Coolant Heater Thermo 300.
WEBASTO THERMO 300 TABLE OF CONTENTS Table of Contents 1. Introduction 1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Additional Documentation to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 General Safety Regulations and Information . . . . . . . . . . . . . . . . .
TABLE OF 5.10 6. CONTENTS WEBASTO THERMO 300 5.9.5 Wiring Diagram - with Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.9.6 Wiring Diagram - with 7-Day Digital Timer Model 1531 . . . . . . . . . . . . . . . . . . . 5-12 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Basic Troubleshooting 6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEBASTO THERMO 300 1. Introduction 1.1 Scope and Purpose This manual is intended to support authorized Webasto trained distributors, dealers and personnel in the installation and servicing of Thermo 300 coolant heaters. Webasto Thermosystems, Inc. does not recommend the installation and servicing of Webasto products by untrained, unauthorized personel or end-users. Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users will release Webasto Thermosystems, Inc.
1 INTRODUCTION In the vicinity of the coolant heater, a temperature of 185 °F (85 °C) must not be exceeded under any circumstances (e.g. during body paint work). A violation of this temperature limit may cause permanent damage to the electronics. When checking the coolant level, proceed in accordance with the vehicle manufacturer’s instructions. The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based anti-freeze.
WEBASTO THERMO 300 2. General Description 2.
2 2-2 GENERAL DESCRIPTION WEBASTO THERMO 300
WEBASTO THERMO 300 3. 3 FUNCTIONAL DESCRIPTION Functional Description Activation and deactivation is by means of a • switch • timer dependent on the type of installation. For monitoring operation an operating indicator light is provided. Switch off initiates the rundown procedure (see ”Switch off”). The heaters may be • operated with power save for reduced fuel consumption (see circuit diagram) • equipped or retrofitted with nozzle preheating for extreme low temperatures. 3.
3 3-2 FUNCTIONAL DESCRIPTION WEBASTO THERMO 300
WEBASTO THERMO 300 4. Technical Data 4.1 General Information 4 TECHNICAL DATA Where no threshold values are specified, technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 20 °C (+ 68 °F) and at nominal voltage. Electrical components: Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle pre-heater and timer are 24V components.
4 TECHNICAL DATA 4.2.1 Thermo 300.102 Heater Dimensions Fig. 4-1 Thermo 300.
WEBASTO THERMO 300 4.3 4 TECHNICAL DATA U 4814 & U 4852 Coolant Pump Data NOTE: The allocation of circulation pumps to heater units must be in accordance with coolant resistances. Circulation pump Volume flow U 4814 l/h (US. Gal/min) U 4852 5200 (22.9) against 0.15 bar 6000 (26.4) against 0.4 bar Nominal voltage V 24 24 Operating voltage range V 20 ... 28 18 ... 32 Nominal power consumption W 104 209 Dimensions of coolant pump length width height 221 mm (8.7 in.) 100 mm (3.94 in.
4 TECHNICAL DATA 4.3.2 Coolant Circulation Pump U4852 Dimensions Fig. 4-3 Coolant Circulation Pump U4852 Dimensions Fig.
WEBASTO THERMO 300 5. Installation 5.1 General Information 5 INSTALLATION Webasto will take you step by step through the installation process to ensure successful operation for years to come. The installation must be performed in accordance with the installation instructions provided in this manual. IMPORTANT! The proposed heater installation must be approved by Webasto Thermosystems. NOTE: This manual does not cover all possible installation variants.
5 5.5 INSTALLATION WEBASTO THERMO 300 Exhaust Pipe Connection WARNING Due to the danger of poisoning and suffocation, exhaust pipes are to be installed and routed in a manner that does not permit the possibility of exhaust gases entering the vehicle where people are present. Carefully read and understand all information pertaining to the installation of the exhaust system. Rigid exhaust pipe is recommended in installations where the use of an exhaust deflector is not suitable.
WEBASTO THERMO 300 5 INSTALLATION For a straight connection, order a straight adapter under part number 101377 and snap it onto the combustion air inlet and attach air ducting. In the event there is insufficient room for a straight attachment, a 90° snap-on fitting (P.N. 101404) and an adapter ring (P.N. 82315A) are available. Simply snap them onto the combustion air inlet of the heater and attach ducting.
5 5.7.2 INSTALLATION WEBASTO THERMO 300 Supplemental Heating Schematic - Jacket Water and Intercooler Coolant Heaters (fig. 5-1) CAUTION The coolant pump(s) must be operating and a continuous unobstructed coolant path provided during heater operation. Overheating of the heater will quickly develop if coolant flow is interrupted. Fig.
