Spheros Thermo S 350 Installation Instructions Manual

Water Heaters Installation Instructions

Thermo S 160

Thermo S 230

Thermo S 300

Thermo S 350

Thermo S 400

Stand: 02/2012

Ident Nr. XXXXXX

Thermo S 160/230/300/350/400

Improper installation or repair of Spheros heating and cooling systems can cause fire or the leakage of deadly

carbon monoxide leading to serious injury or death.

To install and repair Spheros heating and cooling systerns you need to have completed a Spheros training course

and have the appropriate technical documentation, special tools and special equipment.

NEVER try to install or repair Spheros heating or cooling systems if you have not completed a Spheros training

course, you do not have the necessary technical skills and you do not have the technical documentation, tools and

equiprnent available to ensure that you can complete the installation and repair work properly.

ALWAYS carefully follow Spheros installation and repair instructions and heed all WARNINGS.

Spheros rejects any liability for problems and damage caused by the system being installed by untrained personnel.

Thermo S 160/230/300/350/400

Table of Contents

1 Statutory regulations governing installation 3

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Thermo S 160/230/300/350/400 Statutory regulations governing installation

1 Statutory regulations governing installation

1.1. Statutory regulations governing installation

For the heaters exist type approvals according to the ECE Regulations

R10 (EMC): No. 03 5266 and

R122 (Heater) No. 00 0208 for Thermo S 160

No. 00 0226 for Thermo S 230

No. 00 0227 for Thermo S 300

No. 00 0228 for Thermo S 350

No. 00 0225 for Thermo S 400

Installation is governed above by the provisions in Annex 7 of the

ECE Regulation R122.

NOTE:

The provisions of these Regulations are binding within the territory

governed by ECE Regulations and should similarly be observed in

countries without specific regulations.

(Extract from ECE Regulation R122, Annex 7)

4. The heater must have a manufacturer’s label showing the manufac-

turer’s name, the model number and type together with its rated output

in kilowatts. The fuel type must also be stated and, where relevant, the

operating voltage and gas pressure.

7.1. A clearly visible tell-tale in the operator’s eld of view shall inform

when the combustion heater is switched on or o.

(Extract from ECE Regulation R122, Part I)

5.3 Vehicle Installation Requirements for Combustion Heaters

5.3.1 Scope

5.3.1.1 Subject to paragraph 5.3.1.2., combustion heaters shall be in-

stalled according to the requirements of paragraph 5.3.

5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to

comply with the requirements of paragraph 5.3.

5.3.2 Positioning of combustion heater

5.3.2.1 Body sections and any other components in the vicinity of the

heater must be protected from excessive heat and the possibility of fuel

or oil contamination.

5.3.2.2 The combustion heater shall not constitute a risk of re, even in

the case of overheating. This requirement shall be deemed to be met if

the installation ensures an adequate distance to all parts and suitable

ventilation, by the use of re resi stant materials or by the use of heat

shields.

5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must

not be positioned in the passenger compartment. However, an installa-

tion in an eectively sealed envelope which also complies with the con-

ditions in paragraph 5.3.2.2. may be used.

5.3.2.4 The label referred to in Annex 7, paragraph 1.4., or a duplicate,

must be positioned so that it can be easily read when the heater is in-

stalled in the vehicle.

5.3.2.5 Every reasonable precaution should be taken in positioning the

heater to minimize the risk of injury and damage to personal property.

5.3.3 Fuel supply

5.3.3.1 The fuel ller must not be situated in the passenger compart-

ment and must be provided with an eective cap to prevent fuel spillage.

5.3.3.2 In the case of liquid fuel heaters, where a supply separate from

that of the vehicle is provided, the type of fuel and its ller point must be

clearly labelled.

5.3.3.3 A notice, indicating that the heater must be shut down before re-

fuelling, must be axed to the fuelling point. In addition a suitable in-

struction must be included in the manufacturer’s operating manual.

Statutory regulations governing installation Thermo S 160/230/300/350/400

5.3.4 Exhaust system

5.3.4.1 The exhaust outlet must be located so as to prevent emissions

from entering the vehicle through ventil ators, heated air inlets or opening

windows.

5.3.5 Combustion air inlet

5.3.5.1 The air for the combustion chamber of the heater must not be

drawn from the passenger compartment of the vehicle.

