnosis ............ 503 5.3.1 General ............................
  • Page 5 Thermo 230 / 231 / 300 / 301 / 350 List of Contents 8 7.5 Igniter Box, Replacement ......................807 8.7.6 Flame Sensor, Replacement ...................... 808 8.7.7 Combustion Chamber, Replacement ..................808 First Operation ............................808 8.8.1 Water Circuit, Bleeding....................... 808 8.8.2 Fuel Supply System, Bleeding....................
  • Page 6 List of Contents Thermo 230 / 231 / 300 / 301 / 350 List of Figures Functional Sequence (heaters with control unit 1572) ..................304 Functional Sequence (heaters with control unit 1572D) ................. 305 General Fault Symptoms ..........................501 Automatic Control Circuit with Control Unit 1572 and Switch ................. 702 Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer) ............

  • Page 7: Thermo

    Thermo 230 / 231 / 300 / 301 / 350 1 Introduction Introduction Additional Documentation to be used This workshop manual contains all information and Scope and Purpose procedures necessary for the repair of heaters Thermo 230, 231, 300, 301 and 350 as well as Thermo Rail.

  • Page 8: Thermo

    1 Introduction Thermo 230 / 231 / 300 / 301 / 350 At filling stations and fuel depots the heater must be (Extract from Directive 2001/56/EC Annex VII) switched off to prevent explosions. 1.7.1. A clearly visible indicator within the user's field of vision must show when the heater is switched on or off.

  • Page 9: Thermo

    Thermo 230 / 231 / 300 / 301 / 350 1 Introduction Corrections and Improvements Deficiencies, improvements, or proposals for correction of this workshop manual are to be mailed to: Spheros GmbH Friedrichshafener Straße 9 - 11 D-82205 Gilching Telefon: +49 (0)8105 7721 887 Telefax: +49 (0)8105 7721 889 www.spheros.de / service@spheros.de...

  • Page 10: Thermo

    1 Introduction Thermo 230 / 231 / 300 / 301 / 350 Page empty for notes...

  • Page 11: Combustion Air Fan

    Thermo 230 / 231 / 300 / 301 / 350 2 General Description The heaters Thermo 230, 231, 300, 301 and 350 basically General Description consist of The water heaters Spheros Thermo 230, 231, 300, 301 – the combustion air fan and 350 are used in combination with the vehicle’s own...

  • Page 12: General Description

    2 General Description Thermo 230 / 231 / 300 / 301 / 350 Combustion Air Fan Nozzle block Solenoid valve pre-heater (optional) The combustion air fan supplies the air required for combustion from the combustion air inlet to the combu- stion chamber.

  • Page 13: Nozzle Block Preheater

    Thermo 230 / 231 / 300 / 301 / 350 2 General Description 2.2.1 Nozzle block preheater At extremely low temperatures malfunctions may occur without a nozzle block preheater. At a temperature of < 0°C a thermostat activates the heater cartridge in the nozzle block. The heating period depends on the heat reflected within the combustion chamber.

  • Page 14: Temperature Sensor

    2 General Description Thermo 230 / 231 / 300 / 301 / 350 2.10 Overheat Thermostat for burner Igniter electrodes (Thermo 231 and 301 only) Igniter box Igniter box (green connector (black connector The overheat thermostat is screwed onto the disk and cover;...

  • Page 15: Aquavent 5000 (U4814) And Aquavent 5000S (U4854) Circulating Pumps

    Thermo 230 / 231 / 300 / 301 / 350 2 General Description 2.11.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps The Aquavent 6000C (U4855) andAquavent 6000SC (U4856) circulating pumps are equipped with a brushless Aquavent 5000 motor.

  • Page 16: Fuel Filter

    2 General Description Thermo 230 / 231 / 300 / 301 / 350 2.12 Fuel Filter At compact devices of the series 230/300/350.126 and .190 Rail an optional heatable fuel filter is provided, as an additional option also for .124 and .155 Rail.
  • Page 17 Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description Functional Description Activation and deactivation is by means of a • switch • timer • air conditioning dependent on the type of installation. For monitoring operation at least an operating indicator light is provided.

