Bea_thermo_ac_070__en

Transcript

Water heaters Operating and installation instructions Thermo AC 070 Bus Status: 07/2013 Ident Nr. 11118360A without Power supply unit Thermo AC 070 In these installation instructions the highlighted words CAUTION, ATTENTION and NOTE have the following meanings: CAUTION! This headline word is used if the incomplete compliance or non-compliance with information or procedures can lead to injuries or fatal accidents. This headline word is used if the incomplete compliance or ATTENTION! non-compliance with information or procedures can lead to damage to components. NOTE: This headline word is used if notice is to be drawn to a special feature. NOTE: Subject to modification. The latest version of these Operating and installation instructions can be downloaded from www.spheros.de. II Thermo AC 070 Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 Statutory regulations governing installation 1.1 Statutory regulations governing installation 1.2 Model plate Use / Version 2.1 Installation example Operating and maintenance instructions Installation Maintenance Faults, troubleshooting, repairs Control elements 7.1 Switch or relay 7.2 Pre-selection timer 7.3 Operation indicator Circulation pump Switching thresholds Installation of the heater - fitting of important assemblies 10.1 Installation 10.2 Connection to the vehicle's cooling system 10.3 Installation of the circulating pump 10.4 Installation/removal of the cartridge heaters Technical data Appendix 12.1 Recommended antifreeze agents 1 1 2 3 4 5 6 13 14 15 15 16 18 19 19 20 20 23 24 30 31 32 32 III Thermo AC 070 IV Thermo AC 070 1 Statutory regulations governing installation Statutory regulations governing installation 1.1. Statutory regulations governing installation 5.3.2 Positioning of combustion heater For the heater exists a type approval according to the ECE Regulations R10 (EMC) No. 04 6641 and R122 (Heater) No. 00 0377. 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. 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. 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. 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! 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. Extract from ECE Regulation R122, Annex 7: 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. 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 5.3.2.5 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 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. 1 Statutory regulations governing installation Thermo AC 070 1.2. Model plate CAUTION! 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. 6.6 kW 50 Hz / 10A Figure 1: Model plate (example) NOTE: 2 The year of the initial operation must be durably marked by removing the year numbers that are not applicable. Thermo AC 070 2 Use / Version Use / Version The fully electrical water heater Thermo AC 070 operates independently of the vehicle engine and is connected to the vehicle’s cooling and electrical systems. ATTENTION! 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 heater Thermo AC 070 is operated only with a 230 VAC / 24 VDC voltage converter via the 2 pole connector at wiring harness „external control input“ (see fig. 4). The heater Thermo AC 070 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). The electrical heater can be used in conjunction with a diesel heater in a depot for pre-heating purposes. For this it is connected stably to the depot mains 3/PE/N AC 400/230V 50Hz. During drive heats the diesel unit. Further more the heater also can be used in electric driven buses or hybrid buses where a 3/PE/N AC 400/230V 50Hz power supply is provided, in association with the vehicle‘s heating system for: – to heat the passenger cabin, – to defrost the vehicle windows, – to pre-heat water-cooled engines. 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. CAUTION! Hot surfaces 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). The heaters are approved for horizontal installation only (see Figure 14). 3 Use / Version Thermo AC 070 2.1. Installation example Water heating circuit – wall heater and roof duct heating system 1 2 3 4 5 6 7 8 Wall heater with blower Heat exchanger at entry Heater Circulating pump Roof heat exchanger Vehicle engine Driver’s seat heating system Control panel Supply Return Figure 2: Installation example for the heater 4 Thermo AC 070 3 Operating and maintenance instructions Operating and maintenance instructions The Thermo AC 070 heating appliance may not be operated at temperatures of more than +85°C and without at least a 20 to 60% proportion in the water circuit of the antifreeze agent prescribed by the vehicle manufac-turer (see appendix). 