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Valeo Thermo AC 070 Workshop Manual

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

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Summary of Contents for Valeo Thermo AC 070

  • Page 1 HEATING SYSTEMS Thermo AC 070 Thermo AC 200 Thermo DC 200 Workshop Manual Rev. 03/2019 Id.No. 11123153C...
  • Page 2 Thermo AC/DC Table of contents Introduction Content and purpose Effectivity of the workshop manual Meaning of highlighted content Symbols Further documentation to be used Safety information and regulations 1.6.1 Required qualifications 1.6.2 Emergency stop / de-energizing 1.6.3 Work at the heater 1.6.4 Other safety information Suggestions for improvement and change...

  • Page 3: Table Of Contents

    Thermo AC/DC Table of contents Servicing General Heater servicing 7.2.1 Periodical heater maintenance Components and heater removal and installation General Temperature guards (temperature limiter, control thermostat removal/installation. Hood removal/installation Housing removal/installation (incl. cable connections) Small distribution board removal/installation Heating cartrides/screw plugs removal/installation HV wiring harness (AC/DC) removal/installation LV DC control wiring harness removal/installation Heater removal/installation...
  • Page 4 Spare parts list Thermo AC/DC The respectively currently effectife version is binding. This • Technical Information (TI) version can be found on the Valeo Bus homepage under Service/Downloads/Heating Systems. This service literature is also available at www.valeo-ther- malbus.com/Service/Downloads/Heating Systems or .../Service/Spare Parts &...
  • Page 5 Please direct any complaints, improvement or modifica- Work at electrical equipment may only be started if tion suggestions regarding this manual to: protective measures against electric shock, short circuits and arcing faults have been carried out. service-valeobus@valeo.com...
  • Page 6 Thermo AC/DC 2 Technical data Technical data Except where limit values are specified, these technical data refer to the usual heater tolerances of ±10% at an ambient temperature of +20°C and at the rated voltage. Table 201 Technical data Heater Thermo AC070 Thermo AC200 Thermo DC200 Thermo DC200 Thermo DC200 Kind of design electrical operated heater...
  • Page 7 AMP HDSC 8 pin 1-1564416-1 Mating connector FEP 42121100 or 1-1564512-1 Mating connector Valeo ID No. 11114939_ 11125731_ NOTE: The circuit breaker rating is based on the maximum operating voltage of 900V DC. The rating must be adapted to the highest operating current and the temperature derating of the circuit breaker.
  • Page 8 Thermo AC/DC 3 Assemblies and components Description of assemblies and components The fully electrical water heaters Thermo AC/DC operate where a 600 (690) VDC (DC heaters) or a 3/PE/N AC 400/ independently of the vehicle engine and are connected to 230V 50Hz (AC heaters) power supply is provided in the vehicle’s cooling and electrical systems.
  • Page 9 Thermo AC/DC 3 Assemblies and components HV Control head The heater is bolted down to the vehicle chassis or is secured using an additional cross beam. The heat is generated by the heating of heating cartridges The HV control head consists of an aluminum die-cast by means of electrical energy.
  • Page 10 Thermo AC/DC 3 Assemblies and components 3 ea Double feed-through terminal blocks 1 ea Feed-through terminal block 1 ea Fuse holder Flyback diode Load contactor Feed-through terminal blocks Standard Rail DC-DC Converter Fig. 303 Example of a small distribution board of DC heaters Heat exchanger Heating cartridges In the heat exchanger (1,...
  • Page 11 Thermo AC/DC 3 Assemblies and components 1 Heat exchanger 2 Water, inlet 3 Water, outlet 4 Control thermostat 5 Temperature limiter 6 Heating cartridges Fig. 304 Heat exchanger with installed on/in it components (exploded) The signal is transmitted to the load contactor, where it is processed.
  • Page 12 To monitor the operation an operation indicator or the The heater must be protected and monitored on the Valeo preselection timer is to be provided. vehicle side by a ground fault interrupter (AC) respective an insulation monitoring device.
  • Page 13 Thermo AC/DC 4 Functions of the heater Functional sequence of the heater Malfunctions caused by overheating / tripping of the temperature limiter 4.2.1 Switching on In order to switch on the heater, 24V DC respectively the If the heater is overheated, the temperature limiter is switch on signal must be connected according to the valid tripped and the heater goes into a fault lock-out.
