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COMPANY NEWS: PRODUCT : Refitting instead of re-buying: REVO-E Pro: a new lease of life Cooling and heating for diesel in the electrobus

8 11 Technik Service News Public transport courier I Issue 02.18

Title story INNOVATIVE HEATING CONCEPTS FOR ELECTROBUSES 3

Technik Service News 01/2018 1 Editorial

CONTENTS

Editorial 2

Dear Readers, Title story Innovative heating concepts for electrobuses 3 We can look back on a successful and eventful 2018. Company News Together with the Valeo Group, we presented ourselves for the first time 10th Anniversary of Citysphere 5 with our HVAC products for buses in Hall 16 at IAA Commercial Vehicles. With new innovations such as our electric rooftop air conditioning unit REVO-E Christian Schilder promoted to Head of After-Sales 6 Pro and the SPump PWM/CAN circulation pump, we have also continued to Klaus Flörsheimer appointed Training Manager 6 progress in the field of e-mobility. But electromobility is driving us not only Successful IAA 7 on the product side: it is also placing increasing demands on our service Refitting instead of re-buying: 8 network. Our service team must deal increasingly with e-buses from a new lease of life for diesel buses that are equipped with air conditioning products from Valeo. One of our main goals again in 2019 will be to prepare a seamless change in service Electrobuses: Valeo, SWM and MVG agree 9 to partnership from diesel to electrobuses. Trade Fairs and Exhibitions 2019 9 Besides the developments in e-mobility, 2018 marked the start-off for the topic of predictive maintenance. Early detection of defects in our systems Product News is becoming increasingly important in order to minimise the downtimes For the sake of the environment: 10 of vehicles. Use of alternative fuels 50 hybrid buses with REVO-E for Singapore 10 The coming year promises to be as multi-faceted as the existing year has REVO-E Pro: Cooling and heating in the electrobus 11 closed. We are already in the midst of trade fair preparations for 2019. In with extended operating temperature range February, Valeo Thermal Commercial Vehicles (TCV) is scheduled to make Thermo E+ for mini- und midibuses 12 a presence at the VDV Conference for Electrobuses in Berlin. Furthermore, and as an auxiliary heater for electrobuses in March we will be exhibiting our latest products and innovations at - Premiere: Fuel cell train takes to the tracks 2BUS in Berlin, and this will be followed by UITP in Stockholm in June. 12 Busworld, to be held for the first time next year in Brussels, promises to The new SPump: Electric circulation pump 13 be the highlight of the trade fair year. It goes without saying that we will with tomorrow’s technology not relax our efforts on the product side in 2019. Here we are continuously Crossway LE now available with Citysphere 14 broadening our product portfolio for electric air conditioning systems and expanding our control concepts for total thermal management in the bus New Technologies of the future. The Valeo Team is already looking forward to your positive Dust protection kit: Improved combustion 15 input next year and hopes you enjoy reading the current issue of Technik process in Valeo diesel heaters Service News! Behind the Scenes Testing heaters / circulation pumps 16

Frank Färber

LEGAL NOTICE / CONTACT

Publisher: Editor: Valeo Thermal Commercial Vehicles GmbH Fabienne Ehmann Friedrichshafener Str. 7, D-82205 Gilching Tel.: +49 (0) 8105 7721-828 www.valeo-thermalbus.com [email protected]

Copyright Spheros GmbH. All rights reserved. Duplication or publication, including extracts and irrespective of form, shall only be permitted with our express prior approval and a reference to source.

2 Technik Service News 02/2018 Title story

For most efficient use of the limited electric energy of the traction batteries we need innovative and efficient heating systems for buses.

INNOVATIVE HEATING CONCEPTS FOR ELECTROBUSES

The Roadmap 2050 of the European Union has set some ambitious goals. By the year 2050 the CO2 emissions of all perpetrators are to be cut by 80% compared to the base year 1990. To achieve this, CO2 emissions in the road transport sector alone must be cut by an ambitious 95%. These requirements will inevitably lead to electrification of the power train. For local public transport, predominantly in the form of bus operations, this is an enormous challenge.

In electrically powered buses the The required electric energy must buses. The required heating power order to maintain the preset inte- ‘range’ is directly dependent on be provided by the traction battery, can basically be supplied in two rior temperature. the capacity of the electrochemical thereby reducing the range of the different operating conditions: pre- energy storage, traction batteries. vehicle. In order to deploy the lim- heating at the start of operations The necessary power require- When power is drawn, the chemi- ited electric energy of the traction and heating to maintain the set ment for preheating at the start cally bound energy they contain batteries as efficiently as possible, interior temperature. Fig. 1 shows of operations is disproportionately is directly converted to electric there is a clear need for innovative the heating power requirement at higher than in heating mode dur- energy. At present, lithium-ion and efficient heating systems for different outside temperatures in ing the journey. Against this back- batteries with current energy den- ground, particular importance must sities of 0.2 kWh/kg are deemed be attached to the targeted vehicle to be the basis for future electrifi- 30 preconditioning from a so-called

