Webasto Thermo 350 Manuel de service

Water Heaters Workshop ManualThermo 230Thermo 300Thermo 350with control unit 1572model .30 and upThermo 230Thermo 300Thermo 350with control unit 1572D

1 Introduction Thermo 230 / 231 / 300 / 301 / 350104Page empty for notes

Thermo 230 / 231 / 300 / 301 / 350 2 General Description2012 General DescriptionThe water heaters Spheros Thermo 230, 231, 300, 301 and 350 are use

2 General Description Thermo 230 / 231 / 300 / 301 / 3502022.1 Combustion Air FanThe combustion air fan supplies the air required for combustion fro

Thermo 230 / 231 / 300 / 301 / 350 2 General Description2032.2.1 Nozzle block preheaterAt extremely low temperatures malfunctions may occur without

Igniter box (black connector cover) only in combination with control unit 1572Igniter electrodes2 General Description Thermo 230 / 231 / 300 / 301

(U4814)(U4854)(U4855)(U4856)Aquavent 5000Aquavent 5000SAquavent 6000CAquavent 6000SCThermo 230 / 231 / 300 / 301 / 350 2 General Description2052.11

2 General Description Thermo 230 / 231 / 300 / 301 / 3502062.12 Fuel FilterAt compact devices of the series 230/300/350.126 and .190 Rail an option

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description3013. Functional DescriptionActivation and deactivation is by means of a • switch•timer•

3 Functional Description Thermo 230 / 231 / 300 / 301 / 350302Switching thresholds for Thermo xxx Raill230.040 230.056 300.124 xxx.126 300.155 350.1

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description303Heaters with control unit 1572D onlyGradient evaluationIn case of low coolant flow or

Fig. 301:Functional sequence (heaters with control unit 1572)ABCDEFG16 12 14 16141213 15 13 1512682961035371s 12s12s 30s 90s1s12smax.max.111s12s30s 90

Fig. 302:Functional sequence (heaters with control unit 1572D)ACDEFG12 14141213 15 13 1512682961035371s 12s12s1s12smax.1s12s30s1smax.16max.120smax.max

3 Functional Description Thermo 230 / 231 / 300 / 301 / 350306Malfunctions during run-down:Detection of a flame after more than 30 seconds after st

Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data4014. Technical DataWhere no threshold values are specified technical data are understood to includ

4 Technical Data Thermo 230 / 231 / 300 / 301 / 350402 Heater Thermo 230 Thermo 231 Thermo 300 Thermo 301 Thermo 350TypeThermo 230 Thermo 231 Thermo 3

Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data403 Optional Fuel Filter Heater Circulation pump U 4814Aquavent 5000U 4854Aquavent 5000SU 4855Aqu

4 Technical Data Thermo 230 / 231 / 300 / 301 / 350404

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting5015 Troubleshooting5.1 GeneralThis section describes troubleshooting procedures for the heaters T

5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 350502Heater operation stops because heat exchangers connected do not dissipate enough heat.Rate of f

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting5035.3 Fault Symptoms during Functional Checkouts and Error Code Output or Tests with Diagnostic C

Thermo 230 / 231 / 300 / 301 / 350 List of ContentsIList of Contents1. Introduction1.1 Scope and Purpose ...

5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 3505045.3.2 Fault Symptoms5.3.2.1 Fault Symptom "No Start"NOTEHeaters with control unit 157

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting5055.3.2.2 Fault Symptom "Flame-out"NOTEHeaters with control unit 1572D:If the heater pe

5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 3505065.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down"5.3.2.5 Faul

Thermo 230 / 231 / 300 / 301 / 350 5 Troubleshooting5075.3.2.7 Fault Symptom "Solenoid Valve Defective"Is solenoid valve suppliedwith electr

5 Troubleshooting Thermo 230 / 231 / 300 / 301 / 3505085.3.2.8 Fault Symptom "Temperature Limiter Defective"Is electrical power supplyto com

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts6016 Functional Checkouts6.1 GeneralThis section describes the tests and adjustments on the h

6 Functional Checkouts Thermo 230 / 231 / 300 / 301 / 3506026.3 Components Testing6.3.1 Temperature Sensor Resistance CheckWhen checking the temperatu

Thermo 230 / 231 / 300 / 301 / 350 6 Functional Checkouts6036.3.4 Igniter Box CheckNOTEThe igniter box may also be tested using the PC heater diagnosi

6 Functional Checkouts Thermo 230 / 231 / 300 / 301 / 3506046.3.5.2 Fuel Pump Check on Heaters with Control Unit 1572D NOTEOn heaters with control uni

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams7017 Circuit Diagrams7.1 GeneralThe circuit diagrams (Fig. 701 and 702) show possible heater circ

List of Contents Thermo 230 / 231 / 300 / 301 / 350II5. Troubleshooting5.1 General ...

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350702Fig. 701 Automatic Control Circuit with Control Unit 1572 and Switch3351156226124443322114F1B

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams703Fig. 702 Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer)X4733511562

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350704Fig. 703 Automatic Control Circuit with Control Unit 1572D and Switch413 33333 1 Diagnosti

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams705Fig. 704 Automatic Control Circuit with Control Unit 1572D and Standard Timer13 3333342 1

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350706Fig. 705 System Circuit Daimler Chrysler Citaro, Ident.-Nr. 6713135264rt/wsbrrtM1B4A1E1U2U1SE

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams707Fig. 706 System Circuit Van Hool, Ident.-Nr. 8940133115226443826154B2Y1brgrorgnϑrt/wsblorbrbr

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350708Fig. 707 System Circuit O405 / O407 / O408, Ident.-Nr. 912923351156226124443322114F1B2Y1brgro

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams709Fig. 708 System Circuit MAN, Ident.-Nr. 894043626124rt/wsblbrswrtCM1M2H1B4A1E1U2U1SE-+MM35115

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350710Fig. 709 System Circuit SETRA, Ident.-Nr. 90972ϑϑϑϑ11 1 Diagnostic connectorItem Nomenclat

Thermo 230 / 231 / 300 / 301 / 350 7 Circuit Diagrams711 1 Diagnostic connector 2 Timer P:with plus to connection 4 = continuous operating

Thermo 230 / 231 / 300 / 301 / 350 List of ContentsIII8 7.5 Igniter Box, Replacement ...

