Webasto Thermo Pro 90 Installation Instructions Manual
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Webasto Thermo Pro 90 Installation Instructions Manual

12 v diesel - adr
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See also: Workshop Manual
Wasserheizgerät
Water heater
Appareil de chauffage
Einbauanweisung
Installation Instructions
Notice de montage
Thermo Pro 90
Thermo Pro 90 12 V Diesel - ADR
(Gefahrguttransport)
(Transport of dangerous goods)
(Transport des marchandises dangereuses)
Thermo Pro 90 24 V Diesel - ADR
(Gefahrguttransport)
(Transport of dangerous goods)
(Transport des marchandises dangereuses)
Thermo Pro 90 High Altitude 24 V Diesel

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Summary of Contents for Webasto Thermo Pro 90

  • Page 1 Einbauanweisung Water heater Installation Instructions Appareil de chauffage Notice de montage Thermo Pro 90 Thermo Pro 90 12 V Diesel - ADR (Gefahrguttransport) (Transport of dangerous goods) (Transport des marchandises dangereuses) Thermo Pro 90 24 V Diesel - ADR (Gefahrguttransport)
  • Page 2 Thermo Pro 90 Thermo Pro 90 Thermo Pro 90 High Altitude 219 mm B= 139 mm L= 385 mm...
  • Page 3 Thermo Pro 90...
  • Page 4 Thermo Pro 90 Ø Ø Ø...
  • Page 5 Thermo Pro 90...
  • Page 6 Thermo Pro 90...
  • Page 7 Thermo Pro 90...
  • Page 8 Thermo Pro 90 9032679A03...
  • Page 9 Thermo Pro 90 9032353A04...
  • Page 10 Thermo Pro 90 9037064A01...
  • Page 11 Thermo Pro 90 9033213A02...
  • Page 12 Thermo Pro 90 9032413A03...
  • Page 13 Thermo Pro 90 9032678A03...
  • Page 14 Thermo Pro 90 The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide. This can lead to serious injury or death. To install and repair Webasto heating and cooling systems, you must have completed a Webasto training course and have the appropriate technical documentation, special tools and special equipment.

  • Page 15: Table Of Contents

    10 Electrical Connections dangerous goods................40 10.1 Connecting control unit/heater ............. 51 Use / variants 10.2 Connection when installing Thermo Pro 90-ADR in a vehicle for Intended use .................. 41 transporting dangerous goods (ADR) ..........51 Variants ..................41 10.3 Installing and connecting the control elements ......
  • Page 16 About This Document To enable quick reference to the individual procedures you will find a descrip- tive symbol on the top outer edge of each page. Mechanical system Combustion air Electrical system Technical Information Coolant circuit Attention Fuel Note Exhaust gas...

  • Page 17: Regulations Governing Installation

    • The exhaust system as well as the exhaust pipes shall be so directed or The Thermo Pro 90 heater has been type-tested and approved in accordance protected to avoid any danger to the load through heating or ignition. with ECE-R 10 (EMC) and ECE-R 122 (heater).

  • Page 18: Use / Variants

    Thermo Pro 90 Use / variants 2.2 Variants Thermo Pro 90 12 V diesel - ADR 2.1 Intended use Water heater for diesel fuel.The water heater is designed for 12 volts. The water heater has been designed for installation in commercial vehicles.

  • Page 19: Installation

    For Thermo Pro 90 High Altitude: The combustion heaters and their exhaust gas routing shall be designed, lo- Only install the Thermo Pro 90 High Altitude vertically. See Fig. 1. cated, protected or covered so as to prevent any unacceptable risk of heating or ignition of the load.

  • Page 20: Type Label

    Thermo Pro 90 Technical Information FL vehicles: Type label The combustion heaters shall be put out of operation by at least the following The label referred to in Annex 7, paragraph 4, or a duplicate, must be posi- methods: tioned so that it can be easily read when the combustion heater is installed in the vehicle.

  • Page 21: Installation Example

    Thermo Pro 90 Technical Information Installation example Fig. 3 shows two installation examples of the heater in a vehicle. Legend: 1. Heat exchanger for vehicle heating system 2. Switch for fan of the vehicle heating system 3. Relay for vehicle blower 4.