cation. In contrast, diesel fuel has w 25 ‘off-board’ energy supply, as in this an energy content of 11.8 kWh/ 20 way the energy resources in the kg. This comparison underlines the vehicle battery can be saved to a 15 central challenge facing HVAC ap- large extent. Along the line, how- plications (heating, ventilation, air 10 ever, the aim must be to use the conditioning), because – depend- heating output / k 5 electrical energy resources carried ing on the geographic region and 0 in the bus in the best way possible. operating conditions – the energy -20 -15 -10 -5 0 5 10 15 20 25 30 The necessary heating power can, requirement for heating may be Outside temperature T amb / °c for example, be fed in by elec- greater than for propelling the tric heaters. The COP (coefficient vehicle itself. Fig. 1: Bus heating power requirement as a factor of ambient temperature. of performance) in this case is at

Technik Service News 02/2018 3 COMPANY NEWS

The power requirement for preheating at the start of operations is much higher than for heating operation while on the road. In view of this, special importance must be attached to preconditioning the vehicle.

best 1 and defines the relationship At lower outside temperatures be- ous and highly efficient use. The (system pressure > 1013.25 mbar) between the useful heat output low approx. 5 °C the water vapour ice-bound external heat exchanger ensures that in heat pump opera- and the electrical energy input. in the air condenses and freezes on can be heated up as needed and tion at -20 °C outside temperature the lamellas. Ice forms on the ex- thus de-iced within a short time. no air is suctioned into the system However, feeding the required heat ternal heat exchanger (condenser The thermodynamic properties of by leakage. output via a heat pump system in heat pump operation). Among the coolant used and compressor is a more efficient and thus more other things, the ice coating inhib- operating limits also play a key role Fig. 2 shows the experimentally effective energy-saving method. its heat transfer, and there is a dra- here. Coolants should have suitable measured application limits of This is a highly interesting ap- matic drop in efficiency. A defrost- pressure and temperature ranges, Valeo heat pump systems with proach, as air conditioning systems ing device is necessary in order to together with a large volumetric coolant R744, R449A and R134a. and heat pump basically consist operate the system in heat pump cooling capacity. For use in bus heat Only with coolant R744 (CO2) can of identical components and to- mode. Due to a newly developed pump systems this means that the the systems can be operated as a day almost all vehicles have an air and fully automatic defrosting de- boiling temperature of the coolant heat pump at outside temperatures conditioning system. Heat pump vice, the Valeo’s latest generations at atmospheric pressure should of -20 °C. In future, the develop- functionality can be realised simply of systems can guarantee continu- be below -30 °C. This lower limit ment of innovative heating con- by reverse circulation. The charac- cepts for electrobuses will continue teristic feature of heat pumps is to represent an extremely exciting that the thermal energy stored in 30 field of activity in the Valeo re- the environment is absorbed by a r744/cO search and development depart- 25 change in the state of aggregation w r449 ments. Currently, we are pursuing 20 of the coolant (evaporation). With innovative approaches to holistic the aid of the compressor capac- 15 system optimisation: from the use r134 ity, this thermal energy is boosted 10 of new coolants in heat pump sys-

(pumped) to a higher and thus use- 5 tems and innovative control strate- able temperature level for heating heating output / k gies to the use of radiant heat by 0 purposes. In order to save actual -20 -15 -10 -5 0 5 10 15 20 25 30 means of infrared heaters. electric energy, however, with the Outside temperature T amb / °c aid of heat pump operation, further inherent characteristics must be Fig. 2: Heating output in heat pump operation, independently of coolant used and taken into account. outside temperature.

4 Technik Service News 02/2018 COMPANY NEWS

10TH ANNIVERSARY OF CITYSPHERE

Initially conceived and developed as modular a/c unit for refitting non-air conditioned city buses, today the Citysphere is an inherent part of series production with almost all major vehicle manufacturers. With an eye to the environment and operating costs in their choice of air conditioning for city buses, more and more transport undertakings are opting for the modular a/c unit with its patented air circulation system. With over 16,000 units produced, this year the Citysphere is celebrating its 10-year anniversary.