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 5-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. 5 Installation 4 Thermo AC 070 Installation CAUTION! Earthing, additional protective equipotential bonding An earthing 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 earthing screw. CAUTION! 400V supply line The connection line must have a cross section of at least 5 x 4mm² Cu. The cord grip present on the appliance is to be used for feeding through the cable. Use a dedicated power circuit for the heating system. The appliance must have a fixed connection to the 3 phase supply. The heating appliance must be connected to the protective earthing conductor. The additional protective equipotential bonding must also be connected. The connection must be carried out in accordance with the enclosed connection diagram (see Figure 5). Figure 3: Earthing 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 earthing. 6 Thermo AC 070 Installation Note the prescribed means of protection! - overcurrent protective device all pole, 16A 3/PE/N AC 400/230V 50Hz L1 L2 L3 N Voltage converter 230 V AC/ 24 V DC 24 V PE 1 - 2 + Wiring harness: external control input see Section „Installation“, Figure 8 F 6.3 A mT F 6.3 A mT 68 .. 75°C 3RT10341BB40 1 2 3 N 5KP30A (opt. 5KP33A) 125°C 3 x Cartridge heater HLP 20x300 2200W 230V Figure 4: Electrical schematic Thermo AC 070 7 Installation Thermo AC 070 3/PE/N AC 400/230V 50Hz 14 PE 0,75mm², RT 120mm, FLRY 0,75mm², SW, 90mm, FLRY 3 2 1 A1+ 2 4 2 L1 A2- - 15 large small 17 ϑ M12x1,5 16 + SW 4 BL 3 BR 2 RT 1 68 .. 75°C ϑ 125°C 13 12 L3 L2 2 250mm L3 4mm², GN/GE 4mm², BR 4mm², BL see Section “Installation“, Figure 8 L2 L1 4mm², GR N all pole, 16A 4mm², SW - overcurrent protective device 2,5mm², RT, 250mm 1 2,5mm², RT, Note the prescribed means of protection! 4 4 11 Schütz Siemens T1 T2 T3 N N 3RT1034-1BB40 N PE Cable colors 9 4mm², GR, 180mm T1 5 0,75mm², RT, 160mm, FLRY 9 T3 T2 A1+ A2- 8 Radox 3 GKW 12545290 18 4mm², GR, 180mm 9 10 black BL blue BR brown GN green GR grey OR orange RT red GNGE 5KP30A green/ yellow Connect HLP grey terminal -> orange cable blue terminal -> blue cable HLP 1 4 7 Terminal and Position grey blue (orange cable) (blue cable) 4 9 2 4 9 2 (opt. 5KP33A-E3) 6 4mm², GR, 180mm 7 Figure 5: Wiring diagram (Thermo AC compact distributor board) 8 SW 1 ... 3 Terminal for 3 times: HLP20x300-2200W-230VEN-LETEF500-unclosed (T+H Art. No. 440795) connect each to grey and blue terminal row If not especially noted, all cable ends with ferrules according to their cable cross-section Length of Ferrules : all 4mm²: 12mm 0.75mm² at contactor - aux. circuit: 10mm 0.75mm² and 2.5mm² at circuit breaker terminal: 12mm Thermo AC 070 Installation Legend for figure 5 1 Partition OR, 2004-1494 2 1 … 3, Terminal for 3 ea: HLP20x300-2200W-230V connect each cable to grey and blue terminal row 3 1 x Triple cross bridge 2004-403 4 1x End clamp 249-117 5 3x 4L Terminal row GR, 2004-1401 6 3x 4L Terminal row BL, 2004-1401 7 Freewheeling diode, ends after 6mm bent by 90°, remain approx. 20mm 8 2x 2L fuse terminal GR, 2006-1611 with glass fuse 6.3 x 32mm, 250V, 6.3 A mT 9 1x End plate OR, 2006-922 10 1x 4L Protection clamp GRYE, 2004-1407 11 Support rail 35x7,5mm, hole 6mm 12 1x End clamp 249-117 13 1x End plate OR, 2004-1492 14 Insulating hose 15 Cable fitting Lapp Kabel 53111200 16 End connectors, cable ends w/o ferrules 17 Wiring harness adapter ID 2710251A, connector cut off 9 Installation Thermo AC 070 Hook-up data: Earth conductor terminal, green/yellow (PE) and row terminal, blue (cable N) Stripping length 11 - 13 mm Kind of wire single wire or wire strand or wire strand with ferrules Cable gland for control line (M12x1.5) 4 - 6 mm2 Cable cross section Torque Contactor connections Use suitable tools for installation! 3 - 4.5 Nm The earth conductor must have such a length that it will tear off only after the other cables. Cord grip range: 9 - 17 mm Cord grip Cable diameter 9 - 17 mm Terminals with ferrules 12 mm length Power cable at least 5x4 mm² Cu 200 Torque to 8 Nm see Figure 27 10 Figure 6: Preparation of the cables and hook-up 10 260 blue green/yellow brown black grey Cable gland for power cable (M25x1.5) Thermo AC 070 Installation CAUTION! or L1, L2 and L3 Overcurrent Protection The power supply circuit is to be protected through an all pole overcurrent protection device that allows a max. current of 16A. 