  • Page 14 Thermo AC/DC 5 Troubleshooting Troubleshooting and error correction Allgemeines • Crimp failures on plugs and/or pins Warning! • Corrosion on cable and fuses Danger to life and health! • Cable insulation damage The safety information and regulations of Chapter ATTENTION: (see ) must be observed.
  • Page 15 Thermo AC/DC 5 Troubleshooting Table 501: General error symptoms Error symptom Possible cause Heater can not be switched off. • Supply voltage (24V) not switched off • HV small distribution board defective • Diodes in LV wiring harness defective (if applicable, heater may be hooked-up incorrectly).
  • Page 16 Thermo AC/DC 5 Troubleshooting Error symptom “Total failure of the heater“ Is there a sufficiently high control Check the voltage converter (see voltage? 5.8.3) or the control voltage source. Check fuses in the control circuit and if required remedy the fault and replace fuse(s) (see 3.2).
  • Page 17 Check the control thermostat (see Replace control thermostat. 5.8.6.1). Does the control ther- mostat function properly? Roughly determine water flow rate (see ). Is the water flow rate in Contact Valeo customer service. relation to the heating capacity too high? Contact Valeo customer service.
  • Page 18 Thermo AC/DC 5 Troubleshooting Error symptom „Overheating / the temperature limiter has tripped“ Turn the circulating pump on, check Is the circulating pump switched on its function and the direction of rota- and works properly? tion. Replace if necessary.. Eliminate the fault. Does an adequate cooling and coolant flow exist? Are all shut-off devices open?
  • Page 19 Vehicle-side insulation value Contact the vehicle manufacturer. sufficient? Insulation value up to the load con- Replace the HV wiring harness tactor sufficient? (see 8.7). Insulation value after the load con- Contact Valeo customer service tactor sufficient? Contact Valeo customer service...
  • Page 20 Thermo AC/DC 5 Troubleshooting Individual component tests 5.8.4 Load contactor check or visual inspection • Inspect load contactor for damage (cracks, deforma- Individual components can be basically tested using tion, discoloration etc.) and if required replace small visual inspection or manual electrical testing. distribution board.
  • Page 21 Thermo AC/DC 5 Troubleshooting 5.8.6.2 Temperature limiter check ATTENTION: The retaining spring must be in the temperature limi- ter’s slot and must be locked in place on both sides of the housing. The cables must not be damaged and must not 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.
  • Page 22 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 Installation and operating instruction. The document is available for download at www.valeo-ther- malbus.com/Service/Downloads/Heating Systems.
  • Page 23 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 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 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)
  • Page 26 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 Thermo AC/DC 6 Wiring diagrams Contactor / Schütz Fig. 605 Housing removal for devices Thermo DC 20 kW with DC-DC converter (heater ident. no. acc. to model plate 11117083B)
  • Page 28 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 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 Thermo AC/DC 6 Wiring diagrams Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) Fig. 608 Small distribution board removal for devices Thermo AC 7 kW without converter (heater ident. no. acc. to model plate 11117427A) 11116235_ Connecting HLP / Anschluss HLP orange cable...
  • Page 31 Thermo AC/DC 6 Wiring diagrams Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) DC15 DC14 DC13 DC12 DC11 DC10 DC19 DC20 DC17 Fig. 610 Small distribution board removal for devices Thermo DC 20 kW without converter (heater ident.
  • Page 32 Thermo AC/DC 6 Wiring diagrams Contactor / Schütz Connecting HLP / Anschluss HLP orange cable blue cable (oranges (blaues Kabel) Kabel) Fig. 612 Small distribution board removal for devices Thermo DC 20 kW without converter (heater ident. no. acc. to model plate 11125621A) Connecting HLP / Anschluss HLP orange cable blue cable...

  • Page 33: Servicing

    Thermo AC/DC 7 Servicing Servicing General Warning! Danger to life and health! The safety information and regulations of Chapter 1 (see 1.6) must be observed. Heater 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 periodical maintenance can be found in the maintenance plan contained in the...

  • Page 34: Components And Heater Removal And Installation

    If components are disassembled to a degree not covered in this workshop manual, any warranty claim shall be voided. Only genuine Valeo spare parts should be used. In the figures of the procedures following icon is used: Symbol tightening torque: Features in graphics parts (e.g.