What began in 2008 with the first Additional consumption of fuel in currently order for Autobus Oberbayern comparison to non-air conditioned working on GmbH has developed into a rooftop buses is hardly noticeable. Due to a solution air conditioning unit that has revo- the hermetic sealing concept the with alterna- lutionised the city bus market in the Citysphere is additionally virtually tive coolants moderate climate zones of Western maintenance-free and has ensured such as CO2 and . Alone in the DACH Region, to date unrivalled low life-cycle 1234yf. to date approx. 13,000 buses carry costs. a Citysphere on their roof. Unique on the market intake along an op- From a retrofit solution To date there are no comparable timum comfort curve, other prod- Small unit – big impact to series production products on the market, even ucts on the market are less flexible Other requirements apply for com- In its initial phase, the modular though other manufacturers at- and can often be controlled only in fort in the city bus than in the tour- a/c unit was offered to transport tempt to copy the Citysphere. three fixed stages. These charac- ing . Not only the additional undertakings that had previously However, the latter are no match teristics are supplemented by fur- fuel costs should be kept as low as foregone air conditioning for cost in terms of performance and tech- ther standalone features: the City- possible, but also the service and reasons, as an option for retro- nical standard. The critical differ- sphere’s fans are PWM-controlled; maintenance costs. In this respect fitting their buses. Gradually, how- ences lie in the PWM controlled, they consist of a fresh air portion the Citysphere with its low life- ever, vehicle manufacturers also semi-hermetic scroll compressor of 15%, and the system is virtually cycle costs is simply unparalleled. became alert, for efficiency and LCC with integral motor and infinitely maintenance-free. Furthermore, it It cools the interior not as usual by costs are no longer topics that con- variable power control, and the fulfils the requirements of VDV Di- a radical reduction in temperature, cern only the cost-conscious trans- system’s air manifold with integral rective 236/1. but through a combination of cool- port operator. Today, the Citysphere radial fan. Other products currently ing and air circulation. A radial fan is being installed in series at MAN, on the market have only a (sepa- Nevertheless, the Citysphere will generously distributes the cooled , Iveco, Scania, Volvo, Solaris rate) motor that is adjustable in not be resting on its laurels. In the air directly into the passenger com- and many smaller manufacturers. steps and a compressor. With the next few years a second generation partment and ensures pleasant On account of its small coolant re- aid of integral radial fans in the air of modular a/c units is planned. temperatures without annoying quirements (only a fraction of full manifold, the Citysphere distrib- The latter will be oriented to the draughts. This so-called wind-chill air conditioning) it is also an attrac- utes the cooled air throughout the future requirements and technolo- effect is completely adequate as tive solution in view of the escalat- bus, whereby benchmark products gies of the city bus market. air conditioning in moderate cli- ing cost of coolant R134a. In order introduce air into the vehicle only mate zones and is a far more ef- to ensure that the Citysphere re- at certain points. Where the City- Here’s to 10 more successful years fective way of creating a comfort- mains an eco-friendly and reliable sphere guarantees a combination for Citysphere! able interior climate in the city bus. city bus solution in future, Valeo is of cooling and patented direct air

Major order in Utrecht/Netherlands: 138 Mercedes-Benz Citaros, each with three Major order for Rheinbahn AG: 74 Solaris New Urbino articulated buses, Citysphere units for the Solo and five for the articulated bus (in total 558 Citysphere each with three Citysphere units. units).

Technik Service News 02/2018 5 COMPANY NEWS

Christian Schilder PROMOTED TO HEAD OF AFTER-SALES

With effect from 01.10.2018 Christian Schilder, 47 years old, assumed the role of Head of After-Sales. He is thus responsible for the service and spare parts management sector, as well as the supervision of public passenger transport, chassis manufacturers and service partners.

In his capacity as new Head of level of expertise in After-Sales as After-Sales, he is responsible for plant manager Service & Sales at the pan-European expansion of the Scania Deutschland GmbH and pre- dealer organisation structure with vious to that as Service Manager at a focus on service and spare parts MAN Truck & Bus Germany Division. management. In particular, the co- He completed his law studies with operation with selected, qualified an MBA in General Management and certified service partners will Competences at the universities play a key role. With the advanc- of Linz and Krems (). In ad- ing developments in electromobil- dition, he also passed the Master ity, his tasks will include in ongoing Examination in Motor Vehicle Me- support and consultation for HVAC chanics. systems in buses with alternative drives.

Prior to his employment at Valeo, Schilder was able to gain a high Christian Schilder

Klaus Flörsheimer APPOINTED TRAINING MANAGER

Valeo Thermal Commercial Vehicles has recruited Klaus Flörsheimer in the role of training manager. As of the beginning of next year he will assume responsibility for the expansion of the pan-European training programme.

Klaus Flörsheimer has been em- special training programmes of- ployed by the company since 2001 fered worldwide for trainers (Train and in the past few years he has the Trainer) at partners, manufac- been responsible as applications turers and Valeo locations. Besides engineer for the customers Iveco this, with technical innovations Bus and the train manufacturer Al- greater use is to be made of online stom. In addition, he has worked media for fast data retrieval. as project manager on an air con- ditioning system for Alstom’s iLint Prior to his employment at Valeo/ train. In his new position he will Spheros he spent several years in be responsible for the training pro- technical field service for Webasto gramme for vehicle manufacturers, Bus GmbH (subsequently Spheros public transport undertakings, ser- GmbH). He completed his studies in vice partners and workshops. He mechanical engineering at the Vo- will also be carrying out in-house cational College in Mannheim. training on products and related technologies at the Gilching loca- tion. Further tasks and goals lie in Klaus Flörsheimer

6 Technik Service News 02/2018 COMPANY NEWS

The Thermal Systems Division for the Bus presented itself for the first time in Hall 16 at IAA together with the Valeo Group. LOOKING BACK ON A SUCCESSFUL IAA

Over 250,000 visitors came to this year’s IAA in Hanover, to gain an overview of industry innovations. And the proportion of industry specialists exceeded 80%! The focus of the leading trade fair for Transport, Logistics and Mobility was on areas of future interest: electromobility, digitisation and urban logistics. The central message of this IAA was: Electromobility is coming to our streets; the models are going into series production! This applies in particular to e-transporters, and increasingly to city buses.

