Webasto Thermo 90, Thermo 90-ADR, Thermo 90 S, Thermo 90 S-ADR Installation Instructions

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Water Heaters Installation Instructions
Thermo 90 Thermo 90-ADR Thermo 90 S Thermo 90 S-ADR
(Transport of hazardous goods)
Type BW 80 (Petrol), Type Thermo 90 S B (Petrol) Type DW 80 (Diesel), Type Thermo 90 S D (Diesel)
10/2000
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Table of Contents
Page
Installation Instructions 1 Legal Provisions for Installation 1 Installation 2 Installation Example 3 Connection to the Vehicle’s Cool­ing System 4 Fuel Supply 4 Fuel Lines 6 Metering Pump 6 Combustion Air Supply 7 Exhaust Pipe 7 Electrical Connections 8 Circuit Diagrams 10 Initial Operation 17 Malfunctions 18 Technical Data 20 Variants 21 Template for heater mounting bracket 23
Thermo 90 / Thermo 90 S
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Installation Instructions
Legal Provisions for Installation
For testing the heater in accordance with articles 19, 20 oder 21 StVZO the following regulations are primarily to be observed (§ 22 a StVZO):
NOTE: These provisions are binding within the scope of the StVZO (German Road Licensing Regulations) and should also be observed in countries where no special locally applicable regulations are in effect!
Within the scope of th e StV Z O (G er ma n Roa d Lice nsi n g Regulations) “G en er al Desig n C er tif i cat i on s” ha ve be en granted by the Federal Office for Motor Traffic for the Thermo 90 water heater with the following marks of appro­val:
~
S231 for Thermo 90 heaters Petrol type BW 80
~
S232 for Thermo 90 he at er s Diesel typ e DW 80 an d
for Thermo 90-ADR heater Diesel type DW 80.
~
S299 for Thermo 90 S heaters Petrol type Thermo 90 S B
~
S298 for Thermo 90 S heaters Diesel type
Thermo 90 S D and for Thermo 90 S-ADR heaters Diesel type Thermo 90 S D
The installation of th e he at er s must be pe rf or me d in ac­cordance with these Installation Inst ructio ns. The insta lla­tion must be checked
a) upon the homolog at ion of th e veh icl es in acco rd an ce with § 20 StVZO b) upon any individual tes t in accordance with
§ 21 StVZO, or c) upon any examination in accordance with § 19 StVZO by a registered expert or examin er for mot or t raffic, an expert for automotive vehicles, or any other authorised official, in accordance with paragraph 4 of
Appendix VIIIb to the StVZO and in the case of item c) the proper install a tion must be certified on the appro val cer tif ic at e con ta ine d on the de­sign certification stating the following:
- vehicle manufacturer
- vehicle type and
- vehicle identification number The effectiveness of the design certification (homologa­tion) is dependent on this certificate. The approval certifica­tion is to be kept in the vehicle.
The year of the initial operation must be durably marked on the type plate of the hea t e r by th e inst all e r by re mo ving the years that do not apply.
Extracting the combustion air from the interior of the ve­hicle is not permissible.
The discharge opening of the exhaust pipe must point up­ward, sideways or, in the case of routing the exhaust pipes along the underside of the bottom vehicle, it must be lo­cated near the later al or rea r edge of the driver’s cab or ve­hicle. Exhaust pipes must be so routed that the possibility of exhaust fumes ente rin g th e i nt er ior of th e veh icle i s remote. The functioning of any parts of the vehicle essen­tial for its operation must not be impaired.
The openings of the combustion air inlet and exhaust gas outlet must be so designed that a spherical object of 16 mm in diameter cannot be introduced.
Electric lines, switchgear and control gear of the heater must be so arranged in the veh i cle th at the i r proper func­tioning cannot be impa ire d under normal oper at ing cond i ­tions.
For the routing of fuel lines and the installation of addi­tional fuel tanks articles 45 and 46 StVZO are to be ad­hered to. The most important excerpts therefrom are as fol­lows:
Fuel lines must be designed in such a way that they re­main unaffected by torsio na l stre sses in th e veh icle, en­gine movement and th e lik e. They must be prot ected
against mechani cal da ma ge. Fuel-carrying pa rt s must be protected against excessive heat and must be arranged such that any dripping or evaporating fuel can neither col­lect nor be ignited by hot components or electrical equip­ment. The heater must not be installed in rooms occupied by per­sons.
