Valeo THERMO DC 200 Installation And Operation Instructions Manual
HEATING SYSTEMS
THERMO DC 200
Bus
Installation and
operating instructions
Rev. 01/2017
Id.No. 11118910A
Thermo DC 200
Highlighted words like Warning!, Caution!, ATTENTION: and NOTE: in these Installation and operating instructions signify the following precautions:
Other symbols used in these Installation and operating instructions:
This caption is used to indicate possible severe injuries
or fatal accidents if instructions or procedures are carried out incorrectly or entirely disregarded.
This caption is used to indicate possible 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 used to draw attention to an important
feature.
Symbol
tightening
torque
Identifies in graphics parts (e.g. nuts, bolts) that are to
be mounted with a specific tightening torque. The torque values are shown at the symbol and are binding.
Warning!
Caution!
NOTE: Subject to modification. In multilingual versions the German language is binding. The latest version of this document is provided for download
on www.spheros.de.
II
Thermo DC 200
Table of Contents
1 Statutory regulations governing installation 1
1.1 Statutory regulations governing installation 1
1.2 Model plate 2
2 Safety regulations 3
3 Use / Version 4
3.1 Installation example 5
4 Operating and maintenance instructions 6
5 Installation 7
5.1 Grounding, additional protective equipotential
bonding 7
5.2 690 VDC supply line 7
5.3 Overcurrent protection / insulation
monitoring device 11
5.4 External power supply hook-up 12
5.5 Testing 12
6 Maintenance 13
7 Faults, troubleshooting, repairs 14
8 Control elements 15
8.1 Switch or relay 15
8.2 Pre-selection timer 16
8.3 Activation via mains power 21
8.4 Operation indicator 21
9 Circulation pump 22
10 Switching thresholds 22
11 Installation of the heater - fitting of important
assemblies 23
11.1 Installation 23
11.2 Connection to the vehicle's cooling system 26
11.3 Installation of the circulation pump 27
11.4 Tightening torques 28
12 Technical data 29
III
Thermo DC 200
IV
Thermo DC 200 Statutory regulations governing installation
1 Statutory regulations governing installation
1.1. Statutory regulations governing installation
For the heater exists a type approval according to the ECE Regulations
R10 (EMC) No. 04 6641 and
R122 (Heater) No. 00 0377.
Installation is governed above all by the provisions in Annex 7 of the
ECE Regulation R122. In addition, the electrical safety requirements of
ECE Regulation R100 are to be observed.
NOTE: The provisions of these Regulations are binding within the
territory governed by ECE Regulations and should similarly be observed in countries without specific regulations!
Extract from ECE Regulation R122, Annex 7:
4 The heater must have a manufacturer’s label showing the manufacturer’s name, the model number and type together with its rated
output in kilowatts. The operating voltage and the electric power must
also be stated.
7.1 A clearly visible tell-tale in the operator’s field of view shall inform
when the heater is switched on or off.
Extract from ECE Regulation R122, Part I:
5.3 Installation Requirements for Combustion 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 combustion heater
5.3.2.1 Body sections and any other components in the vicinity of the
heater must be protected from excessive heat and the possibility of fuel
or oil contamination.
5.3.2.2 The heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be met if the installation ensures an adequate distance to all parts and suitable ventilation,
by the use of fire resistant materials or by the use of heat shields.
5.3.2.3 In the case of M2 and M3 vehicles, the heater must not be positioned in the passenger compartment. However, an installation in an
effectively sealed envelope which also complies with the conditions in
paragraph 5.3.2.2 may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 4 or a duplicate,
must be positioned so that it can be easily read when the heater is installed in the vehicle.
5.3.2.5 Every reasonable precaution should be taken in positioning the
heater to minimize the risk of injury and damage to personal property.
5.3.6 Heating air inlet
not applicable
5.3.7 Heating air outlet
not applicable
1
Statutory regulations governing installation Thermo DC 200
Danger to life and health!
Warning!
Thermo DC
0Hz/30A
690 VDC / 20kW
1.2. Model plate
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).
Applicable local regulations, laws and standards for electrical installations, in particular the provisions of ECE Regulation R100 are
to be observed by the vehicle manufacturer and should be appropriately implemented.
