Webasto Heater 300.102 User Manual

Thermo 300.102

Installation Instructions

for use with

The Detroit Diesel

Series 4000 Engine

Coolant Heater

TABLE OF CONTENTS

I

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 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Functional Description

3.1 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.4 Power Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4. Technical Data

4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Thermo 300 Heater Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.1 Thermo 300.102 Heater Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 U 4814 & U 4852 Coolant Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Coolant Circulation Pump U4814 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Coolant Circulation Pump U4852 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5. Installation

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

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

5.3 Mounting the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.4 Mounting the Coolant Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.5 Exhaust Pipe Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.6 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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

5.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.7.2 Supplemental Heating Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.7.3 Supply and Return Plumbing Connection Points . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.7.4 Example of a Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.8.2 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.8.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.9 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.9.2 Timer and Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.9.3 Timer and Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.9.4 Coolant Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

WEBASTO THERMO 300

TABLE OF CONTENTS WEBASTO THERMO 300

II

5.9.5 Wiring Diagram - with Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.9.6 Wiring Diagram - with 7-Day Digital Timer Model 1531 . . . . . . . . . . . . . . . . . . . 5-12

5.10 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

6. Basic Troubleshooting

6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Operational Malfunction Symptoms - Reading the Flash Code . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1 Reading a Malfunction Code with the Digital Timer Model 1531 Installed . . . . . 6-1

6.2.2 Malfunction Codes Stored in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 Operational Malfunction Code via Flash/ Malfunction Code . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Reading and Removing Malfunction Codes Stored in Memory with the Webasto

PC Diagnostics Kit and Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

8. Spare Parts List

8 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9. Warranty Policy

9.1 Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

List of Figures

2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

List of Tables

3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4-1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

WEBASTO THERMO 300 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 and servicing of Thermo 300 coolant heaters.

Webasto Thermosystems, Inc. does not recommend the
installation and servicing of Webasto products by
untrained, unauthorized personel 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
Thermo 300 heater.

The use of additional documentation is normally not
required. Vehicle specific installation guides (when
available) may be used as complimentary information
only.

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 2.6 US Gal. (10 litres).

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 140 °F (60 °C) 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 WEBASTO THERMO 300

1-2

In the vicinity of the coolant heater, a temperature of
185 °F (85 °C) 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. A condensation
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 12
inches (30 cm.) or less 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.

2GENERAL DESCRIPTION

2-1

1 Combustion air fan
2 Motor
3 Electronic control unit
4 Electronic ignition coil
5 Ignition electrodes
6 Water pipes
7 Fuel nozzle

The Webasto Thermo 300 heater has been designed for use on large displacement diesel engines where a
high degree of operational flexibility is desired.

Additionally, the Thermo 300 heaters supplied to Detroit Diesel Corporation have been optimized to meet the
specific requirements of the Series 4000 Detroit Diesel engine.

The Webasto Thermo 300 heater is designed to:

1. Preheat Engine block of liquid cooled engines to help 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 charge-air cooling system in cold weather
when an engine is running at light loads or idling while helping to eliminate white smoke and fuel accumulation in
the vehicle exhaust system.

2. General Description

2.1 General Description

Fig. 2-1: Major Components of the Thermo 300 Coolant Heater

8 Temperature sensor
9 Overheat Thermostat

10 Heat exchanger

11 Combustion chamber
12 Combustion air swirler
13 Exhaust pipe
14 Photo disc

15 Flame detector
16 Fuel pump w/ solenoid valve
17 Combustion air adjusting shutter
18 Fuel supply/ return pipes
19 Coupler
20 Combustion air intake

WEBASTO THERMO 300

2GENERAL DESCRIPTION WEBASTO THERMO 300

2-2

WEBASTO THERMO 300 3FUNCTIONAL DESCRIPTION

3-1

3. Functional Description

Activation and deactivation is by means of a

• switch

• timer
dependent on the type of installation.
For monitoring operation an operating indicator light is provided.
Switch off initiates the rundown procedure (see ”Switch off”).
The heaters may be

• operated with power save for reduced fuel consumption (see circuit diagram)

• equipped or retrofitted with nozzle preheating for extreme low temperatures.

3.1 Switching On

Upon switching on, an operating indicator light will illuminate.
Combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 °C (< 32 °F)
nozzle preheating is also activated).
After approximately 12 seconds a high voltage ignition spark is generated at the electrode tips. Approximately 1
second later the solenoid valve in the fuel pump opens and the nozzle sprays fuel into the combustion chamber to be
ignited by the spark at the electrode tips. A photo control device detects a flame in the combustion chamber and
deactivates the ignition system (Combustion process is self-sustaining).

3.2 Heating Operation

After reaching operating temperature the control unit takes over to provide controlled operation by activation and
deactivation of the burner in order to maintain a nearly constant temperature of the heat exchanger.
A rise in temperature above the upper switching point makes the solenoid valve in the fuel pump shut off the fuel
supply and initiates the rundown procedure. The flame extinguishes, the combustion air fan and the circulation pump
continuing their operation. After approximately 90 seconds rundown is completed with deactivation of the combustion
air fan.
The circulation pump remains in operation during the control idle period. The operating indicator light is on.

3.3 Switch Off

Switching off the heater stops combustion. The operating indicator light goes out and the rundown procedure
commences.
The combustion air fan and circulation pump are deactivated after approximately 90 to 120 seconds.
Reactivation of the heater during rundown is permitted.

3.4 Power Save

With the power save feature on, the control temperatures of the heating circuit are kept low.
This results in a reduced heat radiation loss when limited heating performance is required (e.g. in heat hold
operation) and reduces fuel consumption.

3FUNCTIONAL DESCRIPTION WEBASTO THERMO 300

3-2

WEBASTO THERMO 300 4TECHNICAL DATA

4-1

4. Technical Data

4.1 General Information

Where no threshold values are specified, technical data are understood to include standard tolerances for heater
units of ± 10% at ambient temperature of + 20 °C (+ 68 °F) and at nominal voltage.

Electrical components:

Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle pre-heater and
timer are 24V components. Temperature limiter, flame sensor, temperature sensor and switches are voltage
independent components.

Heater

Type

Mark of conformity

Heater design principle

Heat output kW/h (BTU/h)

Fuel

Fuel consumption kg/h (US. Gal/h)

Rated nominal voltage V

Operating voltage V

Nominal power consumption W
(without circulation pump)

Permissible operating ambient °C (°F)
temperature range
(heater, control unit, circulation pump)

Permissible storage temperature °C (°F)

Permissible operating pressure bar (psi)
of coolant system

Heat exchanger capacity l (US. Gal)

Minimum capacity of circuit l (US. Gal)

CO

2

in exhaust at nominal voltage Vol.-%

Dimensions of heater length

width

height

Weight kg (lb.)

Thermo 300

DW 300.

~ S229

High pressure fuel atomizing nozzle

30 (104,000)

Diesel #1, Diesel #2, Arctic grade and Kerosene

3.3 (1.2)

24

20 ... 28

110

- 40 ... + 60 (- 40 … + 140)

+ 85 max. (+ 185)

0.4 ... 2.0 (06 … 29)

1.8 (0.475)

10.00 (2.64)

10 + 0.5 related to 500 m above S.L.

610 mm (24.01 in.)
246 mm (9.69 in.)
220 mm (8.66 in.)

19 (41.88)

NOTE:

The allocation of circulation pumps to heater units must be in accordance with coolant resistances.

4.2 Thermo 300 Heater Data

Table 4-1: Thermo 300 Heater Data