Valeo is also looking back on a suc- nents such as the emission-reduced cessful trade fair experience: the Thermo plus heater that is ideally Thermal Systems Division present- suited to use in the electrobus on ed itself for the first time in Hall account of its unrivalled low emis- 16 together with the Valeo Group. sion values, and its SPump pump Here again, the predominant topic generation with the new PWM and was electromobility. The air con- CAN versions. ditioning specialist celebrated a world premiere at the leading trade We thank all customers, service fair for commercial vehicles with partners and other interested par- the new REVO-E Pro. The new roof- ties for their numerous visits to our top air conditioning unit for electro- trade fair stand and the construc- buses is responsible for cooling and tive discussions that took place. heating the electrobus. With its heat pump technology it manages to efficiently heat the electrobus even at outside temperatures of up to -15 °C and thus possesses a unique selling point on the market. In addition, the Product Group TCV (Thermal Commercial Vehicles) showcased efficient HVAC compo- With the new REVO-E Pro Valeo celebrated a world premiere.

Technik Service News 02/2018 7 COMPANY NEWS

Retrofitted bus with electric drive at eMove360° Exhibition in Munich.

First e-trofit bus with Valeo HVAC system at eMove360° Exhibition REFITTING INSTEAD OF RE-BUYING: A NEW LEASE OF LIFE FOR DIESEL BUSES

At the world’s biggest trade fair for electromobility and networked and autonomous driving “eMove360°” in Munich from 16–18 October 2018, in-tech GmbH presented itself with its first e-trofit prototype bus.

The engineering company speciali- Holistic approach sel) in one device. Emission-free ing of the driver’s section, sidewall sing in electronics and software to air conditioning preheating is thus possible before heaters for heating the floor zone, has set itself the goal of con- One of the key components is the going on the road, and at low out- as well as all small parts such as verting existing diesel buses to newly developed REVO-E Pro with side temperatures additional fossil- valves and sensors. electric drive – retrofitting heat pump technology for electro- fuel heating is possible in order to that is modularly and individually buses. The all-electric rooftop unit avoid an unnecessary load on the The different system components adapted to the different customer is capable of simultaneous air con- traction battery storage. can be interconnected and con- requirements. Compared to the ditioning and heating. trolled in combination with intelli- new purchase of an e-bus, a con- The newly developed SPump 500 W gent software via the central con- version is up to 50% less costly and Due to its optimised heat pump CAN version ensures coolant flow. trol unit HMI SC1000. Depending gives the diesel bus, so-to-speak, a with virtual icing sensors and a With a flow rate of over 10,000 l/h on outside conditions (mainly tem- new lease of life. In addition, this fully automatic hot gas defrosting, and high counterpressure stability perature), the battery charging sta- approach saves the consumption of the unit can be operated at outside (0.5 bar counterpressure) the pump tus and the geographical position valuable resources and the solution temperatures of up to -5 °C (cool- delivers the required high power the control system always selects is therefore extremely sustainable. ant R134a) and up to -15 °C (cool- needed for e-bus applications. The the component with maximum ef- Besides the total electrification of ant R449A). CAN interface permits demand-ori- ficiency. Through this holistic ap- the drive, the refitting is focused ented speed control, which enables proach to ecological and economi- on the complete replacement of At low outside temperatures the optimum tuning to the overall ve- cal air conditioning of electrobuses the vehicle’s HVAC system. In this Thermo H is ideal as an auxiliary hicle systems, conserving energy at the highest level, the limited project, Valeo is responsible for the heating concept to supplement and increasing the range. energy resources of the traction total heating and air conditioning the heat pump. The hybrid heater battery are put to best-possible works, and supplies all the neces- combines the advantages of both Furthermore, the delivery contents use and the range of the vehicle is sary devices and components. energy forms (electricity and die- include a frontbox for air condition- maximised.

8 Technik Service News 02/2018 COMPANY NEWS

ELECTROBUSES: VALEO, SWM AND MVG AGREE TO INNOVATION PARTNERShIP

Stadtwerke München (SWM) and Münchner Verkehrsgesellschaft (MVG) have become key drivers in the development of electrobuses: to this end SWM and MVG have entered into an innovation partnership with Valeo. The purpose of the joint venture is to realise more efficient air conditioning and heating in electrobuses by the use of a heat pump.

