Webasto Thermo 230 Workshop Manual - page 7
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 operation. The same applies for repairs
performed by unskilled personnel and repairs without
using original spare parts.
The year of first operation must be permanently
marked on the identification label by removing the
relevant number of the year.
The heaters are cleared for heating the vehicle engine
and the passenger cabin. The use of the heater in
vehicles not subject to the StVZO (e.g. ships) is partly
governed by regional regulations.
The heaters are not cleared for the installation in vehicles
intended for the transportation of dangerous goods (TRS).
The heater may only be fitted in vehicles or in independent
heating systems with a minimum coolant capacity of
10 liters.
The heater may only be installed in motor vehicles or in
independent heating systems with a minimum coolant
capacity of 6 liters.
The heater must not be installed in the passenger or driver
compartments of vehicles. Should the heater neverthe-
less be installed in such a compartment, the installation
box must be sealed tight against the vehicle interior.
There must be sufficient ventilation of the installation box
from the exterior in order not to exceed a maximum
temperature of 85 °C in the installation box. Excessive
temperatures may cause malfunctions.
WARNING
Due to the danger of poisoning and suffocation the
heater must not be operated, not even with timed
operation, in enclosed areas such as garages or
workshops not equipped with an exhaust venting
facility.
At filling stations and fuel depots the heater must be
switched off to prevent explosions.
CAUTION
Where flammable fumes or dust may build up (e.g. in
the vicinity of fuel, coal, wood, cereal depots, or
similar installations) the heater must be switched off
to prevent explosions.
In the vicinity of the water heater a temperature of 110 °C
(storage temperature) must not be exceeded under any
circumstances (e.g. during body paint work).
A violation of this temperature limit may cause permanent
damage to the electronics.
When checking the cooling water level proceed in
accordance with the vehicle manufacturer’s instructions.
The water in the heating circuit of the heater must contain
a minimum of 10% of a quality brand anti-freeze.
Additives in the heating circuit must not affect metals,
plastics and rubber and must leave no deposits.
The opening pressure in the vehicle cooling system -
normally indicated on the radiator filler cap - must be
between 0.4 and 2.0 bar above operating pressure (also
applicable to separate heating circuits).
1.6
Legal Provisions for Installation
For testing the heater in accordance with § 19, 20, or 21
of the StVZO the following regulations are to be observed
in particular (§ 22 a StVZO):
NOTE
These regulations are binding within the jurisdiction of the
StVZO and should also be observed in countries where no
particular regulations exist.
Extracting combustion air from the vehicle interior is
prohibited.
The exhaust line outlet is to be positioned to the top,
to the side, or in case of exhaust venting below the vehicle
floor, to the nearest possible location of the vehicle’s or
cockpit side or rear end. Exhaust pipes must be routed so
that exhaust fumes are unlikely to penetrate into the
vehicle’s interior. The function of any parts vital for vehicle
operation must not be impaired. Condensate accumu-
lations in the exhaust line must be directly drained.
A condensation drain hole may be provided as required.
The openings of the combustion air inlet and the exhaust
outlet must not allow a ball of 16 mm in diameter to be
inserted.
Electrical lines, switch gear, and control gear of the heater
must be located in the vehicle so that their proper function
cannot be impaired under normal operating conditions.
For the routing of fuel lines and the installation of
additional fuel tanks §§ 45 and 46 of the StVZO are to be
complied with. The most important regulations are:
•
Fuel lines are to be designed in such a way that they
remain unaffected by torsional stress in the vehicle,
engine movement, and the like. They must be
protected against mechanical damage. Fuel-carrying
parts are to be protected against excessive heat and
are to be arranged so that any dripping or evaporating
fuel can neither accumulate nor be ignited by hot
components or electrical equipment.