Valeo Thermo AC 070, Workshop Manual

Page 1: ...Rev 03 2019 Id No 11123153C Thermo AC 070 Thermo AC 200 Thermo DC 200 Workshop Manual HEATING SYSTEMS...

Page 2: ...ctional sequence of the heater 402 4 2 1 Switching on 402 4 2 2 Heating operation 402 4 2 3 Switching off 402 4 3 Malfunctions caused by overheating tripping of the temperature limiter 402 5 Troublesh...

Page 3: ...emoval installation incl cable connections 803 8 5 Small distribution board removal installation 803 8 6 Heating cartrides screw plugs removal installation 806 8 7 HV wiring harness AC DC removal inst...

Page 4: ...important feature 1 4 Symbols 1 5 Further documentation to be used The use of additional service literature is required References are provided in the workshop manual at appropriate locations Use the...

Page 5: ...sure it cannot be switched on again verify system is voltage free all poles ground and short circuit the de energized circuit cover or block neighbouring parts under voltage Electrical cables and oper...

Page 6: ...Minimum capacity of the water system l 25 Antifreeze ratio in the cooling system 30 60 Device dimensions tolerance 3 mm mm length 578 wide 247 height 225 Weight kg 12 5 15 Heater electrical system The...

Page 7: ...mm Min cable cross section at vehicle side mm 5x4 4 6 10 Total resistance of all HV heating cartridges L N 23 3 L L 46 6 L N 7 8 L L 15 5 23 3 23 3 11 65 Insulation resistance new device at 1000V M 10...

Page 8: ...PE N AC 400 230V 50Hz Further more the heaters also can be used in electric driven buses or hybrid buses where a 600 690 VDC DC heaters or a 3 PE N AC 400 230V 50Hz AC heaters power supply is provided...

Page 9: ...f the main components HV Control head Small distribution board Heat exchanger 3 6 or 9 heating cartridges Temperature sensors 3 1 HV Control head The HV control head consists of an aluminum die cast r...

Page 10: ...t has receiving openings with threads for the heating cartridges 6 3 4 Heating cartridges At the end of the rod shaped water proof heating cart ridges 6 Fig 304 there is an external thread with a hexa...

Page 11: ...ture limiter 5 Fig 304 protects the heater from unacceptably high temperatures The temperature limiter switches off the heater at a temperature greater than 125 C The temperature limiter is mechanical...

Page 12: ...peration On the heater side a control thermostat and a temperature limiter are integrated which are attched to the heater In operation they enable the heating cart ridges to be switched on automatical...

Page 13: ...eating cartridge now con verts the electrical energy into heat 4 2 2 Heating operation The control thermostat opens its contact at 75 C and closes it again at 68 C In this way the heating operation is...

Page 14: ...e 5 2 General error symptoms he following table lists possible general error symptoms Danger to life and health Warning Table 501 General error symptoms Error symptom Possible cause Heater can not be...

Page 15: ...ive Heating power too high HV supply power too high Overheating temperature limiter has triggered Control thermostat defective Heater stops as the connected heat exchangers provide insufficient heat F...

Page 16: ...se s see 3 2 Eliminate the fault cause Replace fuse s NO YES Is the HV over current protection ok Eliminate the fault cause Reset ground fault interrupter or the ISO guard Is the ground fault interrup...

Page 17: ...over current protection ok Establish the correct contact at all connections at the small distribution board Are all connections at the small distribution board correct contac ted Replace control therm...

Page 18: ...rota tion Replace if necessary NO YES Replace temperature limiter Check the temperature limiter see 5 8 6 2 Does the temperature limiter function properly Does an adequate cooling and coolant flow ex...

Page 19: ...resistance must be measured at a test voltage of 1000V DC Wires undamaged and free Replace damaged or pinched cables Contact the vehicle manufacturer NO YES Vehicle side insulation value sufficient R...

Page 20: ...ation etc and if required replace small distribution board Inspect wires for corrosion contact and crimp errors etc and replace if required 5 8 4 Load contactor check or visual inspection Inspect load...

Page 21: ...be located above the release button Check During the test with a digital multimeter CAT III the temperature limiter is to be tested for continuity The temperature limiter is connected to pins 1 and 2...

Page 22: ...s Electrical work at the heater may only be performed by persons which have the required qualification see 1 6 1 NOTE Consider also the information on the electrical installation given in the Installa...

Page 23: ...602 Thermo AC DC 6 Wiring diagrams Fig 601 Housing removal for devices Thermo AC 7 kW without converter heater ident no acc to model plate 11117427A...

Page 24: ...603 Thermo AC DC 6 Wiring diagrams Fig 602 Housing removal for devices Thermo AC 20 kW with AC DC converter heater ident no acc to model plate 11116255A...

Page 25: ...04 Thermo AC DC 6 Wiring diagrams Fig 603 Housing removal for devices Thermo AC 20 kW without DC DC converter with HVIL contact at the hood heater ident no acc to model plate 11125621A Contactor Sch t...

