Webasto Heater 90 User Manual

Thermo 90 Thermo 90 S
Workshop Manual
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
1.5 Corrections and Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. General Description
2.1 Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Burner Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.6 Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.7 Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.8 Combustion Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.9 Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.10 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.11 Fuel Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. Functional Description (Fig.3-1)
3.1 Switch-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.5 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.1 Switch-off upon Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.2 Diagnosis after Switch-off upon Failure (Thermo 90) . . . . . . . . . . . . . . . . . . . . 3-3
3.5.3 Diagnosis after Switch-off upon Failure (Thermo 90 S) . . . . . . . . . . . . . . . . . . . 3-3
3.5.4 Reading and Understanding the Flash Code . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4. Technical Data (Standard Measure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4. Technical Data (Metric Measure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
5. Troubleshooting
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 General Failure Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Failure Symptoms after Switch-off upon Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Storing a Fault Code in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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5.4.1 Reading and Removing Error Codes Stored in Memory using the
PC Diagnostics Kit P.N. 92542C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Visual Inspection for Assessment of Burner Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5.1 Burner Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5.2 Rear Wall with Metal Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.3 Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.4 Burner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6. Functional Tests
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.1 Adjustment of the CO
2
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Components Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.1 Temperature Sensor Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.2 Glow Pin Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.3 Flame Sensor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.4 Combustion Air Fan Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. Circuit Diagrams
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. Servicing
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Work on the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Work on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.4 Heater Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.5 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.6 Visual Inspections and Installation Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.6.1 Connection to the Vehicle’s Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.6.2 Connection to the Vehicle’s Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.6.2.1 Fuel Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6.2.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.3 Fuel Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.3.1 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.3.2 Installation and Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.4 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.5 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.6 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
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8.7.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.2 Replacement of Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.3 Replacement of Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.4 Replacement of Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.5 Replacement of Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.8 First Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
9. Repair
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Work on Components after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1 Electrical Connections (Fig. 9-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1.1 Disconnecting Electrical Connections (Connection X1) . . . . . . . . . . . . . . . . . . . 9-2
9.2.1.2 Making Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.2 Replacement of Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.2.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.3 Replacement of Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.4 Replacement of Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2.5 Replacement of Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.6 Replacement of Burner, Flame Sensor and Glow Pin . . . . . . . . . . . . . . . . . . . . 9-7
9.2.6.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.7 Replacement of Burner Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.8 Replacement of Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.2.8.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.2.8.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
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1INTRODUCTION
1-1
1. Introduction
1.1 Scope and Purpose
This repair shop manual is intended to support familiarized personnel in the repair of
Thermo 90
and
Thermo 90 S
coolant heaters.
The coolant heater may only be operated with the specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene and certain military spec. fuels).
The coolant heater may only be operated within the specified operating voltage range designated by type.
1.2 Meaning of Warnings, Cautions, and Notes
Warnings, Cautions and Notes in this manual have the following meaning:
WARNING
This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents to personnel.
CAUTION
This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment.
NOTE:
This heading is used to highlight and draw specific attention to information.
1.3 Additional Documentation to be Used
This workshop manual contains all information and procedures necessary for the repair of heaters
Thermo
90
and
Thermo 90 S.
The use of additional documentation is normally not necessary. Operating instructions/installation instructions and the 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 motor vehicles, or in independent heating systems, with a minimum coolant capacity of 6 litres (1.6 US Gal.).
The heater must not be installed in the passenger compartments of vehicles. 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.
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.
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.
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Ignoring the installation instructions and its procedures will void the warranty granted by Webasto. The same applies for repairs preformed by unskilled, unauthorized personnel and repairs without using genuine Webasto spare parts. This will void the coolant heaters “Official Marks of Conformity.”
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 or cockpit side or rear end. 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.