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 specified for the fasteners torque value must be met. CAUTION! It should be noted that with vehicles, which are to be connected to the earthed external power supply unit via the conductive connection, 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 made with this device and the connection able to be maintained until the external voltage is interrupted. Figure 7: Terminals L1, L2 und L3 11 Installation CAUTION! Thermo AC 070 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). 3/PE/N AC 400/230V 50Hz L1 L2 L3 16A 16A 16A L1 L2 L3 N PE N PE Circuit breaker after counter A current measurement per phase ensures that all cartridge heaters are functioning. The current should be at 9.5A ±1A per phase. Testing of individual cartridge heaters Limit values for evaluation: Insulation measurement of each connection against the housing: R Iso > 100 MOhm Resistance measurement between the two connection wires at 20°C Ambient temperature: 23.3 Ohm ±10% Overcurrent protection device all pole, 16A ATTENTION! Under no circumstances may the heaters be operated 'dry' (without water-filling), since the internal construction could be damaged! Spheros Thermo AC without PSU Figure 8: Connection schematic 12 Thermo AC 070 5 Maintenance Maintenance NOTE: CAUTION! The connecting screws on the heating appliance may only be replaced with genuine original parts from Spheros. A current measurement per phase ensures that all cartridge heaters are functioning. The current should be at 9.5A ±3A per phase. Maintenance work on the electrical equipment may only be carried out by a qualified electrician. The appliance must be disconnected from the power supply prior to any maintenance work and in particular prior to repair work. 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 could 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. 13 Faults, troubleshooting, repairs 6 Faults, troubleshooting, repairs ATTENTION! If a safety switch has been triggered, this should only be reset after a qualified person has determined the cause of the fault and eliminated the error. CAUTION! The opening of the appliance, troubleshooting and repairs must only be carried out by a qualified electrician. In all cases the heating appliance must be disconnected from the mains. NOTE: Damaged or defective components should only be replaced with identical components. ATTENTION! Overheating The temperature switch 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. 14 Thermo AC 070 Thermo AC 070 7 Control elements 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: Manufacturer: FEP Manufacturer No.: 42064500 or identical design 42064000 Only use the following mating connector: Manufacturer: FEP Manufacturer No.: 4212 1100, Spheros-ID: 11114402_ Figure 9: Spheros switch to continue the wiring. Operation indicator Kinds of control: 24V DC max. 250mA – potential-free contact (at least 30V DC, 1.5A) when mains supply is connected – switch or relay - para. 7.1 or – pre-selection timer - para. 7.2 7.1. Switch or relay Alternatively you can deploy each switch with an indicator light and a current load capacity of at least 1.5A. Use preferably the Spheros switch: 2711011A, switch complete with light. For monitoring there should be an operating display provided at the vehicle, which displays the status of the switching signal/heating system. min. 30V DC, 1.5A External control input connection 2 rt 24V DC 1 rt Spheros Thermo AC without PSU 3/PE/N AC 400/230V 50Hz Note the prescribed means of protection! - Overcurrent protective device all pole, 16A See Section: „Installation“, Figure 8 Figure 10: Wiring diagram with switch 15 Control elements Thermo AC 070 7.2. Pre-selection timer If the Spheros pre-selection timer is used as an operational element (ID: 2710824A), 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. Kl. 58 Kl. 15 Kl. 30 Kl. 31 Operation indicator 1 10 5A 0,75mm² 5A 0,75mm² 0,75mm² Pre-selection timer 1531 5A 30V DC max. 250mA 24V max. 0.4A 11 Connection external control 1 rt Spheros Thermo AC without PSU mind. 30V DC 1.5A 2 2 rt 8 12 4 max. 10m at least 2.5mm2 3/PE/N AC 400/230V 50Hz Note the prescribed means of protection! - Overcurrent protective device all pole, 