Webasto Thermo 230 Workshop Manual
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Webasto Thermo 230 Workshop Manual

With control unit 1572 model .30 and up
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See also: Instruction and Installation Manual
Water Heaters
05/1999
Workshop Manual
Thermo 230
Thermo 300
Thermo 350
with control unit 1572
model .30 and up
Thermo 230
Thermo 300
Thermo 350
with control unit 1572D
model .030 and up

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Summary of Contents for Webasto Thermo 230

  • Page 1 Water Heaters Workshop Manual Thermo 230 Thermo 300 Thermo 350 with control unit 1572 model .30 and up Thermo 230 Thermo 300 Thermo 350 with control unit 1572D model .030 and up 05/1999...

  • Page 2: Table Of Contents

    Thermo 230 / 300 / 350 List of Contents List of Contents Introduction Scope and Purpose ..........................101 Applicability of Manual ........................... 101 Meaning of Warnings, Cautions and Notes ................... 101 Additional Documentation to be used ....................101 Safety Information and Regulations....................... 101 1.5.1 General Safety Notes .........................
  • Page 3 List of Contents Thermo 230 / 300 / 350 Functional Checkouts General ..............................601 Adjustments ............................601 6.2.1 Adjustment of CO Contents ..................... 601 Components Testing..........................602 6.3.1 Temperature Sensor Resistance Check..................602 6.3.2 Flame Sensor Resistance Check ....................602 6.3.3 Igniter Electrodes Check ......................
  • Page 4 Thermo 230 / 300 / 350 List of Contents Repair General ..............................901 9.1.1 Work on Components after Disassembly ................... 901 9.1.2 Incorporation of Modifications..................... 901 Disassembly and Assembly........................904 9.2.1 Temperature Limiter, Replacement .................... 904 9.2.2 Temperature Sensor, Replacement ................... 904 9.2.3 Burner, Replacement........................
  • Page 5 List of Contents Thermo 230 / 300 / 350 List of Figures Functional Sequence (heaters with control unit 1572) ..................302 Functional Sequence (heaters with control unit 1572D) ................. 303 General Fault Symptoms ..........................501 Automatic Control Circuit with Control Unit 1572 and Switch ................. 702 Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer) ............

  • Page 6: Introduction

    General Approvals" laid down by the Federal Office for In combination with control unit 1572D additionally a Motor Traffic exist for the Water Heaters Thermo 230, 300 different type of igniter box is installed (refer to 2.7). and 350 with the following official marks of conformity:...

  • Page 7: Legal Provisions For Installation

    1 Introduction Thermo 230 / 300 / 350 CAUTION When checking the cooling water level proceed in Non-compliance with the installation instructions and the accordance with the vehicle manufacturer’s instructions. information contained therein will void the Webasto The water in the heating circuit of the heater must contain warranty.

  • Page 8: Corrections And Improvements

    Webasto Thermosysteme GmbH tank. Abt. Technische Dokumentation D-82131 Stockdorf Installation Instructions for Webasto fuel tanks for the fuel Telephone: 0 89 / 8 57 94 - 5 42 supply of water heaters in vehicles: Telefax: 0 89 / 8 57 94 - 7 57 •...
  • Page 9 1 Introduction Thermo 230 / 300 / 350 Page empty for notes...

  • Page 10: General Description

    Thermo 230 / 300 / 350 2 General Description General Description The heaters Thermo 230, 300 and 350 basically consist of – the combustion air fan The water heaters Webasto Thermo 230, 300 and 350 – the fuel pump with nozzle block and nozzle are used in combination with the vehicle’s own heating...

  • Page 11: Combustion Air Fan

    2 General Description Thermo 230 / 300 / 350 Combustion Air Fan 2.2.1 Nozzle block preheater NOTE The combustion air fan supplies the air required for com- For operation with PME (Bio Diesel) the installation of a bustion from the combustion air inlet to the combustion nozzle block preheater is mandatory.

  • Page 12: Control Unit

    Thermo 230 / 300 / 350 2 General Description Control Unit Igniter Box with Igniter Electrodes The control unit 1572 or 1572D is the central component The igniter box generates the high voltage for igniting the to ensure controlled operation and monitoring of fuel/air mix by a high voltage ignition spark across the combustion.
  • Page 13 2 General Description Thermo 230 / 300 / 350 2.10 Circulation Pump The circulation pump mounted externally ensures the coolant circulation in the vehicle and heater circuit. The pump is activated by the control unit to operate as long as the heater is in operation.

