Operating instructions

ManualsBrandsWebasto ManualsElectric HeaterThermo 90

Contents

1. Introduction

1.1 General Description ........................................................................................................ 101

1.2 Legal Provisions ............................................................................................................. 102

1.3 Meaning of Warning, Caution and Note.......................................................................... 102

2. Operating your Webasto Thermo 90 S

2.1 Switching On................................................................................................................... 201

2.2 Switching Off................................................................................................................... 202

2.3 Engine Preheating .......................................................................................................... 202

2.4 Engine and Sleeper Heating........................................................................................... 202

2.5 Operation with Digital Timer Models 1529 & 1531 ......................................................... 202

2.6 Digital Timer Operating Instructions ............................................................................... 203

3. Technical Data

3.1 Technical Data................................................................................................................ 301

3.2 Enclosure Dimensions .................................................................................................... 302

3.3 Heater Dimensions ......................................................................................................... 303

4. Installation

4.1 General Information ........................................................................................................ 401

4.2 Installation Locations ...................................................................................................... 401

4.3 Mounting the Heater ....................................................................................................... 402

4.4 Muffler and Exhaust Pipe Connection ............................................................................ 404

4.5 Combustion Air Supply ................................................................................................... 405

4.6 Plumbing the System...................................................................................................... 406

4.6.1 General Information ............................................................................................. 406

4.6.2 Select Your Plumbing........................................................................................... 406

4.6.3 Sleeper and Engine Block Heating ...................................................................... 406

4.6.4 Contents – Engine Connections........................................................................... 409

4.7 Fuel System.................................................................................................................... 421

4.7.1 General Description ............................................................................................. 421

4.7.2 Fuel Metering Pump............................................................................................. 421

4.7.3 Fuel Line .............................................................................................................. 422

4.7.4 Fuel System Limitations ....................................................................................... 423

4.7.5 Fuel Stand Pipe.................................................................................................... 423

4.7.6 Fuel Filter ............................................................................................................. 424

4.8 Wiring Connections......................................................................................................... 425

4.8.1 General Information ............................................................................................. 425

4.8.2 Power Connection to Batteries............................................................................. 425

4.8.3 Timer and Switch Connections ............................................................................ 425

4.8.4 Sleeper Fan Wiring .............................................................................................. 427

4.8.5 Wiring Diagram- Thermo 90 S Enclosure and Compact Kit................................. 429

4.8.6 Wiring Diagram- Thermo 90 S German Version .................................................. 430

Thermo 90 S Installation / Operation Manual Contents

Summary of content (50 pages)

