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  5. Installation Instructions Manual

Webasto Thermo 90 Installation Instructions Manual

Summary of Thermo 90

  • Page 1

    Water heaters installation instructions thermo 90 thermo 90-adr thermo 90 s thermo 90 s-adr (transport of hazardous goods) type bw 80 (petrol), type thermo 90 s b (petrol) type dw 80 (diesel), type thermo 90 s d (diesel) operating instructions must be read before attempting to start up the heater. 1...

  • Page 2: Table of Contents

    Table of contents page installation instructions 1 legal provisions for installation 1 installation 2 installation example 3 connection to the vehicle’s cool- ing system 4 fuel supply 4 fuel lines 6 metering pump 6 combustion air supply 7 exhaust pipe 7 electrical connections 8 circuit diagrams 10 i...

  • Page 3: Installation Instructions

    Installation instructions legal provisions for installation for testing the heater in accordance with articles 19, 20 oder 21 stvzo the following regulations are primarily to be observed (§ 22 a stvzo): note: these provisions are binding within the scope of the stvzo (german road licensing regulatio...

  • Page 4: Thermo 90 / Thermo 90 S

    Installation caution: - the legal provisions on page 1, relating to the installa- tion of the heater, must be observed - when installing the thermo 90-adr in vehicles de- signed for the transport of hazardous materials the re- quirements laid down in adr 002 and adr 003 (techni- cal guidelines relat...

  • Page 5: Thermo 90 / Thermo 90 S

    Without non-return valve cable harness fuel line exhaust pipe water circuit with non-return valve and thermostat fig. 3: installation examples for the thermo 90 / thermo 90 s heater legend of fig. 3 1 heat exchanger of vehicle heating system 2 switch for vehicle heating fan 3 relay for vehicle fan 4...

  • Page 6: Thermo 90 / Thermo 90 S

    Connection to the vehicle cooling system in the case of thermostat circuits only thermostats that open at temperatures the heater is connected to the vehicle cooling system in accordance with fig. 3. The amount of coolant in the cool- ing system should be at least 6 liters. In principle, only the wa...

  • Page 7: Thermo 90 / Thermo 90 S

    Vehicles with diesel engines fuel must be drawn from the fuel tank or a separate tank (see figs. 5, 6 and 7). When fuel is supplied from a separ- ate tank, any pressure-related influence can be excluded. Note: after tank extracting device has been cut to length by saw- ing, remove any burr and metal...

  • Page 8: Thermo 90 / Thermo 90 S

    If the heater is installed in vehicles equipped with injection systems it is therefore to be determined whether the fuel pump is mounted inside or outside the tank. Where the fuel pump is located inside the tank, fuel may only be extracted from the return line in which case it must be ensured that t...

  • Page 9: Thermo 90 / Thermo 90 S

    Installation and mounting the metering pump is to be attached by vibration-damping suspension. The installation position is restricted in accord- ance with figs. 10 and 11 in order to ensure sufficient self- ventilation. Fuel filter if dirt in the fuel must be reckoned with, only webasto fil- ter, o...

  • Page 10: Thermo 90 / Thermo 90 S

    Unique to thermo 90-adr: for legal provisions relating to the routing of the exhaust pipe refer to technical informa- tion e3 - 5.10 (order no. 776 623). Electrical connections control unit/heater connection the electrical connection of the heaters is to be carried out in accordance with circuit dia...

  • Page 11: Thermo 90 / Thermo 90 S

    Control unit thermo 90 note: control units for the 12-volt variant are provided with red la- belling, those for the 24-volt variant with green labelling. The control unit should be installed in a protected location, preferably in the driver’s cab. In the installation position as shown in fig. 14 the...

  • Page 12: Thermo 90 / Thermo 90 S

    Legend for circuit diagrams: ➀ this terminal is not used for petrol-operated heaters . ➁ for temperature codification (temperature at water outlet) refer to the table on page 31 ➂ digital timer p1: with positive voltage connected to pin 4 = continuous operation when “instant heat” is selected positi...

