Webasto Blue Bird Scholastic Series, Transit Model (Engine Front), Transit Model (Engine Rear) User Manual

The Scholastic Series School Bus Heater

Operating Instructions Installation Instructions Service Parts Listing

For:

Conventional Model Transit Model (Engine Front) Transit Model (Engine Rear)

TABLE OF CONTENTS

Table of Contents

1. Introduction

1.1 Scope and Purpose .................................................... 1-1

1.2 Meaning of Warnings, Cautions and Notes .................................. 1-1

1.3 Additional Documentation to be Used ...................................... 1-1

1.4 General Safety Regulations and Information ................................. 1-1

1.4.1 General Safety Notes ........................................... 1-1

2. General Description

2.1 Scholastic Heater Description ............................................ 2-1

3. Functional Description

3.1 Operating your Webasto Scholastic Heater .................................. 3-1

3.2 Switching On ......................................................... 3-1

3.3 Switching Off ......................................................... 3-2

3.4 Engine Preheating ..................................................... 3-2

3.5 Boost Heating for Engine and Passenger Compartment ......................... 3-2

3.6 Operation with 7-Day Digital Timer Model 1531 ............................... 3-2

3.7 7-Day Digital Timer Programming and Operating Instructions ..................... 3-4

4. Technical Data

4.1 Scholastic Series Heater Data ............................................ 4-1

4.1.1 Scholastic Series Heater Dimensions ............................... 4-2

4.2 Coolant Circulation Pump Data ........................................... 4-3

4.2.1 Coolant Circulation Pump Dimensions ............................... 4-3

4.3 Tray Mount Dimensions ................................................. 4-4

5. Installation

5.1 General Information .................................................... 5-1

5.2 Installation Locations ................................................... 5-1

5.3 Mounting the Heater ................................................... 5-2

5.4 Exhaust Pipe Connection ............................................... 5-2

5.5 Combustion Air Supply ................................................. 5-3

5.6 Plumbing into the Coolant System ......................................... 5-3

5.6.1 General Information ............................................. 5-3

5.6.2 Engine and Passenger Compartment Heating ......................... 5-4

5.6.3 Instructions for Integrating into the Coolant System ..................... 5-5

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TABLEOFCONTENTS

5.7 FuelSystem.........................................................5-7

5.7.1 GeneralDescription.............................................5-7

5.7.2 FuelSupply...................................................5-7

5.7.3 FuelFilter....................................................5-9

5.8 WiringConnections....................................................5-10

5.8.1 GeneralInformation.............................................5-10

5.8.2 ConnectingPowerHarnesstoaConstantPowerSource.................5-10

5.8.3 TimerandSwitchConnections....................................5-11

5.8.4 TimerandSwitchInstallation......................................5-11

5.8.5 WiringDiagram-ScholasticSeriesHeater...........................5-12

5.8.6 WiringDiagram-Chassis/PowerHarnesswithSwitch..................5-13

5.8.7 WiringDiagram-Chassis/PowerHarnesswithSwitch..................5-14

5.8.8 WiringDiagram-Chassis/PowerHarnesswithDigitalTimerModel1531....5-15

5.8.9 WiringDiagram-Chassis/PowerHarnesswithDigitalTimerModel1531....5-16

5.9 InitialOperation.......................................................5-17

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6. MaintenanceoftheHeater

6.1 AnnualMaintenance...................................................6-1

7. BasicTroubleshooting

7.1 GeneralInformation....................................................7-1

7.2 QuickCheckTroubleshootingMatrix.......................................7-1

7.3 HeaterTestUnit(WebastoP.N.440280)....................................7-2

7.4 TestProcedures......................................................7-3

8. SparePartsListing

SparePartsListing....................................................8-1

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TABLE OF CONTENTS

III

List of Figures

2-1 Webasto Scholastic Series Heater ......................................... 2-1

3-1 7-Day Digital Timer – Typical ............................................. 3-3

4-1 Scholastic Series Heater Dimensions (Millimeters) ............................. 4-2

