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Webasto Thermo 90 ST Installation Manual

Bluecool premium chiller
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See also: Service & Repair Manual , Workshop Manual
Webasto BlueCool Premium
Thermo 90 ST - Chiller
Installation Manual
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
CAUTION

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Summary of Contents for Webasto Thermo 90 ST

  • Page 1 – Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures.

  • Page 3: Table Of Contents

    Version with Light ............25 www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 4: Foreword

    General Webasto Product North America, Inc. is pleased to provide this installation manual with the Thermo 90 ST designed for the BlueCool Premium System. When used according to the guidelines stated in this manual, you can expect to provide years of trouble-free, enjoyable operation for your customer.

  • Page 5: Safety And Important Information

    Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto Product. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts.

  • Page 6: Symbol Identification

    Heater Dimensions ø ø ø 1. Combustion Air Intake 2. Exhaust Fume Outlet 3. Fuel Intake 4. Coolant Inlet 5. Coolant Outlet ø ø ø Fig. 1 Dimensions of the Thermo 90 ST www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 7: Packaged Components

    Manuals / Warranty ENVELOPE WHITE 9"X12" WARRANTY CARD THERMO 90 ST INSTALLATION MANUAL Heater Parts THERMO 90 ST 12V MARINE HEATER HARNESS POWER / SWITCH INTERNAL HARNESS THERMO 90 S Parts Bag Clamps CLAMP HOSE 13-32MM 1/2" SS MARINE GRADE...

  • Page 8: Installation

    • Radial blower on the heat exchanger (arranged on inlet side) up to 131°F (55 °C) • For this reason, a Thermo 90 ST with a specialized control unit must be used. The heater has a pre-programmed nominal temperature of 126°F (52 °C).

  • Page 9: Installation Site / Installation Position

    The heater must be installed in as low a position as possible to allow the heater and circulating pump to be bled auto- matically. This is particularly important as the circulating pump is not self-priming. Fig. 2 Correct installation positions for the Thermo 90 ST Mounting the Heater The heater must be secured with at least three M8 screws.

  • Page 10: Hose Connections To Chiller Unit

    Installation Hose Connections to Chiller Unit The Thermo 90 ST is intragrated into the Chiller unit water circuit via a electrically actuated 3-way valve assembly. Fig. 3 BlueCool Premium System with a Thermo 90 ST Components: 1. Stop valve at ship’s side inlet 2.
  • Page 11 Perfect ventilation can be identified by the circulating pump operating almost silently. Poor bleeding may cause the resetting temperature limiter to trip while the heater is operating. Fig. 4 Electrically Actuated 3-way Valve www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 12: Fuel Supply

    Only use a tank connector if the fuel tank is made from metal Tank fittings Fig. 7 Webasto Tank Connector Fig. 6 Fuel Pickup from the Plastic Tank NOTE: Ensure to deburr the sharp edges from the standpipe after cutting.
  • Page 13 Fig. 9 in order to ensure effective auto-bleeding. Fuel filter Only a Webasto filter P/N: 50487171A is permitted when a fuel filter is needed. Install vertically if possible. (See Fig.10). NOTE: Ensure to follow the correct fuel filter direction flow marked on the side of the filter.

  • Page 14: Combustion Air Supply

    Secure the intake tube to the heater with the provided hose clamps. Ensure the fuel pump connector harness is in place in the slot provided in the air intake port before tightening clamp. Secure the tube to the adjacent structures with P-clips or nylon wire ties. www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 15: Heater Exhaust

    If additional protection is required, it is recommended to over-sleeve with an additional layer of insulation (available from your local Webasto marine dealer). DO NOT connect the heater exhaust into the engine or generator exhaust. Doing so will result in CAUTION unacceptable back-pressure levels and may damage the heater or cause operational failure.
  • Page 16 Avoid asphyxiation! If the exhaust pipe is routed through the inside of the vessel, exhaust gas tube must be as leakproof as possible: • use only Webasto approved exhaust clamps and firmly tighten clamps. • an approved exhaust sealant can be used on the inside of the exhaust tube at all connection points •...

  • Page 17: Electrical System

    Thermo 90 ST Control Module The control module offers protection type 6K9K if it is installed in the position shown in Fig. 13. 24 V XXXXXXX_.XXXXX Fig. 13 Thermo 90 ST Control Module, Arbitrary Installation Position www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 18 TECC Program 412 and Higher with Thermo 90 ST and Electrical 3-Way Valve Because an external water heater (Thermo 90 ST) is being installed with a BlueCool Chiller Unit, the TECC Card must be reprogrammed for proper operation. This step must be completed in order for proper operation of the Thermo 90 ST.
  • Page 19 Connections on the TECC Card: R1 - Connection C1 R1 - Connection R1 R1 - Connection T1 R1 - Connection C2 R1 - Connection R2 R1 - Connection T2 Fig. 15 Chiller Unit TECC Card www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 20: Information About Air Guidance

    • The distance between the (hot) air outlet and the (circulating) air inlet must be at least 5’ (1.5m). (Danger of air closed circuit) • Consider the installation complexity (price) • The customer must perform the changeover manually. • Currently unavailable as a single part www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 21: Circuit Diagrams

    Circuit Diagrams Circuit Diagrams Thermo 90 ST Circuit Diagram Legend Circuit diagram legend for the Thermo 90 ST Item Designation Comment Heater 1. Temperature coding (temperature at water outlet): Control module Refer to following circuit diagram legend for further Flame sensor information.
  • Page 22 Circuit Diagrams Fig. 17 System Circuit for Thermo 90 ST, 12 / 24V Fig. 18 TECC Card from Chiller Unit www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 23: Initial Start-Up

    After the heater is installed and the TECC Card is programmed to reflect Function F4 (Preferred Function), the end user will enjoy seamless comfort control. The TECC Card will now request the Thermo 90 ST rather than reverse compressor cycling when heat is requested.

  • Page 24: Technical Data

    12 V or 24 V. The temperature limiter, temperature sensor and flame sensor are identical on 12 V and 24 V heaters. Fuel for Thermo 90 ST The diesel fuel specified by the manufacturer must be used. There are no known negative influences due to fuel additives.

  • Page 25: Troubleshooting

    Once the cause of the fault has been eliminated, the fault lock-out is cancelled by switching the heater off and on again. If the under voltage guard switches off the system for longer than 20 seconds, the fuel supply is interrupted. Thermo 90 ST 12 V 10.5V –...
  • Page 26 Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 27 Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 28 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us Org. 05/2005 Rev. N/A P/N: 5000988A www.techwebasto.com...

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