ATTENTION:
Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Spheros. The
same applies if repairs are carried out incorrectly or with the use of
parts other than genuine spare parts. This results to the invalidation of the type approval of the heater.
2
Figure 1: Model plate (example)
NOTE: The year of the initial operation must be durably marked by
removing the year numbers that are not applicable.
Thermo DC 200 Safety regulations
High voltage! Danger to life!
Warning!
2 Safety regulations
NOTE:
The provisions of these Regulations are binding within the territory
governed by DGUV Regulations and should similarly be observed in
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.
Before starting the work at the heater, it is to make voltageless acc.
to DIN VDE 0105-100 and this state must be ensured for the duration of the work.
In particular, the following safety precautions must be observed:
– switch 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
– cover or block neighbouring parts under voltage
Electrical cables and operating elements of the heater must be arranged in the vehicle in such a way that their functioning is faultless under normal operating conditions and cannot be hampered.
Work at electrical equipment may only be started if protective
measures against electric shock, short circuits and arcing faults
have been carried out.
Electrical work may only be performed by a qualified electrician for
HV systems in motor vehicles, craftsman, activity with repetitive
character. Training acc. to DGUV 200-005 (previously BGI 8686).
countries without specific regulations.
3
Use / Version Thermo DC 200
Danger to life and health!
Warning!
Hot surfaces!
Caution!
3 Use / Version
The fully electrical water heater Thermo DC operates independently of
the vehicle engine and is connected to the vehicle’s cooling and
electrical systems.
The electrical heater can be used in a depot for pre-heating purposes.
For this it is connected stably to the depot 690 VDC power supply.
Further more the heater also can be used in electric driven buses or
hybrid buses where a 690 VDC power supply is provided, in association
with the vehicle‘s own heating system:
– to heat the passenger cabin,
– to defrost the vehicle windows,
– for pre-heating.
The heaters are approved for horizontal installation only (see Figure 18).
The heater Thermo DC is approved for heating the diesel engine
and the passenger cabin of buses, but not for use in vehicles
subjected to the Directive 94/55/EC (ADR, TRS).
General Information / Safety
Check the information given on your heaters rating plate and compare
this with your mains voltage!
In addition to the statutory regulations the specific connection conditions
of local electricity companies are to be observed.
No alterations to the electrical installation may be undertaken.
The installation and commissioning may only be carried out by a qualified electrician.
Only have any work on the appliance carried out by a specialist
company or a qualified person.
The installation instructions are to be considered.
Under no circumstances touch the heat exchanger and the water
hoses during operation, in particular when they are overheated due
to lack of water.
Ensure an adequate distance to all surrounding parts and a sufficient
ventilation during installation.
Alternately use fire resistant materials or heat shields (see Statutory
Regulations governing installation, para. 5.3.2.2).
4
Thermo DC 200 Use / Version
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 heating circuit – wall heater and roof duct heating system
Supply
Return
3.1. Installation example
Figure 2: Installation example for the heater
5
Operating and maintenance instructions Thermo DC 200
4 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 warming up water.
They must not be operated in the depot unattended for a longer
period. The pump operation, the water cycle and the water temperature of the vehicle should be monitored. In case of any
malfunction unplug immediately the 2-pole mains plug.
Another utilization or any utilization going beyond these ones is to
be considered as unintended use. The manufacturer/supplier shall
not be liable for damages resulting from unintended use; the user
shall bear the risk alone.
6
Thermo DC 200 Installation
5Installation
5.1. Grounding, additional protective equipotential
bonding
A grounding cable, at least 1x4 mm² Cu, should be attached to the position on the housing which is marked and provided for it. Ideally this
should be carried out with a ring cable lug for fastening with the M10x1
grounding screw (for tightening torque, refer to figure 19).
Figure 3: Grounding screw
The connecting screws on the heating appliance may only be replaced
with genuine original parts from Spheros, since these are part of the
electrical equipment and they ensure proper grounding.
5.2. 690 VDC supply line
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
installed cable length. For the cable feed through, the cable gland at the
device is to be used.
Use a dedicated power circuit for the heating system.
The appliance must have a fixed connection to the DC power supply.
The heating appliance must be connected to the protective equipotential
bonding.
The connection must be carried out in accordance with the enclosed
connection diagram (see Figure 4).
7
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