16A See Section: „Installation“, Figure 8 Figure 11: Wiring diagram with pre-selection timer 16 Thermo AC 070 Control elements will flash. The current time and weekday must be set. ATTENTION! Operation 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). heater ’’on’’ indicator day of the week time display alarm indicator memory location time Switching the heater on MO standard timer 2 forward program selection The timer can be operated in that all flashing symbols can be adjusted by means of the and buttons. If the buttons are not pressed within 5 seconds, the time displayed will be stored. If the and buttons are pressed for more than 2 seconds, the fast time-setting mode is activated.If the ignition is switched off while the heater is operating in the continuous mode, the remaining operating time of 15 minutes is displayed and the heater continues to operate for this period of time. instant reverse heating Figure 12: Pre-selection timer Manually: by pressing the button (continuous heating mode) Automatically: by programming the heater starting time Switching the heater off Manually: by pressing the button Automatically: by programming the operating time With the heater running: by programming the remaining operating time Setting time/day of the week Press the button for more than 2 seconds - time of the day is flashing - and set the clock using the and buttons. Day of the week is flashing - adjust the day of the week. Viewing the time The pre-selection timer enables you to preset the start of the heater operation up to 7 days in advance. It is possible to program 3 different starting times, only one of which can be activated. The standard digital timer features a wake-up alarm function. When the ignition is switched on, the timer displays the current time and the day of the week. When the heater is switched on, the display and the buttons are illuminated. After the power supply has been connected, all symbols on the display With the ignition switched off: press the button Programming heater starting time Press the button - the memory location is flashing - using the and buttons, set the heater starting time. Day of the week is flashing - set the day of the week. By repeatedly pressing the button, 17 Control elements Thermo AC 070 memory locations 2 and 3 can be programmed or the time display mode can be reached. Remote control Recalling/erasing preset times Vehicles with ADR equipment Repeatedly press the button until the desired memory location is displayed. To erase the preset time, press the button several times until the time of the day is displayed instead of the memory location. On ADR vehicles it is not possible to program a preset starting time. The remaining time is shown on the display while the heater is in operation. The clock can be set. The alarm clock function can be programmed on the standard digital timer. Programming duration of operating time The heater must be switched off. Press the button for 3 seconds operating time is flashing - and set the desired operating time (10 to 120 minutes) using the and buttons. Setting the remaining operating time Set the desired remaining operating time (1 to 120 minutes) using the and buttons. The remaining operating time refers to the time the heater still continues to remain in operation. It can only be changed while the heater is in operation and the ignition switched off. Setting the wake-up time A wake-up time can only be programmed on the standard digital timer. The wake-up time is not bound to a specific day of the week. Repeatedly press the button until the bell symbol appears on the display. Set the desired wake-up time using the and buttons. The alarm clock turns off after 5 minutes or when one of the buttons is pressed. Recalling/erasing the wake-up time Repeatedly press the button until the bell symbol appears on the display - read off wake-up time. To erase the wake-up time: press the button until the bell symbol is no longer visible on the display. 18 Possible by means of an optional external "instant heating" button 7.3. Operation indicator For monitoring there should be an operation indicator provided at the vehicle, which displays the status of the switching signal/heating system. If the operation indicator is integrated into the power circuit for external control, this must only require a current of max. 250mA. For the voltage range of 18 - 30V only suitable lamps are to be used (ref. also para. 7.1). Thermo AC 070 8 Circulation pump Circulation pump ATTENTION! For a correct switching on of the heating appliance an adequate circulation of the cooling medium must be ensured before switching on. The heating appliance is preferably to be equipped with the Spheros circulation pumps, see para. 10.2. The water flow rate through the heat exchanger of the Thermo AC 070 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 provided for at the vehicle. 