4-2 Coolant Circulating Pump Assembly (P.N. 906017) Dimensions (Inches) ............ 4-3

4-3 Tray Mount Dimensions (Inches) .......................................... 4-4

5-1 Installation Locations ................................................... 5-1

5-2 Tray Mount Template (Supplied with Heater Kit) ............................... 5-2

5-3 Typical School Bus Heating Circuit ........................................ 5-3

5-4 Series Plumbing Circuit - Conventional Model ................................ 5-4

5-5 Series Plumbing Circuit - Transit Model (Engine Front) ......................... 5-4

5-6 Series Plumbing Circuit - Transit Model (Engine Rear) .......................... 5-5

5-7 Fuel Standpipe Installation ............................................... 5-7

5-8 Fuel Line Parameters .................................................. 5-8

5-9 Harness Connection Points ..............................................5-10

5-10 On/Off Switch ........................................................5-11

5-11 7-Day Digital Timer Model 1531 ...........................................5-11

5-12 Wiring Diagram - Scholastic Series Heater ..................................5-12

5-13 Wiring Diagram with Switch ..............................................5-13

5-14 Wiring Diagram with Switch ..............................................5-14

5-15 Wiring Diagram with Timer Model 1531 .....................................5-15

5-16 Wiring Diagram with Timer Model 1531 .....................................5-16

7-1 Test Unit P.N. 440280 .................................................. 7-2

List of Tables

3-1 Digital Timer Instructions ................................................ 3-4

4-1 Scholastic Series Heater Data ............................................ 4-1

4-2 Coolant Circulation Pump Data ........................................... 4-3

7-1 Quick Check Troubleshooting Matrix ....................................... 7-1

7-2 Test Procedures and Results ............................................. 7-3

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1INTRODUCTION

1-1

1. Introduction

1.1 Scope and Purpose

This manual is intended to support authorized Webasto trained distributors, dealers and personnel in the installation of the Scholastic Series coolant heater.

Webasto Thermosystems, Inc. does not recommend the installation and servicing of Webasto products by untrained, unauthorized personnel or end-users.

Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users will release Webasto Thermosystems, Inc. and Webasto authorized distributors, dealers and personnel from responsibility for damage to Webasto product or collateral property and personal injury.

Any use, operation, installation, modification or application of the product not described in Webasto manuals, or subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics is misuse of the product.

Failure to comply with all installation instructions is a misuse of Webasto product. The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters “Official Marks of Conformity.”

1.2 Meaning of Warnings, Cautions, and Notes

Warnings, Cautions and Notes in this manual have the following meaning:

1.3 Additional Documentation to be Used

This manual contains all of the information and procedures necessary for the installation of the Scholastic Series heater.

The use of additional documentation is normally not necessary. Vehicle specific installation guides (when available) may be used as complementary information if necessary.

1.4 General Safety Regulations and Information

The general safety regulations for the prevention of accidents and relevant operating safety instructions must be observed at all times.

The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings, Cautions and Notes.

1.4.1 General Safety Notes

The heater may only be installed in vehicles, with a minimum coolant capacity of 10 litres (2.6 US Gal.).

The heater must not be installed in the passenger compartments of the vehicle. Should the heater be installed in such a compartment, the installation box must be sealed tight against the vehicle interior. There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 60 °C (140 °F) in the installation box. Excessive temperatures may cause malfunctions.

NOTE:

This heading is used to highlight and draw specific attention to information.

CAUTION

This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment.

WARNING

This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents to personnel.

WARNING

Due to the danger of poisoning and suffocation, the heater must not be operated in enclosed areas, such as garages or workshops, without an exhaust venting system, not even if the start-up is activated by the timer or remote start device.

At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosions.

Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal grain deposits or similar situations) the heater must be switched off to prevent explosions.

1INTRODUCTION

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1-2

In the vicinity of the coolant heater, a temperature of 85 °C (185 °F) must not be exceeded under any circumstances (e.g. during body paint work). A violation of this temperature limit may cause permanent damage to the electronics.

