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Valeo THERMO DC 200 Installation And Operation Instructions Manual

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HEATING SYSTEMS
THERMO DC 200
Bus
Installation and
operating instructions
Rev. 01/2017
Id.No. 11118910A

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Summary of Contents for Valeo THERMO DC 200

  • Page 1 HEATING SYSTEMS THERMO DC 200 Installation and operating instructions Rev. 01/2017 Id.No. 11118910A...
  • Page 2 Thermo DC 200 Highlighted words like Warning!, Caution!, ATTENTION: and NOTE: in these Installation and operating instructions signify the following precautions: This caption is used to indicate possible severe injuries Warning! or fatal accidents if instructions or procedures are car- ried out incorrectly or entirely disregarded.

  • Page 3: Table Of Contents

    Thermo DC 200 Table of Contents Statutory regulations governing installation 11.1 Installation 11.2 Connection to the vehicle's cooling system 1.1 Statutory regulations governing installation 11.3 Installation of the circulation pump 1.2 Model plate 11.4 Tightening torques Safety regulations Technical data Use / Version 3.1 Installation example...
  • Page 4 Thermo DC 200...

  • Page 5: Statutory Regulations Governing Installation

    Thermo DC 200 Statutory regulations governing installation Statutory regulations governing installation 1.1. Statutory regulations governing installation 5.3.2 Positioning of combustion heater 5.3.2.1 Body sections and any other components in the vicinity of the For the heater exists a type approval according to the ECE Regulations...

  • Page 6: Statutory Regulations Governing Installation

    Statutory regulations governing installation Thermo DC 200 1.2. Model plate Warning! Danger to life and health! The model plate must be protected from damage and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used).

  • Page 7: Safety Regulations

    Thermo DC 200 Safety regulations Safety regulations NOTE: Warning! The provisions of these Regulations are binding within the territory High voltage! Danger to life! governed by DGUV Regulations and should similarly be observed in countries without specific regulations. Installation, maintenance and repairs may only be carried out when the vehicle's engine is not running and the high voltage supply is switched off.

  • Page 8: Use / Version

    Use / Version Thermo DC 200 Use / Version The fully electrical water heater Thermo DC operates independently of General Information / Safety the vehicle engine and is connected to the vehicle’s cooling and Check the information given on your heaters rating plate and compare electrical systems.

  • Page 9: Installation Example

    Thermo DC 200 Use / Version 3.1. Installation example Water heating circuit – wall heater and roof duct heating system Wall heater with blower Heat exchanger at entry Heater Circulating pump Roof heat exchanger Vehicle engine Driver’s seat heating system...

  • Page 10: Operating And Maintenance Instructions

    Operating and maintenance instructions Thermo DC 200 Operating and maintenance instructions The Thermo DC heating appliance may not be operated at temperatures of more than +85°C. Amount of antifreeze in the water circuit - see technical data. ATTENTION: The heaters may be only used in closed vehicle systems for war- ming up water.

  • Page 11: Installation

    Thermo DC 200 Installation Installation 5.1. Grounding, additional protective equipotential 5.2. 690 VDC supply line bonding The connection line must have a cross section of at least 2 x 4mm² Cu. The cable cross-section must be chosen according to the power and A grounding cable, at least 1x4 mm²...
  • Page 12 Installation Thermo DC 200 Note the prescribed means of protection! - overcurrent protective device 690 VDC see Section “Installation“, Figure 8 68 ... 75 °C M12x1,5 4mm², GR, 180mm, Radox 3 GKW 12545290 0,75mm², RT, 200mm, FLRY 125 °C 4mm², GR, 180mm,...
  • Page 13 Thermo DC 200 Installation Note the prescribed means of protection! - overcurrent protective device 690 VDC see Section “Installation“, Figure 8 ϑ 125°C M12x1,5 ϑ 68 .. 75°C 6mm², GR, 220mm,Radox 3 GKW 12548127 Load Cable colors Contactor black blue...
  • Page 14 Installation Thermo DC 200 Hook-up data: Contactor connections Stripping length 11 - 13 mm Kind of wire single wire or wire strand or wire strand with cable end sleeves Cable cross section 4 - 6 mm Cable gland for control line Torque 3 - 4.5 Nm...

  • Page 15: Overcurrent Protection / Insulation Monitoring Device

    Thermo DC 200 Installation 5.3. Overcurrent protection / insulation monitoring device ATTENTION: The power supply circuit is to be protected through an all pole Cable to the terminal overcurrent protection device that allows a max. current of 35A. already exists...

  • Page 16: External Power Supply Hook-Up

    Installation Thermo DC 200 5.4. External power supply hook-up ATTENTION: DC 690 V 0Hz It should be noted that with vehicles, which are to be connected to L1 L2 the earthed external power supply unit via the conductive connec- tion, a device must be present by which the galvanic connection of the electrical earth with the ground can be made.

  • Page 17: Maintenance

    Thermo DC 200 Maintenance Maintenance Warning! High voltage! Danger to life! – Maintenance work on the electrical equipment may only be car- ried out by a qualified electrician. – The appliance must be disconnected from the power supply pri- or to any maintenance work and in particular prior to repair work (see 2 Safety regulations).