9 Switching thresholds Upper switching threshold: 75°C Lower switching threshold: 68°C 19 Installation of the heater - fitting of important assemblies Thermo AC 070 10 Installation of the heater - fitting of important assemblies 10.1. Installation ATTENTION! The legal regulations for the installation are to be observed. If the operation of the water heating appliance is to be part of a separately installed heating system, an installation plan should be presented in all cases to Spheros for approval. If this approval is not given, the installation is not permitted and all warranties and liability claims become void. Mechanical strain must not be applied to the cables of the temperature switches (e.g. by using them to carry the heating appliance). Heating appliances and circulation pumps must fundamentally be built in such that any damage through contamination from the track, water spray, exhausts and other damaging influences is excluded. The disassembly of the individual components (contactor, cartridge heaters) is not permitted and makes all warranty claims void. 20 CAUTION! Risk of injury and burns The cooling water and the components of the cooling water circuit achieve high temperatures. – Water-carrying parts are to be routed and fastened in such a manner that no temperature risk to humans, animals or material sensitive to temperature due to radiation / contact occurs. – Before working on the cooling water circuit, switch off the heater and wait until all parts are cooled down, if necessary wear protective gloves. The dimensions of the heating appliance, the permitted installation locations, and the hole pattern for the fastening can be found in figures 13 and 14. Installation location Attention should be paid to the particular location conditions of the specific vehicle type. The heating appliance and the circulation pump are integrated into the cooling system (or into a separate heating circuit). The heating appliance should be installed as low as possible so that bleeding of the heating appliance and the circulation pump is automatically assured. This is particularly important since the circulation pump is not selfpriming. If the heating appliance and the circulation pump can not be accommodated in the engine room of the vehicle, they can be installed in a sealed housing. This housing must be adequately ventilated from the outside, so that a maximum temperature of +85°C inside is not exceeded. Thermo AC 070 Installation of the heater - fitting of important assemblies 1 2 3 4 5 Air ventilation for the compact distributor board Coolant - Inlet Coolant - Outlet Space required for removal of the electric components and the cartridge heaters HLP20x300 Vent screw Figure 13: Dimensions of the heating appliance Thermo AC 070 21 Installation of the heater - fitting of important assemblies Thermo AC 070 Welded nut M8 - DIN 929 10.8 Figure 14: Installation position and hole pattern Thermo AC 070 22 1 Attachment variant 1 4x screw M8 2 Attachment variant 2 4x screw M8 (through going) + 4x hexagonal nut M8 + 4x Washer 8.4 Thermo AC 070 Installation of the heater - fitting of important assemblies 10.2. Connection to the vehicle's cooling system The heating appliance is connected to the vehicle's cooling system according to figure 13. The volume of coolant fluid present in the circuit must be at least 35 litres. The water in the heating circuit of the heating appliance must contain at least 20 to 60% of a branded antifreeze agent (see specification of vehicle manufacturer). The water hoses approved for use with the appliance by Spheros must always be used. If this is not the case then the hoses must at least comply with DIN 73411. The hoses are to be laid without kinks and also rising where possible for the proper bleeding of the heating appliance. The heater must be mounted below the minimum water level of the cooling circuit. Hose connections are to be secured with hose clips against falling off. When installing the electric heater the direction of the