When checking the coolant level, proceed in accordance with the vehicle manufacturer’s instructions.

The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based anti-freeze.

Extracting combustion air from the vehicle interior is not permissible under any circumstance.

The exhaust line outlet is to be positioned below the vehicle floor, to the nearest possible location of the vehicle’s left side. Exhaust pipes must be routed so that exhaust fumes will not penetrate into the vehicle’s interior.

The function of any parts vital for vehicle operation must not be impaired. Condensation accumulation in the exhaust line must be directly drained. Acondensation drain hole may be provided as required.

Electrical lines, switch gear, and control gear of the heater must be located in the vehicle so that their proper function cannot be impaired under normal operating conditions.

The coolant heater may only be operated within the specified operating voltage range designated by type.

The coolant heater may only be operated with the specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene and certain military spec. fuels).

For the routing of fuel lines, the following important regulations must be adhered to:

• Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by vehicle and engine movement. They must be protected against mechanical damage. Fuel lines must be securely fastened to the vehicle every 30 cm. (12 inches) or more often along the total length from heater to fuel tank. Fuel-carrying parts are to be protected against excessive heat and are to be installed so that any dripping or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment.

• In buses, fuel lines are not to be located in the passenger area or in the driver’s compartment. Fuel supply must not be by means of gravity or pressurization of the fuel tank.

• The fuel tank must either be equipped with a vent cap or be ventilated in another way (ventilation line).

• The operational state of the heater, i.e. an indication “On” or “Off”, must be clearly visible to the operator.

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2GENERAL DESCRIPTION

2-1

1 Electronic control unit 2 Motor 3 Electronic ignition coil 4 Coupler 5 Combustion air fan 6 Solenoid valve 7 Electrode holder 8 Outlet water pipe - 25 mm (1 in. OD.) 9 Inlet water pipe - 25 mm (1 in. OD.)

The Webasto Scholastic Series Heater has been designed for use on diesel powered school buses. Equipped with 1-inch coolant line connections, heavy-duty coolant pump, single fuel line and additional safety features makes this an ideal choice for school bus applications.

Webasto Scholastic Series Heaters are designed to:

1. Preheat Engine block of liquid cooled engines to ensure reliable starting in cold weather and to reduce cold start wear and emissions (white smoke).

2. Boost heating levels with the engine running. The heater will boost the heating system in cold weather when an engine is running at light loads, even at high speeds or idling. The heat rejection of modern diesel engines to the coolant, especially in school buses, is often not adequate to heat the vehicle’s interior.

3. Increase Safety by providing higher levels of heat for quick defrosting of windshield and side glass for greatly improved visibility.

2. General Description

2.1 Scholastic Heater Description

Fig. 2-1: Webasto Scholastic Series Heater

10 Ignition electrodes 11 Fuel nozzle 12 Overheat fuse 13 Control thermostat 14 Overheat limiter 15 Heat exchanger 16 Exhaust pipe 17 Combustion air swirler 18 Combustion tube

19 Flame detection photocell 20 Fuel pump (single line, no return) 21 Fuel connection pipe (JIC #4) 22 Combustion air intake 23 Reduction gearing 24 Nozzle preheat cartridge 25 Preheat thermostat 26 Bleed screw

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3FUNCTIONAL DESCRIPTION

3-1

3. Functional Description

3.1 Operating your Webasto Scholastic Heater

Before switching the Webasto heater on, set vehicle-heating system to the “Heat” position and open any shut off valves. Depending on the type of control installed in the instrument panel of the vehicle, the heater can be operated by the following methods.

WARNING

Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction.

WARNING

Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations.

WARNING

Due to the risk of explosion, the heater must never be operated in areas where explosive materials, fumes or dusts may be present.

3.2 Switching On

Timer: Switch:

Using a Timer:

Upon pressing the “Instant Heat” button on the timer face, the “Operation Indicator” on the timer lights up and the heater begins operation.

Using a Switch:

When the switch is used for switching “ON” the Webasto heater, the “Operation Indicator” integrated in the switch is illuminated.