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Thermo 90 S Installation / Operation Manual Contents Contents 1. Introduction 1.1 General Description ........................................................................................................ 101 1.2 Legal Provisions ............................................................................................................. 102 1.3 Meaning of Warning, Caution and Note.......................................................................... 102 2. Operating your Webasto Thermo 90 S 2.
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Contents Thermo 90 S Installation / Operation Manual Contents 4.9 Initial Operation............................................................................................................... 431 5. Maintenance of the Heater 5.1 Annual Maintenance ....................................................................................................... 501 6. Basic Troubleshooting 6.1 General Information ......................................................................................................
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Thermo 90 S Installation / Operation Manual Contents List of Figures 413 414 415 416 417 418 419 420 421 422 423 424 Fuel Metering Pump Mounting (DP 30) .......................................................................... Fuel Line Connection...................................................................................................... Fuel System Limitations.................................................................................................. Fuel Stand Pipe ...................
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Thermo 90 S 1. Introduction 1.1 General Description 1 Introduction Fig. 101: Webasto Thermo 90 S Coolant Heater The Webasto Thermo 90 S is designed to be used on any diesel or gasoline equipped vehicle (diesel and gasoline versions available) including: trucks, small buses, vans, construction, off-road and military equipment, generators and independent heating systems. Webasto Thermo 90 S Coolant Heater Applications: 1.
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1 Introduction Thermo 90 S 5. Marine - For use as an auxiliary or primary heat source for interior comfort or, as an engine pre-heater. Boat installations should only be performed by a Webasto authorized marine dealer. It is the dealer’s responsibility that the installation complies with all applicable Coast Guard regulations. 1.2 Legal provisions Heater installation must be performed in accordance with the manufacturer`s installation instructions.
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Thermo 90 S 2. 2 Operating the Webasto Thermo 90 S Operating the Webasto Thermo 90 S WARNING Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must not be operated in enclosed spaces such as garages or workshops without adequate exhaust extraction. WARNING Do not operate any Webasto heater in an area where toxic or explosive materials or fumes may be present. The heater must be switched “OFF” while refueling and at fueling stations.
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2 1. 2. 3. 4. 5. Operating the Webasto Thermo 90 S Thermo 90 S The Thermo 90 S is switched off. Time has elapsed on the timer. The vehicle battery voltage drops below 10.5V (20.5V). The Thermo 90 S runs out of fuel. A fault lock out occurs, indicated by a coded flashing signal on the operating indicator light during the after run cycle of the heater or if equipped with a model 1531 7-Day Digital Comfort Timer a fault code number (i.e. 07) will be displayed in the timer window until the fault is cleared.
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Thermo 90 S 2 Operating the Webasto Thermo 90 S Both timers enable you to preset the start time of the heater up to 7 days in advance. It is possible to program 3 different starting times, of which only one can be activated at any one time. The model 1531 “Comfort” Timer features a wakeup alarm function and an error code display. The Timer can be programmed in that all flashing symbols can be adjusted by means of the and buttons.
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Thermo 90 S 3. Technical Data 3.1 Technical Data 3 Technical Data The following data is subject to the normal tolerance for heaters, if no tolerance is specified. This is approximately +/-10% in an ambient of 68°F (20°C) at nominal voltage. Heater Thermo 90 S Diesel (D) Design Coolant heater with evaporator burner (Ferro-Tech Technology) Heat Output Btu/hr (kW) Boost (Maximum 2 hours) Variable Heat Output From To Thermo 90 S Gasoline (B) 31,000 (9.1) Not Applicable 6,100 (1.8) 26,000 (7.
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3 3.2 Technical Data Enclosure Dimensions Fig.
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Thermo 90 S 3 Technical Data Fig. 302: Enclosure Cover Dimensions 3.3 Heater Dimensions Fig.
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3 Technical Data Fig. 304: Control Unit Dimensions Fig. 305: Fuel Pump Dimensions Fig.
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Thermo 90 S 4. Installation 4.1 General Information 4 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. WARNING The heater must not be installed in either the driver’s compartment or in the passenger area of vehicles. NOTE: This manual does not cover all possible installations.
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4 Installation Thermo 90 S Fig. 402: Permissible Enclosure Box Mounting Positions 4.3 Mounting the Heater A. Enclosure box frame rail mounting. 1. Remove the enclosure cover. 2. Pick 4 mounting holes in the back wall of enclosure, 2 on each side and mark frame rail. Drill holes (Ø 1/2") on each side where marked. 3. With bolts supplied, fasten the enclosure box to frame frame rail. Fig. 403: Enclosure Box Mounting (Back Wall Shown) CAUTION Do not weld enclosure or angle brackets to the frame.
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Thermo 90 S 4 Installation Fig. 404: Perpendicular Mounting Brackets NOTE Brackets for perpendicular mounting are available. Order part # 905.822. B. Enclosure box top frame bracket mounting (behind cab). 1. Drill and install top frame brackets with clamps provided (optional top frame mounting bracket kit part no. 600.055). 2. Remove the enclosure cover. 3. Position enclosure box on brackets making adjustments where necessary to ensuring adequate clearance for muffler and muffler attachment bracket. 4.