Besides the joint venture with Va- leo, further innovation partnerships already exist between MVG and the vehicle manufacturers MAN and EBUSCO B.V. The basic purpose of the cooperations is to test new products or develop partial compo- nents under real operating condi- tions at MVG.

Latest generation of heat pump At the focus of the partnership with Valeo is the conversion of an e-bus already in operation at MVG. This vehicle – fitted with the latest Valeo heat pump generation – is the first to be put into public ser- vice at MVG in Munich. The system The Valeo heat pump heater installed in this MVG service bus heats the passenger compartment even at temperatures should heat the passenger com- below zero. partment even in winter at temper- atures below 0° and as a fall-back all operational conditions and en- electrobuses constitutes one of the tems that – as far as possible – do solution it should make the existing vironmental parameters in long- primary challenges in the develop- not draw their energy from the diesel auxiliary heating virtually re- term operation along the line. The ment of series-production-ready vehicle batteries. Diesel auxiliary dundant. The heat pump that was analysis of the readings supplies e-vehicles. MVG Bus Manager Ralf heating can also only be an interim hitherto installed functions only at critical findings for Valeo, in its en- Willrett says: “The range and thus solution until heat pumps are so temperatures significantly above 0° C. deavours to make the heat pump deployment of our electrobuses efficient that they can operate at For system optimisation, the ve- technology even more efficient in should not be dependent on the full capacity in almost any weather. hicle was fitted out with extensive the long term. In addition to bat- weather. That is why we need We want the operation of our measuring instruments that record tery efficiency, air conditioning in heating and air conditioning sys- e-buses to be climate-neutral.”

TRADE FAIRS AND EXHIBITIONS 2019

WE ARE LOOKING FORWARD TO MEETING YOU

Date Trade Fair Location February 05 – 06.02.2019 10th VDV Conference on Electrobuses Berlin, Germany March 19 – 21.03.2019 BUS2BUS Berlin, Germany 21 – 23.03.2019 Transport 2019 Herning, 01 – 02.03.2019 Hausmesse TS Fahrzeugtechnik Weida, Germany April 08 – 14.04.2019 bauma München Munich, Germany May 07 – 10.05.2019 FIAA Madrid Madrid, June 09 – 12.06.2019 UITP Global Public Summit Stockholm, April & June Solarisposium October 02 – 03.10.2019 Coach and Bus UK NEC Birmingham, UK 18 – 23.10.2019 Busworld Europe Brussels, Belgium November 21 – 23.11.2019 Czechbus Prague,

Technik Service News 02/2018 9 PRODUCT INNOVATIONS

Use of alternative fuels in Valeo bus heaters FOR THE SAKE OF THE ENVIRONMENT

Valeo now offers its fuel-burning Thermo heaters for use with alternative fuels such as HVO (hydrogenated vegetable oils) and GtL (gas-to-liquids) an. With up to 50% less soot particles and CO2 emissions the heaters are even more climate-friendly.

Due to their nature (HVO consists in compliance with the requested of vegetable oils / GtL is a syn- retrofit of fuel hoses and filters, the thetic diesel fuel that is produced heaters Thermo, Thermo E, Thermo S from biogas, among other things) and Thermo plus are now designed alternative fuels reduce green- according to DIN EN 15940 for use house emissions, are simple in ap- with alternative fuels such as HVO plication, odourless and guarantee and GtL. already installed heaters clean and efficient burning of the can also be retrofitted at any time, fuel. Particularly the CO2 avoidance thus reducing emissions. potential of HVO and GtL in contrast to conventional fossil fuels must be The extension to include alternative noted. fuels makes Valeo Thermo heaters Furthermore, alternative fuels are attractive not only for diesel buses, 100% renewable and sustainable. but also for use in electrobuses. For due to the limited energy resources Clean combustion Valeo’s fuel burning Thermo heaters are suitable for the use of alternative fuels the latter is still reliant on an ad- in the heater such as HVO and GtL. ditional, fuel-operated heater at The use of alternative fuels in bus lower outside temperatures. heaters results in a brighter flame in the burner that is more difficult combustion behaviour. With the guarantee perfect functioning of for the flame detector to recog- use of an additional component both flame recognition and com- nise and may adversely impact the and optimised software, Valeo can bustion stability.

50 VOLVO HYBRID BUSES WITH VALEO’S REVO-E A/C SYSTEM FOR SINGAPORE

The Land Transport Authority (LTA) in Singapore has signed a contract with Volvo Buses for the delivery of 50 hybrid chassis. Egyptian body builder MCV is constructing the bodywork. The buses are being air conditioned by Valeo’s REVO-E all-electric rooftop air conditioning unit.

