Valeo THERMO DC 200 User manual

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

II
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 car-
ried 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 tor-
que 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.valeo-thermalbus.com.

III
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 Additional potential equalization (PE) 7
5.2 690 VDC supply line 7
5.3 Overcurrent protection / insulation
monitoring device 9
5.4 External power supply hook-up 10
5.5 Testing the installation 10
6 Maintenance 11
7 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 the heater - fitting of important
assemblies 17
11.1 Installation 17
11.2 Connection to the vehicle's cooling system 20
11.3 Installation of the circulation pump 21
11.4 Tightening torques 22
12 Technical data 23
13 Annex 26
13.1 Differing installation instructions for Thermo
DC 11126153_ 26
13.2 Differing installation instructions for Thermo
DC 11139411_ 29
13.3 Differing installation instructions for Thermo
DC 11141607_ 31
13.4 Differing installation instructions for Thermo
DC 11125620_ 33

IV
Thermo DC 200

1
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. 06 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 similar-
ly 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 manu-
facturer’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 installa-
tion 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 po-
sitioned 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 in-
stalled 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

2
Statutory regulations governing installation Thermo DC 200
Applicable local regulations, laws and standards for electrical in-
stallations, in particular the provisions of ECE Regulation R100 are
to be observed by the vehicle manufacturer and should be appro-
priately implemented.
ATTENTION:
Failure to follow the installation instructions and the notes contai-
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.
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).
NOTE: The year of the initial operation must be durably marked by
removing the year numbers that are not applicable.
Danger to life and health!
Warning!
Figure 1: Model plate (example)
Thermo DC
0 Hz / 30A
690 VDC / 20kW

3
Thermo DC 200 Safety regulations
2 Safety 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.
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 dura-
tion 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 (the de-energized circuit)
– cover or block neighbouring parts under voltage
Electrical 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 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), at
least level 2.
NOTE:
The provisions of these Regulations are binding within the territory
governed by DGUV Regulations and should similarly be observed in
countries without specific regulations.
Country specific rules / standards are to be considered additionally.
High voltage! Danger to life!
Warning!

4
Use / Version Thermo DC 200
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, and
– for pre-heating.
Deviating installation / use must be agreed in advance with the Valeo
product support.
The heaters are approved for horizontal installation only (see Figure 10).
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 the rating plate of your heater / in the
technical data 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 quali-
fied 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).
Danger to life and health!
Warning!
Hot surfaces!
Caution!

5
Thermo DC 200 Use / Version
3.1. Installation example
Figure 2: Installation 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 heating circuit – wall heater and roof duct heating system
Supply
Return

6
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 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 monitored. In case of any
malfunction make the heater immediately voltageless.
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.

7
Thermo DC 200 Installation
5 Installation
ATTENTION!
Any changes to the heaters or to the installation described below
are strictly prohibited and will void both the warranty and, if
applicable, the E1 approval.
5.1. Additional potential equalization (PE)
A grounding cable, at least 1x6 mm² Cu, should be attached to the posi-
tion on the housing which is marked and provided for it. This is done with
a ring cable lug which is fastened with a M10x1 potential equalization
screw (for tightening torque, refer to figure 11).
The connecting screws on the heating appliance may only be replaced
with genuine original 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
heater connection cable (HV). The cable cross-section must be chosen
according to the power and installed cable length.
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 potential equalization.
The connection must be carried out in accordance with the enclosed
hook-up diagram (see Figure 4).
ATTENTION:
When connecting the HV cable, it is essential to ensure the correct
current direction. A polarity reversal can lead to the destruction of
the heater.
Figure 3: Potential equalization screw

8
Installation Thermo DC 200
Figure 4: Hook-up diagram
2115
37 26
48
X2 X1
HV LV
Thermo DC 200
690V DC
Note the prescribed
means of protection!
- overcurrent protective device
see Section “Installation“, Figure 5
Note: Heater internal connections not shown.
HV Hook-up LV Hook-up
Connection HU Cable Color Connector HDSCS 1-1418479-1
+6 mm² red Contact 1241380-1
-6 mm² black Seal 963530-1
Connection HU Cable Pin
0.75 mm²
1
Activation signal 600V DC 2
Overheat protection feedback 3
Thermostat feedback 4
Ground 5
6
Auxiliary contact input * 7
Auxiliary contact feedback * 8
Pin assignment
see table below
* The auxiliary contact is closed when the heater/contactor is on.