The operating state of the heater at any given time – at least an indication as to whether it is “on” or “off” – must be easily recognizable.
Webasto will not assume any liability if the installation in­structions and the no te s cont ai n ed the re in ar e no t ob ­served. The same applies to improperly performed repairs or those where others than genuine replacement parts have been used. In those cases, the heater’s General De­sign Certification and thus the General Operating Permit (homologation) will be invalidated as a consequence.
Use of the Water Heaters
The Webasto Thermo 90 water heater in conjunction with the vehicle heating system is designed to provide the fol­lowing features:
- heating the driver’s cab,
- de-frosting the vehicle ’s win dscree n as w ell as
- preheating of w at er -cool e d en gin es. The water heater operates independently of the vehicle’s engine and is connected to the cooling system, the fuel system and the electrical system of the vehicle.
Thermo 90 / Thermo 90 S
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Installation
CAUTION:
- The legal provisions on page 1, relating to the installa­tion of the heat er, must be observed
- When installing the Thermo 90-ADR in vehicles de­signed for the transport of hazardous materials the re­quirements laid down in ADR 002 and ADR 003 (Techni­cal Guidelines relating to the ordinance of transporting hazardous goods on the road) must be fulfilled in addi­tion to those of the StVZO.
- If the water heater is to be operated in a separately in­stalled heating system, it is mandatory that the installa­tion drawing be submit t ed to Webasto for approval prior to installation.
NOTE:
The different vehicle-specific installation conditions should be taken into account.
Installation Location
The heater should be installed at a level as low as possible so as to ensure automa tic ven tin g of the heater and the cir­culating pump. This is of special importance as the circulat­ing pump is not of the self-priming type.
Type Plate
The type plate m ust be located in a place where it is pro­tected against damage and be easily accessible once the
heater has been installed (or else, a type plate duplicate is to be used). The years not applicable are to be removed from the type plate.
Fig. 1: Installation Position T90 / T90S
1 Combustion air in let 2 Exhau st ga s out let 3 Fuel inlet 4 Coolant inlet 5 Coolant outlet
1
2
4
3
5
Thermo 90
Fig. 2: Dimensions of the Heater
1 Combustion air in let 2 Exhau st ga s out let 3 Fuel inlet 4 Coolant inlet 5 Coolant outlet
1
2
4
3
5
Thermo 90 S
Thermo 90 / Thermo 90 S
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without non-return valve
cable harness fuel line
exhaust pipe water circuit
with non-return valve and thermostat
Fig. 3: Installatio n Exa m pl es for th e Th erm o 90 / Th er m o 90 S He at er Legend of Fig. 3
1 Heat exchanger of vehicle hea tin g syste m 2 Switch for vehicle heating fan 3 Relay for vehicle fan 4 Digital timer 5 Fuse bank in vehicle 6 Non-return valve wit h lea kag e hole
7T-piece 8 Vehicle engine 9Heater 10 Circulating pump 11 Water pump 12 Radiator 13 Regulating valve
14 Exhaust silencer 15 Metering pump 16 Combustion air intake pipe 17 Thermostat 18 Electronic control unit 19 Control unit (alternative installation locatio n of
Thermo 90 S)
Thermo 90 / Thermo 90 S
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Connection to the Vehicle Cooling System
In the case of thermosta t circu its on ly the rmost ats that open at temperatures < 65°C should be used.
The heater is connected to the vehicle cooling system in accordanc e with Fig. 3. The amount of coolant in the cool­ing system should be at least 6 liters. In principle, only the water hoses supp lied by Weba sto should be used. If this is not the case, the hoses must at least comply with th e re qu ire me nt s of DIN 73 41 1. The hoses are to be routed without any kinks and – for proper venting – in an upward pitch, if possible. Hose connections must be secur ed against slipping off by mean s of hose clamps.
NOTE:
The hose clam ps must be tightened to a torque of 4 Nm.
Before the heater is started up for the first time or after the coolant has been replaced, it must be ensured that the cooling system is properly bled. Heater and piping should be so installed that permane nt self- bleed ing of th e syste m is ensured.
Proper bleeding action can be recognized by the nearly si­lent operation of the circulating pump. Insufficient bleeding can result in tripping the resettable temperature limiter.
Fuel Supply
Fuel is drawn from the veh icle fuel tank or from a separat e fuel tank.