  • Page 14: Functional Description

    Thermo 230 / 300 / 350 3 Functional Description Functional Description run-down is completed with deactivation of the com- bustion air fan. Activation and deactivation is by means of a The circulation pump remains in operation during the • switch control idle period.
  • Page 15 3 Functional Description Thermo 230 / 300 / 350 Operating indicator light Heater cartridge Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor Switch on Start Combustion operation Temperature sensor – upper switching threshold Flame sensor – dark Control idle Temperature sensor –...
  • Page 16 Thermo 230 / 300 / 350 3 Functional Description Operating indicator light Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor Switch on Start Flame-up, combustion operation Temperature sensor – upper switching threshold Flame sensor – dark Control idle Temperature sensor –...
  • Page 17 3 Functional Description Thermo 230 / 300 / 350 Malfunctions by overheating: Error Code Output (heaters with Overheating results in deactivation of the heater by the control unit 1572D) temperature limiter/thermostat. Dependent on heater configuration: When equipped with a standard timer an error code –...

  • Page 18: Technical Data

    Thermo 230 / 300 / 350 4 Technical Data Technical Data may be used if their quality is in accordance with the German standard. Where no threshold values are specified technical data A bad influence caused by additives is not known.
  • Page 19 4 Technical Data Thermo 230 / 300 / 350 Circulation pump U 4814 U 4816 U 4851 Volume flow 5200 6000 6000 (against 0.15 bar) (against 0.4 bar) (against 0.4 bar) Nominal voltage Operating voltage range 20 ... 28 Nominal power consumption...

  • Page 20: Troubleshooting

    The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunction: This section describes troubleshooting procedures for the heaters Thermo 230, 300 and 350 . corrosion on connector loose contact on connector CAUTION...
  • Page 21 5 Troubleshooting Thermo 230 / 300 / 350 Symptom Probable Cause • excessive system resistance (especially high when cold). • circulation pump defective. Heat exchanger (water/air) dissipate not enough heat, because • air or gas in heat exchangers or in system sections.

  • Page 22: Fault Symptoms During Functional Checkouts And Error Code Output Or Tests With

    Thermo 230 / 300 / 350 5 Troubleshooting Fault Symptoms during Functional PC Heater Diagnosis Checkouts and Error Code Output or By use of the PC heater diagnosis heaters (with control Tests with Diagnostic Computer, unit 1572 or 1572D) may be tested in the vehicle.
  • Page 23 5 Troubleshooting Thermo 230 / 300 / 350 5.3.2 Fault Symptoms to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. 5.3.2.1 Fault Symptom "No Start"...
  • Page 24 Thermo 230 / 300 / 350 5 Troubleshooting 5.3.2.2 Fault Symptom "Flame-out" stops any further attempts to start. This error lockout is superior to the normal error lockout condition. NOTE The error lockout reset is achieved by switching the heater...
  • Page 25 5 Troubleshooting Thermo 230 / 300 / 350 5.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down" Has heater been in long time operation Flame sensor defective, replace. shortly before? Control unit defective, replace. Allow heater to cool down and restart (approx. 2 min.).
  • Page 26 Thermo 230 / 300 / 350 5 Troubleshooting 5.3.2.7 Fault Symptom "Solenoid Valve Defective" Is solenoid valve supplied Make electrical connections. with electrical power? Replace solenoid valve. Is components test with diagnostic computer o.k. Control unit defective, replace. (audible click of solenoid valve)? Does fuel leak from nozzle in run-down? Replace solenoid valve.
  • Page 27 5 Troubleshooting Thermo 230 / 300 / 350 Page empty for notes...
  • Page 28 Thermo 230 / 300 / 350 6 Functional Checkouts Functional Checkouts General This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities.

  • Page 29: Components Testing

    6 Functional Checkouts Thermo 230 / 300 / 350 Components Testing 6.3.3 Igniter Electrodes Check NOTE 6.3.1 Temperature Sensor Resistance The insulator of the igniter electrodes must show no Check damage. Igniter electrodes with a gap out of tolerance or not working properly must be replaced.
  • Page 30 Thermo 230 / 300 / 350 6 Functional Checkouts 6.3.4 Igniter Box Check 6.3.5 Fuel Pump Check NOTE 6.3.5.1 Fuel Pump Check on Heaters with Control Unit The igniter box may also be tested using the PC heater 1572 diagnosis (component test).
  • Page 31 6 Functional Checkouts Thermo 230 / 300 / 350 6.3.5.2 Fuel Pump Check on Heaters with Control Unit 6.3.7 Solenoid Valve Check 1572D NOTE NOTE A solenoid valve leaking valve seat shows by rather long A fuel pump check of heaters with control unit 1572D may smoke emissions during run-down.

