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Webasto Thermo 230 Workshop Manual

Other manuals for Thermo 230: Installation Instructions Manual

Summary of Thermo 230

  • Page 1

    Water heaters 05/1999 workshop manual thermo 230 thermo 300 thermo 350 with control unit 1572 model .30 and up thermo 230 thermo 300 thermo 350 with control unit 1572d model .030 and up.

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    Thermo 230 / 300 / 350 list of contents i list of contents 1. Introduction 1.1 scope and purpose ............................................................................................................................... 101 1.2 applicability of manual ..............................................

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    List of contents thermo 230 / 300 / 350 ii 6. Functional checkouts 6.1 general ................................................................................................................................................. 601 6.2 adjustments ..........................................................

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    Thermo 230 / 300 / 350 list of contents iii 9. Repair 9.1 general .................................................................................................................................................. 901 9.1.1 work on components after disassembly ...........................................

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    List of contents thermo 230 / 300 / 350 iv list of figures 301 functional sequence (heaters with control unit 1572) .................................................................................... 302 302 functional sequence (heaters with control unit 1572d) ........................................

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    Thermo 230 / 300 / 350 1 introduction 101 1. Introduction 1.1 scope and purpose this repair shop manual is intended to support familiarized personnel in the repair of water heaters thermo 230, 300 and 350. The water heater may only be operated with the specified fuel (diesel or also fuel oil el) and...

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    1 introduction thermo 230 / 300 / 350 102 caution non-compliance with the installation instructions and the information contained therein will void the webasto warranty. Installations not legally authorized will void the water heater’s "official marks of conformity" and thus the vehicle’s permit of ...

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    Thermo 230 / 300 / 350 1 introduction 103 • in busses fuel lines and fuel tanks may be located neither in the passenger area nor in the driver’s com- partment. In these type of vehicles the fuel tanks must be located such that they do not pose a direct hazard to the exits in the event of a fire. Fue...

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    1 introduction thermo 230 / 300 / 350 104 page empty for notes.

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    Thermo 230 / 300 / 350 2 general description 201 2. General description the water heaters webasto thermo 230, 300 and 350 are used in combination with the vehicle’s own heating installation to – heat the passenger compartment – defrost the windscreen – preheat water-cooled engines the water heater o...

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    2 general description thermo 230 / 300 / 350 202 2.1 combustion air fan the combustion air fan supplies the air required for com- bustion from the combustion air inlet to the combustion chamber. The fan consists of a fan motor with fan wheel. Air is taken in through a splash protection cover or a sc...

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    Thermo 230 / 300 / 350 2 general description 203 2.5 control unit the control unit 1572 or 1572d is the central component to ensure controlled operation and monitoring of combustion. If the heater has a control unit 1572 installed, a retrofit of control unit 1572d is possible (see section 9). 2.6 fl...

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    2 general description thermo 230 / 300 / 350 204 2.10 circulation pump the circulation pump mounted externally ensures the coolant circulation in the vehicle and heater circuit. The pump is activated by the control unit to operate as long as the heater is in operation. The heaters may be operated wi...

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    Thermo 230 / 300 / 350 3 functional description 301 3. Functional description activation and deactivation is by means of a • switch • timer • air conditioning dependent on the type of installation. For monitoring operation at least an operating indicator light is provided. Switch off releases a run-...

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    3 functional description thermo 230 / 300 / 350 302 a b c d e f g 16 12 14 16 14 12 13 15 13 15 1 2 6 8 2 9 6 10 3 5 3 7 1s 12s 12s 30s 90s 1s 12s max. Max. 11 1s 12s 30s 90s 1s fig. 301 functional sequence (heaters with control unit 1572) 3.7 switch-off upon failure (heaters with control unit 1572)...

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    Thermo 230 / 300 / 350 3 functional description 303 a c d e f g 12 14 14 12 13 15 13 15 1 2 6 8 2 9 6 10 3 5 3 7 1s 12s 12s 1s 12s max. 1s 12s 30s 1s max. 16 max. 120s max. Max. 30s 16 max. 120s fig. 302 functional sequence (heaters with control unit 1572d) 3.8 switch-off upon failure (heaters with ...

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    3 functional description thermo 230 / 300 / 350 304 malfunctions by overheating: overheating results in deactivation of the heater by the temperature limiter/thermostat. Dependent on heater configuration: – the reset button on the temperature limiter must be reset. – the reset of the thermostat is p...