The values relating to the permissible pressure at the fuel extraction point can be tak en from the Table below.
permissible fuel feed height
H (m)
at max. permissible
overpressure (bar) in fuel
line
0.00 0.2
1.00 0.11
2.00 0.03
permissible fuel suction
height S (m)
at max. permissible
underpressure (bar) in fuel
tank
0.00 -0.10
0.50 -0.06
1.00 -0.02
l1 + l2 10 m l1 1.2 m l2 8.8 m
Fig. 4: Fuel Supply
Thermo 90 / Thermo 90 S
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Vehicles wit h D ie se l E ng in es
Fuel must be drawn from the fuel tank or a separate tank (see Figs. 5, 6 and 7). Whe n fu el i s supp lied fro m a sep ar ­ate tank, any pressure-related influence can be excluded.
NOTE:
After tank extracting device has been cut to length by saw­ing, remove any burr and metal chips from cut edge.
* tank extracting device only to be used wi th
metal fuel tanks
NOTE:
The fitting must be made of sheet metal!
Vehicles wit h P et r ol Engines
In the case of carburettor or injection engines equipped with return lines, the heate r’s fuel syste m is to be inte ­grated in the return line.
In the case of carburettor engines without return line, the fuel circuit of the heater is to be integrated in the flow line between the vehicl e’s fu el ta nk an d pu mp.
ANNOTATION
A fuel flow line can usually be identified by the in-line fuel filter.
NOTE:
If the vehicle’s fuel system is equi pp ed with a vap our sep ­arator, fuel extraction is to take place upstream of same.
For fuel extraction from flow or return lines it is manda-
tory that the special Webasto fuel pickup (see Fig. 8)
be used.
The fuel pickup is to be so mounted that any air or gas bubbles that may form are automatically discharged to­ward the tank (see Fig. 8).
Air or gas bubbles in the fuel li ne of the vehicle can form if there is a leak in the vehicle’s carburettor or fuel pump or in the case of ambient temperatures exceeding the vaporiz­ing temperatur e of the fuel.
Fuel should not be extracted from within the vicinity of the engine as gas bubbles are likely to form in the lines owing to the heat radiat ing fro m th e en gin e whi ch may re sult in malfunctions in the he ating operation.
Fuel extracting device
Tank fitting
Sealing ring
Fig. 5: Fuel Extraction From the Plastic Tank
(Extraction v ia Tank Fitting)
Plastic tank
Sealing ring
Fig. 6: Fuel Extraction From the Plastic Tank
(Extraction via Tank Drain Plug)
Hole Pattern
Fig. 7: Webasto Tank Extracting Device
Thermo 90 / Thermo 90 S
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If the heater is installed in vehicles equipped with injection systems it is therefore to be determined whether the fuel pump is mounted inside or outside the tank.
Where the fuel pump is located inside the tank, fuel may only be extracted from the return line in which case it must be ensured that th e re tu rn line ext en ds al m ost to th e bo t­tom of the tank and th at it is no t close d by a no nr et ur n valve. Failing this, the return pipe can be extend ed .
Where the fuel pump is mounted outside the tank, the con­nection to the fuel system can be acco mp lishe d be twe en the fuel tank and the fuel pump.
Fuel Lines
Only steel, copper and plastic pipes made of plasticized, light-resistant and temperature-stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) in accordance with DIN 73378 may be used.
NOTE:
Do not cut Mecanyl lines using a side cutter.
As in the majority of cases it is not possible to route the lines in a continuous up war d pit c h, the inside di ameter must not exceed a given dim en sion . If the inside di ameter equals or is greater than 4 mm, air or gas bubbles accumu­late which result in malfunctions if the lines sag or are routed in a downward pitch. When the diamters shown in Fig. 4 and 8 are used, you can be sure that no unwanted bubbles will form.
The lines leading from the metering pump to the heater should not be route d in a do wnw a rd pitch .
To prevent the fuel lines fr om sagg ing , fr ee ly suspe nd ed lines must be secured . Mo un tin g sho ul d be pe rf or me d i n such a manner that the lines are protected against flying stones and thermal influence (exhaust pipe).
Connecting 2 Pipes Using a Hose
The proper connection of fuel lines using a hose is shown in Fig. 9.
Check for leakage!
Metering Pump with Damper
The metering pump is a combined delivery/metering and shutoff system and is subject to certain insta llat ion crite ria (see Figs. 4, 10 and 11).
Installation Location
Prior to installing the metering pump it must be ensured that the maximum pressure prevailing at the fue l extract ion point is less than 0,2 bar.
