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Webasto Thermo 90 Installation Instructions Manual

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Water Heaters

10/2000

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)
Operating Instructions must be read before
attempting to start up the heater.

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Summary of Contents for Webasto Thermo 90

  • Page 1: Water Heaters

    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) Operating Instructions must be read before attempting to start up the heater.

  • Page 2: Table Of Contents

    Thermo 90 / Thermo 90 S Table of Contents Page Installation Instructions Legal Provisions for Installation Installation Installation Example Connection to the Vehicle’s Cool- ing System Fuel Supply Fuel Lines Metering Pump Combustion Air Supply Exhaust Pipe Electrical Connections Circuit Diagrams...

  • Page 3: Installation Instructions

    Thermo 90-ADR heater Diesel type DW 80. of exhaust fumes entering the interior of the vehicle is S299 for Thermo 90 S heaters Petrol type Thermo 90 S B remote. The functioning of any parts of the vehicle essen- S298 for Thermo 90 S heaters Diesel type tial for its operation must not be impaired.

  • Page 4: Installation

    - The legal provisions on page 1, relating to the installa- Exhaust gas outlet tion of the heater, must be observed Fuel inlet - When installing the Thermo 90-ADR in vehicles de- Coolant inlet signed for the transport of hazardous materials the re- Coolant outlet...

  • Page 5: Installation Example

    Fig. 3: Installation Examples for the Thermo 90 / Thermo 90 S Heater Legend of Fig. 3 T-piece Exhaust silencer Heat exchanger of vehicle heating system Vehicle engine...

  • Page 6: Connection To The Vehicle's Cool- Ing System

    Fig. 3. The amount of coolant in the cool- extraction point can be taken from the Table below. ing system should be at least 6 liters. In principle, only the water hoses supplied by Webasto permissible fuel feed height at max. permissible should be used.
  • Page 7 Thermo 90 / Thermo 90 S Vehicles with Diesel Engines Vehicles with Petrol Engines Plastic tank Fuel must be drawn from the fuel tank or a separate tank In the case of carburettor or injection engines equipped (see Figs. 5, 6 and 7). When fuel is supplied from a separ- with return lines, the heater’s fuel system is to be inte-...

  • Page 8: Fuel Lines

    Thermo 90 / Thermo 90 S Fuel Lines correct 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 clamp be used. incorrect NOTE: Do not cut Mecanyl lines using a side cutter.

  • Page 9: Combustion Air Supply

    Fuel Filter preferably 15°-90° If dirt in the fuel must be reckoned with, only Webasto fil- When the heater is installed in the vicinity of the vehicle ter, order no. 487 171, should be used. Filter is preferably tank in a common installation space, combustion air must...

  • Page 10: Electrical Connections

    The heater can be switched on and off using the following Webasto heater controls: Connection upon the installation of Thermo 90 S into a - Digital timer see circuit diagram Fig. 16, 18 or 19 vehicle for the transport of dangerous goods (ADR).
  • Page 11 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”/"Motor off" (terminal D+) is con- Fig. 15: Control Unit T 90 S (from 03/97), Installation nected to the control unit X12 / 7, different control thre- shold values will take effect.

  • Page 12: Circuit Diagrams

    Thermo 90 / Thermo 90 S Legend for circuit diagrams: Colour of cables Wire cross sections blue petrol-operated heaters this terminal is not used for < 7,5 m 7,5 - 15 m brown yellow 0,75 mm 1,0 mm For temperature codification (temperature at water outlet) refer to the table on page 31...

  • Page 13: System Diagram

    Thermo 90 / Thermo 90 S Pos. Designation Comment Pos. Designation Comment Heater Thermo 90/Thermo 90 S Digital timer, standard (1531) for presetting operating times Electronic control unit Resistor series resistor for H4 Flame detector Switch for circulating pump for separate switch-on...
  • Page 14 Thermo 90 / Thermo 90 S ϑ ϑ Fig. 16: System Diagram Thermo 90, 12 and 24V, with Digital Timer with 3 Time Settings, for legende refer to page 10 and 11...
  • Page 15 Thermo 90 / Thermo 90 S ϑ ϑ Fig. 17: System Diagram Thermo 90-ADR, 24V, for legende refer to page 10 and 11...
  • Page 16 Thermo 90 / Thermo 90 S ϑ ϑ Fig. 18: System Diagram Thermo 90 S, 12 and 24V, with Digital Timer (standard), for legende refer to page 10 and 11...
  • Page 17 X12 (ST 2) X13 (ST 3) X12 (ST 2) (ST 1) (ST 3) 1 12 ϑ ϑ 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...
  • Page 18 Thermo 90 / Thermo 90 S ϑ ϑ Fig. 20: System Diagram Thermo 90 S - ADR, 24V, for legende refer to page 10 and 11...
  • Page 19 Thermo 90 / Thermo 90 S ϑ ϑ Fig. 21: System Diagram Thermo 90 S - ADR, 24V, without auxiliary drive, for legende refer to page 10 and 11...

  • Page 20: Initial Operation

    Malfunctions After the heater has been installed, the water circuit and Fault Shutdown Diagnosis in the Event of a Fault Shutdown of Thermo 90 the fuel supply system must be thoroughly bled. When so the flame fails to materialize doing, the vehicle manufacturer’s instructions must be ad- fuel is delivered for max.
  • Page 21 Thermo 90 / Thermo 90 S Diagnosis in the Event of a Fault Shutdown Thermo 90 S If the heater is activated by the switch, the types of mal- coded flashing signals functions are indicated by via the Check fuses and electrical connections.

  • Page 22: Technical Data

    Dimensions of heater length 310 mm (355 mm (tolerance 3 mm) width 133 mm height 220 mm Weight 4,8 kg Thermo 90-ADR: 24 volts only Thermo 90 S with control unit mounted to the heater...

  • Page 23: Variants

    12 V, the Thermo 90 S water heaters are designed to Diesel heaters on 12 or 24 V, and operate on 12 V, the Thermo 90 S the Thermo 90-ADR heaters oper- Diesel heaters on 12 or 24 V, and ate on 24 V only.
  • Page 24 Thermo 90 / Thermo 90 S...

  • Page 25: Template For Heater Mounting Bracket

    Template for heater mounting bracket Scale 1:1...
  • Page 26 Thermo 90 / Thermo 90 S...
  • Page 28 Subject to change Webasto Thermosysteme GmbH 82131 Stockdorf . Kraillinger Str. 5 . Phone (089) 85794-0 Fax (089) 8 57 94-448 . Telex 5 23 647 webas d...

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Thermo 90-adr

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