  • Page 18: Switch On

    3 Functional Description Thermo 230 / 231 / 300 / 301 / 350 Switching thresholds for Thermo xxx Raill 230.040 230.056 300.124 xxx.126 300.155 350.190 Version Thermo xxx* 350.056 350.155 „VOSSLOH „VOSSLOH “ “ 973 13A 90 162 37x 90 210 12B...

  • Page 19: Switch Off

    Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description burner after control idle period is raised above that for Heaters with control unit 1572D only normal operation and is automatically shifted up or down Gradient evaluation...
  • Page 20 3 Functional Description Thermo 230 / 231 / 300 / 301 / 350 Operating indicator light Heater cartridge Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor Switch on Start Combustion operation Temperature sensor – upper switching threshold Flame sensor –...

  • Page 21: Switch-Off Upon Failure (Heaters With Control Unit 1572D)

    Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description Operating indicator light Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor Switch on Start Flame-up, combustion operation Temperature sensor – upper switching threshold Flame sensor – dark Control idle Temperature sensor –...

  • Page 22: Error Code Output (Heaters With Control Unit 1572D)

    3 Functional Description Thermo 230 / 231 / 300 / 301 / 350 Error Code Output (heaters with Malfunctions during run-down: Detection of a flame after more than 30 seconds after control unit 1572D) start of run-down with the circulation pump and...

  • Page 23: Electrical Components

    Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data Technical Data Where no threshold values are specified technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 20 °C and at nominal voltage.

  • Page 24: Technical Data

    4 Technical Data Thermo 230 / 231 / 300 / 301 / 350 Heater Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350 Type Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350 Mark of conformity up to 4/03...
  • Page 25 Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data Circulation pump U 4814 U 4854 U 4855 U4856 Aquavent 5000 Aquavent 5000S Aquavent 6000C Aquavent 6000SC Volume flow 5000 (against 0,2 5000 (against 0,2 6000 (against 0,4...
  • Page 26 4 Technical Data Thermo 230 / 231 / 300 / 301 / 350...

  • Page 27: General

    Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components. General The following possible causes for trouble have not been taken into consideration and must always be excluded...
  • Page 28 5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 Symptom Probable Cause Heater operation stops because heat exchangers Rate of flow too low, because connected do not dissipate enough heat. • air in heater, in heat exchangers or in system sections.

  • Page 29: Fault Symptoms During Functional Checkouts And Error Code Output Or Tests With Diagnostic Computer, Components Tester Or Pc Heater Diagnosis

    Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting Symptom Probable Cause Wrong combustion value cannot be set to rated value, • air bubbles in suction line (suction line leaking). combustion irregular. • fuel filter contaminated or leaking.

  • Page 30: Fault Symptoms

    5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2 Fault Symptoms to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition.
  • Page 31 Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting 5.3.2.2 Fault Symptom "Flame-out" stops any further attempts to start. This error lockout is superior to the normal error lockout condition. NOTE The error lockout reset is achieved by switching the heater...
  • Page 32 5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down" Has heater been in long time operation Flame sensor defective, replace. shortly before ? Control unit defective, replace.
  • Page 33 Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting 5.3.2.7 Fault Symptom "Solenoid Valve Defective" Is solenoid valve supplied Make electrical connections. with electrical power ? Has safety thermostat responded ? Safety thermostat defective, (Thermo 231/301 only) replace.
  • Page 34 5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350 5.3.2.8 Fault Symptom "Temperature Limiter Defective" Is electrical power supply Make electrical connections. to components o.k.? Control unit defective, replace. Has temperature limiter responded? (Reset according to type of temperature limiter) Determine why temperature limiter has responded, e.g.:...

  • Page 35: Adjustments

    Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts Functional Checkouts General This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities.