For the routing of fuel lines and the installation of additional fuel tanks, 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-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 busses, fuel lines and fuel tanks must not be located in the passenger area or in the driver’s compartment. In these type of vehicles the fuel tanks must be located such that they do not pose a direct hazard to the exits in the event of a fire. Fuel supply must not be by means of gravity or pressurization of the fuel tank.
Installation instructions for Webasto fuel tanks for the fuel supply of coolant heaters in vehicles: In busses the installation is not permitted in the passenger or driver’s compartment.
The fuel filler neck must not be located in the passengers or driver’s compartment of any vehicle.
Fuel containers for gasoline fuel must not be located immediately behind the front paneling of the vehicle. They must be separate from the engine so that even in the case of accident the inflammation of fuel is unlikely to be expected.
This does not apply for towing vehicles with an open cockpit.
All fuel containers offered in the Webasto Accessories Catalog are suitable for a maximum operating pressure of 0.15 bar over-pressure.
All fuel containers offered in the Webasto Accessories Catalog are subjected during manufacture to individual pressure testing with at least 0.3 bar over-pressure.
The fuel containers must either be equipped with a vent cap or be ventilated in another way (ventilation line). Only filler caps in accordance with DIN 73400 may be used.
The operational state of the heater, i.e. an indication “on” or “off”, must be clearly visible.
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HERMO
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2GENERAL DESCRIPTION
2-1
2. General Description
The Webasto Thermo 90 and 90 S coolant heater, in combination with the vehicle’s own heating system, is used to:
heat the cab, sleeper or interior areas of vehicles
defog/defrost windshields
preheat water cooled engines The coolant heater operates independent from the
vehicle engine and is connected to the cooling system, the fuel system and the electrical system of the vehicle.
The heater is designed around the Ferro-Tec Technology evaporator burner system and operates intermittently, controlled by the temperature sensor.
Dependent on the deviation of the current coolant temperature from the rated value of the temperature sensor, combustion performance is continuously controlled within a range from 1.8 to 7.6 kW (6,100 to 26,000 Btu/hr) for Diesel operated heaters and within 2.0 to 7.6 kW (6,800 to 26,000 Btu/hr) for gasoline operated coolant heaters. For an extremely high heating performance requirement (preheating) the maximum performance of 9.1 kW (31,000 Btu/hr) is available with
diesel operated coolant heaters for up to 2 hours after heater actuation.
The Webasto Thermo 90 and 90 S coolant heaters basically consist of:
combustion air fan
heat exchanger
burner insert with combustion tube
circulation pump For control and monitoring, the following are located
inside the heater unit:
control unit (external)
flame sensor
glow pin
temperature sensor
temperature limiter On the Thermo 90 S heater, the control unit is flanged to
the combustion air fan. It is possible to remote mount the control unit using an optional mounting bracket.
1 Combustion Air Fan 2 Fuel Connection 3 Temperature Sensor 4 Temperature Limiter 5 Heat Exchanger 6 Inlet, Coolant 7 Circulation Pump 8 Outlet, Coolant 9 Outlet, Exhaust
10 Inlet, Combustion Air
NOTE:
One of the newer models shown. Older models have the temperature sensor cable located on the side.
Heater Thermo 90
2GENERAL DESCRIPTION
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1 Combustion Air Fan 2 Fuel Connection 3 Temperature Sensor 4 Temperature Limiter 5 Heat Exchanger 6 Inlet, Coolant 7 Circulation Pump 8 Outlet, Coolant 9 Outlet, Exhaust
10 Inlet, Combustion Air
11 Control unit (may
also be located remotely in the vehicle)
Heater Thermo 90 S
2.1 Combustion Air Fan
The combustion air fan delivers the air required for combustion from the combustion air inlet to the burner insert.
2.2 Heat Exchanger
The heat exchanger transfers the heat provided by combustion to the coolant circuit.
T
HERMO
90 / 90 S
2GENERAL DESCRIPTION
2-3
2.3 Temperature Sensor
The temperature sensor senses the coolant temperature in the heat exchanger of the heater unit as electrical resistance. This signal is fed to the control unit for processing.
