Webasto Thermo 90 S-ADR Workshop Manual
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Webasto Thermo 90 S-ADR Workshop Manual

Webasto Thermo 90 S-ADR Workshop Manual

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Water heaters
09/2005
Workshop manual
Thermo 90 S
Thermo 90 S-ADR
(Transport of hazardous goods)
Thermo 90 ST
Thermo 90 ST-ADR
(Transport of hazardous goods)

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Summary of Contents for Webasto Thermo 90 S-ADR

  • Page 1 Water heaters Workshop manual Thermo 90 S Thermo 90 S-ADR (Transport of hazardous goods) Thermo 90 ST Thermo 90 ST-ADR (Transport of hazardous goods) 09/2005...

  • Page 2: Table Of Contents

    Thermo 90 S / Thermo 90 ST Table of contents Table of contents Introduction Contents and purpose ........................... 101 Meaning of signal words ........................101 Additional documentation to be used..................... 101 Safety instructions and regulations......................101 1.4.1 General safety regulations......................101 Statutory regulations governing installation ....................102 General description Combustion air fan..........................

  • Page 3: Settings

    Table of contents Thermo 90 S / Thermo 90 ST Function tests General ..............................601 Settings ..............................601 6.2.1 Setting the CO content......................601 Testing individual components......................601 6.3.1 Resistance test of the temperature sensor ................. 601 6.3.2 Resistance test of the glow plug ....................601 6.3.3 Resistance test of the flame monitor ..................
  • Page 4 Thermo 90 S / Thermo 90 ST Table of contents Repair General ..............................901 9.1.1 Work on stripped-down components ................... 901 Dismantling and assembling........................902 9.2.1 Electrical connections (Thermo 90 S)..................902 9.2.2 Changing the circulating pump ....................903 9.2.3 Changing the temperature limiter ....................904 9.2.4 Changing the temperature sensor ....................
  • Page 5 System circuit for Thermo 90 S-ADR, 24 V, with switch ................704 System circuit for Thermo 90 S-ADR, 24 V, with switch without power take-off ........705 System circuit for Thermo 90 ST, 12 and 24 V, with standard digital timer ..........706 System circuit for Thermo 90 ST, 12 and 24 V, with standard digital timer and separate circulating pump control ..........................

  • Page 6: Contents And Purpose

    The “General safety regulations” that go beyond the liability by Webasto. The same applies if repairs are scope of the above regulations are stated below. carried out incorrectly or with the use of parts other than genuine spare parts.

  • Page 7: Statutory Regulations Governing Installation

    1 Introduction Thermo 90 S / Thermo 90 ST Statutory regulations governing installation Refer to the installation instructions for the statutory regulations if necessary.

  • Page 8: Combustion Air Fan

    Thermo 90 S / Thermo 90 ST 2 General description General description 2 hours after the heater is switched on. The Thermo 90 S and Thermo 90 ST heater is principally composed of Thermo 90 S and Thermo 90 ST water heaters operate in –...
  • Page 9 2 General description Thermo 90 S / Thermo 90 ST 1 Combustion air fan 2 Fuel connection 3 Temperature sensor 4 Temperature limiter 5 Heat exchanger 6 Inlet, coolant 7 Circulating pump 8 Outlet, coolant 9 Outlet, exhaust gas 10 Inlet, combustion air 11 Control unit Thermo 90 ST heater Combustion air fan...

  • Page 10: Metering Pump

    Thermo 90 S / Thermo 90 ST 2 General description Temperature sensor Combustion pipe The mixture of fuel and air burns in the combustion pipe, The temperature sensor records the coolant temperature thus causing the heat exchanger to become hot. at the coolant outlet of the heater as an electrical resistance.
  • Page 11 2 General description Thermo 90 S / Thermo 90 ST Page for notes...

  • Page 12: Switching On

    Thermo 90 S / Thermo 90 ST 3 Function description Function description (Fig. 301) Switching on The “operating indicator” on the digital timer lights up when the “immediate heating” button is pressed. When switching on with the switch, the operating indicator in the switch lights up.

  • Page 13: Switching Off

    3 Function description Thermo 90 S / Thermo 90 ST If no flame is formed, the start is automatically repeated (20 s pulse pre- glow, 90 s safety time). o Possible regulating temperatures that can be °C set, see table below Safety time Fig.