It is recommended that the metering pump be installed in a location which is sufficiently cool. On no account must the permissible ambient temperature at any given operating stage be in excess of + 20 °C in the case of petrol, and + 40°C in the case of Diesel variants. Metering pump and fuel lines must not be locate d wi th in the radiation range of hot vehic le parts. If nec essary, a radi­ation protection is to be provided. The preferred installation location is near the tank.
to metering pu mp
to engine
from tank
Fig. 8: Webasto Fuel Pi ck up
correct
incorrect
clamp
bubble
bubble
Fig. 9: Pipe/Hose Connection
Thermo 90 / Thermo 90 S
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Installation and Mounting
The metering pump is to be attached by vibration-damping suspension. The installation position is restricted in accord­ance with Figs. 10 and 11 in order to en sur e suf fi cie nt self ­ventilation.
Fuel Filter
If dirt in the fuel must be recko ned with, only Webasto fil­ter, order no. 487 171, should be used. Filter is preferably to be installed in vertical position, where this is not possible, it may also be installed horizontally (installation position 0°-90°). Direction of flow to be observed!.
Combustion Air Supply
On no account must the combustion air be extracted from areas where persons ar e prese nt . Th e com bu sti o n air in­take opening must not point in the direction of travel. It must be so located that the possibility of clogging du e to contamination or snow and the drawing in of splash water is remote.
The combustion air line (inside diameter min. 30 mm) may have a length between 0.5 m an d 5m and may fe at ur e sev­eral bends totalling 360°. The smallest bending radius is 45 mm.
The combustion air inlet must not be located above the ex­haust gas outlet.
NOTE:
If it is not possible to route the combustion air line in a downward pitc h, a ø 4mm water drai n hole is to be pro­vided at the lo wermost point.
When the heater is installed in the vicinity of the vehicle tank in a common installation space, combustion air mus t be drawn in from the outside of the vehicle and the ex­haust gas be discharged to the atmosphere. Lead-through openings must be splash-pro of .
If the heater is loca te d in an enclo sed in sta llat i on hou sing , a ventilation opening of at least 6 cm2 is required. If the temperature in the installation housing exceeds the per­missible ambient temperature of the heater (see Technical Data), the ventilation opening must be enlarged after con­sultation with Webasto.
Exhaust Pi p e
The exhaust pipe (insid e di a met e r 38 mm) can ha ve a length between 0.5m and 5 m and may feature several bends (totalling 360°, smallest bending radius 85 mm). It is mandatory to provide an exhaust silencer which is to be in­stalled near the heater.
The discharge opening of the exhaust pipe must not point in the direction of travel (see Fig. 13).
The exhaust pipe discharge opening must be so located that any clogging caused by snow or mud is not to be ex­pected.
Rigid pipes made of unalloyed or alloyed steel with a mini­mum wall thickness of 1.0 mm or flexible tubes of alloyed steel only are to be used as exhau st pi p es. The exha ust pipe is to be secured to the heater, e.g. by means of a clamp. For further regulations ref er to the Legal Provisions.
12-volts and 24-volts - Petrol and Diesel
preferably 15°-90°
Fig. 10: Metering Pum p
Installation Position and Mounting
12-volts and 24-volts - Diesel only
Fig. 11: Metering Pum p
Installation Position horizontal
0 - 90°
Fig. 12: Fuel Filter
Installation Position to be Observed
Thermo 90 / Thermo 90 S
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Unique to Thermo 90-ADR: For legal provisions relating to the routing of the exhaust pipe refer to Technical Informa­tion E3 - 5.10 (order no. 776 623).
Electrical Connections
Control Unit/Heater Connection
The electrical connection of the heaters is to be carried out in accordance with circuit diagrams Figs. 16, 17, 18, 19, 20 and 21.
Connection upon the installation of Thermo 90 into a vehicle for the transport of dangerous goods (ADR).
For legal provisions relating to the electrical connection refer to Technical Informa tion E3 - 5.10 (order no. 776
623). The electrical connect i on is to be car rie d ou t in acco rd -
ance with circ uit diagram Fig. 17.
NOTE:
Switch S6 must be so installed that up on the start- up of a pumping device eithe r po sitive or ne ga tive pot en tia l is ap­plied to the respective inputs of the control unit.
Connection upon the installation of Thermo 90 S into a vehicle for the transport of dangerous goods (ADR).
