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  5. Installation Instructions Manual

Webasto Thermo 90 ST Installation Instructions Manual

Summary of Thermo 90 ST

  • Page 1

    Wasserheizgerät water heater xxx einbauanweisung installation instructions thermo 90 st wdt thermo 90 st wdt (diesel).

  • Page 2

    Thermo 90 st wdt improper installation or repair of webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. To install and repair webasto heating and cooling systems you need to have completed a webasto training course and have ...

  • Page 3: Table Of Contents

    Table of contents ii table of contents 1 regulations governing installation .................................................. 34 1.1. Statutory regulations governing installation ................... 34 1.2. Additional documentation to be used............................ 34 2 use / version ............

  • Page 4: Note

    Thermo 90 st wdt 33 note mechanical system electrical system coolant circuit fuel exhaust gas combustion air caution technical information explanatory notes on document to provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top corne...

  • Page 5

    Technical information 34 1 regulations governing installation 1.1. Statutory regulations governing installation type approvals according to ece-r 10 (emc) and ece-r 122 (heater) exist for the thermo 90 st wdt heater. See chapter 14, "technical data" for the approval number. 1.2. Additional documenta...

  • Page 6

    Technical information 35 2 use / version 2.1. Use of the water heaters 2.1.1. Parking heater the thermo 90 st wdt water heater was designed for use in military vehicles. When installing in other special vehicles, the applicable regulations must be taken into account. Other uses are possible in consu...

  • Page 7

    Technical information 36 3 installation the water heater must be installed outside the passenger cabin. If the vehicle manufacturer has issued instructions, they must be followed. 3.1. Installation location/installation position of the heater and control unit body sections and any other components i...

  • Page 8

    Technical information 37 3.4. Using rub guard a suitable rub guard must be provided when installing the heater wiring harness (see fig. 1, marked with “x”) to prevent damage to the braided shield. 4 type label the label referred to in annex 7, paragraph 4, or a duplicate, must be positioned so that ...

  • Page 9

    Technical information 38 5 installation example fig. 3 example of thermo 90 st wdt installation in a vehicle. Without check valve (on left) and with check valve and thermostat (on right) coolant circuit exhaust pipe fuel line wiring harness combustion-air intake pipe 1) heat exchanger of vehicle hea...

  • Page 10

    Coolant circuit 39 6 integration in coolant system 6.1. Connection in thermostat circuits, only use thermostats which start to open at the heater is connected to the vehicle cooling system as shown in fig. 3. The coolant quantity present must at least be equivalent to the volume specified in chapter...

  • Page 11

    Fuel 40 7 fuel integration 7.1. General information the fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage. (requirement from ece-r 122, point 5.3.3.1.). In the case of liquid fuel heaters, where a supply separate from th...

  • Page 12

    Fuel 41 fig. 4 fuel supply suction side: d1: inside diameter of fuel line = 2 mm. H1: dimension for fuel tank over metering pump [m] s1: dimension for fuel tank under metering pump [m] l1: length of fuel line l1  1.2 m pressure side: d2: inside diameter of fuel line = 2 mm. L2: length of fuel line ...

  • Page 13

    Fuel 42 7.2. Integration in vehicle fuel tank the fuel must be removed from the fuel tank or a separate tank (see fig. 5, fig. 6 and fig. 7). Also see chapter 5, "installation example", with fig. 3. The specified securing measures of the vehicle manufacturer must be complied with. Deburr the cut on ...

  • Page 14

    Fuel 43 fig. 6 fuel removal from a plastic fuel tank; removal via fuel- tank drain screw fig. 7 webasto fuel standpipe on fig. 7: the valve and/or fuel tank must be made from metal! 7.3. Integration in engine return line fuel may only be removed from the return line with the special webasto fuel sta...

  • Page 15

    Fuel 44 fig. 8 webasto fuel standpipe 7.4. Fuel line since the lines normally cannot be routed with a constant rising gradient, the internal diameter must not be allowed to exceed a certain size. Air or gas bubbles will accumulate in lines with an internal diameter of more than 4 mm and these will c...

  • Page 16

    Fuel 45 7.4.2. Line design only steel and plastic lines made of light and temperature-resistant pa11 or pa12 (e.G. Mecanyl rwtl) approved by webasto and in accordance with din 73378 may be used as fuel lines. 7.4.3. Connecting two lines with a hose the correct connection of fuel lines with a hose is...

  • Page 17

    Fuel 46 fig. 10 dp2 metering pump installation position and mounting fig. 11 30.2 metering pump horizontal installation position 7.4.7. 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 l...

  • Page 18

    Fuel 47 7.5. Label a notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. (requirement from ece-r 122, point 5.3.3.3.). Use included adhesive label (for an example, see fig. 13). The sticker "switch off heater when refuelling“ must be applied...