  • Page 35: Temperature Guards

    Thermo AC/DC 8 Repairs Temperature guards (temperature until it can be put in its installation position. 4. Position temperature limiter (2) in the reception neck limiter, control thermostat) (5) and push in the retaining clip (3). removal/installation. ATTENTION: The retaining spring must be located in the groove of Removal the reception neck and must be latched in position 1.

  • Page 36: Hood Removal/Installation 803

    Thermo AC/DC 8 Repairs Hood removal/installation Installation 1. Position housing over the small distribution board onto the heater and then secure it using screws (6, Fig. Removing the hood provides access to the following com- 803, Sheet 1) and washers (7). ponents for maintenance, inspection and repair purposes: 2.
  • Page 37 Thermo AC/DC 8 Repairs Hood Hood screw (2) Stabilizer Cable gland power supply Cable gland control cables Nut (2) Washer (2) A Blatt 2 Screw (2) Washer (2) 10 Separation disk 11 Stay bolts (2) 12 Gasket ring (2) 16 +1 Nm 13 Connecting pice 14 Washer 15 Grounding screw...
  • Page 38 Thermo AC/DC 8 Repairs Heating cartridges (3)* Gasket ring (9)* Screw plug (6)* Screw (2) Washer (2) Gasket ring Vent screw Temperature guards Screw-in socket 10 Gasket ring 11 Coolant outlet 12 Coolant inlet 13 Heater stand (2) 14 Heat exchanger 20 ±2 Nm 20 ±2 Nm A Blatt 1...

  • Page 39: Heating Cartrides/Screw Plugs Removal/Installation 806

    Thermo AC/DC 8 Repairs Heating cartrides/screw plugs removal/installation Removal Actuation tool 1. Establish voltage-free state of the heater and secure it for duration of the work (Observe 1.6.3!) wire NOTE: To ensure the safe removal and installation of the heating cartridges, the heat exchanger is to be removed and placed in a vertical mounting position.

  • Page 40: Hv Wiring Harness (Ac/Dc) Removal/Installation 807

    Thermo AC/DC 8 Repairs NOTE: Installation The groove of the gasket ring must in installed position rest on the heat exchanger. NOTE: During the next step pay attention that the cables are not 3. Apply thread sealant according to the manufacturer‘s jammed.

  • Page 41: Heater Removal/Installation 808

    Thermo AC/DC 8 Repairs 4. If necessary reconnect connectors to the HVIL socket. 3. Unscrew grounding screw (15, Fig. 803, Sheet 5. Check the hook-up again using the wiring in Fig. 601 Reinstall grounding screw with grounding cable and thru Fig.

  • Page 42: Bleeding Of The Coolant Circuit 809

    Thermo AC/DC 8 Repairs 8.11 Bleeding of the coolant circuit NOTE: The coolant circuit must be principally bleeded according to the manufacturer specification. Caution! Risk of scalds! Risk of injuries if coolant temperature is increased. The vent screw (7, Fig. 803, Sheet 2) can be used as an additional venting possibility.

  • Page 43: Modifications And Retrofits

    Thermo AC/DC 9 Modifications and retrofits Modifications and retrofits General For further optimization the heaters are continuously improved. Units in the field can usually be upgraded or retrofitted. For this purpose respective modification kits will be available.

  • Page 44: Packing/Storage/Shipping

    Thermo AC/DC 10 Packing/storage/shipping Packing/storage/shipping 10.1 General The heater or its components, which are sent to Valeo for inspection or repair, must be cleaned and 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.
  • Page 45 In principle the regulations of the vehicle manufacturers – ground and short circuit (the de-energized circuit) must be adhered. If there no such regulations, Valeo – cover or block neighbouring parts under voltage prescribes the here shown maintenance intervals for common applications.
  • Page 46 Maintenance plan Check / Maintenance Interval Results Note Measured values/ accomplished repairs During the maintenance, check all screw connections for tightness (for corresponding torque values see Workshop Manual). 1. Electrics (connections, components) a) Examine electrical plug connections and the wiring annually harness for visible damages, replace as required.
  • Page 47 memos...
  • Page 48 Valeo Thermal Commercial Vehicles Germany GmbH Friedrichshafener Str. 7 - 82205 Gilching - Germany - Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889 www.valeo-thermalbus.com - service-valeobus@valeo.com...

This manual is also suitable for:

Thermo ac 200Thermo dc 200

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