Webasto HL 90 Owner's Manual

Webasto hl 90 air heater owner's manual

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HL 90
1
Introduction
1.1
Scope and Purpose ............................................................................................................................... 101
1.2
Meaning of Warnings, Cautions, and Notes .......................................................................................... 101
1.3
Additional Documentation to be used .................................................................................................... 101
1.4
Safety Information and Regulations....................................................................................................... 101
1.4.1 Legal Provisions for Installation.................................................................................................. 101
1.4.2 General Safety Notes ................................................................................................................. 102
1.5
Corrections and Improvements.............................................................................................................. 103
2
General Description
2.1
Drive ...................................................................................................................................................... 201
2.2
Heat Exchanger ..................................................................................................................................... 201
2.3
Control Unit............................................................................................................................................ 201
2.4
Flame Sensor ........................................................................................................................................ 202
2.5
Glow Plug .............................................................................................................................................. 202
2.6
Temperature Limiter .............................................................................................................................. 202
2.7
Dosing Pump ......................................................................................................................................... 202
3
Functional Description
3.1
Controls ................................................................................................................................................. 301
3.2
Switch On ...............................................................................................................................................301
3.3
Heating Operation.................................................................................................................................. 301
3.3.1 Operation with Room Thermostat (mechanical) ......................................................................... 301
3.3.2 Operation with Switch................................................................................................................. 301
3.3.3 Operation with Timer .................................................................................................................. 301
3.4
Switch Off .............................................................................................................................................. 301
3.5
Ventilation Operation ............................................................................................................................. 301
4
Technical Data
4.1
Electrical Components........................................................................................................................... 401
5
Troubleshooting
5.1
General .................................................................................................................................................. 501
5.2
General Fault Symptoms ....................................................................................................................... 501
6
Functional Checkouts
6.1
General .................................................................................................................................................. 601
6.2
Adjustments ........................................................................................................................................... 601
6.2.1 Adjustment of CO
6.3
Components Testing.............................................................................................................................. 601
6.3.1 Temperature Limiter Resistance Check ..................................................................................... 601
6.3.2 Flame Sensor Resistance Check ............................................................................................... 601
List of Contents
Contents ...................................................................................................... 601
2
List of Contents
I

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Summary of Contents for Webasto HL 90

  • Page 1 HL 90 List of Contents List of Contents Introduction Scope and Purpose ..........................101 Meaning of Warnings, Cautions, and Notes ..................101 Additional Documentation to be used ....................101 Safety Information and Regulations....................... 101 1.4.1 Legal Provisions for Installation....................101 1.4.2 General Safety Notes .........................
  • Page 2 List of Contents HL 90 Circuit Diagrams and Examples for Electrical Installation General ..............................701 Servicing General ..............................801 Work on the Air Heater ......................... 801 Work on the Vehicle..........................801 Air Heater Test Run ..........................801 Servicing ............................... 801 Visual Inspections and Installation Regulations..................
  • Page 3 Hot Air Temperatures with Drop of Pressure (12V Heaters)................802 Fuel Supply ..............................802 Webasto Fuel Tank Tap........................... 803 Fuel Tapping from Plastic Tank (tapping via fuel drain plug)................803 Fuel Tapping from Plastic Tank (tapping via fitting plate) ................803 Pipe/Hose Connection .............................
  • Page 4 Your Notes...
  • Page 5: Additional Documentation To Be Used

    General Approvals", laid down by the Federal Office for This repair shop manual is intended to support Motor Traffic, exist for the Air Heaters HL 90 with the familiarised personnel in the repair of air heaters HL 90 of following official marks of conformity: the Diesel type.
  • Page 6 The line must require tools for installation and The heaters HL 90 are marked with the word "Diesel" removal, must be protected against damage, and must be on their identification plate. The heaters may only be shockproof.
  • Page 7: Corrections And Improvements

    It is mandatory to install the seal between the heater Non-compliance with the installation instructions and its mounting and the vehicle floor to prevent poisonous procedures will void the warranty by Webasto. The same exhaust fumes from entering the vehicle interior. applies for repairs performed by unskilled personnel or All fuel line connections must be tight, must show no not using original spare parts.
  • Page 8 Your Notes...
  • Page 9: General Description

