Valeo THERMO DC 200 User manual

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

II
Thermo DC 200
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.
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!

Thermo DC 200
III
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

IV
Thermo DC 200

Thermo DC 200 Statutory regulations governing installation
1
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 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

Statutory regulations governing installation Thermo DC 200
2
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 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 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
0Hz/30A
690 VDC / 20kW

Thermo DC 200 Safety regulations
3
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
– 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).
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.
High voltage! Danger to life!
Warning!

Use / Version Thermo DC 200
4
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 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!

Thermo DC 200 Use / Version
5
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

Operating and maintenance instructions Thermo DC 200
6
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 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.

Thermo DC 200 Installation
7
5Installation
5.1. Grounding, additional protective equipotential
bonding
A grounding cable, at least 1x4 mm² Cu, should be attached to the posi-
tion 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).
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).
Figure 3: Grounding screw

Installation Thermo DC 200
8
Figure 4: Connecting schematic with integrated DC-DC converter (Thermo DC compact distributor board)
4mm², GR, 180mm, Radox 3 GKW 12545290
0,75mm², RT, 200mm, FLRY
Schütz Siemens
3TC4417/0AB4
2,5mm², RT, 250mm
2,5mm², RT, 250mm
QUINT/PS/ 3AC/
24DC
Radox 3 GKW 12545290
4mm², GR, 180mm,
SW
BL
BR
RT 1
1
2
2
3
4
68 ... 75 °C
125 °C
M12x1,5
1
7
2
8
3
9
4
10
5
11
6
12
14 14
-
-
-
16
13 17
18
19
20
1313
DC
OK
15
+
N++
L1 L2 L3 GND 2
T1 4
T2
A2
24-
4mm², RT
4mm², SW
1
L1
3
L2
A1
24+
Cable colors
SW black
BL blue
BR brown
GN green
GR grey
OR orange
RT red
GNGE green/
yellow
690 VDC
Note the prescribed
means of protection!
- overcurrent protective device
see Section “Installation“, Figure 8
Note: Heater internal connections not shown.
Load
Contactor

Thermo DC 200 Installation
9
Figure 5: Connecting schematic without integrated DC-DC converter (Thermo DC compact distributor board)
+-
ϑ68 .. 75°C
ϑ125°C
1L1
+L-
2T1
A1
24+
A2
24-
0,75mm², SW, 130mm, FLRY
15
16 19
6mm², GR, 220mm,Radox 3 GKW 12548127
1
2
3
4
RD
BR
BU
BK
1
2
10 11 12
6mm², GR, 180mm, Radox 3
GKW 12548 12 7
L+
0,75mm², BK
2
1-
DC
+
M12x1,5
0,75mm², BN
13
14
7 8 91 2 3
4 5 6
17 19
2018
6mm², RT
6mm², BL
Cable colors
SW black
BL blue
BR brown
GN green
GR grey
OR orange
RT red
GNGE green/
yellow
690 VDC
Note the prescribed
means of protection!
- overcurrent protective device
see Section “Installation“, Figure 8
Note: Heater internal connections not shown.
Load
Contactor

Installation Thermo DC 200
10
Figure 6: Preparation of the cables and hook-up
Hook-up data:
Cord grip range: 9 - 17 mm
Use suitable tools for installation!
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 mm2
Torque 3 - 4.5 Nm
250
Cable ends with end sleeves
Cord grip
Cable diameter
9 - 17 mm
Power cable
at least 2x4 mm²
10
Cable gland
for control line
(M12x1.5)
Cable gland
for power
cable (M25x1.5)
4mm², 12 mm length and
square pressure
black
red

Thermo DC 200 Installation
11
5.3. Overcurrent protection / insulation monitoring device
ATTENTION:
The power supply circuit is to be protected through an all pole
overcurrent protection device that allows a max. current of 35A.
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 8 (for example if monitoring the stand alone device).
The specified for the fasteners torque value must be met.
Figure 7: Terminals L1 and L2
L1 und L2
Cable to the terminal
already exists
High voltage! Danger to life!
Warning!

