Coolant heater thermo pro 90 d (diesel) 12 / 24 volt 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. – to install and repair webasto heating and cooling systems yo...
Thermo pro 90 table of contents www.Webasto.Us 3 webasto thermo & comfort n.A., inc. Contents page 1. Safety and general information 5 1.1 warning symbols in this installation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 g...
Table of contents thermo pro 90 www.Webasto.Us 4 webasto thermo & comfort n.A., inc. 14.2 heater interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 14.2.1 interlock reset procedure . . . ...
Www.Webasto.Us 5 webasto thermo & comfort n.A., inc. Thermo pro 90 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 o...
Webasto thermo & comfort n.A., inc. 6 www.Techwebasto.Com regulation for installation in the vehicle thermo pro 90 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....
Www.Webasto.Us 7 webasto thermo & comfort n.A., inc. Thermo pro 90 regulation for installation in the vehicle 2.7.2 the water outlet hose must be protected so that it cannot be obstructed by other objects or the flow of water through the hoses. Important! Failure to follow the installation instructi...
Webasto thermo & comfort n.A., inc. 8 www.Techwebasto.Com purpose / version thermo pro 90 3. Purpose / version 3.1 purpose of the coolant heater the webasto thermo pro 90 coolant heaters are used in connection with the vehicle’s own heating system – to heat the cab, – to defrost vehicle windows and ...
Www.Webasto.Us 9 webasto thermo & comfort n.A., inc. Thermo pro 90 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...
Webasto thermo & comfort n.A., inc. 10 www.Techwebasto.Com installation location examples thermo pro 90 5. Installation location examples figure 1: installation locations.
Www.Webasto.Us 11 webasto thermo & comfort n.A., inc. Thermo pro 90 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 install...
Webasto thermo & comfort n.A., inc. 12 www.Techwebasto.Com mounting the heater to the vehicle thermo pro 90 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 ...
Www.Webasto.Us 13 webasto thermo & comfort n.A., inc. Thermo pro 90 mounting the heater to the vehicle figure 7: optional perpendicular mounting with bracket kit p/n 905838 484mm 500mm 150mm 150mm 158mm 363mm.
Webasto thermo & comfort n.A., inc. 14 www.Techwebasto.Com connection to the vehicle cooling system thermo pro 90 7. Connection to the vehicle cooling system 7.1 general information the heater is connected to the vehicle cooling system as shown in figures 9 through 14, depending on the type of heati...
Www.Webasto.Us 15 webasto thermo & comfort n.A., inc. Thermo pro 90 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 op...
Webasto thermo & comfort n.A., inc. 16 www.Techwebasto.Com connection to the vehicle cooling system thermo pro 90 figure 11: system configured in series with rear heat exchanger in a “dual” circuit heating system. Figure 12: system configured in the rear heat exchanger circuit using an optional 4-wa...
Www.Webasto.Us 17 webasto thermo & comfort n.A., inc. Thermo pro 90 connection to the vehicle cooling system figure 14: system configured with an additional auxiliary heat exchanger connected in “series / parallel” with rear heat exchanger circuit. 1 2 2 3 4 5 6 7 8 11 9 9 1. Coolant supply connecti...
Webasto thermo & comfort n.A., inc. 18 www.Techwebasto.Com fuel supply thermo pro 90 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 16. The fuel is taken from the vehicle fuel tank or from a separate ...
Www.Webasto.Us 19 webasto thermo & comfort n.A., inc. Thermo pro 90 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 f...
Webasto thermo & comfort n.A., inc. 20 www.Techwebasto.Com fuel supply thermo pro 90 7. Bring standpipe up to horizontal and insert opposite shoulder under the tank hole. See figure 19. Figure 19: standpipe installation - illustration 2 8. Center standpipe in tank hole. See figure 20. Figure 20: sta...
Www.Webasto.Us 21 webasto thermo & comfort n.A., inc. Thermo pro 90 fuel supply 8.3 fuel lines only steel and plastic lines made of plasticized, light and temperature-stabilized may be used for the fuel lines. Since the lines normally cannot be routed with a constant rising gradient, the internal di...
Webasto thermo & comfort n.A., inc. 22 www.Techwebasto.Com fuel supply thermo pro 90 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 in order to ensure effective automatic bleeding. As a result of the r...
Www.Webasto.Us 23 webasto thermo & comfort n.A., inc. Thermo pro 90 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 ...
Webasto thermo & comfort n.A., inc. 24 www.Techwebasto.Com exhaust system thermo pro 90 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 ...