  • Page 14: Malfunctions

    Thermo 90 S / Thermo 90 ST 3 Function description Glow plug Metering pump Combustion air fan Flame monitor Operation indicator light Circulating pump Vehicle fan Malfunctions 3.6.1 Fault lock-out Fuel is supplied for max. 240 seconds if the flame does not start to burn.
  • Page 15 3 Function description Thermo 90 S / Thermo 90 ST 3.6.2 Diagnosis after fault lock-out 3.6.2.2 Version with switch Thermo 90 S and Thermo 90 ST If the system is operated with a switch, the nature of the fault is indicated by a flashing code on an operating Check the fuses and plug connectors.
  • Page 16 Thermo 90 S / Thermo 90 ST 3 Function description Page for notes...

  • Page 17: Technical Data

    Both leaded and unleaded fuel may be used. Heater Operation Thermo 90 S Thermo 90 ST Thermo 90 S diesel Thermo 90 ST diesel Petrol Petrol Thermo 90 S-ADR Thermo 90 ST-ADR EC licensing symbol ~S299 ~S298 Model Water heater with Ferro-Tec technology Heat output Max.
  • Page 18 4 Technical data Thermo 90 S / Thermo 90 ST Page for notes...

  • Page 19: General

    Control unit enters fault lock-out status. automatically restart Switch the heater off and back on again. Flame extinguishes during Contact a Webasto service centre if heater operation operation does not start again Heater overheats due to lack/ Top up coolant.

  • Page 20: Fault Indications On Fault Lock-Out

    5 Troubleshooting Thermo 90 S / Thermo 90 ST Fault indications on fault lock-out NOTE After five short signals, count the long flashes. If the system is operated with a switch, the nature of the In the Thermo 90 S heater with a standard clock, the fault fault is indicated by a flashing code on an indicator light is output on the clock display (see 3.6.3).

  • Page 21: Visual Check For Assessing The Burner

    Thermo 90 S / Thermo 90 ST 5 Troubleshooting Fault indication Possible cause Remedy 9 Flashing pulses Cabling Check cabling for damage, discontinuity and (glow plug defective) short-circuit Flow plug defective Replace glow plug 10 Flashing pulses (overheating) Heater overheats Check coolant and top up if necessary.

  • Page 22: Back Wall With Metal Evaporator

    5 Troubleshooting Thermo 90 S / Thermo 90 ST 5.4.2 Back wall with metal evaporator 5.4.3 Combustion chamber • The pilot flame outlet opening (Fig. 504) must be clear • The combustion chamber (Fig. 505) should not be otherwise no start will occur. damaged (e.g.

  • Page 23: General

    Thermo 90 S / Thermo 90 ST 6 Function tests Function tests 6.3.3 Resistance test on the flame monitor If you conduct this electrical test with a digital multimeter, General the flame monitor should have the following values: This section describes the tests conducted on the heater Cold test: 3.0 ±0.4 Ω...
  • Page 24 6 Function tests Thermo 90 S / Thermo 90 ST Page for notes...

