Valeo Thermo DC 200 Installation And Operating Instructions Manual
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Valeo Thermo DC 200 Installation And Operating Instructions Manual

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

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Summary of Contents for Valeo Thermo DC 200

  • Page 1 HEATING SYSTEMS THERMO DC 200 Installation and operating instructions Rev. 05/2020 Id.No. 11118910E...
  • Page 2 The tor- tightening que values are shown at the symbol and are binding. torque NOTE: Subject to modification. In multilingual versions the German language is binding. The latest version of this document is provided for download on www.valeo-thermalbus.com.

  • Page 3: Table Of Contents

    Thermo DC 200 Table of Contents Statutory regulations governing installation 11.3 Installation of the circulation pump 11.4 Tightening torques 1.1 Statutory regulations governing installation 1.2 Model plate Technical data Safety regulations Annex Use / Version 13.1 Differing installation instructions for Thermo DC 11126153_ 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

    Failure to follow the installation instructions and the notes contai- 690 VDC / 20kW ned therein will lead to all liability 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 of the heater.

  • 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 Country specific rules / standards are to be considered additionally.

  • Page 8: Use / Version

    – for pre-heating. Only have any work on the appliance carried out by a specialist company or a qualified person. Deviating installation / use must be agreed in advance with the Valeo The installation instructions are to be considered. product support.

  • 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

    Installation Installation ATTENTION! with genuine original parts from Valeo, since these are part of the Any changes to the heaters or to the installation described below electrical equipment and they ensure proper grounding. are strictly prohibited and will void both the warranty and, if applicable, the E1 approval.
  • Page 12 Installation Thermo DC 200 Pin assignment 690V DC see table below Note the prescribed means of protection! - overcurrent protective device see Section “Installation“, Figure 5 Thermo DC 200 HV Hook-up LV Hook-up Connection HU Cable Color Connector HDSCS 1-1418479-1 6 mm²...

  • Page 13: Overcurrent Protection / Insulation Monitoring Device

    Thermo DC 200 Installation 5.3. Overcurrent protection / insulation monitoring device ATTENTION: DC 690 V 0Hz The power supply circuit is to be protected through an all pole L1 L2 overcurrent protection device acc. to table Technical Tata on page...

  • Page 14: External Power Supply Hook-Up

    Installation Thermo DC 200 5.4. External power supply hook-up ATTENTION: It should be noted that with vehicles, which are to be connected to 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 15: Maintenance

    – Avoid cleaning with liquid media, as the insulation resistance can be reduced by water that may ingress. See maintenance manual 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, available at www.valeo-thermalbus.com/...

  • Page 16: Faults, Troubleshooting, Repairs

    In all cases the hea- ting appliance must be disconnected 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-AC-DC. NOTE: Damaged or defective components should only be replaced with identi- cal components.

  • Page 17: Control Elements

    18-30V DC and a current carrying capacity See para.: „Installation“, Fig. 5 of at least 1.5A. Use preferably the Valeo switch: 2711011A, switch complete with light. Figure 7: Wiring diagram with switch, 2 pole, without DC-DC...

  • Page 18: Pre-Selection Timer

    Thermo DC 200 8.2. Pre-selection timer If the Valeo pre-selection timer is used as an operational element, a 24V vehicle relay (switching current >1.5A), with a current consumption smaller than 400mA must be used in accordance with the following circuit diagram.

  • Page 19: Operation Indicator

    You can use the following relay: ID: 98559A (Fa. Wehrle, 29 201 045). NOTE: All information on the Valeo pre-selection timer VC Preheater can be found on the Valeo website. 8.3. Operation indicator For monitoring there should be an operation indicator provided at the vehicle, which displays the status of the switching signal/heating system.

  • Page 20: Circulation Pump

    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 Valeo circulation pumps. NOTE: For information about these circulating pumps and their installation, see http://www.valeo-thermal-...

  • Page 21: Installation Of The Heater - Fitting Of Important Assemblies

    9 and be presented in all cases to Valeo for approval. If this approval is not given, the installation is not permitted and all warranties and liability claims become void.
  • Page 22 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 9: Dimensions of the heating appliance Thermo DC...
  • Page 23 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 24: Connection To The Vehicle's Cooling System

    Valeo website. they ensure a static bleeding of the system. Basically, the by Valeo approved water hoses must be used. If this is not The correct degree of bleeding results in an almost silently operating the case, the hoses must at least comply with DIN 73411. The hoses are circulation pump.