2.4 Temperature Limiter
The overheat protection (bimetal) protects the heater unit from excessive operating temperatures. The overheat protection responds at a coolant temperature higher than 105 °C to switch off the heater.
2.5 Burner Insert
Within the burner insert, fuel is distributed in the combustion tube across the burner cross-section.
2.6 Glow Pin
The glow pin ignites the fuel/air mixture at the start of heater operation. The glow pin is acting as an electrical resistor and is located in the burner insert opposite the flame source.
2.7 Flame Sensor
The flame sensor is a low-Ohm PTC resistor, changing its resistance dependent on its heating by the flame. The signals are routed to the control unit for processing. The flame sensor monitors the flame operating condition over the complete duration of heater operation.
2.8 Combustion Tube
Inside the combustion tube the combustion of the fuel/air mixture takes place, heating up the heat exchanger.
2.9 Circulation Pump
The circulation pump provides for circulation of the coolant in the vehicle and heater circuits. The control unit switches the pump on for operation throughout the entire time of heater operation (also in control idle).
2.10 Control Unit
The control unit is the central controlling device for functional sequencing and monitoring of the combustion operation. It is mounted to the heat exchanger on Thermo 90 heaters and flanged to the combustion air fan on Thermo 90 S heaters.
2.11 Fuel Dosing Pump
Fuel supply to the heater and its dosing is ensured externally by a fuel dosing pump. When the heater is deactivated, it also serves as a shut-off valve. The magnetic coil of the dosing pump receives the pulses from the microprocessor of the control unit.
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HERMO
90 / 90 S
3FUNCTIONAL DESCRIPTION
3-1
3. Functional Description (Fig. 3-1)
3.1 Switch-on
When operating the push button "Immediate Heating", the "Operating Indicator" on the timer illuminates
or by activation with the switch, the “Operating Indicator”
integrated in the switch illuminates. Circulation pump, glow pin, and combustion air fan are
put into operation.
3.2 Heating Operation
After approx. 50 seconds, combustion commences with the automatically controlled heating operation in full load for a maximum of 2 hours.
The vehicle's own heating blower starts to operate only after the heat carrier (coolant) has accumulated enough heat. After reaching the pre-coded rated temperature (see table Control Temperatures) heating performance, precision control will take over in stages down to the lowest part load operation.
3.3 Control Operation
If the coolant temperature rises up to the control idle threshold, the heater enters the control idle phase. The circulation pump, the vehicle's own blower, and the operating indicator remain in operation during the control idle period. After the coolant has cooled down to the pre-coded reactivation temperature, the heater resumes operation.
Diesel Operated Coolant heaters
If the coolant heater's coolant temperature is above the rated temperature but has not yet reached the threshold for control idle, with the temperature dropping within 10 minutes back to rated temperature (after reaching it for the first time), the coolant heater reverts to the 9.1 kW (31,000 Btu/hr) heating stage. Should the rated temperature be obtained after 10 minutes, there will be an automatic reactivation to a maximum performance output of 7.6 kW (26,000 Btu/hr).
Gasoline Operated Coolant Heaters
The maximum heating performance of gasoline operated coolant heaters is always 7.6 kW (26,000 Btu/hr).
3.4 Switch-off
When switching the heater off, the operation indicator on the timer/switch extinguishes. Combustion ends and the run-down cycle is initiated. The circulation pump and combustion air fan, however, continue operation to cool down the heater (run-down) and are automatically deactivated after about 90 seconds. A reactivation of the heater during run-down is permitted.
Room temperature control by means of the vehicle's own heating blower may be provided in addition to employing a room thermostat.