  • Page 36: Components Testing

    6 Functional Checkouts Thermo 230 / 231 / 300 / 301 / 350 Components Testing 6.3.3 Igniter Electrodes Check NOTE 6.3.1 Temperature Sensor Resistance The insulator of the igniter electrodes must show no Check damage. Igniter electrodes not working properly must be replaced.

  • Page 37: Igniter Box Check

    Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts 6.3.4 Igniter Box Check 6.3.5 Fuel Pump Check NOTE 6.3.5.1 Fuel Pump Check on Heaters with Control Unit The igniter box may also be tested using the PC heater 1572 diagnosis (component test).

  • Page 38: Fan Motor Check

    6 Functional Checkouts Thermo 230 / 231 / 300 / 301 / 350 6.3.5.2 Fuel Pump Check on Heaters with Control Unit 6.3.7 Solenoid Valve Check 1572D NOTE NOTE A solenoid valve leaking valve seat shows by rather long On heaters with control unit 1572D the fuel pump may smoke emissions during run-down.

  • Page 39: General

    Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams Circuit Diagrams General The circuit diagrams (Fig. 701 and 702) show possible The circuit diagrams (Fig. 705 through 710) show possible heater circuits for Thermo 230, 300 and 350 with control...

  • Page 40: Circuit Diagrams

    7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 rt/ws F1/B3 ϑ B1 Y1 ϑ Wire colors blue brown yellow Diagnostic connector green Wire gauges gray orange < 7.5 m 7.5 - 15 m 1.5 mm 0.75 mm...
  • Page 41 Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams 75(15) 75(15) rt/ws F1/B3 ϑ B1 Y1 ϑ Wire colors blue brown Diagnostic connector yellow green Wire gauges to vehicle terminal +75 if available, otherwise terminal 15...
  • Page 42 7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 Wire colors Diagnostic connector blue brown Pin assignment: Pin assignment 4wire lead 7wire lead yellow 0,75 gr 0,75 rt green Wire gauges 0,75 or 0,75 or gray...
  • Page 43 Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams Diagnostic connector Wire colors Timer P: blue with plus to connection 10 = continuous operating during immediate heating brown terminal 10 not connected = duration of heating programmable (10 min to 120 min);...
  • Page 44 7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 UPFA Signal UP rt/ws B3/B5 ϑ ϑ B1 Y1 Wire colors blue brown yellow Diagnostic connector green Wire gauges gray < 7,5 m 7,5 - 15 m...
  • Page 45 Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams rt/ws F1/B3 ϑ ϑ B1 Y1 Fuse acc. to SAE J 1284 / DIN 72581 Wire colors DW 230 DW 300 DW 350 blue 25A / 16A...
  • Page 46 7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 rt/ws F1/B3 ϑ ϑ B1 Y1 Fuse acc. to SAE J 1284 / DIN 72581 Wire colors DW 230 DW 300 DW 350 blue 25A / 16A...
  • Page 47 Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams rt/ws B3/B5 ϑ ϑ B1 Y1 Wire colors blue brown yellow Diagnostic connector green Wire gauges gray < 7,5 m 7,5 - 15 m orange 1,5 mm...
  • Page 48 7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350 ϑ ϑ ϑ ϑ Wire colors blue brown yellow Diagnostic connector green Wire gauges gray < 7,5 m 7,5 - 15 m orange 1,5 mm 0,75 mm...
  • Page 49 Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams Diagnostic connector Wire colors Timer P: blue with plus to connection 4 = continuous operating during immediate heating brown without plus to connection 4 = heating period 1 hour...
  • Page 50 7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350...

  • Page 51: Heater Test Run

    Thermo 230 / 231 / 300 / 301 / 350 8 Servicing plished twice per heating season. Servicing • in case of leakage the fuel pump and the fuel lines must be replaced immediately, otherwise every 5 General years. •...
  • Page 52 8 Servicing Thermo 230 / 231 / 300 / 301 / 350 3. If no muffler is found in exhaust end pipe check if Inspection and Attachment muffler is upstream in exhaust pipe. If muffler is dislocated in the exhaust pipe, arrest muffler as...