9
Thermo DC 200 Installation
5.3. Overcurrent protection / insulation monitoring device
ATTENTION:
The power supply circuit is to be protected through an all pole
overcurrent protection device acc. to table Technical Tata on page
23.
If the overcurrent device has been triggered, the heater is to be switched
off. It is essential that the cause is identified and the error rectified by a
qualified electrician in a specialised workshop. Only then the heating
appliance can be reconnected to the mains.
The use of overcurrent protection devices with another as specified load
ability is not 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 MΩ)
against fault currents.
If the Thermo DC is monitored as a subcomponent of the BUS
system, the value can be adapted according to the applicable
statutory requirements.
The connecting schematic of the insulation monitoring device is shown
in figure 5 (for example if monitoring the stand alone device).
The specified for the fasteners torque value must be met.
High voltage! Danger to life!
Warning!
Figure 5: Hook-up schematic
L1 L2
L1 L2
35A
Valeo Thermo DC
Circuit breaker
DC 690 V 0Hz
after electricity
IMD 0.5 MΩ
meter
Overcurrent protec-
tion device acc. to
table Technical Data
on page 23
DC 24V 0Hz

10
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.
Before an external voltage is applied to the vehicle, the connection 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 completed, the heating appliance is to be
checked by a qualified electrician for operational safety and function!
A current measurement ensures that all cartridge heaters are functio-
ning. For limits to be checked, refer to table Technical Data on page 23.
ATTENTION:
Under no circumstances may the heaters be operated “dry“
(without water filling), since the internal construction could be
damaged!

11
Thermo DC 200 Maintenance
6 Maintenance
– 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).
– The heating appliance, and in particular the electrical control
system, must be checked at least once a year according to DIN
VDE 0701/0702 (VDE 0701/0702) or according to comparable
test specifications. Independently of this the mandatory local
regulations must be observed.
– 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/
eu_en/Service/Downloads/Heating-systems/Thermo-AC-DC.
ATTENTION:
– Under no circumstances may the heaters be operated 'dry' to
the air, since the internal construction will be damaged!
– Do not operate the cartridge heaters for a short period of time,
even for checking purposes, since they can be permanently
damaged or destroyed by this. Only carry out checks as
instructed.
NOTE:
The connecting screws on the heating appliance may only be replaced
with genuine original parts from Valeo.
A current measurement ensures that all cartridge heaters are functio-
ning. For limits to be checked, refer to table Technical Data on page 23.
High voltage! Danger to life!
Warning!

12
Faults, troubleshooting, repairs Thermo DC 200
7 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.
The opening of the appliance, troubleshooting and repairs must
only be carried out by a qualified electrician. 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.
ATTENTION:
The temperature limiter is triggered at 125°C and interrupts the
heating process. To reset you must activate the reset button. Prior
to this the heating appliance must be checked for any possible
damage or faults and the cause of the fault established and elimi-
nated.
High voltage! Danger to life!
Warning!

13
Thermo DC 200 Control elements
8 Control elements
The control line should be kept as short as possible so that the voltage
drop is not too great.
The minimum cable cross sections indicated in the
table must be applied.
* The cable cross section is to be reduced in front of the heater
to 0.75 respective 2.5 mm².
If greater lengths have to be bridged, a relay must be used to split the
power circuits and limit the length.
For the PN of the connector at the heater and of the maiting plug, refer
to table Technical Data on page 23.
Kinds of 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 DC and a current carrying capacity
of at least 1.5A.
Use preferably the Valeo switch: 2711011A, switch complete with light.
Cable length <7,5m Cable length 7,5 - 15m
0.75 mm² 1.5 mm² *
2.5 mm² 4.0 mm² *
Figure 6: Valeo switch
Figure 7: Wiring diagram with switch, 2 pole, without DC-DC
converter
2
5
RD
BN
+
Consider prescribed protection!
- Overcurrent protection device
See para.: „Installation“, Fig. 5
External control
input
Valeo
Thermo DC
690V DC
Switch
at least 30V DC 1.5A
5A
Operation indicator
24V DC max. 250mA
Cable cross section
acc. table on page 13.

14
Control elements 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.
Figure 8: Wiring diagram with pre-selection timer, without DC-DC converter
5A
1 10 11
12 4
5A5A
2
8
0,75mm²
0,75mm²
0,75mm²
BN
5
2RD
T. 58
T. 15
T. 30
T. 31
max.
Valeo
Thermo DC
24V
690V DC
at least 30V DC
0.4A
1,5 A
24V DC max. 250mA
Consider prescribed protection!
- Overcurrent protection device
See para.: „Installation“, Fig. 5
External control
input
Valeo
Pre-selection
Timer
Operation indicator
Cable cross section acc. table
on page 13.

15
Thermo DC 200 Control elements
ATTENTION:
Never connect the timer directly to the heating appliance. This will
damage the timer. 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.
Auxiliary contact
With pin 7 and 8 (see hook up plan Fig. 4) of the control wiring harness
the switching status of the heater can be monitored.
– closed contact: Heater is in operation
– open contact: Heater is off or in a controlled break.
If the operation indicator is integrated into the power circuit for external
control, it may require a current of max. 250mA. Only suitable lamps for
the voltage range of 18 - 30V are to be used (ref. also para. 8.1, Fig. 7
and 8).

16
Circulation pump Thermo DC 200
9 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 Valeo circulation
pumps.
The water flow rate 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 appliance. For this reason the coolant demand must be provi-
ded for at the vehicle.
10 Switching thresholds
Upper switching threshold: 75°C
Lower switching threshold: 68°C
NOTE:
For information about these circulating pumps and
their installation, see http://www.valeo-thermal-
bus.com/eu_en/Products/Pumps