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Webasto Thermo 90 ST Installation Manual

Summary of Thermo 90 ST

  • Page 1

    Coolant heater thermo 90 st b (gasoline) thermo 90 st d (diesel) installation manual – 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. – installation and repair of webasto heating and c...

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    Thermo 90 st table of contents www.Webasto.Us 1 webasto product n.A., inc. Contents page 1. Safety and general information 3 1.1 warning symbols in this installation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 general i...

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    Table of contents thermo 90 st www.Webasto.Us 2 webasto product n.A., inc. 14.1 general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 14.2 fault lock-out . . . . . . . . . . . . . . . . ...

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    Www.Webasto.Us 3 webasto product n.A., inc. Thermo 90 st safety and general information 1. Safety and general information 1.1 warning symbols in this installation manual the purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols ...

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    Webasto product n.A., inc. 4 www.Techwebasto.Com regulation for installation in the vehicle thermo 90 st 2. Regulation for installation in the vehicle read this installation manual in its entirety before installing this equipment. 2.1 scope 2.1.1 subject to the provisions of paragraph 2.1.2, interna...

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    Www.Webasto.Us 5 webasto product n.A., inc. Thermo 90 st regulation for installation in the vehicle 2.7.2 the water outlet line must be protected so that it cannot be obstructed by other objects or the flow of water through the lines be blocked. Important! Failure to follow the installation instruct...

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    Webasto product n.A., inc. 6 www.Techwebasto.Com purpose / version thermo 90 st 3. Purpose / version 3.1 purpose of the coolant heater thermo 90 st coolant heaters are used in connection with the vehicle’s own heating system – to heat the cab, – to defrost vehicle windows and – to preheat water-cool...

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    Www.Webasto.Us 7 webasto product n.A., inc. Thermo 90 st installation 4. Installation important! The water heater must be installed outside the passenger cabin. The requirements of the latest version of “hazmat” must also be observed for the installation of the heater into vehicles used to transport...

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    Webasto product n.A., inc. 8 www.Techwebasto.Com installation location examples thermo 90 st 5. Installation location examples figure 1: installation locations.

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    Www.Webasto.Us 9 webasto product n.A., inc. Thermo 90 st mounting the heater to the vehicle 6. Mounting the heater to the vehicle 6.1 allowable mounting positions figure 2: allowable enclosure kit mounting positions, 1 and 2 only. Position 3 is not permissible. Figure 3: permitted installation posit...

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    Webasto product n.A., inc. 10 www.Techwebasto.Com mounting the heater to the vehicle thermo 90 st do not drill holes through top or bottom of vehicle frame flanges! Do not weld vehicle frame or flanges! Figure 5: drill frame within the shaded area only! Figure 6: mounting heater enclosure via back w...

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    Www.Webasto.Us 11 webasto product n.A., inc. Thermo 90 st mounting the heater to the vehicle figure 7: optional perpendicular mounting with bracket kit p/n 905822 or p/n 905838 (freightliner style) figure 8: optional cross-frame mounting bar/clamp kit p/n 600055 (also see figure 1) 484mm 500mm 150mm...

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    Webasto product n.A., inc. 12 www.Techwebasto.Com connection to the vehicle cooling system thermo 90 st 7. Connection to the vehicle cooling system 7.1 general information the heater is connected to the vehicle cooling system as shown in figures 10 through 15, depending on the type of heating system...

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    Www.Webasto.Us 13 webasto product n.A., inc. Thermo 90 st connection to the vehicle cooling system the cooling system must be bled carefully before using the heater for the first time or after replacing the coolant. Proper venting of trapped air can be identified by the circulating pump operating al...

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    Webasto product n.A., inc. 14 www.Techwebasto.Com connection to the vehicle cooling system thermo 90 st figure 12: system configured in series with rear heat exchanger in a “dual” circuit heating system. Figure 13: system configured in the rear heat exchanger circuit using an optional 4-way back-che...

  • Page 17

    Www.Webasto.Us 15 webasto product n.A., inc. Thermo 90 st connection to the vehicle cooling system figure 15: system configured with an additional auxiliary heat exchanger connected in “series / parallel” with rear heat exchanger circuit. (recommended for kenworth aerocab & studio sleeper built befo...

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    Webasto product n.A., inc. 16 www.Techwebasto.Com fuel supply thermo 90 st 8. Fuel supply 8.1 general information the values for the maximum pressure at the fuel extraction point are shown in the table below and in figure 17. The fuel is taken from the vehicle fuel tank or from a separate fuel tank....

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    Www.Webasto.Us 17 webasto product n.A., inc. Thermo 90 st fuel supply 8.2 fuel standpipe installation this separate fuel pickup precludes any effect of pressure. Where available, a spare npt threaded port can be utilized for the standpipe. If a spare port is not present, proceed with the following i...

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    Webasto product n.A., inc. 18 www.Techwebasto.Com fuel supply thermo 90 st 7. Bring standpipe up to horizontal and insert opposite shoulder under the tank hole. See figure 20. Figure 20: standpipe installation - illustration 2 8. Center standpipe in tank hole. See figure 21. Figure 21: standpipe ins...

  • Page 21

    Www.Webasto.Us 19 webasto product n.A., inc. Thermo 90 st fuel supply 8.3 fuel lines only steel, copper and plastic lines made of plasticized, light and temperature-stabilized pa 11 or pa 12 (e.G. Mecanyl rwtl) pursuant to din 73378 may be used for the fuel lines. Since the lines normally cannot be ...