  • Page 32: Circuit Diagrams

    The circuit diagrams (Fig. 701 and 702) show possible The circuit diagrams (Fig. 703 and 704) show possible heater circuits for Thermo 230, 300 and 350 with control heater circuits for Thermo 230, 300 and 350 with control unit 1572 and with unit 1572D and with –...
  • Page 33 7 Circuit Diagrams Thermo 230 / 300 / 350 rt/ws F1/B3 B1 Y1 Wire colors blue brown yellow Diagnostic connector green Wire gauges gray orange < 7.5 m 0.75 mm 1.0 mm black 1.5 mm violet 2.5 mm white 4.0 mm...
  • Page 34 Thermo 230 / 300 / 350 7 Circuit Diagrams 75(15) 75(15) rt/ws F1/B3 B1 Y1 Wire colors blue brown Diagnostic connector yellow green Wire gauges to vehicle terminal +75 if available, otherwise terminal 15 gray orange < 7.5 m Timer P: 0.75 mm...
  • Page 35 7 Circuit Diagrams Thermo 230 / 300 / 350 75 (15) 75 (15) W1 A 2,0 mm² rt/ws 2,0 mm² rt 2,0 mm² br B3/B5 B1 Y1 2,0 mm² sw Wire colors blue Diagnostic connector brown Pin assignment: Pin assignment...
  • Page 36 Thermo 230 / 300 / 350 7 Circuit Diagrams 75 (15) 75 (15) W1 A 2,0 mm² rt/ws 2,0 mm² rt 2,0 mm² br B3/B5 B1 Y1 1, 2, 3 2,0 mm² sw 4, 5, 6 7, 8, 9 10, 11, 1...
  • Page 37 7 Circuit Diagrams Thermo 230 / 300 / 350 Page empty for notes...

  • Page 38: Inspection And Attachment Of The Exhaust Muffler (Only Heaters From Year Of

    Thermo 230 / 300 / 350 8 Servicing Servicing Replenish coolant to manufacturer’s instructions if on low level. General • at least once a year, in case of contaminated fuel more often, the fuel filter or filter cartridge must be replaced to avoid malfunctions.
  • Page 39 4. If the exhaust muffler has been lost it may be ordered the exhaust end pipe and muffler and arrest muffler with a free of charge from Webasto (ident. no. 206 91C). sheet metal screw B 3.9 x 25 (see figure).
  • Page 40 Thermo 230 / 300 / 350 8 Servicing 8.5.2 Burner Head Opening and Closing Opening 1. Disconnect electrical connections to temperature limiter and temperature sensor. WARNING 2. Loosen nuts (2, Fig. 801) enough to release hinge The igniter box operates with high voltage. Prior to bolts (1).
  • Page 41 Should fuel hoses be installed always use the hoses capacity must be at least 10 liters. supplied or offered by Webasto. If other hoses are used they must at least meet the specifications of DIN 73379. The vehicle cooling system or the separate heating circuit...
  • Page 42 Thermo 230 / 300 / 350 8 Servicing Water heating circuit – Sidewall radiators and roof duct heating Supply Return 1 Sidewall radiator with fan 2 Heat exchanger, entrance 3 Heater unit 4 Circulation pump 5 Heat exchanger, roof 6 Vehicle engine...
  • Page 43 Observe official regulations concerning the installation (see 1.6). A fuel filter or PME special filter supplied as deliverable item or cleared for use by Webasto is to be fitted. The exhaust pipe outlet opening must not point in the Installation position possibly vertical with horizontal direction of motion.