  • Page 25: Circuit Diagrams

    Thermo 90 S / Thermo 90 ST 7 Circuit diagrams Circuit diagrams General The circuit diagrams (Figs. 701 to 704) show the possible circuits for the Thermo 90 S heater with – Standard clock – Standard clock and separate circulating pump control –...
  • Page 26 7 Circuit diagrams Thermo 90 S / Thermo 90 ST X11 (ST 1) X12 (ST 2) X13 (ST 3) X12 (ST 2) (ST 1) (ST 3) 1 12 ϑ ϑ Temperature coding (temperature at water outlet): Cable colours Cable colours Cable cross-sections See table on page 302 Blue...
  • Page 27 Thermo 90 S / Thermo 90 ST 7 Circuit diagrams X11 (ST 1) X12 (ST 2) X13 (ST 3) X12 (ST 2) (ST 1) (ST 3) 1 12 ϑ ϑ Temperature coding (temperature at water outlet): Cable colours Cable cross-sections See table on page 302 Blue <...
  • Page 28 Operating indicator (in item S4) Lamp min. 1.2 W Switch-on indicator pumping device Relay For vehicle fan Motor Combustion air fan Motor Circulating pump Motor Vehicle fan Switch ON/OFF Fig. 703 System circuit for Thermo 90 S-ADR, 24 V, with switch...
  • Page 29 For vehicle fan Motor Combustion air fan Motor Circulating pump Motor Vehicle fan Switch ON/OFF 1 or 2-pin disconnecting switch Emergency off switch electrical or pneumatic Fig. 704 System circuit for Thermo 90 S-ADR, 24 V, with switch without power take-off...
  • Page 30 7 Circuit diagrams Thermo 90 S / Thermo 90 ST ϑ ϑ Cable colours Temperature coding (temperature at water outlet): Cable cross-sections See table on page 302 Blue < 7.5 m 7.5 - 15 m Brown Digital timer P2: 0.75 mm 1.0 mm with positive at connection 10 = Continuous operation with immediate...
  • Page 31 Thermo 90 S / Thermo 90 ST 7 Circuit diagrams ϑ ϑ Temperature coding (temperature at water outlet): Cable colours Cable cross-sections See table on page 302 Blue < 7.5 m 7.5 - 15 m Digital timer P2: Brown 0.75 mm 1.0 mm with positive at connection 10 = Continuous operation with immediate...
  • Page 32 7 Circuit diagrams Thermo 90 S / Thermo 90 ST ϑ ϑ Temperature coding (temperature at water outlet): Cable colours Cable cross-sections See table on page 302 Blue < 7.5 m 7.5 - 15 m Vehicle fuse Brown 0.75 mm 1.0 mm Yellow 1.0 mm...
  • Page 33 Thermo 90 S / Thermo 90 ST 7 Circuit diagrams ϑ ϑ Cable colours Temperature coding (temperature at water outlet): Cable cross-sections See table on page 302 Blue < 7.5 m 7.5 - 15 m Brown Vehicle fuse 0.75 mm 1.0 mm Yellow 1.0 mm...
  • Page 34 7 Circuit diagrams Thermo 90 S / Thermo 90 ST Page for notes...

  • Page 35: Work On The Heater

    Thermo 90 S / Thermo 90 ST 8 Service work Service work General This section describes the service work that can be carried out on the heater when it is installed. Work on the heater Disconnect the main power cable from the vehicle’s battery before carrying out any work on the heater.

  • Page 36: Heater Trial Run

    8 Service work Thermo 90 S / Thermo 90 ST Heater trial run The heater must not be operated in enclosed areas such as garages and workshops without an emissions extraction system, even if you use the timer. Service work The following service work is to be carried out after or before each heating period to maintain the functional reliability of the heater:...
  • Page 37 Thermo 90 S / Thermo 90 ST 8 Service work NOTE The Thermo 90 S and Thermo 90 ST heater is supplied with the control unit mounted on the combustion air fan. With non-return valve and thermostat 1 Heat exchanger vehicle heating 2 Switch for fan of the vehicle heating...

  • Page 38: Visual Inspections And Installation Instructions

    (Accord européen relatif au transport international des marchandises dangereuses par route) governing fuel The coolant hoses supplied by Webasto must always be tanks, part 9 para. 9.2.4.7, must be adhered to. used. If you do not use these hoses, the hoses that you do use must comply with DIN 73411.
  • Page 39 Sealing ring Fuel may only be taken from the supply or return line using the special Webasto fuel extractor (Fig. 806). The fuel extractor must be fitted in such a way that any air or gas bubbles are automatically discharged towards the tank (Fig.
  • Page 40 Fig. 807 Pipe/hose connection from tank to metering pump Fig. 806 Webasto fuel extractor 8.6.2.2 Fuel lines Only steel, copper and plastic lines of plasticised, light and temperature-stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines.

  • Page 41: Metering Pump With Damper

    Fig. 808 in order to ensure effective automatic criteria (Figs. 802 and 808). bleeding. 8.6.4 Fuel filter Only a Webasto filter, order no. 487 171, is allowed to be used if the fuel is expected to be contaminated. Install vertically if possible, however at least horizontally. NOTE Note the installation position and direction of flow.

  • Page 42: Exhaust Line

    8 Service work Thermo 90 S / Thermo 90 ST 8.6.6 Exhaust line – Changing the circulating pump – Changing the temperature limiter – Changing the temperature sensor The exhaust line (internal diameter 38 mm) can be – Changing the combustion air fan installed with a length of 0.5 m to 5 m and several bends –...