  • Page 22: Integration In The Coolant System

    Coolant running out of the system should be collected in a suit- able container. The coolant hoses supplied by Webasto should always be used. If this is not possible, the hoses must comply with DIN 73411 material class B as a minimum.

  • Page 23: Fuel Integration

    When retrofitting the fuel take-off system on a plastic tank: forms a connection between tank and fuel pump, and the pressure line forms Install the Webasto tank extracting device only on the vehi- a connection between fuel pump and heater.

  • Page 24: Integration In Motor Return Line

    Fuel take-off from the return line may only be carried out using the special The tank extracting device (standpipe) must under no circum- Webasto fuel extractor, and care must be taken to ensure that the return line stances be mounted in the tank body, but only in the vehicle's runs almost to the tank bottom and is not closed by a non-return valve.

  • Page 25: Dp42 Fuel Pump

    7.6 Fuel filter Use only steel or plastic fuel lines made from light and temper- Only a Webasto strainer is to be fitted if poor-quality fuel is used. Install verti- ature-resistant PA12/ETFE, PA12/EFEP, PA9T/PA12 in accordance cally if possible, maximum deviation not exceeding 90°. See Fig. 11.

  • Page 26: Combustion Air Supply

    Thermo Pro 90 Combustion air Combustion air supply The air inlet (ø 30 mm) must be so positioned or guarded that blocking by rub- bish or luggage is unlikely. (Requirement from ECE-R 122, point 5.3.5.2.). Under no circumstances may the combustion air be taken from areas occupied by persons.

  • Page 27: Exhaust System

    9.2 Exhaust silencer Care must be taken to ensure that the exhaust outlet cannot be blocked and Operation of the Thermo Pro 90 heater is only approved with the use of an cannot be damaged under any usage conditions. exhaust silencer.

  • Page 28: Electrical Connections

    (Requirement from ECE-R 122, Annex 7, point 7.1). Figs 17 to 22. Installing the control element: follow the Operating Instructions 10.2 Connection when installing Thermo Pro 90-ADR in a vehicle for and Installation Instructions for the control element. transporting dangerous goods (ADR)

  • Page 29: Electrical Connection Of The Wiring Harness

    11 Wiring diagrams Danger of fire The wiring diagrams show the possible connections for 12 or 24 volt heaters. Oxidation in the cable can lead to hazardous circumstances. System wiring diagrams for Thermo Pro 90 and control element: Figure Wiring diagram Page...

  • Page 30: Cable Cross-Sections

    Thermo Pro 90 Electrical system 11.1 Cable cross-sections No. Description Remarks H2 LED (green, blue, white, red) Operation indicator, Ready indicator, ON in- Graphic <7.5 m 7.5 – 15 m dicator, fault list 0.75 mm2 1.0 mm2 H5 Bulb/LED ON indicator, pumping device (max.

  • Page 31: Legend For Comments

    The SmartControl or MultiControl control elements can optionally be con- X31 10-pin To Item P2 nected in analogue or W-bus (Webasto bus system) mode. Two interfaces are Y2 Solenoid valve / pump Auxiliary drive / pumping device provided in the wiring harness for this purpose.

  • Page 32: Initial Start-Up

    Mechanical system 12 Initial start-up 13 Malfunctions Observe the safety information given in the operating instruc- Detailed fault localisation and troubleshooting is included in the Thermo Pro 90 service manual. tions!. Carefully read the operating instructions before operating the heater.

  • Page 33: Technical Data

    The diesel fuel in accordance with DIN EN 590 specified by the vehicle manu- facturer must be used. The Thermo Pro 90 device is also approved for use with PME (biodiesel) con- forming to DIN EN 14214. If fuel is taken from the vehicle fuel tank, follow the additive instructions issued by the vehicle manufacturer.
  • Page 34 Thermo Pro 90 Technical Information Thermo Pro 90 Diesel Heater 12 V 24 V ECE R122 (Heating) E1 122R 00 0320 Type approval ECE R10 (EMC) E1 10R 04 6196 Design Water heater with vaporising burner Partial load Heat flow [kW] Full load Boost (max.
  • Page 35 Dans le cas d‘une version rédigée en plusieurs langues, l‘allemand est alors la langue qui fait foi. Pour trouver le numéro de téléphone du pays concerné, veuillez consulter le dépliant des points-service Webasto ou la page web de la représentation Webasto de votre pays.

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