Webasto Thermo 90 S Installation Instructions Manual
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Webasto Thermo 90 S Installation Instructions Manual

Webasto water heaters installation instructions
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Wasserheizgeräte
Water Heaters
Chauffages à eau
Einbauanweisung
Installation Instructions
Instructions de montage
Thermo 90 S
Thermo 90 ST
Thermo 90 S
(Benzin) (Petrol) (Essence)
Thermo 90 S
(Diesel) (Gas-oil)
Thermo 90 S-ADR
(Gefahrguttransport)
(Transport of hazardous goods)
(Transport de marchandises dangereuses)
Thermo 90 ST
(Benzin) (Petrol) (Essence)
Thermo 90 ST
(Diesel) (Gas-oil)
Thermo 90 ST-ADR (Gefahrguttransport)
(Transport of hazardous goods)
(Transport de marchandises dangereuses)

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Summary of Contents for Webasto Thermo 90 S

  • Page 1 Wasserheizgeräte Einbauanweisung Water Heaters Installation Instructions Chauffages à eau Instructions de montage Thermo 90 S Thermo 90 ST Thermo 90 S (Benzin) (Petrol) (Essence) Thermo 90 S (Diesel) (Gas-oil) Thermo 90 S-ADR (Gefahrguttransport) (Transport of hazardous goods) (Transport de marchandises dangereuses)
  • Page 2 NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.

  • Page 3: Table Of Contents

    Thermo 90 S / Thermo 90 ST Inhaltsverzeichnis Table of contents Gesetzliche Bestimmungen für den Einbau ... . 1 Statutory regulations governing installation ..35 Verwendung / Ausführung .

  • Page 5: Statutory Regulations Governing Installation

    Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto. The same use of fire resistant materials or by the use of heat shields.
  • Page 6 Statutory regulations governing installation Thermo 90 S / Thermo 90 ST 5.3.2.5 Every reasonable precaution should be taken in positioning the 5.3.7 Heating air outlet heater to minimize the risk of injury and damage to personal property. 5.3.7.1 Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it 5.3.3 Fuel supply...
  • Page 7 Thermo 90 S / Thermo 90 ST Statutory regulations governing installation 1.3. Extract from directive ECE-R 122 Annex 9           Start of extract. 3.3.1 The combustion heaters shall be put out of operation by at least the following methods: Additional provisions applicable to certain vehicles as specified in the ADR.

  • Page 8: Use / Version

    The water heaters are designed for 12 V (Thermo 90 S petrol) and for The Thermo 90 S and Thermo 90 ST heaters differ from each other in 12 or 24 V (Thermo 90 S diesel).

  • Page 9: Installation

    The heater must be installed in as low a position as possible to allow the heater and circulating pump to be bled automatically. This is particularly important as the circulating pump is not self-priming. Fig. 1: Permitted installation positions for the Thermo 90 S / Thermo 90 ST...

  • Page 10: Examples For Installation

    Water circuit Without non-return valve With non-return valve and thermostat Fig. 2: Installation example for the Thermo 90 S / Thermo 90 ST heater 1 Heat exchanger, car’s heating system 7 T-piece 14 Exhaust silencer 2 Switch for car’s heating system fan...

  • Page 11: Connection To The Vehicle Cooling System

    The heater is connected to the vehicle cooling system as shown in Figure 2. The system must contain at least 6 litres of coolant. The water hoses supplied by Webasto must always be used. If you do not use these hoses, the hoses that you do use must comply with DIN 73411.

  • Page 12: Fuel Supply

    Fuel supply Thermo 90 S / Thermo 90 ST Fuel supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in the table below.

  • Page 13: Fuel Supply

    Thermo 90 S / Thermo 90 ST Fuel supply 6.1. Vehicles with diesel engines The fuel must be taken from the vehicle fuel tank or from a separate tank (see Figs. 4, 5 and 6). Plastic tank Sealing ring Fuel extractor Sealing ring Fig.
  • Page 14 Fuel supply Thermo 90 S / Thermo 90 ST 6.2. Vehicles with petrol engines The heater must be integrated into the return line of fuel systems in carburettor and injection engines with a return line. In carburettor engines without a return line the heater must be integrated into the fuel system in the supply line between the fuel tank and the vehicle pump.
  • Page 15 Thermo 90 S / Thermo 90 ST Fuel supply NOTE: Correct Cut Mecanyl lines without burr and do not crush them. Do not cut them with side-cutting pliers. Clip Since the lines normally cannot be routed with a constant rising gradient, the internal diameter must not be allowed to exceed a certain size.
  • Page 16 Its installation position is limited as shown in Figs. 9 and 10 in order to ensure effective auto-bleeding. 6.5. 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:...

  • Page 17: Combustion Air Supply

    Thermo 90 S / Thermo 90 ST Combustion air supply Combustion air supply Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt or snow and cannot suck in splashing water.

  • Page 18: Exhaust Pipe

    Exhaust pipe Thermo 90 S / Thermo 90 ST Exhaust pipe The exhaust pipe (internal diameter 38 mm) can be installed with a The exhaust pipe opening must be located so that it cannot become length of 0.5 m to 5 m and several bends (360° alto gether, minimum clogged with snow and mud.