5.3.5.2 The air inlet must be so positioned or guarded that blocking by

rubbish or luggage is unlikely.

5.3.6 Heating air inlet

not applicable

5.3.7 Heating air outlet

not applicable

5.3.8 Automatic control of the heating system

5.3.8.1 The heating system must be switched o automatically and the

supply of fuel must be stopped within ve seconds when the vehicle’s

engine stops running. If a manual device is already activated, the hea-

ting system can stay in operation.

IMPORTANT:

Failure to follow the installation instructions and the notes contai-

ned therein will lead to all liability being refused by Spheros. The

same applies if repairs are carried out incorrectly or with the use of

parts other than genuine spare parts. This will result in the invali-

dation of the type approval for the heater and therefore of its ECE

Type Approval.

CAUTION:

At petrol stations and other fuel filling facilities the heater must be

switched off due to the explosion hazard. To advice to this require-

ment the self-adhesive label with the text ’’Switch off heater before

refueling!“, delivered with each heater, is to be affixed next to the

filler neck.

1.2. Provisions relating to the installation in rail vehicles

For heater models Thermo S 230 / 300 / 350 / 400 Rail a design certi-

cation acc. to § 33 EBO (= Federal Railway Authority) has been issued

with the following approval number: EBA 32AZ3/0006/10.

Particular attention must be given to incidental provision 1.6 of the

design certication:

Should the manufacturer, operator or service technician gain knowledge

of any accidents and damage (caused by re, explosion, escape of

Diesel fuel or heating oil EL) that may have occurred despite proper use

of the heater, he is required to immediately notify the certifying body

thereof.

Thermo S 160/230/300/ noisrev / esU004/053

2 Use / version

2.1. Use of the water heaters

The water heaters are used in connection with the vehicle’s own heating

system

– to heat the passenger cabin,

– to defrost the vehicle windows and

– to preheat water-cooled engines.

NOTE:

If the heater is used mostly in altitudes > 1500m above NN, the CO2

value is to be readjusted by means of the diagnostic tool.

The water heater operates independently of the engine and is connec-

ted to the cooling system, the fuel system and the electrical system of

the vehicle.

IMPORTANT:

The heater is approved for heating the passenger cabin or the

driver’s cab, but not for use in vehicles subjected to the Directive

94/55/EC (ADR, TRS).

NOTE:

The heaters are only licenced for horizontal installation.

(see Figure 2)

2.2. Versions

Thermo S 160 – 24V

Water heater for “diesel“

with 16 kW (55,000Btu/h) heat current

Thermo S 230 – 24V

Water heater for “diesel“

with 23 kW (80,000Btu/h) heat current

Thermo S 300 – 24V

Water heater for “diesel“

with 30 kW (104,000Btu/h) heat current

Thermo S 350 – 24V

Water heater for “diesel“

with 35 kW (120,000Btu/h) heat current

Thermo S 400 – 24V

Water heater for “diesel“

with 40 kW (137,000Btu/h) heat current

Depending on request and on the requirements of conguration, the

heater may be equipped with a nozzle preheating system.

mrehTnoitallatsnI o S 160/230/300/350/400

3 Installation

IMPORTANT:

– The statutory regulations governing installation on pages 3

and 4 must be adhered to.

– If the water heater is to be operated in a separately installed hea-

ting system, prior to installation an installation planning report

must always be submitted to Spheros for approval.

If this approval is not obtained, all warranty and liability claims

will be void. The water heater has been designed, tested and

approved for specific bus requirements.

– To the temperature sensor cable no mechanical load must be

applied (e.g. carry the heater with it).

– Heater and circulating pump shall be always installed in such a

way that a negative impact by road dirt, splashing water, ex-

haust gases or other harmful influences is excluded.

NOTE:

Consider the installation situation of the relevant vehicle type.

3.1. Installation location

The heater and circulating pump are to be integrated into the cooling

system (or in a separate heating system).

The heater must be installed in as low a position as possible to allow the

heater and circulating pump to be bled automatically. This is particularly

important as the circulati ng pump is not self-priming.

If it is not possible to install the heater and the circulating pump in the

vehicle’s engine bay it may be installed in a box. The installation box

must have sucient external ventilation to ensure that a maximum

temperature of 60 °C is not exceeded in the box.