  • Page 13: Thermo 90 / Thermo 90 S

    Pos. Designation comment a1 heater thermo 90/thermo 90 s a2 electronic control unit b1 flame detector b2 temperature sensor b3 temperature limiter b4 interior-temperature thermostat e pencil-type glow plug f1 fuse 20a flat fuse sae j 1284 f2 fuse 5a flat fuse sae j 1284 f3 fuse 20a flat fuse sae j 1...

  • Page 14: Thermo 90 / Thermo 90 S

    ϑ ϑ fig. 16: system diagram thermo 90, 12 and 24v, with digital timer with 3 time settings, for legende refer to page 10 and 11 thermo 90 / thermo 90 s 12.

  • Page 15: Thermo 90 / Thermo 90 S

    ϑ ϑ fig. 17: system diagram thermo 90-adr, 24v, for legende refer to page 10 and 11 thermo 90 / thermo 90 s 13.

  • Page 16: Thermo 90 / Thermo 90 S

    ϑ ϑ fig. 18: system diagram thermo 90 s, 12 and 24v, with digital timer (standard), for legende refer to page 10 and 11 thermo 90 / thermo 90 s 14.

  • Page 17: Thermo 90 / Thermo 90 S

    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 ws/b l vi bl vi/b l gr gn or or 58 15 1 2 2 4 58 15 f2 f3 x6 f1 bl br 30 30 31 31 sw rt sw sw rt ws a2 11 6 12 2 2 3 1 0 7 10 3 2 1 1 4 5 8 11 9 9 4 3 7 1 5 6 8 10 2 12 m2 m3 m1 br br bl 2 3 ...

  • Page 18: Thermo 90 / Thermo 90 S

    ϑ ϑ fig. 20: system diagram thermo 90 s - adr, 24v, for legende refer to page 10 and 11 thermo 90 / thermo 90 s 16.

  • Page 19: Thermo 90 / Thermo 90 S

    ϑ ϑ fig. 21: system diagram thermo 90 s - adr, 24v, without auxiliary drive, for legende refer to page 10 and 11 thermo 90 / thermo 90 s 17.

  • Page 20: Thermo 90 / Thermo 90 S

    Initial operation after the heater has been installed, the water circuit and the fuel supply system must be thoroughly bled. When so doing, the vehicle manufacturer’s instructions must be ad- hered to. During a test run of the heater, all water and fuel connec- tions must be checked for leakage and ...

  • Page 21: Thermo 90 / Thermo 90 S

    Diagnosis in the event of a fault shutdown thermo 90 s check fuses and electrical connections. After the occurrence of a malfunction, the fault is indicated on the display of the digital timer if the heater is equipped with a standard digital timer: f 01 no start (after 2 start-up attempts) f 02 fla...

  • Page 22: Technical Data

    Technical data unless tolerances are shown within the technical data table on the right, a tolerance of 10% applies at an am- bient temperature of +20°c and at rated voltage. Electrical components: control unit, motors for combustion air fan and circulating pump, pencil-type glow plug, switch and di...

  • Page 23: Variants Thermo 90

    Variants thermo 90 variants thermo 90 s thermo 90 petrol-type (type bw 80) water heater for “petrol” fuel thermo 90 diesel-type (type dw 80) water heater for “diesel” fuel thermo 90-adr (type dw 80) water heater thermo 90 with adr configuration specially designed for use in ve- hicles carrying hazar...

  • Page 24: Thermo 90 / Thermo 90 S

    Thermo 90 / thermo 90 s 22.

  • Page 25

    Template for heater mounting bracket scale 1:1.

  • Page 26: Thermo 90 / Thermo 90 S

    Thermo 90 / thermo 90 s 24.

  • Page 28

    Webasto thermosysteme gmbh 82131 stockdorf . Kraillinger str. 5 . Phone (089) 85794-0 fax (089) 8 57 94-448 . Telex 5 23 647 webas d subject to change.