When installing the Thermo 90 S heaters in vehicles for the transport of dangerous goods, the requirements laid down in ADR 002 and ADR 003 (Technical Guidelines re­lating to the directive concerning the carriage of dangerous goods by road) must be fulfilled in addition to those of the StVZO. The electrical connection is to be performed in ac­cordance with circuit diagram Fig. 20 or 21 .
NOTE:
Switch S7 must be installed in such a way that posit ive potential is applie d acr oss th e cor re spo nd i ng inpu t of the electronic control unit when a pumping device is put into operation.
CAUTION:
If no ground connection is provided via Y2 or H5 when the heater is activated, all ADR functions will be inoperative.
After positive potential has been applied across the X12/5 control unit input (auxiliary drive “ON”), a short 20-second after-run period will follow and subsequently the control unit will be in the ’fault lock-out’ state.
CAUTION:
In accordance with the Technical Guidelines relating to the ordinance c oncerning the carriage of dangerous goods by road, heaters may only be activated by means of a special, manually operated switch located in the driver’s cabin. If the heater is eq uip pe d w ith a stan dard digital timer it must be ensured that pin 4 of the timer remains unas­signed so that the heater can only be activated by means of the instant heat but ton (circuit diagram ava il ab le up on re­quest).
No other digital timers are allowed to be used in ADR ve­hicles.
Connection of the Heater Controls
The heater can be switched on and off using the following Webasto heater controls:
- Digital timer see circuit diagram Fig. 16, 18 or 19
- Switch see circuit diagram Fig. 17 or 20.
Vehicle Fa n
The vehicle fan is activated by means of a relay, see cir­cuit diagram Fig. 16, 17, 18, 19, 20 or by means of a relay provided with an interior-temperature thermostat.
To ensure an angle of discharge of 90° 10°, it is re­quired that the pipe clamp be attached no more than 150 mm, from the exhaust pipe end
direction of discharge approximately vertical 90° 10°
Fig. 13: Exhaust Pipe Discharge Opening
Installation Position
Thermo 90 / Thermo 90 S
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Control Unit Thermo 90
NOTE:
Control units for the 12-volt variant are provided with red la­belling, those for the 24-volt varian t with green labelling .
The control unit should be installed in a protected location, preferably in the driver’s cab. In the installatio n po siti o n as sho wn in Fig . 14 the cont ro l unit has the degree of pr ot ect ion I P 54 an d in an y oth er in­stallation positio n th e de gr ee of pr ot ect i on is IP 50 .
(only required for degree of protection IP 54 DIN 40050) * Space required for removing the rece pt acl e
housings
Control Unit Thermo 90 S
In the installation position as shown in Fi g. 15 the control unit conforms to IP6K4K type of enclosure.
Setting the Control Temperatures for Thermo 90
Table Preset
Temperature at Sensor
Control Idle Period
Restart After Control Idle Period
negative at B6 80°C 90°C 75°C
B6 open 72°C 82°C 67°C
positive at B6 65°C 75°C 60°C
On the standard cable harness B6 is open.
NOTE:
The selected control idle period temperature of the heater should lie below the opening temperature of the radiator thermostat!
Setting the Control Temperatures for Thermo 90 S
If the signal “Motor on” /" Mo to r of f" (te rm ina l D+) is con­nected to the control unit X12 / 7, different control thre­shold values will take effect.
Preset Temperature at Sensor
Control Idle Period
Restart After Control Idle Period
“Motor on” 72°C 82°C 67°C “Motor off” 80°C 90°C 75°C
If the signal of termi n al D+ is not con ne cte d, the tem pe ra ­tures correspond t o th ose of “Motor off”.
NOTE:
The temperature selected for the control idle period of the heater should be lower than the opening temperature of the radiator thermostat.
Fig. 14: Control Unit, Installation Position
Fig. 15: Control Unit T 90 S (from 03/97), Installation
Position
Thermo 90 / Thermo 90 S
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Legend for circuit diagrams:
this terminal is not used fo r petrol-operated heaters.For temperature codification (temperature at water outlet) refer to the table on page 31Digital timer P1:
with positive voltage conn ect ed to pi n 4 = contin uo us operation when “inst an t he at ” is select ed positive voltage not connected to pin 4 = heating operation: 1 ho ur
Digital timer P2:
with positi ve voltage connected to pin 10 = continuous operation when “instant heat” is selected pin 10 open = variable heating times can be programmed
(10 min. to 120 min.); ba sic sett ing : 12 0 mi n .