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    Thermo 230 / 300 / 350 4 technical data 401 4. Technical data where no threshold values are specified technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 20 °c and at nominal voltage. Electrical components control unit, fan and circulati...

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    4 technical data thermo 230 / 300 / 350 402 circulation pump u 4814 u 4816 u 4851 volume flow l/h 5200 (against 0.15 bar) 6000 (against 0.4 bar) 6000 (against 0.4 bar) nominal voltage v- 24 operating voltage range v- 20 ... 28 nominal power consumption w 104 215 209 dimensions mm mm mm lenght 221 wi...

  • Page 20

    Thermo 230 / 300 / 350 5 troubleshooting 501 5. Troubleshooting 5.1 general this section describes troubleshooting procedures for the heaters thermo 230, 300 and 350. Caution troubleshooting requires profound knowledge about components and their theory of operation and may only be performed by train...

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    5 troubleshooting thermo 230 / 300 / 350 502 symptom rough calculation of rate of flow fault in fuel supply no fuel delivery to heater. Wrong combustion co 2 value cannot be set to rated value, combustion irregular. Probable cause • excessive system resistance (especially high when cold). • circulat...

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    Thermo 230 / 300 / 350 5 troubleshooting 503 5.3 fault symptoms during functional checkouts and error code output or tests with diagnostic computer, components tester or pc heater diagnosis 5.3.1 general error code output note only heaters with a control unit 1572d provide an error code output. When...

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    5 troubleshooting thermo 230 / 300 / 350 504 5.3.2 fault symptoms 5.3.2.1 fault symptom "no start" note heaters with control unit 1572d: if the heater performs 5 subsequent attempts to start due to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error ...

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    Thermo 230 / 300 / 350 5 troubleshooting 505 5.3.2.2 fault symptom "flame-out" note heaters with control unit 1572d: if the heater performs 3 subsequent attempts to start due to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior ...

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    5 troubleshooting thermo 230 / 300 / 350 506 5.3.2.4 fault symptom "foreign light detection during run-up or run-down" 5.3.2.5 fault symptom "flame sensor defective" 5.3.2.6 fault symptom "temperature sensor defective" has heater been in long time operation shortly before? Yes no flame sensor defect...

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    Thermo 230 / 300 / 350 5 troubleshooting 507 5.3.2.7 fault symptom "solenoid valve defective" 5.3.2.8 fault symptom "temperature limiter defective" is solenoid valve supplied with electrical power? Yes no is components test with diagnostic computer o.K. (audible click of solenoid valve)? Make electr...

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    5 troubleshooting thermo 230 / 300 / 350 508 page empty for notes.

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    Thermo 230 / 300 / 350 6 functional checkouts 601 6. Functional checkouts 6.1 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 with ...

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    6 functional checkouts thermo 230 / 300 / 350 602 6.3 components testing 6.3.1 temperature sensor resistance check when checking the temperature sensor with a digital multimeter the values of the following diagram must be obtained. Resistance checking is preferably performed at ambient temperatures ...

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    Thermo 230 / 300 / 350 6 functional checkouts 603 6.3.4 igniter box check note the igniter box may also be tested using the pc heater diagnosis (component test). Warning high voltage; 20.000 volts arcing across the igniter electrodes. Caution do not apply voltage to igniter box without electrodes. C...

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    6 functional checkouts thermo 230 / 300 / 350 604 6.3.5.2 fuel pump check on heaters with control unit 1572d note a fuel pump check of heaters with control unit 1572d may only be performed after consulting webasto. 6.3.6 fan motor check note the fan motor check is performed with the burner installed...

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    Thermo 230 / 300 / 350 7 circuit diagrams 701 7. Circuit diagrams 7.1 general the circuit diagrams (fig. 701 and 702) show possible heater circuits for thermo 230, 300 and 350 with control unit 1572 and with – switch – timer 1529 (triple timer) the circuit diagrams (fig. 703 and 704) show possible h...