Www.Webasto.Us 25 webasto thermo & comfort n.A., inc. Thermo pro 90 exhaust system figure 27: exhaust pipe termination important! If the exhaust tube cannot be installed so that it slopes downwards at all points, a condensation drain hole with a diameter of 4 mm (5/32”) is to be made at its lowest p...
Webasto thermo & comfort n.A., inc. 26 www.Techwebasto.Com electrical connections thermo pro 90 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 w...
Www.Webasto.Us 27 webasto thermo & comfort n.A., inc. Thermo pro 90 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 29 and 33. • timer, see circuit diagrams in figures 30 and 34....
Webasto thermo & comfort n.A., inc. 28 www.Techwebasto.Com electrical connections thermo pro 90 the control panel should be installed in a suitable location on a flat surface if possible in a visible area. – connect control panel to existing connectors on heater-unit wiring harness (see “connections...
Www.Webasto.Us 29 webasto thermo & comfort n.A., inc. Thermo pro 90 electrical connections 11.3 vehicle fan the vehicle's own heater fan can be controlled using a relay, see circuit diagram figs. 33 or 34 (connecter x8 contact 2 violet or contact d of x13. 11.4 setting control temperatures of thermo...
Webasto thermo & comfort n.A., inc. 30 www.Techwebasto.Com circuit diagrams thermo pro 90 12. Circuit diagrams cable cross sections cable colors legend.
Www.Webasto.Us 31 webasto thermo & comfort n.A., inc. Thermo pro 90 circuit diagrams 12.1 thermo pro 90 circuit diagram legend item designation comment a1 heater a2 control module b1 exhaust temperature sensor b2 coolant temperature sensor b3 temperature limiter/ overheat sensor bt battery vehicle b...
Webasto thermo & comfort n.A., inc. 32 www.Techwebasto.Com circuit diagrams thermo pro 90 figure 33: thermo pro 90 with on/off switch - connection diagram.
Www.Webasto.Us 33 webasto thermo & comfort n.A., inc. Thermo pro 90 circuit diagrams figure 34: thermo pro 90 with 7-day smartemp control fx timer - connection diagram.
Webasto thermo & comfort n.A., inc. 34 www.Techwebasto.Com initial start-up thermo pro 90 13. Initial start-up important! Refer to the safety instructions in the operating and maintenance instructions. The operating and maintenance instructions must be read thoroughly before starting the heater. Hea...
Www.Webasto.Us 35 webasto thermo & comfort n.A., inc. Thermo pro 90 initial start-up electrical complete (yes/no/comments) 1 has all wiring been safely secured away from moving components and / or heat sources? 2 check for proper power and ground connections. 3 has blower motor functionality been te...
Webasto thermo & comfort n.A., inc. 36 www.Techwebasto.Com initial start-up thermo pro 90 if you have any questions, contact our technical support team at (800) 860-7866 or via email at: info-us@webasto.Com . Heater must be switched “off” when refueling at filling stations and/or while loading or un...
Www.Webasto.Us 37 webasto thermo & comfort n.A., inc. Thermo pro 90 troubleshooting 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 con...
Webasto thermo & comfort n.A., inc. 38 www.Techwebasto.Com troubleshooting thermo pro 90 4x premature flame recognition 5x n/a 6x coolant temperature sensor interrupt or temperature sensor short-circuit 7x metering pump interrupt or metering pump short-circuit 8x blower motor interrupt or blower mot...
Www.Webasto.Us 39 webasto thermo & comfort n.A., inc. Thermo pro 90 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 ...
Thermo pro 90 notes www.Webasto.Us 40 webasto thermo & comfort n.A., inc. 15.3 thermo pro 90 dimensions figure 35: dimensions of the thermo pro 90 heater / enclosure box 1 combustion air intake 2 exhaust outlet 3 fuel inlet pipe 4 coolant inlet 5 coolant outlet l 355mm (14”) l* 381mm (15”) h 232mm (...
Www.Webasto.Us 41 webasto thermo & comfort n.A., inc. Thermo pro 90 technical data notes.
Webasto thermo & comfort n.A., inc. 42 www.Techwebasto.Com technical data thermo pro 90
Www.Webasto.Us 43 webasto thermo & comfort n.A., inc. Thermo pro 90 technical data.
Webasto thermo & comfort n.A., inc. 44 www.Techwebasto.Com technical data thermo pro 90
Webasto thermo & comfort n.A., inc. 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 860-7866 canada: (800) 667-8900 www.Techwebasto.Com org. 5/2014 rev. 9/2015 p/n 5010926b.