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    Webasto product n.A., inc. 20 www.Techwebasto.Com fuel supply thermo 90 st 8.4.2 attachment the metering pump must be secured with a vibration- damping mounting. Its installation position is limited as shown in figure 24 and 25 in order to ensure effective automatic bleeding. As a result of the risk...

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    Www.Webasto.Us 21 webasto product n.A., inc. Thermo 90 st combustion air supply 9. 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 in that it ca...

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    Webasto product n.A., inc. 22 www.Techwebasto.Com exhaust system thermo 90 st 10. Exhaust system the exhaust pipe (internal diameter 38 mm) can be installed with a length of 0.5 m to 5 m (1.6 ft to 16 ft) and several bends totalling a maximum of 360° altogether. The minimum bending radius is 85 mm (...

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    Www.Webasto.Us 23 webasto product n.A., inc. Thermo 90 st exhaust system figure 28: exhaust pipe termination important! If the exhaust line cannot be installed so that it slopes downwards at all points, a water drain hole with a diameter of 4 mm (5/32”) is to be made at its lowest point to allow con...

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    Webasto product n.A., inc. 24 www.Techwebasto.Com electrical connections thermo 90 st 11. Electrical connections 11.1 power / control harness connections ideally, the heater power supply should be directly from the vehicle’s batteries or main buss-bar. The heater control unit is equipped with low vo...

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    Www.Webasto.Us 25 webasto product n.A., inc. Thermo 90 st electrical connections 11.2 connecting the controls the heater can be switched on and off using the following webasto controls: • switch, see circuit diagrams in figures 30 and 32. • timer, see circuit diagrams in figures 31 and 33. Figure 30...

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    Webasto product n.A., inc. 26 www.Techwebasto.Com circuit diagrams thermo 90 st 12. Circuit diagrams 12.1 thermo 90 st circuit diagram legend c digital timer p2: connection x14 to red jumper of switch harness results in continuous operation with immediate heating (recommended for trucks requiring sl...

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    Www.Webasto.Us 27 webasto product n.A., inc. Thermo 90 st circuit diagrams figure 32: thermo 90 st with on/off switch - connection diagram (includes optional blower interface harness) x1 x8 x11 x10 x12 x15 x3 x4/x5/x6/x7 1 2 1 2 1 2 a b c eb 2 b3 m1 m2 b1 1 3 5 7 9 11 3 4 1 2 1 2 1 2 1 2 x2 0 0 1 1 ...

  • Page 30

    Webasto product n.A., inc. 28 www.Techwebasto.Com circuit diagrams thermo 90 st figure 33: thermo 90 st with 7-day digital timer model 1531 - connection diagram 2 8 11 10 1 12 7 4 h3 p2 h1 h6 6 3 4 1 2 7 5 8 x1 x8 x13 x11 x10 x12 x15 x9 x3 x4/x5/x6/x7 3 6 9 12 1 2 1 2 1 2 a b c 3 4 6 7 8 5 1 2 eb 2 ...

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    Www.Webasto.Us 29 webasto product n.A., inc. Thermo 90 st initial start-up 13. Initial start-up important! 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. Note: as...

  • Page 32

    Webasto product n.A., inc. 30 www.Techwebasto.Com troubleshooting thermo 90 st 14. Troubleshooting 14.1 general information the control unit continuously monitors the heater operation. The control unit identifies errors on individual heater components and faults during operation. Should the control ...

  • Page 33

    Www.Webasto.Us 31 webasto product n.A., inc. Thermo 90 st technical data 15. Technical data except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10% at an ambient temperature of +20 °c (68 °f) and at the nominal voltage and conditions. 15.1 electrical...

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    Webasto product n.A., inc. 32 www.Techwebasto.Com technical data thermo 90 st table 2: technical data - us standard measurement figure 34: thermo 90 st control module, arbitrary installation position heater operation thermo 90 st gasoline thermo 90 st diesel ec licensing symbol e1*2001/56*0019*__ e1...

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    Www.Webasto.Us 33 webasto product n.A., inc. Thermo 90 st technical data figure 35: dimensions of the thermo 90 st heater 381 = = 99 89 ø74 45 ø20 ø5 ø39 92 152 88 95 ø30 ø38 ø20 352 131 49 99 137 100 thermo 90 st 3 5 1 2 4 1 combustion air intake 2 exhaust outlet 3 fuel inlet pipe 4 coolant inlet 5...

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    Webasto product n.A., inc. 34 www.Techwebasto.Com additional installation accessories thermo 90 st 16. Additional installation accessories sleeper pack - complete auxiliary heat exchanger kit. P/n 905670 sleeper pack - oem hvac to webasto coolant heater interface kits. P/n 906558a - kenworth aerocab...

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    Thermo 90 st notes www.Webasto.Us 35 webasto product n.A., inc..

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    Notes thermo 90 st www.Webasto.Us 36 webasto product n.A., inc..

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    Thermo 90 st notes www.Webasto.Us 37 webasto product n.A., inc..

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    Webasto product n.A., inc. 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 860-7866 canada: (800) 667-8900 www.Techwebasto.Com www.Webasto.Us org. 01/2007 rev. 05/2007 p/n 5000994a © 2007 webasto product n.A., inc..