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    7 circuit diagrams thermo 230 / 300 / 350 702 fig. 701 automatic control circuit with control unit 1572 and switch 3 3 5 1 1 5 6 2 2 6 1 2 4 4 4 3 3 2 2 1 1 4 f1 b2 y1 br gr or gn ϑ ϑ rt/ws bl or br br sw rt sw a2 x1 a x3 d x2 c k2 k1 m1 m2 h2 h1 b3 b4 s2 s3 s4 s1 a1 b1 e1 u2 u1 se - + m m m1 a2 u1 ...

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    Thermo 230 / 300 / 350 7 circuit diagrams 703 1 diagnostic connector 2 to vehicle terminal +75 if available, otherwise terminal 15 3 timer p: with plus to connection 4 = continuous operation during immediate heating without plus to connection 4 = heating period 1 hour 4 vehicle lighting terminal 58 ...

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    7 circuit diagrams thermo 230 / 300 / 350 704 1 2 4 6 5 3 3 2 2 2 2 6 2 4 4 3 3 5 1 1 5 6 1 1 1 4 b2 y1 ϑ ϑ ϑ a2 x3 x1 d f w2 x2 c m1 h1 h2 b4 s3 s1 s4 a1 b1 e1 u2 u1 se - + m2 m m x3 8 7 6 5 4 3 2 1 x2 2 1 x1 1 3 5 2 4 6 58 75 (15) 58 61 75 (15) f3 f1 f2 30 31 30 61 31 c f 1 2 a 6 5 4 3 2 1 d 4 3 2...

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    Thermo 230 / 300 / 350 7 circuit diagrams 705 1 2 4 6 5 3 3 2 2 2 2 6 2 4 4 3 3 5 1 1 5 6 1 1 1 4 b2 y1 ϑ ϑ ϑ a2 x3 x1 x4 d f w2 x2 c m1 h2 b4 s3 s4 a1 b1 e1 u2 u1 se - + m2 m m 58 75 (15) 58 61 75 (15) f3 f1 f2 30 31 30 61 31 2 8 11 10 1 12 7 4 p h4 h1 2 1 3 3 3 3 3 3 4 b3 b5 m1 a2 u1 a1 b1 y1 e1 b...

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    7 circuit diagrams thermo 230 / 300 / 350 706 page empty for notes.

  • Page 38

    Thermo 230 / 300 / 350 8 servicing 801 8. Servicing 8.1 general this section describes the servicing procedures allowed on the heater when installed. 8.2 heater servicing as long as the heater is in operation or in run-down the battery main power supply must not be disconnected to prevent the heater...

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    8 servicing thermo 230 / 300 / 350 802 inspection and attachment note the exhaust muffler must always be secured with a sheet metal screw. Drill a hole with a diameter of 2.5 mm into the exhaust end pipe and muffler and arrest muffler with a sheet metal screw b 3.9 x 25 (see figure). 1. Check exhaus...

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    Thermo 230 / 300 / 350 8 servicing 803 8.5.2 burner head opening and closing warning the igniter box operates with high voltage. Prior to opening the burner head the connectors of the cable harness in the vehicle have to be disconnected to prevent lethal injuries. After closing burner head, reconnec...

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    8 servicing thermo 230 / 300 / 350 804 8.6 visual inspections and regulations for installation 8.6.1 connection to vehicle cooling system the installation of the heater should be in a location as low as possible to ensure self-venting of the heater and circu- lation pump. This applies in particular ...

  • Page 42

    Thermo 230 / 300 / 350 8 servicing 805 4 8 3 1 1 1 1 2 7 5 6 water heating circuit – sidewall radiators and roof duct heating 1 sidewall radiator with fan 2 heat exchanger, entrance 3 heater unit 4 circulation pump 5 heat exchanger, roof 6 vehicle engine 7 cockpit heating 8 control element supply re...

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    8 servicing thermo 230 / 300 / 350 806 when installing a shut-off device in the return line a clearly visible information label must be provided. Caution operation with the return line shut off causes damage to the fuel pump. Fuel may escape. Danger of fire. Loose fuel lines must be secured in order...

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    Thermo 230 / 300 / 350 8 servicing 807 rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only. The exhaust pipe is secured to the air heater e.G. With a clamp. Permissible exhaust line dimens...

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    8 servicing thermo 230 / 300 / 350 808 8.7.6 flame sensor, replacement note the replacement procedure for the flame sensor is identi- cal with the heater installed or removed. Perform replacement in accordance with 9.2.8. Warning the igniter box operates on high voltage. Prior to replace- ment of fl...