Colour of cables
bl br ge gn gr or rt sw vi ws
blue brown yellow green grey orange red black violet white
Wire cross sections
< 7,5 m 7,5 - 15 m
0,75 mm
2
1,0 mm
2
1,0 mm
2
1,5 mm
2
1,5 mm
2
2,5 mm
2
2,5 mm
2
4,0 mm
2
4,0 mm
2
6,0 mm
2
Thermo 90 / Thermo 90 S
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Pos. Designation Comment
A1 Heater Thermo 90/Thermo 90 S A2 Electronic control unit B1 Flame detector B2 Temperature sensor B3 Temperature limiter B4 Interior-temperature thermostat E Pencil-type glow plug F1 Fuse 20A flat fuse SAE J 1284 F2 Fuse 5A flat fuse SAE J 1284 F3 Fuse 20A flat fuse SAE J 1284 H1 Symbol for “ Hea tin g” o n display operation indicator (in pos. P1 or P2) H2 LED in pos. S4 operation indicator (max. 2W) H3 LED illumination of symbols (in pos. P1 or P2) H4 LED max. 20 mA flame indicator (option) H5 Lamp min. 1.2 W Operation indicator of pumping device H6 Red LED (in pos. P2) Illumination of ’instant heat’ button,
stand-by state indicator, operation in dica to r K1 Relay (in pos. A2) main relay K2 Relay (in pos. A2) for circulating pump K3 Relay K5 Relay for vehicle fan K6 Relay only req. if battery switch connected to neg. pole M1 Motor combustion air fan M2 Motor circulating pump M3 Motor vehicle fan P Tester fo r fa ult diagnosis P1 Digital timer 1529 for presetting operating times
Pos. Designation Comment
P2 Digit al timer, standard (1531) for presetting operati ng times R Resisto r series resistor for H4 S1 Switch for circulating pump for separate switch-on S2 Switch battery switch connected to positive pole S3 Switch battery switch connected to negative pole S4 Switch on / off S5 Disc onnect switch 1 or 2-pole Emerge ncy Stop switch electr. or pneum. S6 Switch at pumping device connected to positive or neg at ive po le S7 Switch, pumping device connecte d to posit ive volt ag e S8 Pushbutton ’instant heat’ button, remote control S9 Switch heating/external control of circulating pump V106 Transistor in po s . A2 V107 Transistor in po s . A2 V108 Transistor in po s . A2 X1 Connector 12-pole part of pos. A1 X2 Connector 8-pole part of po s. P 1 X3 Connector 12-pole part of pos. P2 X4 Connector 2-pole X5 Connector 2-pole X6 Connector 2-pole diagnostic system X11 Connector 12-pole at pos. A2 (ST 1) X12 Connector 12-pole at Pos. A2 (ST 2) X13 Connector 2-pole at pos. A2 (ST 3) Y1 Metering pump Y2 Magnetic valve for pumping device
Thermo 90 / Thermo 90 S
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ϑϑ
Fig. 16: System Diagram Thermo 90, 12 and 24V, with Digital Timer with 3 Time Settings, for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Fig. 17: System Diagram Thermo 90-ADR, 24V, for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Fig. 18: System Diagram Thermo 90 S, 12 and 24V, with Digital Timer (standard), for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Page 17
2
8
11
101
12
7
4
H3
P2
H1
H6
3030 8585
8686 8787
87a87a
K5K3
br
br
br
rt
rt
br gn/ws
rt/bl
ge
sw
rt
ws/bl
viblvi/bl
grgnor
or
58 15
12
2
4
58 15
F2 F3
X6
F1
bl
br
30
30
31
31
sw
rt
sw
sw
rt
ws
A2
11 6
12
2
2
3
1
0
710
32
1
1458
11
9
9
4
3
71568
10
212
M2M3M1
br
br
bl
239
8657
112
11 10 4
sw
br
X1
X12 (ST 2)
X3
X5
X13
(ST 3)
X11
(ST 1)
Y1
vi
vi
gr
grgngn
B3
B4
B1 B2
A1
E
M
M
M
X5
X6
ϑϑ
X13 (ST 3)
11221131049586
7
X1
1
122
X11 (ST 1) X12 (ST 2)
ge
B1
B3
B2
E
X1
M1
M2
21
X3
S8
6
9
3
12
1
11
3
9
5
7
1
11
3
9
5
7
1
2
S9
Fig. 19: System Diagram Thermo 90 S, 12 and 24V, with Digital Timer (standard) and circulating pump, for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Fig. 20: System Diagram Thermo 90 S - ADR, 24V, for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Fig. 21: System Diagram Thermo 90 S - ADR, 24V, without auxiliary drive, for legende refer to page 10 and 11
Thermo 90 / Thermo 90 S
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Initial Operation
After the heater has been installed, the water circuit and the fuel supply system must be thoroughly bled. When so doing, the vehicle manufacturer’s instructions must be ad­hered to.
