Valeo THERMO DC 200, Installation And Operating Instructions Manual

Page 1: ...Rev 05 2020 Id No 11118910E Installation and operating instructions THERMO DC 200 Bus HEATING SYSTEMS...

Page 2: ...ossible minor injuries if instructions or procedures are carried out incorrectly or entirely disregarded ATTENTION This caption points to actions which may cause material damage NOTE This caption is u...

Page 3: ...Faults troubleshooting repairs 12 8 Control elements 13 8 1 Switch or relay 13 8 2 Pre selection timer 14 8 3 Operation indicator 15 9 Circulation pump 16 10 Switching thresholds 16 11 Installation of...

Page 4: ...IV Thermo DC 200...

Page 5: ...tion Heaters and Electrical Heaters into Vehicles 5 3 1 Scope 5 3 1 1 Subject to paragraph 5 3 1 2 heaters shall be installed according to the requirements of paragraph 5 3 5 3 2 Positioning of combus...

Page 6: ...iability being refused by Valeo The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts This results to the invalida tion of the type approval o...

Page 7: ...lectrical cables and operating elements of the heater must be ar ranged in the vehicle in such a way that their functioning is fault less under normal operating conditions and cannot be hampered Work...

Page 8: ...bjected to the Directive 94 55 EC ADR TRS General Information Safety Check the information given on the rating plate of your heater in the technical data and compare this with your mains voltage In ad...

Page 9: ...tion example for the heater 1 Wall heater with blower 2 Heat exchanger at entry 3 Heater 4 Circulating pump 5 Roof heat exchanger 6 Vehicle engine 7 Driver s seat heating system 8 Control panel Water...

Page 10: ...hicle systems for war ming up water They must not be operated in the depot unattended for a longer period The pump operation the water cycle and the water tem perature of the vehicle should be monitor...

Page 11: ...iginal parts from Valeo since these are part of the electrical equipment and they ensure proper grounding 5 2 690 VDC supply line The hook up must be made with at least a cable corresponding to the he...

Page 12: ...nal connections not shown HV Hook up LV Hook up Connection HU Cable Color Connector HDSCS 1 1418479 1 6 mm red Contact 1241380 1 6 mm black Seal 963530 1 Connection HU Cable Pin 0 75 mm 1 Activation s...

Page 13: ...t permitted and will result in loss of the operating approval The heater must be protected on the vehicle side with all poles by an insulation monitoring device tripping resistance 0 5 M against fault...

Page 14: ...onnection with the ground must be established by this device and must be able to be maintained until the external voltage is interrupted 5 5 Testing the installation After the installation is complete...

Page 15: ...for more information It is available at www valeo ther malbus com eu_en Service Downloads Heating systems Ther mo AC DC Maintenance must be carried out in accordance with the current maintenance plan...

Page 16: ...onnected from the mains Troubleshooting and repair must be done in accordance with the current Workshop Manual at available at www valeo thermalbus com eu_en Service Downloads Heating systems Thermo A...

Page 17: ...f control switch para 8 1 relay para 8 1 or via pre selection timer para 8 2 8 1 Switch or relay When switching the heater with a switch or relay these must be de signed for a voltage range of 18 30V...

Page 18: ...following circuit diagram Figure 8 Wiring diagram with pre selection timer without DC DC converter 5A 1 10 11 12 4 5A 5A 2 8 0 75mm 0 75mm 0 75mm BN 5 2 RD T 58 T 15 T 30 T 31 max Valeo Thermo DC 24V...

Page 19: ...ation indicator provided at the vehicle which displays the status of the switching signal heating system Auxiliary contact With pin 7 and 8 see hook up plan Fig 4 of the control wiring harness the swi...

Page 20: ...through the heat exchanger of the Thermo DC must be more than 1 500 litres hour The system must be completely bled The triggering activation of the circulation pump is not carried out by the heating...

Page 21: ...peratures Water carrying parts are to be routed and fastened in such a manner that no temperature risk to humans animals or material sensitive to temperature due to radiation contact occurs Before wor...

Page 22: ...important assemblies Thermo DC 200 Figure 9 Dimensions of the heating appliance Thermo DC 1 2 3 4 125 1 Coolant Inlet 2 Coolant Outlet 3 Space required for removal of the electric components and the...