flow of the cooling water in the circuit is to be considered (see figure 13). ATTENTION! The specified tightening torques of the hose clamps used must be adhered. In the vehicle cooling system, or in the case of a separate heating circuit, only overpressure valves with an opening pressure of maximum 2 bar should be used. Attention should be paid to the careful bleeding of the cooling system without usage of the circulating pump, before the first commissioning of the heating appliance, or after the coolant fluid has been replaced. For that the additional venting option via the vent screw item 5, figure 13 is to be used after the system has been filled and the pump has been switched on. The heat exchanger and the water hoses of the Thermo AC 070 should be pre-filled completely. Loosen the vent screw slightly until no air further emerges, but only water. Then retighten the screw to a torque of 20 ± 1 Nm. ATTENTION! If air bubbles are present, they could cause destruction of the cartridge heaters! The heating appliance and pipes must be installed in such a way that they ensure a static bleeding of the system. The correct degree of bleeding results in an almost silently operating circulation pump. An inadequate bleeding can lead during heating operation to the switching-off of the heating appliance due to overheating. Where the U 4855 / Aquavent 6000C circulation pump is used, the circulation pump is automatically switched off ca. 15 seconds after switching on, if the cooling agent is not present or there is blockage of the pump impeller, and it can be started up again after ca. 2 minutes. Where the U 4856 / Aquavent 6000SC circulation pump is used, the circulation pump is automatically switched off ca. 45 minutes after switching on, if the cooling agent is not present or there is blockage of the pump impeller, and it can be started up again after ca. 2 minutes. Circulation pump Preferably use of the Spheros circulation pumps for greatest efficiency and maximum reliability. 23 Installation of the heater - fitting of important assemblies 10.3. Installation of the circulating pump The circulating pump must be installed as shown in Figure 15, 18, 21 or 24. Note the installation position! NOTE: The pump ports and connection lines from the water intake and water outlet must be flush (no stress). ATTENTION! If the pump is not controlled by the heater, its operation is to be ensured by all means during whole heater operation (initial cycle, heating operation and purge cycle). At least turn on the Thermo AC 070 and pump at the same time, but ensure the operation of the pump by an appropriate control circuit at least 2 to 3 min. after switching-off the heater. 24 Thermo AC 070 Thermo AC 070 10.3.1. Installation of the heater - fitting of important assemblies U 4814 (Aquavent 5000) circulating pump Figure 16: Hole pattern for the stand for U 4814 circulating pump Br- Sw+ Delivery rate (with water at 20°C) Figure 15: U 4814 circulating pump Einbaulage Δ Flow resistance (with the pump stopped) Figure 17: Delivery rate and flow resistance U 4814 circulating pump 25 Installation of the heater - fitting of important assemblies U 4854 (Aquavent 5000S) circulating pump 249 99,5 225 38 110 31 38 60 32 131,5 53 23 10.3.2. Thermo AC 070 0-90° 0-85° Br- Sw+ Figure 19: Hole pattern for the stand for U 4854 circulating pump min. 5° bar Delivery rate (with water at 20°C) 1,1 1,0 Figure 18: U 4854 circulating pump installation position 0,9 0,8 Flow resistance (with the pump stopped) 0,7 P 24 V 0,6 0,5 NOTE: 26 When connecting the circulating pump it must be ensured that the volume flow does not drop below 2500 l/h for longer than a brief period only! Continuous operation at less than 2500 l/h will result in undue wear of the wearing disc of the impeller! 0,4 0,3 0,2 0,1 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Q (l/h) Figure 20: Delivery rate and flow resistance U 4854 circulating pump Thermo AC 070 10.3.3. Installation of the heater - fitting of important assemblies U 4855 (Aquavent 6000C) circulating pump 224±2 115 98 60 52,8 32 Ø38 Ø38 23 30,8 0-85° min. 5° Figure 22: Hole pattern for the stand for U 4855 circulating pump 0-90° bar Delivery rate (with water at 20°C) 1,1 Figure 21: U 4855 circulating pump installation position 1,0 0,9 0,8 P Flow resistance (with the pump stopped) 24 V 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Q (l/h) Figure 23: Delivery rate and flow resistance U 4855 