In order to ensure a pleasant inte- oriented depending on the avail- rior bus climate despite tropical cli- able energy, in order to avoid matic conditions, major alterations unnecessary stress on the traction must be made to the bus and its air batteries in the electric or hybrid conditioning system. On account of bus. To ensure that the bus interior the pioneering role of Singapore in is pleasantly cool, even in the hot south-east Asian local public trans- and humid climate of south-eastern port, the order is also pathbreaking , the system’s cooling capacity for other megacities in this region. had to be increased to 30 kW and the regulating parameters adjusted With a cooling capacity of 25 kW in order to reach the target tem- (European version) the REVO-E ex- perature. Furthermore, important cels in particular with its intelligent modifications were made on the energy management. The genera- buses: tinted double-glazing of the tion of cooling capacity is demand- windows and additional insolation Volvo 7900 Hybrid Chassis with the bodywork from MCV.

10 Technik Service News 02/2018 PRODUCT INNOVATIONS

of the bodywork and roof ducts 2018. The remaining buses are to east Asia on account of the hot on the subjects of sensitisation in now protect the bus from the ef- be delivered to Singapore by the and humid climate – and the sys- handling high-voltage technology, fects of extreme heat exposure. end of the year. tems are often up to 18 hours in control logics and in particular The fully-electric rooftop air condi- continuous operation – service and practical work or troubleshooting tioning unit is now able to cool the Service and maintenance maintenance play a critical role. For on the vehicle. A specialist of Valeo hybrid bus in extreme climatic con- training for LTA, MCV and this reason Valeo organised a train- Thermal Commercial Vehicles was ditions, offering optimum energy- Volvo ing workshop for the colleagues available directly on site. efficiency. The first vehicles were Because air conditioning has high from LTA, MCV and Volvo in which already handed over in September priority in public transport in south- important content was conveyed

The REVO-E Pro electric rooftop conditioning unit can be used at outside temperatures up to -15 °C.

REVO-E PRO: COOLING AND HEATING IN THE ELECTROBUS WITH EXTENDED OPERATING TEMPERATURE RANGE

With the new REVO-E Pro rooftop air conditioning unit with heat pump technology for electrobuses, due to go into series production in the second quarter of 2019, Valeo is celebrating a world premiere. Thanks to the virtual icing sensors and a fully automatic hot gas defrosting, the unit can be operated at outside temperatures of up to -5 °C with coolant R134a and up to -15 °C with R449A.

Icing of the external heat exchang- the vehicle battery are thus con- depending on the available energy. unit and the control concept is er, which occurs due to a physical served and the range is maximised. The electric compressor is infinitely uncoupled from the on-board sys- effect of the condenser when the adjustable, offers optimum effi- tems. The new air conditioning heat pump is operated at below A real stand-alone solution ciency and is extremely low-noise system can thus be installed in vir- 5 °C, is successfully eliminated by With a cooling capacity of up to 25 thanks to the physical scroll com- tually any bus worldwide, regard- the system’s defrosting device. This kW and a heating capacity of up to pressor. Together with the Valeo less of vehicle design. Due to the makes it possible to heat efficiently 16 kW the REVOE Pro also features control element SC 620, the REVO- integration of all components car- even at low outside temperatures intelligent energy management, E Pro is a real standalone solution, rying coolant, the closed system is with a high COP (coefficient of per- i.e. the cooling/heating output is i.e. all a/c and control components efficient, airtight and almost main- formance). The energy resources of generated according to demand, are compactly integrated into the tenance-free.

Technik Service News 02/2018 11 PRODUCT INNOVATIONS

THERMO E+ FOR MINI-, MIDIBUSES AND AS AN AUXILIARY HEATER FOR ELECTROBUSES

Based on the previous model Thermo E, the new Thermo E+ heater, alongside the 20 and 32 kW models, is the first 12 kW version. Whereas the first two were developed primarily for the Chinese, Russian and North American markets, the 12 kW version is suitable for use in mini- and midibuses worldwide.

As an auxiliary heating to supple- use in electrobuses, which are to- ed energy resources at low outside For the highest degree of service ment the heat pump, the Thermo day reliant on an additional fuel- temperatures. and maintenance friendliness, it of- E+/ 12 kW heater is also ideal for powered heater due to their limit- fers the option of fast data retrieval With a length of 435 mm and a via Valeo’s Diagnosis Thermo Test weight of 13.6 kg, the 12 kW ver- (DTT). In addition, the circulation sion is one of the shortest and most pump can be externally controlled lightweight heaters in its class. This without additional electronics and is in turn reflected in reduced fuel independently of the heater, fur- consumption. Available in 12 or 24 ther reducing fuel consumption. Volt as a single or dual fuel feed The Thermo E+ is also designed system, the Thermo E+ can be de- for use with alternative fuels such ployed at outside temperatures of as HVO (hydrogenated vegetable up to -40 °C and is thus extremely oils) and GtL (gas-to-liquids) in ac- powerful and robust. Highly ef- cordance with DIN EN 15940. The ficient heat transfer coupled with temperature sensors with a self- clean combustion help to achieve protection function furthermore the highest-possible efficacy. The guarantee a high quality and safety device produces emission values standard. that are significantly below the The new 12 kW version of the Thermo E+ is one of the shortest and most light- legal limits. weight heaters in its class.