7 Circuit Diagrams Thermo 230 / 231 / 300 / 301 / 350712

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing8018. Servicing8.1 GeneralThis section describes the servicing procedures allowed on the heater when ins

8 Servicing Thermo 230 / 231 / 300 / 301 / 350802Inspection and AttachmentNOTEThe exhaust muffler must always be secured with a sheet metal screw. Dri

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing8038.5.2 Burner Head Opening and Closing or Removal and InstallationWARNINGThe igniter box operates with

8 Servicing Thermo 230 / 231 / 300 / 301 / 3508048.6 Visual Inspections and Regulations for Installation8.6.1 Connection to Vehicle Cooling SystemThe

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing805Fig. 802 Example of a Heater Installation in a Passenger BusVorlaufRücklauf489311112756Water heating

8 Servicing Thermo 230 / 231 / 300 / 301 / 350806When installing a shut-off device in the return line a clearly visible information label must be prov

Thermo 230 / 231 / 300 / 301 / 350 8 Servicing807Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be use

8 Servicing Thermo 230 / 231 / 300 / 301 / 3508088.7.6 Flame Sensor, ReplacementNOTEThe replacement procedure for the flame sensor is identi-cal with

Thermo 230 / 231 / 300 / 301 / 350 9 Repair9019Repair9.1 GeneralThis section describes the repairs that may be performed on the heaters Thermo 230, 23

List of Contents Thermo 230 / 231 / 300 / 301 / 350IVList of Figures301 Functional Sequence (heaters with control unit 1572) ...

9 Repair Thermo 230 / 231 / 300 / 301 / 3509029.1.1 Work on Components after DisassemblyCAUTIONAll gaskets located between disassembled components m

Thermo 230 / 231 / 300 / 301 / 350 9 Repair9039.1.2.1 Installation of Control Unit 1572D as Substitute for Control Unit 1572GeneralDue to the progress

9 Repair Thermo 230 / 231 / 300 / 301 / 3509049.2 Disassembly and Assembly9.2.1 Temperature Limiter, Replacement9.2.1.1 Removal1. Disconnect electrica

Thermo 230 / 231 / 300 / 301 / 350 9 Repair905Fig. 901 Temperature Limiter, Temperature Sensor and Burner, ReplacementRubber capTemperatureRetaining

9 Repair Thermo 230 / 231 / 300 / 301 / 3509069.2.4 Combustion Air Fan, ReplacementNOTEFor replacement of the combustion air fan the burner may be lef

Thermo 230 / 231 / 300 / 301 / 350 9 Repair907Fig. 902 Combustion Air Fan, Replacement1234567891 Splash protection cover2 Cap3 Screw (2)4 Fan whe

9 Repair Thermo 230 / 231 / 300 / 301 / 3509089.2.5 Control Unit, ReplacementNOTEFor replacement of the control unit the burner head may be left insta

Thermo 230 / 231 / 300 / 301 / 350 9 Repair909Fig. 903 Control Unit and Fuel Pump, Replacement12398741011121314151617181920212322242556Control unit23

9 Repair Thermo 230 / 231 / 300 / 301 / 3509109.2.8 Igniter Box, Replacement9.2.8.1 Removal1. Remove burner if required (refer to 9.2.3.1).2. Using sc

Thermo 230 / 231 / 300 / 301 / 350 9 Repair911Fig. 904 Igniter Box and Flame Sensor, Replacement (Sheet 2 of 2)12398741011121314151617181920212322242

Thermo 230 / 231 / 300 / 301 / 350 1 Introduction1011. Introduction1.1 Scope and PurposeThis repair shop manual is intended to support familiarized

9 Repair Thermo 230 / 231 / 300 / 301 / 3509129.2.10 Heat Exchanger, Replacement9.2.10.1 Removal1. Remove temperature limiter (refer to 9.2.1.1).2. Re

Thermo 230 / 231 / 300 / 301 / 350 10 Packaging / Storage / Shipping100110 Packaging, Storage andShipping10.1 GeneralThe heater or its components ship

10 Packaging / Storage / Shipping Thermo 230 / 231 / 300 / 301 / 3501002Page empty for notes

Thermo 230 / 231 / 300 / 301 / 350 Annex AA-1Annex AScheduled Maintenance

Annex A Thermo 230 / 231 / 300 / 301 / 350A-2Heater, Scheduled Maintenance *The heater should be checked in regular intervals at least at the beginnin

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1 Introduction Thermo 230 / 231 / 300 / 301 / 350102At filling stations and fuel depots the heater must be switched off to prevent explosions.CAUTIO

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Thermo 230 / 231 / 300 / 301 / 350 1 Introduction1031.7 Corrections and ImprovementsDeficiencies, improvements, or proposals for correction of

Spheros Europa GmbH · After SalesTel.+49 (0) 8105 7721 887 · Fax +49 (0) 8105 7721 889 · www.spheros.de · [email protected] · 09.11.2009New spare pa

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