Functional Sequence for Thermo 90/90 S
1 Switch-on 2 Configuration Check 3 Preheating 40 sec. (cycled) 4 Fuel Dosing Pump Priming 5 - 7 sec. (1) 5 Fuel Dosing Pump / Part Load (1/4) 6 Flame Sensor Take-over 7 Stabilization Period 8 Full Load
9 Vehicle Blower ‘On’ (optional) 10 Control Range 11 Control Idle 12 Flame Sensor ‘cold’ (0) 13 Run-down completed 14 Preheating 15 - 20 sec. (cycled) 15 Fuel Dosing Pump Priming 5 - 7 sec. (1) 16 Fuel Dosing Pump / Part Load (1/4) 17 Flame Sensor Take-over 18 Stabilization Period 19 Coolant Temperature down 20 Full Load 21 Switch-off (run-down) 22 Flame Sensor ‘cold’ (0) 23 Run-down completed
A Glow Pin B Fuel Dosing Pump C Combustion Air Fan D Flame Sensor E Operation Indicator Light F Circulation Pump G Vehicle Blower (optional)
Setting of Control Temperatures - Thermo 90
Table Rated Temp. Control Reactivation
at Sensor Idle after
Control Idle
Minus to B6 80 °C 90 °C 75 °C B6 not used 72 °C 82 °C 67 °C Plus to B6 65 °C 75 °C 60 °C
On the enclosure and compact kits, B6 is connected to minus (–).
Setting of Control Temperatures - Thermo 90 S
Connection of a plus (+) or minus (–) signal to the control unit (connector X12, contact 7) will enable different threshold values.
Table Rated Temp. Control Reactivation
at Sensor Idle after
Control Idle
Plus (+) 72 °C 82 °C 67 °C Minus (–) 80 °C 90 °C 75 °C
On the enclosure and compact kits, connector X12, contact 7 is connected to minus (–).
NOTE:
In the case of both heater models, the selected control idle temperature of the heater should be below the opening temperature of the engine thermostat.
3FUNCTIONAL DESCRIPTION
T
HERMO
90 / 90 S
3-2
Fig. 3-1 Functional Sequence
T
HERMO
90 / 90 S
3FUNCTIONAL DESCRIPTION
3-3
3.5 Malfunctions
3.5.1 Switch-off upon Failure
In case of a no-flame condition, fuel is delivered for a maximum of 180 seconds.
In the event of a flame-out during operation, fuel is delivered for a maximum of 90 seconds.
Should an overheat condition exist (after response of the temperature limiter), no fuel will be delivered.
After switch-off by low voltage protection for more than 20 seconds, there will be no fuel delivery.
Thermo 90 Thermo 90 S 12 Volt 10.5 ± 0.5 V 10.5 – 0.5 V 24 Volt 21 ± 1 V 21 – 1 V
After the correction of the fault, there will be an error lock-out. Reset by switch-off and reactivation of the heater.
In case of overheating, the temperature limiter has to be reset after the unit has cooled down.
CAUTION
To avoid damage to the component, do not attempt to reset the temperature limiter by force while hot.
3.5.2 Diagnosis after Switch-off upon Failure (Thermo 90)
When operated with switch or digital timer, the type of error lock-out condition is indicated by an operation indicator light flash code while the heater is in run-down.
After five short signals the following long flash pulses are counted:
1x No start (after 2 start attempts) 2x Flame-out during operation (repeated > 5) 3x Voltage too low 4x Premature flame detection 5x Flame sensor open or short circuit 6x Temperature sensor open or short circuit 7x Fuel Dosing pump open or short circuit or
Temperature limiter tripped (overheating)
8x Fan motor open or short circuit or wrong speed of
fan motor
9x Glow pin open or short circuit
3.5.3 Diagnosis after Switch-off upon Failure (Thermo 90 S)
When equipped with a standard timer model 1531, an error code will be indicated on the timer display:
F 01 No start (after 2 start attempts) F 02 Flame-out during operation (repeated > 5) F 03 Voltage too low or too high F 04 Premature flame detection F 05 Flame sensor open or short circuit F 06 Temperature sensor open or short circuit F 07 Fuel Dosing pump open or short circuit F 08 Fan motor open or short circuit or wrong speed
of fan motor F 09 Glow pin open or short circuit F 10 Overheating F 11 Circulation pump open or short circuit
When operated with a switch, the type of error lock-out condition is indicated by an operation indicator light flash code while the heater is in run-down.