Bear in mind the space required for servicing accessibility (for example

for removing the combustion chamber) (see Figure 1) when installing

the heater.

3.1.1. Installation Location in Rail Vehicles

In rail vehicles the heater is to be installed either in the engine room (e.g.

locomotive) or in a special mounting box. Other installation locations

require Spheros's approval in writing.

NOTE:

No metallic antivibration mounts must be used for securing the heater in

rail vehicles.

noitallatsnI004/053/003/032/061 S omrehT

Fig. 1: Dimensions of the Thermo S 160/230/300/350/400 heater

386

ca. 440

8243 50

600

303

247

022.ac

190

011

232

70 43

1 Combustion air intake

2 Exhaust outlet

3 Fuel intake

4 Fuel discharge

5 Coolant intake

6 Coolant outlet

7 Temperature sensor

8 Space required to remove the burner chamber

mrehTnoitallatsnI o S 160/230/300/350/400

3.2. Installation of a Thermo S heater

The heater may be secured either with four M8 screws or with four bolts

and nuts (see Figure 3) .

Fig. 2: Installation position

Fig. 3: Hole pattern

0° - 5°

320 150

136

0° - 15° 0° - 15°

0° - 5°

Welded nut

M8 Din 929 D = ø 4,5 if M4 screws are

used

D = ø 2,9 if sheet metal

screws B 3.9 are used

Attachment variant 1

Attachment variant 2

4x screw M8

4x nut M8

320

150

180

011

ø75

ø88

noitallatsnI004/053/003/032/061 S omrehT

3.3. Model plate

The model plate must be protected from damage and must be clearly le-

gible when the heater is installed (otherwise a duplicate model plate

must be used).

NOTE:

The year of the initial operation must be durably marked by remo-

ving the year numbers that are not applicable.

3.4. Additional Plate

Heaters approved for use in rail vehicles are additionally identied by the

type plate illustrated below:

Fig. 4: Model plate

2008 2009 2010

Thermo S 300

30kW / 102000 BTU/h

24V / 90W

2710210A

0208

5266

Fig. 5: Additional plate

Made in Germany

Eisenbahn-Bundesamt

BauartzulassungsNr.

EBA 32AZ3/0006/10

Installation example Thermo S 160/230/300/350/400

4 Installation example

Fig. 6: Installation example for the heater

1 Wall heater with blower

2 Heat exchanger at entry point

3 Heater

4 Circulating pump

5 Roof heat exchanger

6 Vehicle engine

7 Driver’s position heating system

8 Control element

Supply

Return

Water heating circuit – wall heater and roof duct heating system

latsnI004/053/003/032/061 S omrehT lation of the circulating pump

5 Installation of the circulating pump

The circulating pump must be installed as shown in Figure 7, 10, 13 or

16. Note the installation position!

NOTE:

The pump ports and connection lines from the water intake and wa-

ter outlet must be flush (no stress).

IMPORTANT:

The heater should be installed preferably with Spheros circulating

pumps.

If the pump is not controlled by the heater, its operation is to be en-

sured by all means during whole heater operation (initial cycle,

heating operation and purge cycle).

Installation of the circulat 004/053/003/032/061 S omrehTpmup gni

5.1. U 4814 (Aquavent 5000) circulating pump

Fig. 7: U 4814 circulating pump

installation position

Sw+Br-

Fig. 8: Hole pattern for the stand for U 4814 circulating pump

Fig. 9: Delivery rate and flow resistance

U 4814 circulating pump

∆

Delivery rate

(with water at 20°C)

Flow resistance

(with the pump stopped)

latsnI004/053/003/032/061 S omrehT lation of the circulating pump

5.2. U 4854 (Aquavent 5000S) circulating pump

NOTE:

When connecting the circulating pump it must be ensured that the

volume flow does not drop below 2500 l/h for longer than a brief

period only! Continuous operation at less than 2500 l/h will result

in undue wear of the wearing disc of the impeller!

Fig. 10: U 4854 circulating pump

installation position

5°min.