Page 26: ...605 Thermo AC DC 6 Wiring diagrams Fig 604 Housing removal for devices Thermo DC 20 kW without converter heater ident no acc to model plate 11122596B...

Page 27: ...606 Thermo AC DC 6 Wiring diagrams Fig 605 Housing removal for devices Thermo DC 20 kW with DC DC converter heater ident no acc to model plate 11117083B Contactor Sch tz...

Page 28: ...607 Thermo AC DC 6 Wiring diagrams Fig 606 Housing removal for devices Thermo DC 20 kW without DC DC converter with HVIL contact at the hood heater ident no acc to model plate 11125620A...

Page 29: ...608 Thermo AC DC 6 Wiring diagrams Fig 607 Housing removal for devices Thermo DC 20 kW without DC DC converter heater ident no acc to model plate 11126153A...

Page 30: ...on board removal for devices Thermo AC 20 kW with AC DC converter heater ident no acc to model plate 11116255A AC Connecting HLP Anschluss HLP HLP orange cable oranges Kabel blue cable blaues Kabel 1...

Page 31: ...DC converter heater ident no acc to model plate 11117083B DC Connecting HLP Anschluss HLP HLP orange cable oranges Kabel blue cable blaues Kabel 1 DC15 DC9 2 DC14 DC4 3 DC13 DC3 4 DC12 DC11 5 DC10 DC...

Page 32: ...20 kW without converter heater ident no acc to model plate 11126153A AC Connecting HLP Anschluss HLP HLP orange cable oranges Kabel blue cable blaues Kabel 1 AC4 N5 2 AC5 N6 3 AC3 N3 4 AC9 N11 5 AC8 N...

Page 33: ...r servicing In order to achieve a lasting functional reliability of the heater the heater should be periodically maintained 7 2 1 Periodical heater maintenance Scope and intervals of the heater period...

Page 34: ...ted threads must be discarded and replaced It is permitted to remove components from the heater while the heater is installed in the vehicle assuming that sufficient space is available and no componen...

Page 35: ...ption neck 5 and push in the retaining clip 3 ATTENTION The retaining spring must be located in the groove of the reception neck and must be latched in position both perceptibly and audibly twice at t...

Page 36: ...15 and remove it with washer 14 and vehicle grounding cable lug 7 Remove nuts 6 and washers 7 NOTE During the next step pay attention that the cables are not jammed or are still connected Danger of da...

Page 37: ...1 Nm 10 1 Nm 16 1 Nm 1 Hood 2 Hood screw 2 3 Stabilizer 4 Cable gland power supply 5 Cable gland control cables 6 Nut 2 7 Washer 2 8 Screw 2 9 Washer 2 10 Separation disk 11 Stay bolts 2 12 Gasket rin...

Page 38: ...a 6 7 8 9 10 A Blatt 1 C Blatt 1 D Blatt 1 11 12 13 2ea B Blatt 1 14 20 2 Nm 20 2 Nm 30 1 Nm 30 1 Nm 8 1 Nm 1 Heating cartridges 3 2 Gasket ring 9 3 Screw plug 6 4 Screw 2 5 Washer 2 6 Gasket ring 7 V...

Page 39: ...established refer to wiring dia grams in Chapter 6 Fig 608 thru Fig 613 depending on the heater version Compare the heater ident number under the wiring dia gram with that on the model plate of your h...

Page 40: ...ten it 2 Install housing see 8 4 3 Check the wiring again using the appropriate wiring diagram in Chapter 6 4 Bundle single wires using cable ties 5 Install hood see 8 3 6 Connect all supply cables to...

Page 41: ...f the heat exchanger 13 Fig 803 Sheet 2 tighten bolts 3 Unscrew grounding screw 15 Fig 803 Sheet 1 Reinstall grounding screw with grounding cable and washer and tighten it 4 Feed the cables through th...

Page 42: ...eat exchanger and the water hoses fully with coolant 2 Lightly loosen the vent screw 3 Turn the circulating pump on 4 As soon as no air escapes close the vent screw and tighten for torque value see Fi...

Page 43: ...retrofits 9 Modifications and retrofits 9 1 General For further optimization the heaters are continuously improved Units in the field can usually be upgraded or retrofitted For this purpose respective...

Page 44: ...d packaged to ensure that handling transport and storage will not damage them ATTENTION If a complete heater is sent back it must be comple tely drained While packaging and or shipping it must be ensu...

Page 45: ...tch off the power supply to the heater ensure it cannot be switched on again verify system is voltage free all poles ground and short circuit the de energized circuit cover or block neighbouring parts...

Page 46: ...rheat pro tection 3 Temperature sensors a Check temperature switch water outlet for function b Check temperature limiter for function c Replace temperature switch annually annually every 5 years 4 Bur...

Page 47: ...memos...

Page 48: ...ial Vehicles Germany GmbH Friedrichshafener Str 7 Tel 49 0 8105 7721 0 Fax 49 0 8105 7721 889 82205 Gilching Germany www valeo thermalbus com service valeobus valeo com Valeo Thermal Commercial Vehicl...