After five short signals the following long flash pulses are counted:
1x No start (after 2 start attempts) 2x Flame-out during operation (repeated > 5) 3x Voltage too low or too high 4x Premature flame detection 5x Flame sensor open or short circuit 6x Temperature sensor open or short circuit 7x Fuel Dosing pump open or short circuit 8x Fan motor open or short circuit or wrong speed of
fan motor 9x Glow pin open or short circuit 10xOverheating 11x Circulation pump open or short circuit
3.5.4 Reading and Understanding the Flash
Code
The five short flashes are only an indication that an error code has been registered and not to be counted. Count only the long flash pulses following the five short flashes to obtain the correct code.
Example ( x = 1 Flash) Error code 7x would appear as this: xxxxx ... x ... x ... x ... x ... x ... x ... x
The sequence will repeat until the heater completes the run-down cycle and switches off after which the error code will be stored in the control unit memory. See section 5. “Troubleshooting” for further information.
T
HERMO
90 / 90 S
4TECHNICAL DATA
4-1
4. Technical Data (Standard Measure)
As long as no threshold values are given, the following technical data is understood to include tolerances of ±10% usual for heaters at an ambient temperature of +68 °F and at nominal voltage and conditions.
Electrical Components:
Control unit, combustion air fan motor and fuel dosing pump, glow pin, control switch and timer are either of the 12V or 24V type. The components temperature limiter, temperature sensor and flame sensor are identical in the 12V and 24V units.
Coolant Heater Operation Thermo 90 / 90 S Thermo 90 / 90 S
Gasoline Diesel
Type BW 80 DW 80 Mark of conformity – S231 – S232 Heater type Coolant heater with Ferro-Tec Technology Heat output Maximum 31,000 Btu/hr
Control range 6,800 - 26,000 Btu/hr 6,100 - 26,000 Btu/hr Type of fuel Gasoline Diesel #1, #2 and Arctic Fuel consumption Maximum 0.28 gal/hr
(US gallon) Control range 0.06 - 0.26 gal/hr 0.05 - 0.24 gal/hr Rated voltage 12 Volt 12 or 24 Volt Operating voltage range 10 ... 15 Volt 10 ... 15 or 20 ... 30 Volt Rated power consumption Maximum 90 W
with circulation pump Control range 37 - 83 W 37 - 83 W (without vehicle blower)
Permitted ambient temperature: Heater: -operation –40° ... +230 °F
-storage –40° ... +266 °F
Control unit: -operation –40° ... +167 °F
-storage –40° ... +185 °F
Fuel dosing pump: -operation –40° ... +68 °F –40° ... +104 °F
-storage –40° ... +185 °F
Permitted over-pressure Maximum 29 psi. (heat exchanger)
Heat exchanger capacity 0.04 US gal. Maximum combustion air +104 °F
intake temperature Coolant circuit minimum capacity 1.6 US gal. Volume flow of circulation pump 7.25 US gal/min.
against 2.0 psi. CO2 in exhaust 10 ... 12.0 Vol.-%
(permissible operating range) CO2-setting values at approx. +68 °F 0 ft. 1640 ft. 3280 ft.
and geographical height above SL 10% 10.6% 11.3% Dimensions of heater Length 12.2 in. (14.0 in.)
1)
(Tolerance ± 0.11 in.) Width 05.24 in.
Height 08.66 in.
Weight 10.5 lb
1)
Thermo 90 S with control unit mounted on heater
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