Page 23: ...ng of important assemblies Figure 10 Installation position and hole pattern Thermo DC 10 8 Welded nut M8 DIN 929 1 Attachment variant 1 4x screw M8 15Nm 5Nm 2 Attachment variant 2 4x screw M8 through...

Page 24: ...ioning of the heating appliance or after the coolant fluid has been replaced For that the additional venting option via the vent screw item 4 figure 9 is to be used after the system has been filled an...

Page 25: ...ction 9 NOTE The pump ports and connection lines from the water intake and water outlet must be flush no stress ATTENTION If the pump is not controlled by the heater its operation is to be en sured by...

Page 26: ...ng of important assemblies Thermo DC 200 11 4 Tightening torques Figure 11 Tightening torques Grounding screw Cable gland Cable gland control power supply cable M12x1 5 M10x1 Bleed screw 20 1 Nm 1 5 0...

Page 27: ...pstream resistances and the minimum flow rate Heater Thermo DC200 Ident no 11117083_ 11122596_ 11139411_ Kind of Design full electrical heater Ambient temperature during operation C 40 85 Storage temp...

Page 28: ...690V DC A 29 6 Rated current at 750V DC A 32 3 Rated current at 900V DC A 38 6 Type of electrical protection 1000V DC xxA 10kA fast blow 1000V DC xxA 10kA fast blow Circuit breaker rating A 35 50 Ope...

Page 29: ...reaker Insulation resistance end of life at 1000V M 50 Control signal nominal voltage VDC 24 Operating voltage range LV VDC 16 32 Max control current LV A 0 42 1 58 LV circuit breaker current rating A...

Page 30: ...liance may only be replaced with genuine original parts from Valeo since these are part of the electrical equipment and they ensure proper grounding 486V DC supply line The hook up must be made with a...

Page 31: ...ernal connections not shown HV Hook up LV Hook up Connection HU Cable Color Connector HDSCS 1 1418479 1 6 mm red Contact 1241380 1 6 mm black Seal 963530 1 Connection HU Cable Pin 0 75 mm 1 Activation...

Page 32: ...requency Hz Nominal current A 41 7 Rated current at 400V DC A 34 4 Rated current at 486V DC A 41 7 Rated current at 540V DC A 46 4 Rated current at 600V DC A 51 5 Type of electrical protection 1000V D...

Page 33: ...stallation instructions for Thermo DC 11139411_ The hook up is to be done according to the hook up diagram see Fig 15 Control signal nominal voltage VDC 24 Operating voltage range LV VDC 16 32 Max con...

Page 34: ...nnections not shown HV Hook up LV Hook up Pin Connection HU Cable Color Connector HDSCS 1 1418479 1 A AWG 8 red Contact 1241380 1 D AWG 8 black Seal 963530 1 B HVIL AWG 16 black Connection HU Cable Pi...

Page 35: ...5 6 23 3 Rated current at 690V DC A 9 8 19 5 29 6 Rated current at 750V DC A 10 7 21 5 32 2 Rated current at 900V DC A 12 9 25 7 38 6 Type of electrical protection 1000V DC xxA 10kA fast blow Circuit...

Page 36: ...U Cable Pin 0 75 mm 1 Activation 690V 1 DC 2 Overheat protection feedback 3 Thermostat feedback 4 HVIL Input 5 HVIL Output 6 Feedback contactor input 7 8 Feedback contactor 1 9 Activation signal 690V...

Page 37: ...DC A 23 3 Rated current at 690V DC A 29 6 Rated current at 750V DC A 32 2 Rated current at 900V DC A 38 6 Type of electrical protection 1000V DC xxA 10kA fast blow Circuit breaker rating A 50 Operatin...

Page 38: ...Contact 1241380 1 8mm 6mm RD Seal 963530 1 10mm BU BK BN Connection HU Cable Pin 0 75 mm 1 Activation signal 600V DC 2 Overheat protection feedback 3 Thermostat feedback 4 GND 5 HVIL In 6 HVIL Out 7...

Page 39: ...memos...

Page 40: ...al Commercial Vehicles Germany GmbH Friedrichshafener Str 7 Tel 49 8105 7721 0 Fax 49 8105 7721 889 82205 Gilching Germany www valeo thermalbus com service valeobus valeo com Valeo Thermal Commercial...