  • Page 25: 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! Refer to Section 9.

  • Page 26: 11.4 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 27: 12 Technical Data

    Thermo DC 200 Technical data 12 Technical data Unless limit values are given, the technical data below is understood to NOTE: be subject to the usual tolerances for heating appliances of +/-10% at an The allocation of the circulation pumps to the heating appliances must ambient temperature of +20°C and at nominal voltage.
  • Page 28 Technical data Thermo DC 200 Heater (electrical system) Thermo DC200 Ident. no. 11117083_ 11122596_ 11129411_ Nominal heating flow Nominal voltage Nominal power consumption Nominal current 29.6 Rated current at 540V DC 23.2 Rated current at 690V DC 29.6 Rated current at 750V DC 32.3...
  • Page 29 Thermo DC 200 Technical data Heater (electrical system) Thermo DC200 Ident. no. 11117083_ 11122596_ 11129411_ Insulation resistance end of life at MΩ >50 1000V Control signal nominal voltage Operating voltage range LV 16 - 32 Max. control current LV 0.42 1.58...

  • Page 30: Differing Installation Instructions For Thermo Dc 11126153

    The connecting screws on the heating appliance may only be replaced instructions described in the EBA (Chapter 1-11), except for the devia- with genuine original parts from Valeo, since these are part of the tions described and illustrated on the following pages.
  • Page 31 Thermo DC 200 Annex Pin assignment 486V DC 690V DC see table below Note the prescribed means of protection! - overcurrent protective device see Section “Installation“, Figure 5 Thermo DC 200 HV Hook-up LV Hook-up Connection HU Cable Color Connector HDSCS 1-1418479-1 6 mm²...
  • Page 32 Annex Thermo DC 200 Technische Daten 486V DC Heater (electrical system) Thermo DC200 (486V) L1 L2 Ident. no. 11126153_ Nominal heating flow Circuit breaker Nominal voltage after electricity meter Frequency Nominal current 41,7 Rated current at 400V DC 34,4 IMD 0.5 MΩ...

  • Page 33: Differing Installation Instructions For Thermo Dc 11139411

    Thermo DC 200 Annex Heater (electrical system) Thermo DC200 (486V) Ident. no. 11126153_ Control signal nominal voltage Operating voltage range LV 16 - 32 Max. control current LV 1,58 LV circuit breaker current rating LV control harness connector AMP HDSC 8 pin 1-...
  • Page 34 Annex Thermo DC 200 690V DC 690V DC Pin assignment see table below HVIL Note the prescribed means of protection! - overcurrent protective device see Section “Installation“, Figure 5 Thermo DC 200 HV Hook-up LV Hook-up Connection HU Cable Color...

  • Page 35: Differing Installation Instructions For Thermo Dc 11141607

    Thermo DC 200 Annex 13.3. Differing installation instructions for Thermo DC Thermo DC200 Heater (electrical system) 11141607_ (690V) 690 VDC supply line Ident. no. 11141607_ The hook up must be made with at least a cable corresponding to the Type of electrical protection 1000V DC/xxA/10kA heater connection cable (HV).
  • Page 36 Annex Thermo DC 200 Note the prescribed HV Hook-up LV Hook-up means of protection! Connection HU Cable Color Connector HDSCS 1-1564337-1 - overcurrent protective device 10 mm² Contact 96427C-1 see Section “Installation“, Figure 5 10 mm² black Seal 963530-1 Connection HU...

  • Page 37: Differing Installation Instructions For Thermo Dc 11125620

    Thermo DC 200 Annex 13.4. Differing installation instructions for Thermo DC Thermo DC200 Heater (electrical system) 11125620_ (690V) 690 VDC supply line Ident. no. 11125620_ The hook up must be made with at least a cable corresponding to the Type of electrical protection 1000V DC/xxA/10kA heater connection cable (HV).
  • Page 38 Annex Thermo DC 200 690V DC Pin alignment see table below Note the prescribed means of protection! - overcurrent protective device see Section “Installation“, Figure 5 Thermo DC 200 HV Hook-up LV Hook-up Connector HDSCS 1-1418479-1 Ring t ype Connection HU...
  • Page 39 memos...
  • Page 40 HEATING SYSTEMS Valeo Thermal Commercial Vehicles Germany GmbH Friedrichshafener Str. 7 - 82205 Gilching - Germany - Tel. +49 8105 7721-0 - Fax +49 8105 7721-889 www.valeo-thermalbus.com - service-valeobus@valeo.com...

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