During a test run of the heater, all water and fuel connec­tions must be checked for leakage and security. Should the heater shut down during operation, troubleshooting ac­tivities must be carried out.
Malfunctions
Fault Shutdown
If the flame fails to materialize fuel is delivered for max. 180 seconds .
If the flame is extinguished during operation fuel is de­livered for max. 90 seconds.
In the event of overheating (tripping of temperature limiter) no fuel is delivered.
In the event of a shutd own in itia te d by th e un de rvo l ta ge protection device
Thermo 90 Thermo 90 S 12 volts 10,5V 0,5V 10,5V – 0,5V 24 volts 21V 1V 21V – 1V
for more than 20 seconds,no fuel is delivered. After the cause of malfunction has been eliminated, inter-
lock deactivation is to be performed by switching the heater off and then back on. If an overheating condition has occurred the pushbutton of the temperature limiter must be reset.
Diagnosis in t he E vent of a F au lt S h ut do wn o f Th er m o 9 0
Check fuses and electrical conne ctio ns. If the heater is activated by the switch or the timer with 3
time settings, the differ ent types of malfunctions are indi­cated by coded flashing signals via the operation indicator light during the after-run period of the heater.
After five short signals have been emitted, the long flash­ing pulses can be counted:
1x No start (after 2 start-up attempts) 2x Flame extinction (recurrent >5) 3x Undervoltage 4x Premature flame detection 5x Flame detector interruption or flame detector short circuit 6x Temperature sensor interruption or temperature sensor short circuit 7x Metering pump interruption or metering pump short circuit 8x Blower motor interruption or blower motor short circuit blower motor incorrect speed 9x Pencil-type glow plug interruption or pencil-type glow plug short circuit
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Diagnosis in t he E v en t of a F au lt S h ut do wn The r m o 90 S
Check fuses and electrical conne ctio ns. After the occurrence of a malfunction, the fault is indicated
on the display of the digital timer if the heater is equipped with a standard dig ita l time r:
F 01 No start (after 2 start-up attempts) F 02 Flame extinction (recurrent >5) F 03 Undervoltage or overvoltage F 04 Premature flame detection F 05 Flame detector interruption or flame detector short circuit F 06 Temperature sensor interruption or temperature sensor short circuit F 07 Metering pump interruption or metering pump short circuit F 08 Blower motor interruption or blower motor short circuit blower motor incorrect speed F 09 Pencil-type glow plug interruption or pencil-type glow plug short circuit F 10 Overheat ing F 11 Circulating pump interruption or circulation pump short circuit
If the heater is activated by the switch, the types of mal­functions are indicated by coded flashing signals via the operation indica to r li gh t du ring the after-ru n pe rio d of the heater.
After five short signals have been emitted, the long flash­ing pulses can be counted:
1x No start (after 2 start-up attempts) 2x Flame extinction (recurrent >5) 3x Undervoltage or overvoltage 4x Premature flame detection 5x Flame detector interrupt i on or flame detector short circuit 6x Temperature sensor interruption or temperature sensor short circuit 7x Metering pump interruption or metering pump short circuit 8x Blower motor interruption or blower motor short circuit blower motor incorrect speed 9x Pencil-type glow plug interruption or pencil-type glow plug short circuit 10x Overheating 11x Circulating pump interruption or circulating pump short circuit
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Technical Data
Unless tolerances are sho w n with i n th e te chn ical da ta table on the rig ht, a tolerance of 10% applies at an am­bient temperature of +20°C and at rated voltage.
Electrica l co m pone nt s:
Control unit, motors for combustion air fan and circulating pump, pencil-t ype gl ow plu g, switch and digital ti me r (p re s­etting of operating times not possible in the case of ADR vehicles) are designed either for 12-volt or 24-volt oper­ation. Components such as thermal cut-out , te mp er at ur e sensor and flame detector are identical in 12 V and 24 V heaters.