circulating pump 27 Installation of the heater - fitting of important assemblies 10.3.4. Thermo AC 070 U 4856 (Aquavent 6000SC) circulating pump 115 229±2 60 126 53 32 Ø38 23 38 31 0-90° Ø 0-85° min. 5° Figure 25: Hole pattern for the stand for U 4856 circulating pump bar Delivery rate (with water at 20°C) 1,1 Figure 24: U 4856 circulating pump installation position 1,0 0,9 0,8 P 24 V 0,7 Flow resistance (with the pump stopped) 0,6 0,5 NOTE: 28 When connecting the circulating pump it must be ensured that the volume flow does not drop below 2500 l/h for longer than a brief period only! Continuous operation at less than 2500 l/h will result in undue wear of the wearing disc of the impeller! 0,4 0,3 0,2 0,1 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Q (l/h) Figure 26: Delivery rate and flow resistance U 4856 circulating pump Thermo AC 070 Installation of the heater - fitting of important assemblies 10.3.5. Motor for circulating pump model U 4855 (Aquavent 6000C) and U 4856 (Aquavent 6000SC) These circulating pumps are equipped with a brushless motor. 10.3.5.1. Soft Start The motor starts up slowly and in a way that is gentle to the material. It takes approx. 5 sec. until maximum speed is reached. 10.3.5.2. Run-dry protection (only U 4855 and U 4856) In the event of a dry running motor the slide ring gasket may be damaged. A dry running motor has a very high speed while the current consumption is slow. The dry running protection is activated if the current consumption (effective) is 0,5 A > I < 4 A, the motor isn’t just in the start phase, n > 3300 1/ min and the waiting period is exceeded. Waiting period: 10.3.5.6. Motor reactivation The motor can be reactivated from sleep mode. This is done by disconnecting it from the power supply for approx. 2 minutes. When the voltage supply is reconnected the motor will restart in soft start mode. 10.3.5.7. Polarity reversal protection The motor does not feature an internal polarity reversal protection. The motor is protected against polarity reversal through the wiring harness and a 25 A fuse. M3G074CF44-17: 8 - 10 sec. M3G074CF44-16: 40 - 45 min. Waiting periods depend on power supply level. The device will be switched into the sleep mode 10 s after the waiting period is passed. 10.3.5.3. Blocking protection If the speed drops below 57 1/min, the motor is switched off after approx. 1 second by the error mode. If the motor does not complete a whole revolution within 1 second despite the medium flow, it will also be shut down by the error mode. 10.3.5.4. Error mode The error mode switches off the motor in the event of faults. The motor is switched to power-saving sleep mode by the error mode after approx. 5 seconds. 10.3.5.5. Sleep Mode In the sleep mode the internal consumers of the motor electronics are switched off. The current consumption in this mode is then < 2 mA. 29 Installation of the heater - fitting of important assemblies Thermo AC 070 10.4. Installation/removal of the cartridge heaters The HLP (high performance cartridge heaters) with a M 26 x 1.5 thread are screwed into the flange of the heat exchanger. Sealing For each cartridge heater and screw plug the seal is provided by a copper sealing ring, RG-DI-DIN7603-CU-C-asbestos free-26x32, and the thread sealing by means of thread sealant from PETEC, TapeTec pipe thread sealant from Sahlberg or Loctite 577 from Henkel. Stud (M8): 10 +1 Nm Screw plug (6ea, M26x1.5) Cartridge heater (3ea, M26x1.5): 30 ±1 Nm Combination screw (M5x16): 5 +1 Nm Apply thread sealant at least three times onto thread M26x1.5 of cartridge heater! In this way also the threaded stud M8 is to be sealed. If a cartridge heater is changed, both seals must under all circumstances be replaced! ATTENTION! Sealing with copper ring alone is not allowed! Earthing screw (M10x1): 16 +1 Nm Cord grip power supply cable (M25x1.5): 8 Nm Cord grip control cable (M12x1.5): 1.5 Nm Figure 27: Torque values 30 Thermo AC 070 Technical data 11 Technical data Unless limit values are given, the technical data below is understood to be subject to the usual tolerances for heating appliances of +/-10% at an ambient temperature of +20°C and at nominal voltage. NOTE: The allocation of the circulation pumps to the heating appliances must be carried out according to the upstream resistances and the minimum flow rate. Heating appliance Thermo AC 070 Design Nominal heating flow max. Rated voltage Fully electrical heater kW 6.6 V 3/PE/N AC 400/230V Rated power consumption kW 6.6 Frequency Hz 50 - 60 Rated current A 10 Electrical circuit protection / overcurrent protection device 16A Ambient temperature during operation °C -40 … +85 Storage temperature °C -40 … +90 Operating overpressure bar max. 2.0 I 9.4 Capacity of the heat exchanger Minimum water flow l/h 1500 Minimum capacity of the water system I 25 Amount of antifreeze in cooling sytem % 20 up to 60 Dimensions heater (tolerance +/-3 mm) length: 578 mm width: 247 height: approx. 