  • Page 44: Removal And Installation

    Thermo 230 / 300 / 350 8 Servicing Rigid pipes made of unalloyed or alloyed steel with a 6. Connect electrical connectors of cable harness in minimum wall thickness of 1.0 mm have to be used as vehicle and to circulation pump.
  • Page 45 8 Servicing Thermo 230 / 300 / 350 8.7.6 Flame Sensor, Replacement 8.8.1 Water Circuit, Bleeding NOTE NOTE The replacement procedure for the flame sensor is identi- Bleeding must always be performed in accordance with cal with the heater installed or removed.
  • Page 46 NOTE This section describes the repairs that may be performed Deposits are to be removed with water jet and brush. on the heaters Thermo 230, 300 and 350 when removed. Any further disassembly will void the warranty. – Inspect heat exchanger for exterior damage, defor- For re-assembly only components of the proper spare part mation, etc.
  • Page 47 9 Repair Thermo 230 / 300 / 350 9.1.2.1 Installation of Control Unit 1572D as Procedure Substitute for Control Unit 1572 CAUTION General Control unit 1572D may only be used in combination with the igniter box delivered (green connector cover).
  • Page 48 Thermo 230 / 300 / 350 9 Repair 9.1.2.2 Installation of Circulation Pump U 4851 as Procedure Substitute for Circulation Pump U 4814 or U 4816 CAUTION When installing circulation pump U 4851 the following General information must be strictly observed to avoid loss of Immediately from now on the circulation pumps U 4814 warranty.

  • Page 49: Disassembly And Assembly

    9 Repair Thermo 230 / 300 / 350 Disassembly and Assembly 9.2.2.2 Installation 1. Manually screw temperature sensor (2, Fig. 901) into 9.2.1 Temperature Limiter, Replacement coolant outlet (4). 2. Torque temperature sensor to 20 Nm +5 Nm. 9.2.1.1 Removal 3.
  • Page 50 Thermo 230 / 300 / 350 9 Repair 1 Temperature limiter 2 Temperature sensor Rubber cap 3 Connector Temperature 4 Coolant outlet limiter 5 Cotter pin 6 Nut (2) 7 Hinge bolt (2) Retaining clip 8 Burner NOTE Cotter pin (5) may be fitted on other side as required for burner head to swing open in opposite direction.
  • Page 51 9 Repair Thermo 230 / 300 / 350 9.2.4 Combustion Air Fan, Replacement 9.2.4.2 Installation NOTE NOTE Fan motor (7, Fig. 902) to be aligned with control unit For replacement of the combustion air fan the burner may (recess in mounting flange) and with clutch (by rotating be left installed.
  • Page 52 Thermo 230 / 300 / 350 9 Repair 1 Splash protection cover 2 Cap 3 Screw (2) 4 Fan wheel 5 Slide lock 6 Screw (3) 7 Fan motor 8 Clutch 9 Electrical connector Fig. 902 Combustion Air Fan, Replacement...
  • Page 53 9 Repair Thermo 230 / 300 / 350 9.2.5 Control Unit, Replacement 9.2.6 Fuel Pump, Replacement NOTE 9.2.6.1 Removal For replacement of the control unit the burner head may be left installed and must only be swung open for 1. Remove burner (refer to 9.2.3.1).
  • Page 54 Thermo 230 / 300 / 350 9 Repair Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and Control unit also control unit 1572D 1572 Igniter box (black connector cover) only in combination with control unit 1572...
  • Page 55 9 Repair Thermo 230 / 300 / 350 9.2.7 Igniter Box, Replacement 9.2.8 Flame Sensor, Replacement 9.2.7.1 Removal 9.2.8.1 Removal 1. Remove burner if required (refer to 9.2.3.1). 1. Remove burner if required (refer to 9.2.3.1). 2. Using screw driver lever off igniter electrodes 2.
  • Page 56 Thermo 230 / 300 / 350 9 Repair Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and Control unit also control unit 1572D 1572 Igniter box (black connector cover) only in combination with control unit 1572...
  • Page 57 9 Repair Thermo 230 / 300 / 350 9.2.9 Heat Exchanger, Replacement 9.2.10 Combustion Chamber, Replacement 9.2.9.1 Removal 9.2.10.1 Removal 1. Remove temperature limiter (refer to 9.2.1.1). 1. Disconnect electrical connections to temperature 2. Remove temperature sensor (refer to 9.2.2.1).

  • Page 58: Packaging, Storage And Shipping

    10 Packaging / Storage / Shipping 10. Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Webasto Thermosysteme GmbH for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage.
  • Page 59 10 Packaging / Storage / Shipping Thermo 230 / 300 / 350 Page empty for notes 1002...

This manual is also suitable for:

Thermo 300Thermo 350

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