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4 Installation Thermo 90 S Fig. 405: Permissible Heater Installation (Compact and Basic Kits) 4.4 Muffler and Exhaust Pipe Connection WARNING Exhaust pipes must be so routed that the possibility of exhaust fumes entering the vehicle is unlikely. CAUTION Route the exhaust pipe in such a way as to prevent touching or being directed toward any part of the vehicle that may be damaged by heat (i.e., brake lines, electrical wiring, hoses). A. Enclosure and Compact Heater Kits. 1.
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Thermo 90 S 4 Installation Fig. 406: Muffler Mounting Detail B. General instructions for exhaust systems. Modification to the exhaust system is permitted and must be done in accordance with the following statements and instructions: An optional exhaust pipe I.D. 1 1/2" (38 mm) can have a length up to 6.5’ (2 m) including muffler and may have several bends (totaling 360°). It is mandatory to use the muffler.
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4 Installation Thermo 90 S Fig. 407: Exhaust Discharge Positioning 4.5 Combustion Air Supply WARNING Never draw combustion air from inside the vehicle, or from areas where fumes or gases can accumulate. Drawing of combustion air from areas where people are present is strictly prohibited! A combustion air intake tube I.D. 1.18" (30 mm) must be installed on the “Basic” and “Compact” versions of the Thermo 90 S heater.
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Thermo 90 S 4.6 Plumbing the System 4.6.1 General Information 4 Installation The Thermo 90 S with coolant circulating pump must be mounted at least 6" (15 cm) below the lowest permissible coolant level of the vehicles cooling system. Minimum amount of coolant in the cooling system should be at least 1.6 gal. (6.0 l). Independent heating systems require a minimum of 3.0 gal. (12.0 l). A minimum of 10% of a good quality antifreeze should be maintained in the cooling system at all times.
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4 4.6.3 Installation Thermo 90 S Sleeper and Engine Block Heating A: Parallel Plumbing Circuits Fig. 408: Parallel Plumbing Circuit Parallel plumbing circuits: Vehicles equipped with heating/air conditioning units and normally closed solenoid coolant shut-off valves require an additional relay and circuitry to overide the solenoid valve whenever the Webasto heater is in operation. This modification is necessary to ensure coolant circulation during Webasto heater operation.
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Thermo 90 S 4 Installation B: Series Plumbing Circuit Fig. 409: Series Plumbing Circuit C: Plumbing with Auxiliary Heat Exchanger Kit P.N. 905.670 NOTE Recommended plumbing for Peterbilt, Navistar, Ford AeroMax and Volvo VN. Fig.
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4 Installation Thermo 90 S Plumbing with auxiliary heat exchanger: For vehicles with continuous fan operation or high amperage heat exchanger fans, Webasto recommends the use of an auxiliary heat exchanger with low power consumption and a Webasto room thermostat (P.N. 560.129). Heat exchanger kit P.N. 905.670 provides everything necessary for this type of installation. D: Engine Block Preheating and/or Boost Heating Fig.
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Thermo 90 S 5 4.6.4 Contents – Engine Connections Caterpillar 3116 ............................................................................................................................. 3176 ............................................................................................................................. 3306 ............................................................................................................................. 3406 ..................................................
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Thermo 90 S 4 Caterpillar Caterpillar 3116 Caterpillar 3176 413
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Thermo 90 S 4 Caterpillar Caterpillar 3306 Caterpillar 3406 414
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Thermo 90 S 4 Caterpillar Caterpillar 3408 Caterpillar C-10, C-12 415
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Thermo 90 S 4 Cummins Cummins B Series 416
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Thermo 90 S 4 Cummins Cummins C Series Cummins KTA1150 417
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Thermo 90 S 4 Cummins Cummins L10 Cummins M11 418
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Thermo 90 S 4 Cummins Cummins NT, BIG CAM II Cummins NT, Big Cam IV, N14 419
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Thermo 90 S 4 Detroit Diesel Detroit Diesel Series 50 Detroit Diesel Series 55 420
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Thermo 90 S 4 Detroit Diesel Detroit Diesel Series 60 Detroit Diesel 6V92, 8V92 421
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Thermo 90 S 4 Mack Mack E6 422
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Thermo 90 S 4 4. Installation 4.7 Fuel System 4.7.1 General Description Installation The metering pump, fuel line and fuel stand pipe are integral to the systems reliability and must be installed according to these instructions to ensure proper heater operation. CAUTION If your installation exceeds the maximum allowable suction height or the fuel line as supplied is not long enough, the fuel pump must be remotely mounted (see detailed instructions in sections 4.7.2 and 4.7.
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4 4.7.2 Installation Thermo 90 S Fuel Metering Pump The fuel metering pump has been properly mounted to the bottom of the heater enclosure. In most applications it will not be necessary to modify the manufacturer’s installation. However, if the heater must be mounted outside the maximum allowable limits of the fuel system (see figure 412, typical installation parameters) the fuel pump must be relocated closer to the fuel source.
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Thermo 90 S 4 Installation Fig. 414: Fuel Line Connection 4.7.4 Fuel System Limitations Fig.
