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  5. Installation Instructions Manual

Webasto Thermo 90 ST Installation Instructions Manual

Summary of Thermo 90 ST

  • Page 1

    Wasserheizgeräte water heaters chauffages à eau 0 5 /200 8 1301494c 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) (t...

  • Page 2

    Das unsachgemäße einbauen oder reparieren von webasto heiz- und kühlsystemen kann feuer verursachen oder zum austritt von tödlichem kohlenmonoxid führen. Dadurch können schwere oder tödliche verletzungen hervorgerufen werden. Für den einbau und die reparatur von webasto heiz- und kühlsystemen bedarf...

  • Page 3

    La réparation ou l’installation impropre des systèmes de chauffage et de refroidissement webasto peut conduire à l’incendie de l’appareil ou encore à des fuites mortelles de monoxyde de carbone pouvant entraîner de graves lésions voire même la mort. Pou l’installation ou la réparation des systèmes d...

  • Page 4

    Visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 5

    Thermo 90 s / thermo 90 st i inhaltsverzeichnis 1 gesetzliche bestimmungen für den einbau ´ . . . . . . . . . . . 1 2 verwendung / ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 einbaub...

  • Page 6

    Thermo 90 s / thermo 90 st statutory regulations governing installation 35 1 statutory regulations governing installation 1.1. Statutory regulations governing installation the thermo 90 s / thermo 90 st heater has been type-tested and approved in accordance with ec directives 72/245/eec (emc), 2001/...

  • Page 7

    Statutory regulations governing installation thermo 90 s / thermo 90 st 36 2.2.5 every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property. 2.3. Fuel supply 2.3.1. The fuel filler must not be situated in the passenger compart...

  • Page 8

    Thermo 90 s / thermo 90 st statutory regulations governing installation 37 ( extract from directive 2001/56/ec annex ix) 3. Technical specifications for heater units for installation in dangerous goods transporters (annex 9) 3.1. General (ex/ii, ex/iii, at, fl and ox vehicles) 3.1.1. The combustion ...

  • Page 9

    Use / version thermo 90 s / thermo 90 st 38 2 use / version 2.1. Use of the water heaters the webasto water heater is used in connection with the vehicle's own heating system – to heat the cab, – to defrost the vehicle windows and – to preheat water-cooled engines. The water heater operates independ...

  • Page 10

    Thermo 90 s / thermo 90 st installation 39 3 installation important – the water heater must be installed outside the passenger cabin. – the requirements of the latest version of the adr must also be observed for the installing the heater into vehicles used to transport hazardous substances. Note: if...

  • Page 11

    Examples for installation thermo 90 s / thermo 90 st 40 4 examples for installation fig. 2: installation example for the thermo 90 s / thermo 90 st heater 1 heat exchanger, car’s heating system 2 switch for car’s heating system fan 3 relay for vehicle fan 4 digital timer 5 fuse strip in the car 6 no...

  • Page 12

    Thermo 90 s / thermo 90 st connection to the vehicle cooling system 41 5 connection to the vehicle cooling system in thermostat circuits, only use thermostats which start to open at the heater is connected to the vehicle cooling system as shown in figure 2. The system must contain at least 6 litres ...

  • Page 13

    Fuel supply thermo 90 s / thermo 90 st 42 6 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. Only for adr: the statutory regulation of adr (accord européen relatif au ...

  • Page 14

    Thermo 90 s / thermo 90 st fuel supply 43 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). Note: deburr the cut on the tank connector after sawing it off and remove any metal chips. Note on fig. 6: the fitting must be...

  • Page 15

    Fuel supply thermo 90 s / thermo 90 st 44 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 t...

  • Page 16

    Thermo 90 s / thermo 90 st fuel supply 45 note: cut mecanyl lines without burr and do not crush them. Do not cut them with side-cutting pliers. 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 bu...

  • Page 17

    Fuel supply thermo 90 s / thermo 90 st 46 the pump should ideally be installed near the tank. 6.4.2. Installation and attachment the metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in figs. 9 and 10 in order to ensure effective auto-blee...

  • Page 18

    Thermo 90 s / thermo 90 st combustion air supply 47 7 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...

  • Page 19

    Exhaust pipe thermo 90 s / thermo 90 st 48 8 exhaust pipe the exhaust pipe (internal diameter 38 mm) can be installed with a length of 0.5 m to 5 m and several bends (360° altogether, minimum bending radius 85 mm). The exhaust silencer is essential and must be installed near the heater. The opening ...

  • Page 20

    Thermo 90 s / thermo 90 st electrical connections 49 9 electrical connections 9.1. Control module / heater connection the electrical connection of the heaters is made as shown in the circuit diagrams in figures 15, 16, 17, 18, 19, 20, 21 and 22. 9.2. Connection when installing thermo 90 s-adr and th...