PREMIERE: FUEL CELL TRAIN TAKES TO THE TRACKS

In mid-September, the world’s first hydrogen powered train – fitted with Valeo’s air conditioning system – started on its inaugural run in Bremervörde.

The emission-free regional train for the team. Valeo’s R&D teams “Coradia iLint” built by Alstom were thus involved in the project will operate regular services, car- right from the beginning. The chief rying passengers on a route of al- components of the modern, en- most 100 kilometres between the ergy-efficient air conditioning are towns of Bremervörde, Cuxhaven, the REVO-E rooftop air conditioning Bremerhaven and Buxtehude. Al- unit, the SPump recirculating pump stom is proposing to put a total and the Thermo DC electric heater of 14 hydrogen fuel cell-powered with intelligent control. The Valeo trains into operation for the Lower air conditioning system features Saxony Regional Transport Group control electronics that ensures a by the end of 2021. In the long high standard of communication term, hydrogen-powered fuel cell between all components and inte- Coradia iLint, the world’s first hydrogen-powered train. trains will be replacing diesel as a grates them into the vehicle’s over- means of propulsion on the rails. all system. Subject to the driving the German-French Alstom teams. Infrastructure. The development of profile and the available energy, it The emission-free passenger train the Coradia iLint was sponsored by Valeo air conditioning ensures that they are always work- was built in the largest production the Federal Government within the in the iLint ing at an optimum level. facility of French train manufacturer scope of the National Innovation The development of the climate Alstom in Salzgitter. The project has Program for Hydrogen and Fuel Cell concept for the hydrogen fuel cell About the “Coradia iLint” received the support of the Federal Technology (NIP). train represented a major challenge The Coradia iLint was developed by Ministry of Transport and Digital

12 Technik Service News 02/2018 PRODUCT INNOVATIONS

With new features such as variable speed control and an intelligent diagnosis function, the SPump circulation pump (PWM and CAN versions) saves energy and offers a solution for any application.

New SPump with additional PWM and CAN versions ELECTRICAL CIRCULATION PUMP WITH TOMORROW’S TECHNOLOGY

Valeo has added three new versions to the SPump product family: the electric circulation pump with ON/OFF control is now available with additional control and communication interfaces PWM (pulse width modulation) and CAN, together with a more powerful 500 W version. By virtue of new features such as a variable speed control and intelligent diagnosis function, the pump now consumes particularly low levels of energy, making it the designated solution for all kinds of commercial vehicles with hybrid, plugin or electric drive.

The pumps represent the core and records critical operating data. to a modular concept, up to nine with integral controller permit di- piece of the water circuit and serve That makes the pump particularly pumps can be installed in a system verse installation options for the to ensure the coolant flow in pre- interesting for commercial vehicles under one part number. Installa- pump. Additional functions such heating or cooling mode, as well with hybrid, plugin or electric drives tion is easy and fast, thanks to the as an anti-lock system, extended as when the vehicle is on the road. that are reliant on efficient energy reduced cabling requirements. Fur- run-dry protection, optional speed The SPump circulation pump with management. The SPump PWM/ thermore, an additional 500 W CAN control (PWM or CAN signal) and the new PWM and CAN (Interface) CAN can also be deployed in the version offers the high performance self-protection in the event of versions offers further critical ad- areas of agriculture, construction needed for e-bus applications with overheating make the SPump to be vantages for the customer: both machines, for cooling of electri- a flow rate of over 10,000 l/h (at suitable for extreme climatic condi- versions have a variable speed cal components (e.g. battery) and 0.5 bar counter-pressure). tions. In addition, the pump is ideal control, enabling optimum syn- other special applications. for higher outside temperatures chronisation with the vehicle’s The SPump pump generation (from -40 °C up to +95 °C). With overall system and curbing energy SPump CAN for even more at a glance a service life exceeding 30,000 consumption, thus increasing the flexibility and performance Shorter dimensions of 205 mm, hours, the flow rates and flow char- range. In addition, the intelligent The customised parameter con- lower weight of 2.3 kg (compared acteristics with counterpressure are diagnosis function in the pump is- figuration of the CAN versions also to its predecessor, the Valeo Aqua- 50% increased compared to the sues early warning signals on the permits flexible integration into vent) and watertight, magnetically previous series. basis of automatic error recognition various vehicle systems. Thanks coupled EC motor (IP6K9K tested)