  • Page 19: Electrical Connections

    If there is no earth via Y2 or H5 at control module input X12/5 (Thermo 90 S) or X8/5 (Thermo 90 ST) when it is switched on, all the ADR functions are disabled. After activating the positive potential at control module input X12/5...
  • Page 20 Thermo 90 S / Thermo 90 ST position shown in Figure 13. If the “Engine on”/”Engine off” signal (terminal D+) is applied to control module plug X12 contact 7 (Thermo 90 S) or plug X8 contact 7 (Thermo 90 ST), different regulating thresholds take effect Nominal...

  • Page 21: Circuit Diagrams

    Thermo 90 S / Thermo 90 ST Circuit diagrams Circuit diagrams 10.1. Circuit diagram legend for the Thermo 90 S and Thermo 90 ST Temperature coding (temperature at water outlet): See table on page 50 Digital timer P2: with positive at connection 10 = Continuous operation...
  • Page 22 Circuit diagrams Thermo 90 S / Thermo 90 ST 10.2. Thermo 90 S circuit diagram legend Item Designation Comment 1 or 2-pin disconnecting switch Emergency off switch, electric or Item Designation Comment pneumatic Heater Pumping device switch to positive Control module...
  • Page 23 Thermo 90 S / Thermo 90 ST Circuit diagrams ϑ ϑ Fig. 15: System circuit for Thermo 90S, 12 and 24 V, with standard timer, see pages 51 and 52 for legend...
  • Page 24 X13 (S T 3) X12 (S T 2) (S T 1) (S T 3) 1 12 Fig. 16: System circuit for Thermo 90 S, 12 and 24 V, with standard timer and separate circulating pump control, see pages 51 and 52 for legend...
  • Page 25 Thermo 90 S / Thermo 90 ST Circuit diagrams ϑ ϑ Fig. 17: System circuit for Thermo 90 S – ADR, 24 V, with switch, see pages 51 and 52 for legend...
  • Page 26 Circuit diagrams Thermo 90 S / Thermo 90 ST ϑ ϑ Fig. 18: System circuit for Thermo 90 S – ADR, 24 V, with switch without auxiliary drive, see pages 51 and 52 for legend...
  • Page 27 Thermo 90 S / Thermo 90 ST Circuit diagrams 10.3. Thermo 90 ST circuit diagram legend Item Designation Comment 1 or 2-pin disconnecting switch Emergency off switch, electric or Item Designation Comment pneumatic Heater Pumping device switch to positive Control module...
  • Page 28 Circuit diagrams Thermo 90 S / Thermo 90 ST Fig. 19: System circuit for Thermo 90 ST, 24 V, with standard timer, see pages 51 and 57 for legend...
  • Page 29 Thermo 90 S / Thermo 90 ST Circuit diagrams Fig. 20: System circuit for Thermo 90 ST, 24 V, with standard timer and separate circulating pump control, see pages 51 and 57 for legend...
  • Page 30 Circuit diagrams Thermo 90 S / Thermo 90 ST Fig. 21: System circuit for Thermo 90 ST – ADR, 24 V, with switch, see pages 51 and 57 for legend...
  • Page 31 Thermo 90 S / Thermo 90 ST Circuit diagrams Fig. 22: System circuit for Thermo 90 ST – ADR, 24 V, with switch without auxiliary drive, see pages 51 and 57 for legend...

  • Page 32: Initial Start-Up

    Initial start-up Thermo 90 S / Thermo 90 ST Initial start-up NOTE: Refer to the safety instructions in the operating and maintenance instructions. The operating and maintenance instructions must be read through without fail before starting the heater. After you have installed the heater, bleed the water system and the fuel supply system carefully.

  • Page 33: Troubleshooting

    12.2. Diagnostic after a fault lock-out Fuel is supplied for max. 240 seconds if the flame does not start to burn. for the Thermo 90 S and Thermo 90 ST Check the fuses and plug connectors. Fuel is supplied for max. 240 seconds if the flame goes out during operation.
  • Page 34 Troubleshooting Thermo 90 S / Thermo 90 ST 12.2.2. Version with switch If the system is operated with a switch, the nature of the fault is indicated by a flashing code on an indicator light during the run-on time of the heater.

  • Page 35: Technical Data

    12 V or 24 V. The temperature limiter, temperature sensor and flame sensor are identical on 12 V and 24 V heaters. 13.2. Fuel for Thermo 90 S and Thermo 90 ST petrol: The fuel specified by the manufacturer must be used.
  • Page 36 Technical data Thermo 90 S / Thermo 90 ST Heater Operation Thermo 90 S / ST Thermo 90 S diesel Thermo 90 ST diesel Petrol Thermo 90 S-ADR Thermo 90 ST-ADR EC/ECE licensing symbol e1 00 0005 (Thermo 90 S, heater)
  • Page 37 Thermo 90 S / Thermo 90 ST Technical data Heater Operation Thermo 90 S / ST Thermo 90 S diesel Thermo 90 ST diesel Petrol Thermo 90 S-ADR Thermo 90 ST-ADR Heater dimensions (tolerance ± 3 mm) L 310 (355*) / 307(352*) mm...
  • Page 38 ø38 48,6 98,6 ø74 137,1 Thermo 90 ST ø ø ø Combustion air intake Exhaust fume outlet Fuel intake Coolant intake ø Coolant outlet ø ø ø Fig. 23: Dimensions of the Thermo 90 S / Thermo 90 ST heaters...
  • Page 40 Landesvertretung. In multilingual versions the German language is binding. The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country. Dans le cas d'une version rédigée en plusieurs langues, l'allemand est alors la langue qui fait foi.

This manual is also suitable for:

Thermo 90 st-adrThermo 90 s-adr

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