  • Page 21

    Electrical connections thermo 90 s / thermo 90 st 50 9.5. Thermo 90 s control module the control module offers protection type ip6k4k if it is installed in the position shown in figure 13. 9.6. Thermo 90 st control module the control module offers protection type 6k9k if it is installed in the posit...

  • Page 22

    Thermo 90 s / thermo 90 st circuit diagrams 51 10 circuit diagrams 10.1. Circuit diagram legend for the thermo 90 s and thermo 90 st 1 temperature coding (temperature at water outlet): see table on page 50 2 digital timer p2: with positive at connection 10 = continuous operation with immediate heati...

  • Page 23

    Circuit diagrams thermo 90 s / thermo 90 st 52 10.2. Thermo 90 s circuit diagram legend item designation comment a1 heater a2 control module b1 flame sensor b2 temperature sensor b3 temperature limiter/ overheating guard b4 room thermostat e glow plug f1 fuse 20 a flat fuse sae j 1284 f2 fuse 5 a fl...

  • Page 24

    Thermo 90 s / thermo 90 st circuit diagrams 53 fig. 15: system circuit for thermo 90s, 12 and 24 v, with standard timer, see pages 51 and 52 for legend ϑ ϑ visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 25

    Circuit diagrams thermo 90 s / thermo 90 st 54 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 2 8 11 10 1 12 7 4 h3 p2 h1 h6 30 30 85 85 86 86 87 87 87a 87a k5 k3 br br br rt rt br gn/ws rt/b l ge sw rt ...

  • Page 26

    Thermo 90 s / thermo 90 st circuit diagrams 55 fig. 17: system circuit for thermo 90 s – adr, 24 v, with switch, see pages 51 and 52 for legend ϑ ϑ visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 27

    Circuit diagrams thermo 90 s / thermo 90 st 56 fig. 18: system circuit for thermo 90 s – adr, 24 v, with switch without auxiliary drive, see pages 51 and 52 for legend ϑ ϑ visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 28

    Thermo 90 s / thermo 90 st circuit diagrams 57 10.3. Thermo 90 st circuit diagram legend item designation comment a1 heater a2 control module b1 flame sensor b2 temperature sensor b3 temperature limiter/ overheating guard b4 room thermostat e glow plug f1 fuse 20 a flat fuse sae j 1284 f2 fuse 5 a f...

  • Page 29

    Circuit diagrams thermo 90 s / thermo 90 st 58 fig. 19: system circuit for thermo 90 st, 24 v, with standard timer, see pages 51 and 57 for legend visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 30

    Thermo 90 s / thermo 90 st circuit diagrams 59 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 visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 31

    Circuit diagrams thermo 90 s / thermo 90 st 60 fig. 21: system circuit for thermo 90 st – adr, 24 v, with switch, see pages 51 and 57 for legend visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 32

    Thermo 90 s / thermo 90 st circuit diagrams 61 fig. 22: system circuit for thermo 90 st – adr, 24 v, with switch without auxiliary drive, see pages 51 and 57 for legend visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 33

    Initial start-up thermo 90 s / thermo 90 st 62 11 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...

  • Page 34

    Thermo 90 s / thermo 90 st troubleshooting 63 12 troubleshooting 12.1. Fault lock-out fuel is supplied for max. 240 seconds if the flame does not start to burn. Fuel is supplied for max. 240 seconds if the flame goes out during operation. The fuel supply is shut off if the system overheats (temperat...

  • Page 35

    Troubleshooting thermo 90 s / thermo 90 st 64 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. After five short signals, count the long flashes: 0x (only five short...

  • Page 36

    Thermo 90 s / thermo 90 st technical data 65 13 technical data except where limit values are specified, the technical data on the right refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °c and at nominal voltage. 13.1. Electrical components: the control module, motors ...

  • Page 37

    Technical data thermo 90 s / thermo 90 st 66 heater operation thermo 90 s / st petrol thermo 90 s diesel thermo 90 s-adr thermo 90 st diesel thermo 90 st-adr ec licensing symbol 00 0005* / 00 19* 00 0005* model water heater with ferro-tec technology heat output max. Regulating range 2.0 kw – 7.6 kw ...

  • Page 38

    Thermo 90 s / thermo 90 st technical data 67 fig. 23: dimensions of the thermo 90 s / thermo 90 st heaters ø30 ø39 ø20 ø5 ø6,5 ø74 ø38 ø20 137,1 100 98,6 384 131 355 48,6 = = 29 45 78 99 89 134 120 126 88 95 100 1 combustion air intake 2 exhaust fume outlet 3 fuel intake 4 coolant intake 5 coolant o...

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    Webasto ag kraillinger strasse 5 82131 stockdorf germany http://dealers.Webasto.Com http://www.Webasto.Com Änderungen vorbehalten subject to modification sous réserve de modifications © 2007 all rights reserved ide n t .-nr. 13 0149 4c im fall einer mehrsprachigen version ist deutsch verbindlich. In...