Installation Thermo DC 200
12
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
After the installation is completed, the heating appliance is to be
checked by a qualified electrician for operational safety and function!
Before the mains power is applied, close the appliance (fit the hood).
A current measurement ensures that all cartridge heaters are functio-
ning. The current should be at 28.5A ±3A per phase.
Testing of individual cartridge heaters
Limit values for evaluation:
Insulation measurement of each connection against the housing:
R Iso > 100 MΩ
Resistance measurement between the two connection wires at 20°C
Ambient temperature: 23.3 Ω±10%
ATTENTION:
Under no circumstances may the heaters be operated “dry“
(without water filling), since the internal construction could be
damaged! Figure 8: Connection schematic
L1 L2
L1 L2
35A
Overcurrent
Spheros Thermo DC
Circuit breaker
protection device
all pole, 35A
DC 690 V 0Hz
after electricity
IMD 0.5 MΩ
meter

Thermo DC 200 Maintenance
13
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.
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 Spheros.
A current measurement ensures that all cartridge heaters are functio-
ning. The current should be 28.5A ±3A.
High voltage! Danger to life!
Warning!

Faults, troubleshooting, repairs Thermo DC 200
14
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.
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
eliminated.
High voltage! Danger to life!
Warning!

Thermo DC 200 Control elements
15
8 Control elements
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
greater lengths have to be bridged, a relay must be used to split the
power circuits and limit the length.
A cable harness with the following plug is attached to the heating
appliance:
2 pin connector:
Manufacturer: FEP
Manufacturer No.: 42064500 or identical design 42064000
Only use the following mating connector:
Manufacturer: FEP
Manufacturer No.: 42121100, Spheros-ID: 11114939_
to continue the wiring.
4 pin connector:
Manufacturer: FEP
Manufacturer No.: 42122100
Only use the following mating connector:
Manufacturer: FEP
Manufacturer No.: 42064100, Spheros-ID: 11123027_
to continue the wiring.
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.
For monitoring purposes in the vehicle an operation indicator has to be
provided, which displays the status of the heater switching signal.
When using a 2-pole external control (see fig. 10) the required operation
indicator must be realized and controlled vehicle-mounted.
If the heater has, as shown in fig. 11, a 4-pole external control, the
operation indicator can be actuated by a switch with two contacts and
powered by the heater.
Use preferably the Spheros switch: 2711011A, switch complete with
light.
Figure 9: Spheros switch

Control elements Thermo DC 200
16
8.2. Pre-selection timer
If the Spheros 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 diagrams.
When using a 2-pole external control (see fig. 13), the required opera-
tion indicator must be realized and controlled vehicle-mounted.
If the heater has, as shown in fig. 14, a 4-pole external control, the
operation indicator can be actuated by a switch with two contacts and
powered by the heater.
Figure 10: Wiring diagram with switch, 2 pole
Figure 11: Wiring diagram with switch, 4 pole
1
2
max. 10m
RD
Spheros
Thermo DC
RD
+
690V DC
24V DC 1.5A
5A
External control
input
Switch
Consider prescribed protection!
- Overcurrent protection device
See para.: „Installation“, Fig. 8
at least 2.5mm2
1
BN
4
RD
-
-
+
3
2
+RD/WH
BK
max. 10m
Spheros
Thermo DC
690V DC
24V DC 1.5A
5A
5A
24V DC
max. 250mA
External control
input
Switch
Consider prescribed protection!
- Overcurrent protection device
See para.: „Installation“, Fig. 8
at least 2.5mm2
Operation indicator
Figure 12: Wiring diagram with switch, 2 pole, without DC-DC
converter
1
2
BK
BN
+
Consider prescribed protection!
- Overcurrent protection device
See para.: „Installation“, Fig. 8
External control
input
max. 10m
at least 2.5mm2
Spheros
Thermo DC
690V DC
Switch
at least 30V DC 1.5A
5A
Operation indicator
24V DC max. 250mA