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4 4.7.5 Installation Thermo 90 S Fuel Stand Pipe The fuel is drawn from the vehicles fuel tank through a fuel stand pipe. This stand pipe can be utilized on vehicles with a spare threaded port, or if no threaded port is available, a 1" hole can be drilled into the tank and the universal tank boss installed as shown in figure 416. Keep the fuel stand pipe 2" from the bottom of fuel tank. Fig. 416: Fuel Stand Pipe Fuel stand pipe installation: 1. Cut or extend fuel stand pipe to length, approx.
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Thermo 90 S 4.8 Wiring Connections 4.8.1 General Information 4 Installation The control unit is equipped with low voltage protection, therefore it is imperative to keep vehicle batteries in good condition. For sleeper and engine block heating, Webasto recommends a four battery system for best results. NOTE The Webasto heating system will not perform to your satisfaction with weak batteries. Fig.
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4 Installation Thermo 90 S CAUTION If welding is done on the vehicle, the main battery cables must be disconnected from the battery to protect the electronic control unit. 4.8.3 Timer and Switch Connections CAUTION When drilling holes on the vehicle, do not drill into existing wiring or other mechanical components. 1. Select a suitable location in the vehicle dash for the timer or On/Off switch. 2. Drill a 1/2" hole through the dash for the switch or see timer dimensions. 3.
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Thermo 90 S 4 Installation Fig. 420: 7 Day Digital Timer Model 1529 Fig. 421: 7-Day Digital Comfort Timer Model 1531 4.8.4 Sleeper Fan Wiring A: Sleeper Fan is Cycled On/Off by Vehicle Thermostat 1. Turn ignition key to “ACC” position to power up sleeper. 2. Select desired temperature on thermostat and turn on sleeper fan to low position. Fan will cycle On/Off to maintain temperature.
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4 Installation Thermo 90 S C: Auxiliary Bunk Heat Exchanger Kit 905.670 Sleepers with continuous fan operation or high amperage heat exchanger fans. 1. Position the auxiliary heat exchanger in a suitable location under the bed, toolbox or other space and secure as required. 2. Plumb coolant lines to the heat exchanger as shown in “C: Plumbing with Auxiliary Heat Exchanger Kit P.N. 905.670” figure 410. 3. Make air duct connection at heat exchanger and route ducting into the sleeper. 4.
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Thermo 90 S 4.8.5 4 Installation Wiring Diagram – Thermo 90 S 12 Volt and 24 Volt Enclosure and Compact Kit with Deutsch Connector Fig.
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4 4.8.6 Installation Wiring Diagram – Thermo 90 S 12 Volt and 24 Volt German Version without Deutsch Connector Fig.
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Thermo 90 S 4. Installation 4.9 Initial Operation 4 Installation 1. Check your installation for: - loose nuts and bolts. - exhaust system routing and clamp tightness. - loose hose clamps. - routing and securing of wiring and heater hoses. - kinked or pinched hoses. - routing and securing of fuel lines. - battery connection and polarity. 2. Top off or refill cooling system with coolant as per engine manufacturers recommendations. 3. Open shut-off valves. 4. Set heater valve to max.
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4 Installation Thermo 90 S NOTE Installation with long fuel lines may need a second start attempt to prime the fuel lines. Cycle ON/OFF switch to reset control unit. 10. Temperature differential between water inlet and outlet should not exceed 10° C (18° F). NOTE The engine temperature gauge may read than actual heater output temperature. This is due to the location of the temperature gauge sensor on the engine. 11.
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Thermo 90 S 5. Maintenance of the Heater 5.1 Annual Maintenance 5 Maintenance of the Heater The Thermo 90 S heater requires a minimum of maintenance to keep in good operating condition. The following maintenance procedures should be performed annually before each heating season: NOTE For major repair and spare parts, return to your authorized Webasto Thermosystems Specialist. Enclosure Box and Heater - Clean the heater and enclosure box from any accumulated debris or dust with compressed air.
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Thermo 90 S 5. Basic Troubleshooting 5.1 General Information 6 Basic Troubleshooting This section describes troubleshooting procedures for the Thermo 90 S coolant heater. Troubleshooting is normally limited to the isolation of defective components. CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater components and may only be performed by skilled personnel.
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6 Thermo 90 S Basic Troubleshooting Failure Symptom Probable Cause Remedy Coolant heater switches off automatically (Fault lock-out) No combustion after start or automatic repeat start Switch off heater momentarily and switch on once again Flame extinguishes during operation Switch off heater momentarily and switch on once again Heater overheats Vehicle electrical system voltage too low Heater expels black fumes from exhaust Combustion air and/or exhaust ducting blocked Table 601: 5.
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Thermo 90 S 6 Basic Troubleshooting 4X Flashes (F 04) Flame sensor permanently hot -Defective flame sensor -Replace flame sensor 5X Flashes (F 05) Flame sensor -Wiring -Defective flame sensor -Damaged wiring, open or short circuit -Replace flame sensor 6X Flashes (F 06) Temperature sensor -Wiring -Defective temperature sensor -Damaged wiring, open or short circuit -Replace temperature sensor 7X Flashes (F 07) Fuel metering pump -Wiring -Defective fuel pump -Damaged or corroded wiring, open or
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6 5.4 Basic Troubleshooting Reading a Fault Code with 1531 “Comfort” Timer Installed Thermo 90 S CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater Where the Thermo 90 S installation includes the model 1531 “Comfort” Digital Timer, you will be able to read the current failure fault code directly from the timer display. For example: fault code “07" (fuel pump) will be visible on the timer display.