Heater Start-up Sequence:

The heater motor and coolant circulating pump begin operation. After approximately 10 to 25 seconds the fuel solenoid valve opens and fuel is sprayed into the combustion chamber. At the same time, the electronic ignition coil produces a high voltage (8000 V) spark at the tip of the ignition electrodes and the mixture of fuel and air in the combustion chamber is ignited. As soon as combustion is detected by the photo resistor (flame detector), the electronic ignition coil is de-energized and combustion continues on its own (ignition process is only required to ignite the flame). At this point the heater is working and producing heat.

The Webasto heater will cycle on and off until:

1. The Webasto heater is switched off.

2. Time has elapsed on the timer.

3. The vehicle battery voltage drops below 10.5V.

4. The Webasto heater runs out of fuel.

5. A fault lock out occurs, indicated by the operating indicator light being off during the cool down cycle (as would happen during an overheat situation).

3FUNCTIONAL DESCRIPTION

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3-2

3.3 Switching Off

When heating is no longer required, switch the Webasto heater off. The fuel solenoid valve halts the fuel supply, combustion stops and the indicator light turns off. The Combustion air fan and the water pump remain on for another 2-3 minutes (after run cycle) purging the combustion chamber of any fumes.

3.4 Engine Preheating

1. Set the timer 30 min. to 1 hr. before you want to start the engine. The heater will start up at the set time. (See timer operating instructions). Or switch the toggle switch or “Instant On” switch on your timer in the vehicle dash to “ON”. The heater will start up.

2. When the run time has elapsed on your timer or engine preheating is no longer required, switch the Webasto heater “OFF”. The heater will begin a brief after-run (cool down) cycle.

3.5 Boost Heating for Engine and Passenger Compartment

1. Switch the toggle switch (or the “Instant On” button of the timer) in the vehicle dash to “On”. The heater will start up if the coolant temperature is below 75 °C (167 °F). Above this temperature only the water pump will run.

2. When boost heating is no longer required, switch the Webasto heater “Off”. The heater will begin a brief after-run (cool-down) cycle.

3.6 Operation with 7-Day Digital Timer Model 1531

The digital timer with 3 time settings permits the Webasto heater to be switched on and off instantly, or automatically at 3 programmable starting times.

The operating time of the heater can be pre-selected. It is possible to program 3 different heating programs according to your individual needs.

Only one preset starting time can be activated at any one time. When the ignition is switched on, the current time of the day and the day of the week are displayed.

When the heater is in operation, the display and the buttons of the timer are illuminated.

Programmed Heater Operation

Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week.

Pre-selected Starting Times

The pre-selected starting time is the time at which the heater will be switched on automatically. We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours of setting the

timer. Memory location 3 can be used for a starting time within the next 7 days of setting the timer.

NOTE:

If the heater is switched on while the engine is at operating temperatures above 68 °C (155 °F) only the operation indicator and the coolant circulation pump will be activated. The engine coolant temperature must fall below 68 °C (155 °F) at the heater before the heater will begin heating operation.

NOTE:

Switching the Webasto heater on during the cool-down or “after-run” period is allowed. The heater will revert to normal operational mode.

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3FUNCTIONAL DESCRIPTION

3-3

Operating Time

The period of time during which the heater is in operation is referred to as operating time. The heater remains in operation for as long as the operating time has been preset.

Heater operation can be pre-selected for any time from as little as 1 minute to a maximum of 120 minutes (factory preset is 60 minutes).

Remaining Operating Time

The remaining operating time refers to the period of time the heater still continues to remain in operation. It can only be changed while heater is in operation.

Fig. 3-1: 7-Day Digital Timer Model 1531

Setting the Digital Timer

After the power has been connected, all symbols on the digital display are flashing. The time of the day and the day of the week must be set.

All flashing displays and symbols of the timer can be set by means of the and buttons.

If the and buttons are not pressed within 5 seconds, the currently displayed time or function will be stored. When the and buttons are pressed for more than 2 seconds, the quick digit advance mode is activated.