  • Page 18: Faults, Troubleshooting, Repairs

    Faults, troubleshooting, repairs Thermo DC 200 Faults, troubleshooting, repairs ATTENTION: If a safety switch has been triggered, this should only be reset after a qualified electrician has determined the cause of the fault and eliminated the error. Warning! High voltage! Danger to life! The opening of the appliance, troubleshooting and repairs must only be carried out by a qualified electrician.

  • Page 19: Control Elements

    Thermo DC 200 Control elements Control elements 8.1. Switch or relay The control line should be kept as short as possible so that the voltage drop is not too great. Max. length: 10 meters and at least 2.5mm². If When switching the heater with a switch or relay, these must be de-...

  • Page 20: Pre-Selection Timer

    Control elements Thermo DC 200 Switch Switch 24V DC 1.5A External control at least 30V DC 1.5A External control input input Spheros Spheros Operation indicator Thermo DC Thermo DC 24V DC max. 250mA max. 10m 690V DC max. 10m 690V DC at least 2.5mm...
  • Page 21 Thermo DC 200 Control elements T. 58 T. 15 T. 30 T. 31 External control input 24V DC 1.5 A Spheros max. Thermo DC 0.4A Spheros Pre-selection Timer max. 10m at least 2.5mm 690V DC Consider prescribed protection! - Overcurrent protection device See para.: „Installation“, Fig.
  • Page 22 Control elements Thermo DC 200 T. 58 T. 15 T. 30 T. 31 External control 24V DC 1.5A input Spheros max. Thermo DC 0.4A Spheros Pre-selection Operation indicator Timer 24V DC max. 250mA max. 10m at least 2.5mm 690V DC...
  • Page 23 Thermo DC 200 Control elements T. 58 T. 15 T. 30 T. 31 External control input at least 30V DC 1,5 A Spheros max. Thermo DC 0.4A Operation indicator Spheros 24V DC max. 250mA Pre-selection Timer max. 10m at least 2.5mm...
  • Page 24 Control elements Thermo DC 200 ATTENTION: by means of the buttons. If the buttons are not pressed Never connect the timer directly to the heating appliance. This will within 5 seconds, the time displayed will be stored. If the damage the timer. You can use the following relay: ID: 98559A (Fa.

  • Page 25: Activation Via Mains Power

    Thermo DC 200 Control elements Recalling/erasing preset times Vehicles with ADR equipment Repeatedly press the button until the desired memory location is On ADR vehicles it is not possible to program a preset starting time. The displayed. remaining time is shown on the display while the heater is in operation.

  • Page 26: Circulation Pump

    Circulation pump Thermo DC 200 Circulation pump ATTENTION: For a correct switching on of the heating appliance an adequate circulation of the cooling medium must be ensured before swit- ching on. The heating appliance is preferably to be equipped with Spheros circu- lation pumps, refer to technical documents “Aquavent Circulation...

  • Page 27: Installation Of The Heater - Fitting Of Important Assemblies

    Thermo DC 200 Installation of the heater - fitting of important assemblies 11 Installation of the heater - fitting of important assemblies 11.1. Installation – Before working on the cooling water circuit, switch off the hea- ter and wait until all parts are cooled down, if necessary wear ATTENTION: protective gloves.
  • Page 28 Installation of the heater - fitting of important assemblies Thermo DC 200 Coolant - Inlet Coolant - Outlet Space required for removal of the electric components and the cartridge heaters HLP20x300 Vent screw Figure 17: Dimensions of the heating appliance Thermo DC...
  • Page 29 Thermo DC 200 Installation of the heater - fitting of important assemblies Welded nut M8 - DIN 929 10.8 Attachment variant 1 4x screw M8 (15Nm +5Nm) Attachment variant 2 4x screw M8 (through going) + 4x hexagonal nut M8 (15Nm +5Nm)+ 4x Washer 8.4...

  • Page 30: Connection To The Vehicle's Cooling System

    Installation of the heater - fitting of important assemblies Thermo DC 200 11.2. Connection to the vehicle's cooling system emerges, but only water. Then retighten the screw (tightening torque - see figure 19). The heating appliance is connected to the vehicle's cooling system ATTENTION: according to figure 17.

  • Page 31: Installation Of The Circulation Pump

    Thermo DC 200 Installation of the heater - fitting of important assemblies 11.3. Installation of the circulation pump Consider the information regarding the installation provided in the documentation of your circulation pump. Note the installation position! NOTE: The pump ports and connection lines from the water intake and water outlet must be flush (no stress).

  • Page 32: Tightening Torques

    Installation of the heater - fitting of important assemblies Thermo DC 200 11.4. Tightening torques Bleed screw 20 ±1 Nm Grounding screw Cable gland (M10x1): power supply cable Cable gland control (M25x1.5): cable (M12x1.5): 16 +1 Nm 1.5 -0.3 Nm...
  • Page 33 Thermo DC 200 Technical data 12 Technical data Unless limit values are given, the technical data below is understood to Heating appliance Thermo DC 200 be subject to the usual tolerances for heating appliances of +/-10% at an Design Fully electrical heater ambient temperature of +20°C and at nominal voltage.
  • Page 34 Technical data Thermo DC 200 For notes:...
  • Page 35 memos...
  • Page 36 HEATING SYSTEMS Valeo Thermal Commercial Vehicles Germany GmbH Postfach 1371 - 82198 Gilching - Germany - Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889 www.valeo-thermalbus.com - service-valeobus@valeo.com...

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