Fuel for Thermo 90 / 90 S Petrol-Type Heater:
The fuel specified by the vehicle manufacturer is suita ble as fuel for the heater. Both leaded and unleaded fuel may be used.
Fuel for Thermo 90 / 90 S and Thermo 90 / 90 S-ADR (Diesel):
The Diesel fuel specifie d by th e veh i cle ma nu fa ctu re r is suitable as fuel for the heater. Any negative effect caused by additives is not known. When the fuel for the heater is drawn from the vehicle’s fuel tank the vehicle manufacturer’s specificatio ns concern­ing additives are to be ob serv ed . When changing to cold-resistant fuels, the heater must be operated for about 15 minutes to ensure that the fuel line and the fuel pump are also filled with the new fuel.
Heater Operation Thermo 90
Petrol
Thermo 90 S
Petrol
Thermo 90
Diesel
Thermo 90-
ADR
Thermo 90 S
Diesel
Thermo 90
S-ADR
Type BW 80 Thermo 90 S B DW 80 Thermo 90 S D Mark of approval ~S231 ~S299 ~S232 ~S298 Type water heater with Ferro-tec technology Heat output Max.
control range 2,0 kW - 7,6 kW
9,1 kW
1,8 kW - 7,6 kW Fuel Petrol Diesel Fuel consumption Max.
control range 0,25 l/h - 1,0 l/h
1,1 l/h
0,19 l/h - 0,9 l/h
Rated voltage 12 Volt 12 oder 24 Volt
1)
Operating voltage range 10 ... 15 volts 10 ... 15 bzw. 20 ... 30 volts Rated power consumption with circulat-
ing pump (without vehicle fan)
Max. control range 37 W - 83 W
90 W
37 W - 83 W
Permissible ambient temperature: Heater: - operation
- storage
Control unit: - operation
- storage
Metering pump: - operation
- storage
-40° ... +110°C (90°C 2))
-40° ... +110°C (90°C 2))
-40° ... + 75°C
-40° ... + 85°C
-40° ... + 20°C | -40° ... + 40°C
-40° ... + 85°C
Permissible operat ing over pr essu re (heat carrier)
Max 2,0 bar
Capacity of heat exchanger 0,15 l Max. combustion air intake temperature +40°C Minimum circuit capacity 6,00 l Flow rate of circulating pump against
0.15 bar
1650 l/h
CO2 content in exhaust gas (permissible operating range)
Max. 10 ... 12,0 Vol .-%
CO2-Setting val ues at RT and a geo­graph. altitude above sea level
Max. 0m 500m 1000m
10% 10,6% 11,3%
Dimensions of heater (tolerance 3 mm)
length 310 mm (35 5 mm 2))
width 133 mm
height 220 mm
Weight 4,8 kg
1) Thermo 90-ADR: 24 volts only
2) Thermo 90 S with control unit mount ed to the heater
Thermo 90 / Thermo 90 S
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Variants Thermo 90 Variants Thermo 90 S
Thermo 90 Petrol-Type (Type BW 80)
Water heater for “petrol” fuel
Thermo 90 Diesel-Type (Type DW 80)
Water heater for “Diesel” fuel
Thermo 90-ADR (Type DW 80)
Water heater Thermo 90 with ADR configuration specially designed for use in ve­hicles carrying hazardous ma­terials
The petrol-fuelled Thermo Top 90 water heaters are designed to operate on 12 V, the Thermo 90 Diesel heaters on 12 or 24 V, and the Thermo 90-ADR heaters oper­ate on 24 V only.
Thermo 90 S Petrol-Type (Typ Thermo 90 S B)
Water heater for “petrol” fuel
Thermo 90 S Diesel-Type (Typ Thermo 90 S D)
Water heater for “Diesel” fuel
Thermo 90-ADR (Typ Thermo 90 S D)
Water heater Thermo 90 S with ADR configuration specially designed for use in ve­hicles carrying hazardous ma­terials
The petrol-fuelled Thermo Top 90 S water heaters are designed to operate on 12 V, the Thermo 90 S Diesel heaters on 12 or 24 V, and the Thermo 90-ADR heaters oper­ate on 24 V only.
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Thermo 90 / Thermo 90 S
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Template for heater mounting bracket
Scale 1:1
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Thermo 90 / Thermo 90 S
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Webasto Thermosysteme GmbH 82131 Stockdorf . Kraillinger Str. 5
.
Phone (089) 85794-0
Fax (089) 8 57 94-448 . Telex 5 23 647 webas d
Subject to change
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