0-90°

249

011

522

99,5

131,5

Sw+Br-

0-85°

Fig. 11: Hole pattern for the stand for U 4854 circulating pump

Fig. 12: Delivery rate and flow resistance

U 4854 circulating pump

1,1

1,0

0,9

0,8

0,7

0,6

0,5

0,4

0,3

0,2

0,1

10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)

bar

24 V

Delivery rate

(with water at 68°F/20°C)

Flow resistance

(with the pump stopped)

Installation of the circulat 004/053/003/032/061 S omrehTpmup gni

5.3. U 4855 (Aquavent 6000C) circulating pump

Fig. 13: U 4855 circulating pump

installation position

30,8

52,8

115

0-90°

0-85°

min. 5°

224±2

Fig. 14: Hole pattern for the stand for U 4855 circulating pump

Fig. 15: Delivery rate and flow resistance

U 4855 circulating pump

1,1

1,0

0,9

0,8

0,7

0,6

0,5

0,4

0,3

0,2

0,1

10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)

bar

24 V

Delivery rate

(with water at 68°F/20°C)

Flow resistance

(with the pump stopped)

latsnI004/053/003/032/061 S omrehT lation of the circulating pump

5.4. U 4856 (Aquavent 6000SC) circulating pump

NOTE:

When connecting the circulating pump it must be ensured that the

volume flow does not drop below 2500 l/h for longer than a brief pe-

riod only! Continuous operation at less than 2500 l/h will result in

undue wear of the wearing disc of the impeller!

Fig. 16: U 4856 circulating pump

installation position

53 126

229

±2

115

0-90° 0-85°

min. 5°

Fig. 17: Hole pattern for the stand for U 4856 circulating pump

Fig. 18: Delivery rate and flow resistance

U 4856 circulating pump

1,1

1,0

0,9

0,8

0,7

0,6

0,5

0,4

0,3

0,2

0,1

10000 2000 3000 4000 5000 6000 7000 8000 9000 (l/h)

bar

24 V

Delivery rate

(with water at 68°F/20°C)

Flow resistance

(with the pump stopped)

Installation of the circulat 004/053/003/032/061 S omrehTpmup gni

5.5. Motor for circulating pump model U 4855 (Aquavent 6000C)

and U 4856 (Aquavent 6000SC)

These circulating pumps are equipped with a brushless motor.

5.5.1. Soft Start

The motor starts up slowly and in a way that is gentle to the material.

It takes approx. 5 sec. until maximum speed is reached.

5.5.2. Run-dry protection (only U 4855 and U 4856)

In the event of a dry running motor the slide ring gasket may be dama-

ged. A dry running motor has a very high speed while the current con-

sumption is slow.

The dry running protection is activated if the current consumption (eec-

tive) is 0,5 A > I < 4 A, the motor isn’t just in the start phase,

n > 3300 1/min and the waiting period is exceeded.

Waiting period: M3G074CF44-17: 8 - 10 s

M3G074CF44-16: 40 - 45 min

Waiting periods depend on power supply level. The device will be swit-

ched into the sleep mode 10 s after the waiting period is passed.

5.5.3. Blocking protection

If the speed drops below 57 1/min, the motor is switched o after approx.

1 second by the error mode. If the motor does not complete a whole rev-

olution within 1 second despite the medium ow, it will also be shut down

by the error mode.

5.5.4. Error mode

The error mode switches o the motor in the event of faults. The motor

is switched to power-saving sleep mode by the error mode after approx.

5 seconds.

5.5.5. Sleep-Mode

In the sleep mode the internal consumers of the motor electronics are

switched o. The current consumption in this mode is then < 2 mA.

5.5.6. Motor reactivation

The motor can be reactivated from sleep mode. This is done by discon-

necting it from the power supply approx. 2 minutes. When the voltage

supply is reconnected the motor will restart in soft start mode.

5.5.7. Polarity reversal protection

The motor does not feature an internal polarity reversal protection. The

motor is protected against polarity reversal through the wiring harness

and a 25 A fuse.

Thermo S 160/230/300/350/400 Connection to the vehicle cooling system

6 Connection to the vehicle cooling system

The heater is to be connected to the vehicle cooling system in

accordance with Figures 1 and 6. The system must contain at least 10

litres of coolant. A minimum of 20 % of a good quality antifreeze should

be maintened in the heating circuit of the heater at all times.

Basically the water hoses supplied by Spheros should be used. If this is

not the case, the hoses must comply with DIN 73411 requirements as a

minimum. The hoses are to be routed without any kinks and - for proper

venting of the heater - in an upward pi tch, if possible. Hose connections

must be secured against slipping o by means of hose clamps.