WEBASTO THERMO 300 5.7.3 5 INSTALLATION Supply and Return Plumbing Connection Points (Charge Air Cooler) WARNING Burn risk! When working on the coolant system, allow the engine to cool down and open the radiator cap carefully. NOTE: Heater hose must meet SAE 20 R3 specifications. Silicone hose requires special hose clamps. Hose clamps must be tightened to 45 lb/in. (5 Nm) torque. Fig.
5 5.7.4 INSTALLATION Example of a Heater Installation Thermo 300 in Enclosure Fig.
WEBASTO THERMO 300 5.8 Fuel System 5.8.1 General Information 5 INSTALLATION The fuel is drawn from the vehicles fuel tank through a fuel standpipe. This standpipe can be utilized on vehicles with a spare threaded port as shown in figure 5-5. The Webasto heater utilizes 37° flare JIC fuel connection fittings. The fuel supply line fitting is a JIC #4 and the return line is a JIC #6. 5.8.2 Fuel Supply IMPORTANT! Keep the submerged end of fuel standpipe at least 2” from bottom of fuel tank.
5 INSTALLATION WEBASTO THERMO 300 2. Install the fuel standpipe. - use 1/4” or 1/2” spare port on fuel tank (if available) and install fuel standpipe securely in fuel tank, use pipe thread sealant on all pipe threads. 3. Route and secure fuel lines from heater to fuel tank. Route according to applicable regulations. Use grommets to protect fuel lines whenever routed through holes. 4. Connect fuel lines to fuel standpipe and heater using 1/4” (6 mm) I.D. fuel line.
WEBASTO THERMO 300 5.9 Wiring Connections 5.9.1 General Information 5 INSTALLATION The control unit is equipped with low voltage protection, therefore it is imperative to keep vehicle batteries in good condition. Thermo 300 heaters are available in 24 volt configurations only. CAUTION Whenever welding is to be performed on the vehicle, the main battery cables must be disconnected from the battery to protect the electronic control unit.
5 5.9.4 INSTALLATION WEBASTO THERMO 300 Coolant Pump Connections Use Eyelet (901.038) supplied with coolant pump harness kit for ground. Run 12 Gauge wire from eyelet to Pin B on connector #905455 for the ground. Run 12 Gauge wire from Pin A on the same connector into Pin D on the flat 4 pin connector of the electrical connector kit. Connector P/N 905.455 Pin A, Coolant Pump Power from Pin D Pin D Coolant Pump Power to Pin A on connector P/N #905.
WEBASTO THERMO 300 5.9.5 5 INSTALLATION Wiring Diagram - with Switch Fig.
5 5.9.6 INSTALLATION Wiring Diagram - with 7-Day Digital Timer Model 1531 Fig.
WEBASTO THERMO 300 5.10 5 INSTALLATION Initial Operation 1. Check your installation for: - loose nuts and bolts. - exhaust pipe routing and clamp tightness. - loose hose clamps. - routing and securing of wiring and heater hoses. - kinked or pinched hoses. - battery connection and polarity. 2. Top off or refill cooling system with coolant as per engine manufacturers recommendations. 3. Open shut-off valves and driver’s heater valve. 4. Set vehicle heater controls to maximum heat position. 5.
5 INSTALLATION WEBASTO THERMO 300 15. Complete the warranty card and mail to Webasto Thermosystems. 16. Install the heater or engine compartment cover if equipped. Installation is now complete. NOTE: Necessary information to complete warranty registration card and ensure full warranty coverage can be found on the name plate on top of the burner head.
WEBASTO THERMO 300 6. 6 BASIC TROUBLESHOOTING Basic Troubleshooting CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components. Troubleshooting and fault correction should only be performed by Webasto trained, skilled personnel unless otherwise stated in this manual. 6.1 General Information This section describes troubleshooting procedures for the Thermo 300 coolant heater.
6 BASIC TROUBLESHOOTING WEBASTO THERMO 300 switch or timer is cycled “Off” and “On” and the heater successfully starts and runs with no further malfunctions, the malfunction code will disappear from the timer display. 6.2.2 Malfunction Codes Stored in Memory Once the Thermo 300 completes the after run (cool down) period initiated by a malfunction, the current flash code will be downloaded (stored) in memory. The Thermo 300 can store up to ten malfunction codes.
WEBASTO THERMO 300 6.3 6 BASIC TROUBLESHOOTING Operational Malfunction Symptoms via Flash/ Malfunction Code The following table lists the possible malfunctions which can be read by flashing code or read directly off of an appropriate timer or with the PC diagnostics kit.
6 6.4 BASIC TROUBLESHOOTING WEBASTO THERMO 300 Reading and Removing Malfunction Codes Stored in Memory with the Webasto PC Diagnostics Kit and Adapter CAUTION Diagnostics equipment is intended for use by Webasto trained personnel at authorized Webasto distributor, dealer and end user service facilities. Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components.
WEBASTO THERMO 300 6 BASIC TROUBLESHOOTING 6-5