NOTE:

If the ignition is switched off while the heater is in operation, the remaining operating time of 5 minutes flashes on the timer display and the heater continues to operate for this period of time. See “Remaining Operating Time” to adjust this time setting.

NOTE:

We recommend that memory locations 1 and 2 be used for presetting starting times within a 24 hour period of setting the timer. Memory location 3 can be reserved for a starting time within the next 7 days of setting the timer. Location 3 is useful for occasional weekend or field trip operations outside of the normal schedule. By repeatedly pressing the

button, starting time program 1, 2 or 3 can be viewed and preset.

3FUNCTIONAL DESCRIPTION

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3-4

3.7 7-Day Digital Timer Programming and Operating Instructions

Setting the time and day of the week

Viewing the time

Switching heater on for instant heater operation

Switching the heater off

Programming heater-starting time

Recalling/canceling pre-selected times

Programming duration of operating time

Setting the remaining operating time

Press the button for more than 2 seconds. Time display flashes.

Press the or button to set time of day. Wait 5 seconds. Time is now stored. Day of week flashes.

Press or button to set day of week. Wait 5 seconds. Day of week is now stored.

With ignition “ON”: Continuous display of current time and day of the week. With ignition “OFF”:

Briefly press button. Display of current time and weekday appears for 5 seconds.

With ignition “ON”: Press button. Heater is switched on (continuous heating) and continues to operate until button is pressed again or

ignition is switched off. With ignition “OFF”:

Press button. Heater is switched on for the preset operating time (the factory-set heater operating duration is 60 minutes).

Press button. Heater begins cool-down (after-run) cycle and is switched off thereafter.

Press button. Memory location number flashes. Press or button to preset starting time.

Wait 5 seconds. Preset starting time is now stored. Day of week flashes.

Press or button to set day of week. Wait 5 seconds. Day of week is now stored. The number of memory location remains on the display. The timer is now in the programmed mode and switches heater on at the preset time.

To recall: Press button until the desired memory location number is displayed. Read off preset time.

To cancel: Press button repeatedly until no memory location numbers are visible on the display.

The heater must be switched off. Press the button. Operating time flashes.

Press or button to set operating duration time (between 1 and 120 minutes).

Heater must be in operation. Press button. Remaining operating time flashes. Press or button to set remaining operating time.

Wait 5 seconds. Remaining operating time is now stored.

Table 3-1: Digital Timer Instructions

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4TECHNICAL DATA

4-1

4. Technical Data

4.1 Scholastic Series Heater Data

The following data is subject to the normal tolerance for heaters, if no tolerance is specified. This is approximately +/-10% in an ambient of 20 °C (68 °F) at nominal voltage.

Heater Scholastic Series

Design Coolant heater with high-pressure nozzle Heat Output kW (BTU/hr) 13.1 (45,000) Fuel Diesel #1 Diesel #2 and Arctic Fuel Consumption l/hr (gal/hr) 1.5 (0.4) Rated Voltage (V) 12 Operating Voltage (V) 10 - 14 Power Consumption w/o Water pump (W) 60 Permissible Ambient Temperature

during Operation °C (°F) -40 ... +60 (-40 ... +140) Storage Temperature °C (°F) +85 max. (185 max.) Min. Capacity of Cooling System l (gal) 10 (2.6) Permissible Operating Pressure

of Coolant bar (psi) 0.4-2(06-29) CO in Exhaust Gas ppm 32 CO2 in Exhaust Gas % by Vol. 10 +/-0.5 NOx in Exhaust Gas ppm 70 HC in Exhaust Gas ppm <5 Emission Bacharach 1 Dimensions of Heater L 584 (23)

W 205 (8.1)

mm (inch) H 228 (9) Dimensions of Heater Enclosure L 603 (23.75)

W 305 (12)

mm (inch) H 254 (10) Dimensions of Heater Tray Mount L 603 (23.75)

W 305 (12)

mm (inch) H 228 (9) Weight on Tray kg (lb.) 27 (60) Weight of Heater incl. Control Unit kg (lb.) 15 (33)