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    Thermo 230 / 300 / 350 9 repair 901 9. Repair 9.1 general this section describes the repairs that may be performed on the heaters thermo 230, 300 and 350 when removed. Any further disassembly will void the warranty. For re-assembly only components of the proper spare part kits are to be used. Warnin...

  • Page 47

    9 repair thermo 230 / 300 / 350 902 9.1.2.1 installation of control unit 1572d as substitute for control unit 1572 general due to the progress in the development of processors control unit 1572 can no longer be supplied. The retrofit of control unit 1572d is performed according to the following proc...

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    Thermo 230 / 300 / 350 9 repair 903 9.1.2.2 installation of circulation pump u 4851 as substitute for circulation pump u 4814 or u 4816 general immediately from now on the circulation pumps u 4814 and u 4816 may be substituted by circulation pump u 4851 as required. The circulation pumps u 4851 and ...

  • Page 49

    9 repair thermo 230 / 300 / 350 904 9.2 disassembly and assembly 9.2.1 temperature limiter, replacement 9.2.1.1 removal 1. Disconnect electrical connection to temperature limiter. 2. Withdraw rubber cap. Using screw driver lever off retaining spring and remove temperature limiter (1, fig. 901). 3. P...

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    Thermo 230 / 300 / 350 9 repair 905 rubber cap temperature retaining clip 8 7 6 5 4 3 2 1 1 temperature limiter 2 temperature sensor 3 connector 4 coolant outlet 5 cotter pin 6 nut (2) 7 hinge bolt (2) 8 burner limiter fig. 901 temperature limiter, temperature sensor and burner, replacement note cot...

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    9 repair thermo 230 / 300 / 350 906 9.2.4 combustion air fan, replacement note for replacement of the combustion air fan the burner may be left installed. In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged. 9.2.4.1 removal 1. Loosen screws (3, fig. 902) and wi...

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    Thermo 230 / 300 / 350 9 repair 907 1 2 3 4 5 6 7 8 9 1 splash protection cover 2 cap 3 screw (2) 4 fan wheel 5 slide lock 6 screw (3) 7 fan motor 8 clutch 9 electrical connector fig. 902 combustion air fan, replacement.

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    9 repair thermo 230 / 300 / 350 908 9.2.5 control unit, replacement note for replacement of the control unit the burner head may be left installed and must only be swung open for disconnection of electrical connector (8, fig. 903). In removed condition ensure that igniter electrodes are not bent and...

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    Thermo 230 / 300 / 350 9 repair 909 1 2 3 9 8 7 4 10 11 12 13 14 15 16 17 18 19 20 21 23 22 24 25 5 6 control unit 23 1572 igniter box (black connector cover) only in combination with control unit 1572 igniter box (green connector cover; mechanically coded) in combination with control unit 1572d and...

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    9 repair thermo 230 / 300 / 350 910 9.2.7 igniter box, replacement 9.2.7.1 removal 1. Remove burner if required (refer to 9.2.3.1). 2. Using screw driver lever off igniter electrodes (fig. 904) from igniter box and remove. 3. Remove disk (6). 4. Remove screws (2) with lock washers. 5. Withdraw ignit...

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    Thermo 230 / 300 / 350 9 repair 911 fig. 904 igniter box and flame sensor, replacement (sheet 2 of 2) 1 2 3 9 8 7 4 10 11 12 13 14 15 16 17 18 19 20 21 23 22 24 25 5 6 control unit 23 1572 igniter box (black connector cover) only in combination with control unit 1572 1 control unit 1572d igniter box...

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    9 repair thermo 230 / 300 / 350 912 9.2.9 heat exchanger, replacement 9.2.9.1 removal 1. Remove temperature limiter (refer to 9.2.1.1). 2. Remove temperature sensor (refer to 9.2.2.1). 3. Remove burner (refer to 9.2.3.1). 4. Withdraw combustion chamber (1, fig. 905) from heat exchanger (2). 5. Remov...

  • Page 58

    Thermo 230 / 300 / 350 10 packaging / storage / shipping 1001 10. Packaging, storage and shipping 10.1 general the heater or its components shipped to webasto thermosysteme gmbh for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and...

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    10 packaging / storage / shipping thermo 230 / 300 / 350 1002 page empty for notes.