    HL 90 2 General Description Drive General Description The drive provides for fuel supply with atomisation and The air heater HL90 is used to combustion air supply to the combustion chamber in the heat exchanger. – heat the driver compartment and the vehicle interior/...
  • Page 10: Flame Sensor

    2 General Description HL 90 Flame Sensor Temperature Limiter The flame sensor is a photo transistor changing its The temperature limiter protects the heater against undue resistance depending on the flame intensity. The signals high operating temperatures. The temperature limiter are supplied to the control unit for processing.The flame...
  • Page 11: Switch Off

    HL 90 3 Functional Description • Part load / off operation Functional Description After reaching the temperature set with the room (Fig. 301) thermostat (upper switching point) the heater is switched off. The operating indicator light remains on to indicate a...
  • Page 12 3 Functional Description HL 90 Switch on Operating indicator light on Preheating 35 s Switch or room thermostat (full load / part load) or timer Fuel priming Flame sensor Full load initiation Glow plug Safety period max. 100 s Dosing pump (full load / part load)
  • Page 13: Electrical Components

    HL 90 4 Technical Data Electrical Components Technical Data Control unit, motor, dosing pump, glow plug resistor, Where no threshold values are specified technical data part load resistor, timer and switch with indicator light are are understood to include standard tolerances for heater 12 V or 24 V components.
  • Page 14 Your Notes...
  • Page 15: General Fault Symptoms

    HL 90 5 Troubleshooting Troubleshooting check fuel, combustion air and exhaust lines for obstructions corrosion on connectors General loose contacts on connectors wrong crimping on connectors This section describes troubleshooting procedures for corrosion on wiring and fuses the heater HL90.
  • Page 16 Your Notes...
  • Page 17: Functional Checkouts