  • Page 19

    Combustion air 48 8 combustion air supply the air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. (requirement from ece-r 122, point 5.3.5.2.). Under no circumstances may the combustion air be taken from areas occu- pied by people. The intake opening for combu...

  • Page 20

    Exhaust gas 49 9 exhaust system 9.1. Exhaust pipe the exhaust pipe (inside diameter 38 mm) can be routed with several bends (360° altogether, minimum bending radius 85 mm). The total line length must be between 0.5 and 5 mm. Lines approved by webasto must be used as exhaust pipes. 9.2. Exhaust silen...

  • Page 21

    Exhaust gas 50 fig. 14 exhaust outlet (installation position).

  • Page 22

    Electrical system 51 10 electrical connections 10.1. Connection of control unit / heater the electrical connection of the heater is designed as shown in fig. 16 and fig. 17. 10.2. Installation and connection of the heater controls a clearly visible tell-tale in the operator’s field of view shall inf...

  • Page 23

    Electrical system 52 10.6. Earth connection to ensure emc protection, a suitable connection to the vehicle earth must be produced via the earthing pin. 10.7. Using adapter wiring harness the use of an adapter wiring harness between the heater and the control unit can affect the emc suitability of th...

  • Page 24

    Electrical system 53 11 circuit diagrams the circuit diagrams show the possible circuits: – circuit diagram for thermo 90 st wdt, parking heater with on/off switch: fig. 16 – circuit diagram for thermo 90 st wdt, parking heater with standard timer: fig. 17 for the legend for wiring diagrams, see tab...

  • Page 25

    Electrical system 54 table 3 legend for wiring diagrams, part 1 of 2 item description comment temperature coding temperature at coolant outlet (see table in section 10.8.) diagnostics only possible via adapter wiring harness earth connection a1 heater thermo 90 st wdt a2 control unit thermo 90 st wd...

  • Page 26

    Electrical system 55 x10 plug connector, 2-pin w bus pc diagnosis x11 plug connector, 2-pin on pos. Y1 x20 plug connector, 12-pin on pos. A2 x21 plug connector, 3-pin on pos. A2 x22 plug connector, 12-pin on pos. A2 x30 plug connector, 12-pin on pos. A1 y1 metering pump fuel pump for heater table 3 ...

  • Page 27

    Electrical system 56 fig. 16 circuit diagram for thermo 90 st wdt, parking heater with on/off switch control unit heater.

  • Page 28

    Electrical system 57 fig. 17 circuit diagram for thermo 90 st wdt, parking heater with standard timer control unit heater.

  • Page 29

    Mechanical system 58 12 initial start-up after the heater has been installed, the coolant circuit and the fuel supply system must be carefully bled. Follow the instructions supplied by the ve- hicle manufacturer for this purpose. It is recommended that the heater circulation pump be put into operati...

  • Page 30

    Mechanical system 59 13 malfunctions to eliminate a fault which has resulted in a fault lock-out, proceed according to the workshop manual. 13.1. Fault lock-out if the flame fails to ignite, fuel will be delivered for a maximum of 240 seconds. If the flame extinguishes during operation, fuel will be...

  • Page 31

    Mechanical system 60 13.2.2. Equipment with switch the type of fault is output with a flashing code via the operating indicator lamp during the heater run-on time with switch operation. After five short signals, the long flashing pulses are counted: f 13 * vehicle fan short-circuit *: f 12 and f 13 ...

  • Page 32

    Technical information 61 14 technical data 14.1. Technical data thermo 90 st wdt except where limit values are specified, the technical data below refer to the usual heater tolerances of 10 % at an ambient temperature of +20 °c and at nominal voltage. 14.2. Electrical components the control unit, ...

  • Page 33

    62 heater operation thermo 90 st wdt approval symbol 122r-00 0217 03 4881 model water heater with ferro-tec technology heat output max. Regulating range 9.1 kw 1.8 to 7.6 kw fuel diesel according to din en 590 and fuels according to nato designation f-34, f-35, f-44 and f-63 fuel consumption +/- 10%...

  • Page 34

    Technical information 63 fig. 18 dimensions of the heater and control unit 1 2 3 4 5 1) combustion-air inlet 2) exhaust outlet 3) fuel inlet 4) coolant inlet 5) coolant outlet 3.

  • Page 36

    Bei mehrsprachiger ausführung ist deutsch verbindlich. Die telefonnummer des jeweiligen landes entnehmen sie bitte dem webasto servicestellenfaltblatt oder der webseite ihrer jeweiligen webasto-landesvertretung. In multilingual versions the german language is binding. The telephone number of each co...