  • Page 43: Start-Up

    Thermo 90 S / Thermo 90 ST 8 Service work 8.7.2 Changing the circulating pump Start-up NOTE After you have installed the heater, bleed the coolant The process for changing the circulating pump is the circuit and the fuel supply system carefully. Comply with same irrespective of whether the heater is installed or the instructions given by the vehicle manufacturer when removed.

  • Page 44: General

    Thermo 90 S / Thermo 90 ST 9 Repair Repair 9.1.1.1 Cleaning • Clean all stripped down components. General 9.1.1.2 Visual inspection This section describes the repair work which is permitted • Check all components for damage (cracks, on the heater when it has been removed. Any further deformation, wear, etc.) and fit new ones if necessary.

  • Page 45: Dismantling And Assembling

    9 Repair Thermo 90 S / Thermo 90 ST Dismantling and assembling 1. Remove the upper cover cap from the heater. 2. Use the removing tool (hook part) to pull the locking wedge out of the plug. 9.2.1 Electrical connections (Thermo 90 S) 3.

  • Page 46: Changing The Circulating Pump

    Thermo 90 S / Thermo 90 ST 9 Repair 9.2.2 Changing the circulating pump 9.2.2.2 Installation 1. Apply acid-free grease (Vaseline) to the sealing ring 9.2.2.1 Removal (1, Fig. 902). 2. Place the circulating pump (2, Fig. 902) in the 1.

  • Page 47: Changing The Temperature Limiter

    9 Repair Thermo 90 S / Thermo 90 ST 9.2.3 Changing the temperature limiter 9.2.4 Changing the temperature sensor 9.2.3.1 Removal 9.2.4.1 Removal NOTE 1. Remove the heater (see 8.7.1.1). The temperature limiter only has to be removed if it is 2.
  • Page 48 Thermo 90 S / Thermo 90 ST 9 Repair NOTE A Thermo 90 ST heater is shown. In the Thermo 90 S heater, the control unit can also be arranged on the combustion air fan without having any effect on changing the temperature sensor.

  • Page 49: Changing The Combustion Air Fan

    9 Repair Thermo 90 S / Thermo 90 ST 9.2.5 Changing the combustion air fan 9.2.5.2 Fitting NOTE 9.2.5.1 Removal Insert the shaped seal (3, Fig. 904) correctly and grease it (e.g. with Vaseline). Take care not to squash it. 1.

  • Page 50: Changing The Burner, Flame Monitor And Glow Plug

    Thermo 90 S / Thermo 90 ST 9 Repair 9.2.6 Changing the burner, flame monitor and CAUTION During the following procedure, make sure that the glow plug cables of the flame monitor (7) and the glow plug (6) are routed as shown in the figure. 9.2.6.1 Removal 1.
  • Page 51 9 Repair Thermo 90 S / Thermo 90 ST 1 Burner 2 Swirl orifice NOTE 3 Burner head A Thermo 90 ST heater is shown. 4 Washer The figure can also be used for the 5 Screw Thermo 90 S heater. 6 Glow plug 7 Flame monitor 8 Bar...

  • Page 52: Changing The Burner Head

    Thermo 90 S / Thermo 90 ST 9 Repair 9.2.7 Changing the burner head 9.2.7.2 Installation NOTE 9.2.7.1 Removal The burner head and exhaust outlet port can also be aligned during installation in the vehicle. 1. Remove the heater (see 8.7.1.1). 2.

  • Page 53: Changing The Heat Exchanger

    9 Repair Thermo 90 S / Thermo 90 ST 9.2.8 Changing the heat exchanger 9.2.8.2 Installation 1. Clip the connector housing onto the heat exchanger 9.2.8.1 Removal and insert the plug into the connector housing. 2. Install the burner head (see 9.2.7.2). 1.

  • Page 54: General

    10 Packing / Storage / Shipment Packing / Storage and Shipment 10.1 General If the heater or its components are sent to Webasto Thermosysteme GmbH for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, transport and storage.
  • Page 55 10 Packing / Storage / Shipment Thermo 90 S / Thermo 90 ST Page for notes 1002...

This manual is also suitable for:

Thermo 90 sThermo 90 st-adrThermo 90 st

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