Technik Service News 02/2018 13 PRODUCT INNOVATIONS IVECO CROSSWAY LE NOW AVAILABLE WITH CITYSPHERE A/C SYSTEM

Valeo was commissioned by Verkehrsbetrieb KVG Stade GmbH to install air conditioning systems in 60 Iveco Crossway Low Entry (LE) vehicles for deployment in Stade, Buxtehude, Lüneburg, Wolfsburg and Celle. The bus operator had set its pre- ference on the modular Citysphere a/c unit, with appealingly low life-cycle costs. The Crossway was thus available for the first time with a Valeo air conditioning system ex works in Vysoké Myto (Iveco Czech Republic). The vehicles were already delivered to the transport undertaking in August 2018.

ing distinguished itself in major respects from conventional full air conditioning. It quickly became clear that the modular Citysphere a/c unit was the right solution. In addition to its unique, patented air circulation system in the passenger compartment, the unit features significantly lower life-cycle costs. What is so special about the City- sphere: in contrast to full air con- ditioning the increase in fuel con- sumption is hardly noticeable. Each of the 60 Iveco vehicles has been equipped with a master system for the front, and a slave system for the rear passenger compart- The Iveco Crossway LE is now available ex works with Citysphere. ment. Valeo has been supporting KVG Stade in the selection of an air conditioning system at every With a production area of over triebe Osthannoversche VOG, Cebus Citaro, MAN Lion’s City, and stage since the publication of the 225,000 m2 and more than 3,000 and Verkehrsbetriebe Bachstein. Volvo buses – 100% equipped with tender. “The excellent cooperation vehicles built every year, the Iveco These companies operate regular Valeo HVAC systems. and commitment of the people at facility in the Czech Republic is one bus services in Buxtehude, Cux- Valeo, together with the eco- of Europe’s leading manufacturers haven, Lüneburg, Stade and Win- 120 Cityspheres friendly and LCC-optimised air con- of city and intercity buses. sen (Luhe) together with overland for KVG Stade ditioning systems, were key factors lines, school and commuter services The tender requirements for the in our decision,” says Thies Henning About Busgruppe KVG Stade in districts of Cuxhaven, Harburg, vehicles in accordance with VDV Di- Tietje (Technical Director of Bus- The members of Busgruppe KVG Lüneburg, Rotenburg (Wümme) rective 236/1 included a life-cycle gruppe KVG Stadt GmbH). Stade with head office in Stade are and Stade. The company’s fleet cost-optimised on-board system Kraftverkehr Lüneburg, Verkehrsbe- mainly consists of Mercedes-Benz whose method of air condition-

60 Iveco vehicles were each equipped with a master unit for the front The air diffuser plate of the Citysphere provides the unique wind-chill effect in the and a slave unit for the rear passenger compartment. passenger compartment.

14 Technik Service News 02/2018 New Technologies

MEASURES TO IMPROVE THE COMBUSTION PROCESS IN VALEO DIESEL HEATERS: THE DUST PROTECTION KIT

Valeo is constantly working on the the flame. This can lead to malfunc- dust protection kit can be quickly improvement of its heaters. A re- tions in the combustion process or and easily retrofitted in all diesel curring theme in the use of these even flame cut-out, and an entry is heaters as needed. heaters is the soiling of the viewing made in the error memory. window on the disk (see Fig.) due The following overview shows to dirty combustion air suctioned in A dust protection kit has been de- which dust protection kit is right for by the heater. This dirt accumulates veloped in order to avoid these your heaters: on the viewing window of the disk, malfunctions. Retrofitting this kit with the result that the flame de- prevents the contamination of the tector is hardly able to recognise viewing window in the disk. The Disk with ID number 88440

Technik Service News 02/2018 15 BEHIND THE SCENES

Testing heaters/circulation pumps ENDURANCE TESTING TO ENSURE LONG-TERM WARMTH…

An important building block in our product development is testing up to the end of the service life. For example, our salt-spray mist chamber in Neubrandenburg exposes heaters and individual components to environmental simulation. Because our heaters are used in a wide range of altitudes, we also test in the Alps at heights of up to 2,800 m.

Testing environmental Endurance testing ment and control instruments are Further test stands at our simulation of circulation pumps attached. A further component of Neubrandenburg location: A corrosive atmosphere is created Up to ten circulation pumps can the test stand is a measurement - walk-in climate chamber (tem- in the test chamber by spraying a be tested fully automatically un- cabinet for recording readings and perature range -40 °C to +100 °C) saline solution that simulates an der close-to-real-life conditions on powering the batteries. The sys- - Temperature shock chamber accelerated corrosive attack on the the state-of-the-art endurance test tem has a medium and ambient (temperature range -70 °C to samples. Real ambient conditions stand. The test stand consists of a temperature control. In addition, +200 °C) can be accelerated at different climate chamber, a heating and system pressure and the respective - heater endurance tests rates by varying the concentration cooling aggregate for the water flow can be set differently. - motor measurement test bench of the saline solution, temperature circuit and a storage tank, to which - Fuel pump test stand and pH value. the feed lines with the measure-

Testing heaters/circulating pumps

16 Technik Service News 02/2018