225 Weight kg 12.5 31 Appendix Thermo AC 070 12 Appendix 12.1. Recommended antifreeze agents Concentrates of corrosion-inhibiting antifreeze agents (containing silicate) Manufacturer Brand Service time hour / year Addinol Antifreeze Super 9000 / 5 Avia Mineralöl AG Antifreeze APN 9000 / 5 BASF AG Glysantin G 48 Glysantin Protect Plus 9000 / 5 Bucher AG Motorex Antifreeze Protect G48 9000 / 5 Castrol Ltd. Castrol Antifreeze NF 9000 / 5 Clariant GmbH Genantin Super 9000 / 5 Deutsche BP Aral Antifreeze Extra Castrol Antifreeze NF Veedol Antifreeze NF 9000 / 5 Fuch Petrolub AG Fricofin Maintain Fricofin 9000 / 5 Ginouves Georges S.A. York 716 9000 / 5 Krafft S.A. Krafft Refrigerante ACU 2300 9000 / 5 Maziva - Zagreb d.o.o. INA Antifriz AI Super 9000 / 5 MOL-LUB Ltd. EVOX Extra G48 Antifreeze Concentrate 9000 / 5 OMV OMV Coolant Plus 9000 / 5 32 Remarks Thermo AC 070 Appendix Manufacturer Brand Service time hour / year Panolin AG Panolin Anti-Frost MT-325 9000 / 5 Samyang Auto Cool S100 9000 / 5 Shell International Glyco Shell 9000 / 5 Sotragal - Mont Blanc Antigel Power Cooling Concentrate 9000 / 5 The Valvoline Company Zerex G 48 9000 / 5 Total Glacelf MDX 9000 / 5 Remarks Ready mixtures of corrosion-inhibiting antifreeze agents Hermann Bantleon GmbH Avilub Antifreeze Mix (50%) 9000 / 5 Castrol Ltd. Castrol Antifreeze NF Premix (45%) 9000 / 5 Samyang Auto Cool S105 (50%) 9000 / 5 Sotragal - Mont Blanc L.R. Power cooling (44%) L.R. Power cooling (52%) 9000 / 5 Total Coolelf MDX 9000 / 5 ATTENTION! Lotus' antifreeze agent from ORGANIKA is not permitted! 33 Appendix 34 Thermo AC 070 Spheros Service Worldwide NORTH AMERICA EUROPE ASIA ASIA USA Spheros North America Inc. ( ++1 734 218 7350 * [email protected] Toll Free: ++1-888-960-4849 www.spheros.us Germany Spheros Europa GmbH ( +49 8105 7721 887 * [email protected] www.spheros.de www.spheros.eu Turkey Spheros Termo Sistemleri A.S. ( +90 (212) 672 15 90 * [email protected] www.spheros.com.tr China Spheros (Suzhou) Ltd. ( +8613901457659 or ( +8613509686076 * [email protected] MIDDLE & SOUTH AMERICA Finland Spheros-Parabus Ltd. ( +358 2 436 60 00 * [email protected] www.parabus.com UAE Dubai Spheros Middle East ( +971 4 8860 665 * [email protected] Mexico Spheros México S.A. de C.V. ( +55 (54) 2101 5700 * [email protected] www.spheros.com.br Brasil Spheros Climatização do Brasil S/A ( +55 (54) 2101 5700 * [email protected] www.spheros.com.br Columbia Spheros Thermosystems Colômbia ( +55 (54) 2101 5700 * [email protected] Spain & Portugal Spheros Europa GmbH ( +34 93 732 3908 * [email protected] www.spheros.es Turkey Spheros Termo Sistemleri A.S. ( +90 (212) 672 15 90 * [email protected] www.spheros.com.tr Ukraine Spheros Elektron GmbH ( +380 (322) 91 15 64 www.spheros.electron.ua India Spheros Motherson Thermal System Ltd. ( +91 120 4712501 * [email protected] www.spheros.in Hong Kong Spheros Ltd. ( +852 3975 8300 www.spheros.asia www.spheros.cn Malaysia / Singapore Senmas Holdings Sdn. Bhd. ( +603 3342 3631 * [email protected] Indonesia PT .Klima Anlage Jaya ( +62 293 363591 * [email protected] Thailand Cherdchai Industrial Factory Co. Ltd. ( +66 44 240 550 * [email protected] AFRICA South Africa Spheros SA (Pty) Ltd. ( +27 (21) 703 7725 www.spheros.com Our country-specific service partners can be found on the specified sites! Unsere länderspezifischen Servicepartner finden Sie auf den angegebenen Websites! AUSTRALIA Spheros Australia (Pty) Ltd. ( +61 (03) 97060084, * [email protected] www.spheros.com.au Für diese Druckschrift wurde ein umweltschonendes, aus 100% chlorfrei gebleichtem Zellstoff hergestelltes Papier verwendet. For this publication an environmentally friendly, 100% chlorinefree bleached pulp based paper was used. Printed in Germany Änderungen vorbehalten Subject to modification © Spheros Europa GmbH Spheros Europa GmbH Ihlenfelder Straße 148 · D-17034 Neubrandenburg Tel. +49 (0) 8105 7721 0 · Fax +49 (0) 8105 7721 889 www.spheros.de