NOTE:

The specified tightening torques of the hose clamps used must be

adhered.

In the vehicle cooling system, or in a separate heating circuit, only pres-

sure control valves with an opening pressure of min. 0.4 bar and max.

2.0 bar may be used.

Before the heater is started up for the rst time, or after the coolant has

been replaced, it must be ensured that the cooling system is properly

bled. Heater and piping should be installed in such a way that static

bleeding of the system is ensured.

Proper bleeding action can be recognised by the nearly silent operation

of the circulating pump. Insucient bleeding can result in tripping of the

resettable temperature limiter when the heater is operating.

In the case of circulating pump U 4855 / Aquavent 6000C the circulating

pump will be automatically deactivated approx. 15 seconds after its ac-

tivation if coolant is lacking or a blockage of the pump impeller has oc-

curred, and can then be restarted after approx. 2 minutes.

If the circulating pump U 4856 / Aquavent 6000SC is used, it will be

automatically deactivated approx. 45 seconds after its activation if cool-

ant is lacking or a blockage of the pump impeller has occurred, and can

then be restarted after approx. 2 minutes.

004/053/003/032/061 S omrehTylppuS leuF

7 Fuel Supply

Fuel is extracted from the vehicle's fuel tank or from a separate fuel tank.

Thereby also during vehicle operation a continuous fuel supply must be

ensured.

7.1. Fuel Lines

To prevent air inclusions from forming in the fuel, the fuel lines should be

routed in an upward pitch, if possible. Connections within the fuel lines

must be secured by means of hose clamps unless mechanical screwed

connections are used.

When using fuel hoses, basically the hoses supplied or oered by

Spheros are to be used. If this is not the case, the fuel hoses must, as a

minimum, comply with the requirem ents of DIN 73379. Fuel hoses must

neither be kinked nor twisted and must be secured by clamps spaced

approx. 25 cm apart.

Materials commonly used in the constr uction of vehicles may be also

used for fuel hoses taking into account a suitable connection system in

each case. The selection should be done considering the ambient tem-

perature range.

IMPORTANT:

If the heater is operated without coolant, the outer shell of the heat-

er may reach a temperature equalling the ignition temperature of

diesel fuel!

– The lines must be protected from stone damage

– Any dripping or evaporating fuel must neither collect nor be ig-

nited by hot components or electrical equipment. Therefore if

necessary a drip pan with defined drain holes is to be installed

in the area below the interface burner housing/fuel line connec-

tors/heat exchanger.

Note:

The fuel pump is delivered in series for a two-pipe system (with return

line).

The fuel pump can be ordered option ally for an appropriate heating

system or burner head also in a single-pipe version. In a single-pipe

system (without return line) accord ing to the delivered application the

return line port at the housing is closed with a screw plug and a gasket

ring.

Bleeding is particularly in a single-pipe system mandatory:

a) With a separate bleeding device according to the prescribed for

this device procedure!

b) While the fan motor is running (initial cycle/pur ge cycle), loosen

the screw plug, ident. no. 149314Z, and hold open until the fuel co-

mes out nearly free of air bubbles (collect fuel with a container).

Then close screw plug, torque to 16 +/-1 Nm.

Refer also to the workshop Manual for further notes on fuel system

bleeding!

IMPORTANT:

The operation with a closed return line will cause damage to the

fuel pump, fuel can leak out - fire hazard!

Unsupported fuel lines must be secured to prevent them from sag-

ging.

The installation of an additional fuel pump is not permitted.

For legal provisions refer to pages 33 and 34.

Thermo S 160/230/300/ ylppuS leuF004/053

7.1.1. Permissible dimensions of the fuel lines

– Inside diameter for suction and return lines: 6 mm (other diameters

on request).

– Max. permissible length of each suction and return line: 15 m

– Max. permissible suction height: 2 m

– Max. permissible admission pressure: 0.3 bar.

– For a differing fuel supply system ensure that the negative pres-

sure in the suction line directly before the heater 500 mbar not

exceeds.

7.2. Fuel Filter

A fuel lter supplied or approved by Spheros must be used (consider the

ow direction). To avoid malfunctions the lter or lter insert is to be re-

placed annually before the cold weather season starts.

Spheros Thermo S 350 Installation Instructions Manual

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