Table 4-1: Scholastic Series Heater Data

4TECHNICAL DATA

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4.1.1 Scholastic Series Heater Dimensions

Fig. 4-1: Scholastic Series Heater Dimensions (Millimeters)

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4TECHNICAL DATA

4-3

4.2 Coolant Circulation Pump Data

Flow Rate l/hr (US gal/min) 3406 - 4542 (15 - 20) Rated Voltage (V) 10 - 14 Power Consumption (W) 72 Dimensions L 214 (8.42)

W 106 (4.16)

mm (inch) H 106 (4.16) Weight kg (lb.) 2.5 (5.5) Hose connection mm (inch) OD. 28.5mm (1-1/8)

Table 4-2: Coolant Circulation Pump Data

4.2.1 Coolant Circulating Pump Dimensions

Fig. 4-2: Coolant Circulating Pump Assembly (P.N. 906017) Dimensions (Inches)

4TECHNICAL DATA

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4-4

4.3 Tray Mount Dimensions

Fig. 4-3: Tray Mount Dimensions (Inches)

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5INSTALLATION

5-1

5. Installation

5.1 General Information

Webasto will take you step by step through the installation process to ensure successful operation for years to come. The installation must be performed in accordance with the installation instructions provided in this manual.

NOTE:

This manual does not cover all possible installations. This manual is a general guideline only. For special applications or installations differing from what is described in this manual, contact Webasto Thermosystems directly at 1-800-555-4518 for further information.

5.2 Installation Locations

Fig. 5-1: Installation Locations

WARNING

Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be installed inside the passenger compartment.

Heater is to be installed in an existing enclosure (spare battery compartment) on the driver’s (road) side of vehicle. The installation template provided with heater kit must be used.

Do not mount to the slide-out tray. The heater and tray must be mounted solidly. The heater inertia safety switch will only function properly if the heater and tray are mounted solidly.

The heater should be installed as low as possible in the cooling system to assure static bleeding of the heater and the circulating pump.

NOTE:

The coolant circulating pump is not self-priming. Always prime coolant circulating pump, heater and cooling circuit before initial starting of heater. See section 5.9 “Initial Operation.”

5INSTALLATION

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5-2

5.3 Mounting the Heater

Tray Kit mounting in existing enclosure on vehicle, i.e. battery box.

1. Ensure that the enclosure is large enough to accommodate the heater. Use the installation template provided with the heater kit.

2. The installation enclosure must provide adequate ventilation for combustion air requirements [20 cm² (4 in²)].

3. Lay the supplied installation template in the enclosure. Center punch the exhaust, fuel, electrical and 4 mounting hole locations.

4. Drill all required holes to the dimensions as shown on the template.

5. Solidly bolt the tray with heater mounted inside the enclosure.

Fig. 5-2: Tray Mount Template (Supplied with Heater Kit)

5.4 Exhaust Pipe Connection

WARNING

Due to the risk of carbon monoxide poisoning and asphyxiation, exhaust system components must be routed in a manner that prevents exhaust fumes from entering the passenger compartment.

1. Insert the supplied flexible exhaust pipe to the heater and fasten with the exhaust clamp. Fasten the outlet end to the chassis with the “P” clamp provided.

2. The exhaust system must discharge on the street (driver) side of vehicle. The discharge opening of the exhaust pipe must not point in the direction of travel, and so located that any clogging caused by snow or mud is not to be expected.

The exhaust pipe I.D. 38 mm (1 1/2”) can have a length up to 5 m (16’) and may have several bends totaling no more than 270° overall.

Rigid exhaust pipe may be used; bends must be formed (smallest bending radius 85 mm (3 3/8”). Do not weld pipe to make 90° corners. Any condensation water in the exhaust pipe must be discharged. If necessary, drill a drain hole at the lowest point.

NOTE:

Route the exhaust components in a way that prevents them from touching vehicle parts that may be damaged by heat (brake lines, electrical wiring, hoses, etc.). Do not direct exhaust outlet towards heat sensitive vehicle components.

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