  • Page 53: Burner Head Opening And Closing Or Removal And Installation

    Thermo 230 / 231 / 300 / 301 / 350 8 Servicing 8.5.2 Burner Head Opening and Closing Opening or removal 1. Disconnect electrical connections to temperature or Removal and Installation limiter and temperature sensor. 2. Loosen nuts (3, Fig. 801) enough to release hinge WARNING bolts (2).

  • Page 54: Visual Inspections And Regulations For Installation

    8 Servicing Thermo 230 / 231 / 300 / 301 / 350 Visual Inspections and Regulations 8.6.2 Connection to Vehicle Fuel System for Installation Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel tank.
  • Page 55 Thermo 230 / 231 / 300 / 301 / 350 8 Servicing Water heating circuit – Sidewall radiators and roof duct heating Vorlauf Supply Rücklauf Return 1 Sidewall radiator with fan 2 Heat exchanger, entrance 3 Heater unit 4 Circulation pump...

  • Page 56: Combustion Air Supply

    8 Servicing Thermo 230 / 231 / 300 / 301 / 350 When installing a shut-off device in the return line a clearly It must be located so that no clogging by contamination, visible information label must be provided. impact of snow, or intake of splash water is to be expected.

  • Page 57: Removal And Installation

    Thermo 230 / 231 / 300 / 301 / 350 8 Servicing Rigid pipes made of unalloyed or alloyed steel with a 5. Secure combustion air inlet line on heater as minimum wall thickness of 1.0 mm have to be used as applicable.

  • Page 58: Flame Sensor, Replacement

    8 Servicing Thermo 230 / 231 / 300 / 301 / 350 8.7.6 Flame Sensor, Replacement 8.8.1 Water Circuit, Bleeding NOTE NOTE The replacement procedure for the flame sensor is identi- Bleeding must always be performed in accordance with cal with the heater installed or removed.

  • Page 59: General

    Repair General This section describes the repairs that may be performed on the heaters Thermo 230, 231, 300, 301 and 350 when removed. Any further disassembly will void the warranty. For re-assembly only components of the proper spare part kits are to be used.

  • Page 60: Work On Components After Disassembly

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.1.1 Work on Components after Disassembly 9.1.2 Incorporation of Modifications CAUTION NOTE All gaskets located between disassembled components Continuous enhancement of heater design is for optimi- must always be replaced and discarded.
  • Page 61 Thermo 230 / 231 / 300 / 301 / 350 9 Repair 9.1.2.1 Installation of Control Unit 1572D as Procedure Substitute for Control Unit 1572 CAUTION General Control unit 1572D may only be used in combination with the igniter box delivered (green connector cover).

  • Page 62: Disassembly And Assembly

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 Disassembly and Assembly 9.2.2.2 Installation 1. Manually screw temperature sensor (2, Fig. 901) into 9.2.1 Temperature Limiter, Replacement coolant outlet (4). 2. Torque temperature sensor to 20 Nm +5 Nm.
  • Page 63 Thermo 230 / 231 / 300 / 301 / 350 9 Repair 1 Temperature limiter Rubber cap 2 Temperature sensor Temperature 3 Connector limiter 4 Coolant outlet 5 Cotter pin 6 Nut (2) Retaining clip 7 Hinge bolt (2) 8 Burner...

  • Page 64: Combustion Air Fan, Replacement

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.4 Combustion Air Fan, Replacement 9.2.4.2 Installation NOTE NOTE Fan motor (7, Fig. 902) to be aligned with control unit For replacement of the combustion air fan the burner may (recess in mounting flange) and with clutch (by rotating be left installed.
  • Page 65 Thermo 230 / 231 / 300 / 301 / 350 9 Repair 1 Splash protection cover 2 Cap 3 Screw (2) 4 Fan wheel 5 Slide lock 6 Screw (3) 7 Fan motor 8 Clutch 9 Electrical connector Fig. 902 Combustion Air Fan, Replacement...