    HL 90 6 Functional Checkouts Functional Checkouts General This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops not provided with exhaust ventilation facilities.
  • Page 18 Your Notes...
  • Page 19 HL 90 7 Circuit Diagrams and Examples for Electrical Installation Circuit Diagrams and Examples for Electrical Installation General Circuit diagrams (Fig. 701 to 703) show possible heater circuits for HL90 with • timer and room thermostat • switch (full load - part load) and ventilation •...
  • Page 20 12/24V Connection 2-pole Timer (1531) Control unit Connection 2-pole Timer (1531) Control unit Connection 2-pole Motor Heater HL 90 Connection 2-pole Motor Heater HL 90 Connection 1-pole Relay in control unit Clamping connection Glow plug + Relay in control unit Clamping connection Glow plug –...
  • Page 21 Control unit Connection 2-pole Relay in control unit Control unit Connection 2-pole Relay in control unit Heater HL 90 Connection 2-pole Relay in control unit Heater HL 90 Connection 2-pole Operating indicator light, heating / ventilation Connection for tab rectable...
  • Page 22 Connection for tab rectable 14-pole Relay in control unit Control unit Connection for tab rectable 2-pole Relay in control unit Heater HL 90 Connection for tab rectable 6-pole Relay in control unit Heater HL 90 Clamping connection Glow plug + Operating indicator light,...
  • Page 23 HL 90 7 Circuit Diagrams and Examples for Electrical Installation Connection Control Unit / Fuse Holder / Switch Control unit Fuse holder to battery (+) Ground (–) Switch Remove two inhibit pins Operating indicator light (heating and ventilation) Fig. 704 Example for Electrical Installation "Operation with Switch and Ventilation"...
  • Page 24 7 Circuit Diagrams and Examples for Electrical Installation HL 90 Intermediary connector dosing pump Connector flame sensor Connector glow plug resistor Connector temperature limiter Connector relay/fuse Connector glow plug Control unit Fig. 705 Example for Electrical Installation "Standard Wiring Harness"...
  • Page 25 20 minutes. on the heater when installed. The heater does not require maintenance. It should however be checked by Webasto-trained skilled personnel in regular intervals, the latest before the heating Work on the Air Heater season begins (point of time, when the heater is more frequently in use due to weather conditions).
  • Page 26 8 Servicing HL 90 ∆P = 0 mm wc 124 °C (Max. temperature) 1. Free flow 20 °C 2. Partial restriction ∆P = 6 mm wc 135 °C 20 °C 3. Max. pressure drop Total pipe length 2,5 m (Temperature limiter B2 responds at 175 °C) ∆P = 25 mm wc...
  • Page 27 Hole Pattern NOTE The fitting plate must be made of sheet metal! Gasket Fig. 803 Webasto Fuel Tank Tap * Use fuel tank tap only on metal fuel tanks Fig. 805 Fuel Tapping from Plastic Tank (tapping via fitting plate) NOTE The fitting plate must be made of sheet metal! 8.6.2.2 Fuel Lines...
  • Page 28 (Fig. 802 and 807). 8.6.4 Fuel Filter If there is the probability of contaminated fuel only the Webasto filter, Order No. 487 171, may be used. Installation possibly vertical up to horizontal the most (observe direction of flow). 15° - 90°...
  • Page 29 HL 90 8 Servicing 8.6.5 Combustion Air Supply 8.6.7 Combustion Air Intake and Exhaust Lines Combustion air must under no circumstances be Length of combustion air intake line: extracted from rooms with persons. The combustion air with muffler: max. 3.0 m...
  • Page 30 8 Servicing HL 90 Removal and Installation 8.7.4 Flame Sensor, Replacement NOTE CAUTION The replacement procedure for the flame sensor is In installed condition only the following disassembly or identical with the heater installed or removed. removal procedures are permitted should enough space Perform replacement in accordance with 9.2.3.
  • Page 31 Repair General This section describes the repairs that may be performed on the air heater HL 90 when removed. Any further disassembly will void the warranty. For re-assembly only components of the original spare part kits are to be used.
  • Page 32 9 Repair HL 90 3. Perform procedures on components after Disassembly and Assembly disassembly (refer to 9.1.1). 9.2.1 Control Unit, Replacement 9.2.1.2 Installation 9.2.1.1 Removal 1. Locate control unit (13, Fig. 901) in installation position and secure with screws (14).
  • Page 33 HL 90 9 Repair 9.2.2 Glow Plug, Replacement 9.2.4.2 Installation 1. Screw temperature sensor (4, Fig. 901) in by hand 9.2.2.1 Removal and tighten with 0.8 ± 0.2 Nm. 2. Form-fit silicone cap (5). 1. Remove knurled nut from glow plug.
  • Page 34 9 Repair HL 90 rt-rt/bl br-vi rt/bl 11 10 NOTE Orifice plate (4) made of plastic has no tooth washers (13) and spacer ring (5). Screws (3) are then locked with tooth washers (37). If screws (15) are sheet metal type...
  • Page 35 HL 90 9 Repair 10. Remove O-ring (22) and discard. 9.2.6 Drive, Disassembly and Assembly 11. Perform procedures on components after disassembly (refer to 9.1.1). The disassembly of the drive is broken down into two subjects: – heating air supply/ electrical components CAUTION Clean bypass fan with pressurized air only.
  • Page 36 9 Repair HL 90 CAUTION Align interlock surfaces in rotor and on motor shaft. WARNING The 12 V type heater has only one glow plug resistor (18) fitted. Make sure to close second opening in air intake housing with a screw plug.
  • Page 37 HL 90 9 Repair 9.2.7 Heat Exchanger, Replacement 9.2.7.2 Installation 1. Apply sealing and bonding compound 9.2.7.1 Removal (Ident. No. 666 05A) to mating surfaces of sealing cord (4, Fig. 903) and heat exchanger (5) and locate 1. Remove control unit (refer to 9.2.1.1).
  • Page 38 Your Notes...
  • Page 39 HL 90 10 Storage and Shipping Storage and Shipping CAUTION When shipping a complete heater assembly it must be drained completely. No fuel is allowed to escape from a packaging or during shipping. Dummy plugs must be fitted to the fuel lines.
  • Page 40 Your Notes...

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