  • Page 66: Control Unit, Replacement

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.5 Control Unit, Replacement 9.2.6.2 Installation 1. Install solenoid valve (7, Fig. 903) on fuel pump (10) NOTE if required. For replacement of the control unit the burner head 2.
  • Page 67 Thermo 230 / 231 / 300 / 301 / 350 9 Repair Igniter box Overheat thermo- (green connector cover; stat (Thermo 231 / mechanically coded) 301 only) in combination with control unit 1572D and Control unit also control unit 1572D...

  • Page 68: Igniter Box, Replacement

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.8 Igniter Box, Replacement 9.2.9 Flame Sensor, Replacement 9.2.8.1 Removal 9.2.9.1 Removal 1. Remove burner if required (refer to 9.2.3.1). 1. Remove burner if required (refer to 9.2.3.1).
  • Page 69 Thermo 230 / 231 / 300 / 301 / 350 9 Repair Igniter box Overheat thermo- (green connector cover; stat (Thermo 231 / mechanically coded) 301 only) in combination with control unit 1572D and Control unit also control unit 1572D...

  • Page 70: Heat Exchanger, Replacement

    9 Repair Thermo 230 / 231 / 300 / 301 / 350 9.2.10 Heat Exchanger, Replacement 9.2.11 Combustion Chamber, Replacement 9.2.10.1 Removal 9.2.11.1 Removal 1. Remove temperature limiter (refer to 9.2.1.1). 1. Disconnect electrical connections to temperature 2. Remove temperature sensor (refer to 9.2.2.1).

  • Page 71: General

    Thermo 230 / 231 / 300 / 301 / 350 10 Packaging / Storage / Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Spheros for testing or repair must be cleaned and packaged so that they are protected against damage during handling, ship- ping and storage.
  • Page 72 10 Packaging / Storage / Shipping Thermo 230 / 231 / 300 / 301 / 350 Page empty for notes 1002...
  • Page 73 Thermo 230 / 231 / 300 / 301 / 350 Annex A Annex A Scheduled Maintenance...

  • Page 74: Heater, Scheduled Maintenance

    Annex A Thermo 230 / 231 / 300 / 301 / 350 The maintenance intervals indicated below apply to appli- Heater, Scheduled Maintenance * cations and requirements typical of busses. Should the heaters be used in other vehicles or applications, these in- The heater should be checked in regular intervals at least tervals may have to be adapted, i.e.
  • Page 75 Spheros-Service Sie haben ein technisches Problem? Spheros bietet Ihnen in Zusammenarbeit mit Webasto ein weltweites Servicenetz! Spheros service telephone. Do you have a technical problem? Spheros offers in co-operation with Webasto a world-wide service net. Spheros Spheros Webasto-Europa Webasto-Europa Webasto-Europa Kroatien Türkei...
  • Page 76 Printed in Germany · 12.12 Druck: Steffendruck Friedland Änderungen vorbehalten Subject to modification Sous réserve de modifications © Spheros GmbH Spheros GmbH Friedrichshafener Straße 9-11 · D-82205 Gilching Tel. +49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 77 The bus operator shall observe this note categorically. The placard in 9 languages and in the new Spheros-Design is provided with each by the factory delivered SPHEROS-Heater since 21.07.08 as depicted.
  • Page 78 386650Z, may only be used for the below stated heaters: Heater Thermo 230/231/300/301/350, with magnetic coil ident. no. 29313_ Heater DBW 230 (2020)/300/350 for 12 V, version with magnetic coil ident. no. 322083 Heater DBW 230 (2020)/300/350/470 for 24 V, version with magnetic coil ident.
  • Page 79 By means of these technical changes the pump is completely protected against splash water. Affected are the Spheros circulation pumps U4818, U4854, U4856, as well as the spare part kits magnetic clutch and the spare part kits motor. The identification numbers of the items remain unchanged.
  • Page 80 Technical Information 05-2008 Shroud design changes Shroud old Shroud new prepared on 22.10.2008 Spheros Europa GmbH, Abteilung After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 81 Technical Information 05-2008 New gasket and membrane New gasket New membrane prepared on 22.10.2008 Spheros Europa GmbH, Abteilung After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 82 Then reinstall the coil body and fix it with the nut and torque as prescribed (ref. figure). prepared on 16.12.2008 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 83 M5x16 (hexagon socket screw with conical spring washer) only. 2710213A 2710315A prepared on 26.01.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 84 Technical Information 02-2009 Nozzle Block Preheater for Thermo Heaters - Installation Notes for Heating Element Retrofit - Spheros spare parts kit to be used: 86711B – Retrofit bag heating element Bag content: - Heating element with thermostat - Shield assy...
  • Page 85 Install serrated lock washer and hand-tighten the nut. For retaining clamp installation, refer to step 3. prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 86 Secure the heating element with the retaining clamp Substep 3: Remove dummy connector; plug in the new connector prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 87 Install ignition electrodes electrodes can be plugged in. prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 88 Please consider during all other activities done at the heater in regard to this retrofit the instructions given in the workshop manual. prepared on 02.02.2009 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 89 Usage of new, optimized, downward compatible Spheros atomizing nozzles for Thermo Heaters Usage of hollow cone nozzles Selected for Spheros quality – optimized spray character / spray angle Below of emission limitation permitted per law Labeled with Spheros logo, heating power and identification number Warranty and product liability only if genuine parts are used Torque to 20 ±...
  • Page 90 2 torx screws M4x12; 1 torx screw M4x20; 1 O-ring 2,9 x 1,78; 1 O-ring 33,08 x 1,78; assembly instruction Spheros Europa GmbH · After Sales Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 · www.spheros.de · service@spheros.de · 09.11.2009...
  • Page 91 Technical Information 01-2010 New Spheros ident. no. for „Small parts for magnetic coil“ As of now, the spare parts kit „Small parts for magnetic coil“ can be ordered only, using the new Spheros ident. no. 11113599B (previously 386650Z). The bag content remains unchanged, solely the package was adapted.
  • Page 92 98640B incl. shipment ) only heater 11114003A pump: 11114893A 11115017A Thermo 350.190 prepared on 18.11.2010 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching,Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...
  • Page 93 That includes also an investigation of the cause of the heater fault lock-out. In order to process complaints faster and more efficient, please consider that the control devices our heaters save the error codes. These codes then can be read out by the Spheros Thermo Test Diagnosis and saved as text file.
  • Page 94 Combustion Chamber Replacement in Thermo Series Ongoing optimization of parts quality and the avoidance of unnecessary version variety are firmly established in the product development process at Spheros. Against this background, we point out that with a need for renewal or...
  • Page 95 Technical Information 06-2011 Service Identification of GENUINE Spheros atomizing nozzles for heaters Spheros label since Spheros ident. Heating power of the 2008 number heater (e.g. 35kW) Nomenclature of production date recurring since 2008 1st letter => production month 2nd letter => production year...
  • Page 96 Technical Information 06-2011 Service Overview on Spheros atomizing nozzles for heaters Spheros Series Designation Power Ident. number label 16kW 2710233B 23kW 2710234B Thermo S 30kW 2710235B 35kW 2710236B 40kW 2710237B 20kW 2711057A Thermo E 32kW 2711056A 23kW 470716Z Thermo 30kW...
  • Page 97 Spheros recommends the usage of a separate bleeding unit. Follow the appropriate instructions provided by the vehicle manufacturer. Verify the fuel supplied to the heater is bubble-free.
  • Page 98 (20654A) with the new one (11117847A) together with the pump. For 1-string pump demand, please contact us. erstellt am 15.4.2013 Spheros Europa GmbH, After Sales Friedrichshafener Straße 9-11, 82205 Gilching · Tel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 www.spheros.de · service@spheros.de...

This manual is also suitable for:

Thermo 300Thermo 350Thermo 301Thermo 231

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