Webasto Thermo 90 Bedienungsanleitung

Wasserheizgeräte

Water Heaters

Chauffages à eau

05/2008

1301494C

Einbauanweisung

Installation Instructions

Instructions de montage

Thermo 90 S

Thermo 90 ST

Thermo 90 S (Benzin) (Petrol) (Essence)

Thermo 90 S (Diesel) (Gas-oil)

Thermo 90 S-ADR (Gefahrguttransport)

(Transport of hazardous goods)

(Transport de marchandises dangereuses)

Thermo 90 ST (Benzin) (Petrol) (Essence)

Thermo 90 ST (Diesel) (Gas-oil)

Thermo 90 ST-ADR (Gefahrguttransport)

(Transport of hazardous goods)

(Transport de marchandises dangereuses)

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Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer

verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder

tödliche Verletzungen hervorgerufen werden.

Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines

Webastotrainings, technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.

Versuchen Sie NIEMALS, Webasto Heiz- oder Kühlsysteme einzubauen oder zu reparieren, wenn Sie

das Webastotraining nicht erfolgreich abgeschlossen und dabei die notwendigen technischen

Fähigkeiten erworben haben und die für einen sachgerechten Einbau und Reparatur nötigen

technischen Dokumentationen, Werkzeuge und Ausrüstungen nicht zur Verfügung stehen.

Befolgen Sie IMMER alle Webasto Einbau- und Reparaturanleitungen, und beachten Sie alle

Warnhinweise.

Webasto übernimmt keine Haftung für Mängel und Schäden, die auf einen Einbau durch ungeschultes

Personal zurückzuführen sind.

Improper installation or repair ofWebasto heating and coolingsystems 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 you need to have completed a Webasto

training course and have the appropriatetechnical documentation, special tools and special equipment.

NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto

training course, you do not have the necessary technical skills and you do not have the technical

documentation, tools and equipment available to ensure that you can complete the installation and

repair work properly.

ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS.

Webasto rejects any liability for problems and damage caused by the system being installed by

untrained personnel.

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La réparation ou l’installation impropre des systèmes de chauffage et de refroidissement Webasto peut

conduire à l’incendie de l’appareil ou encore à des fuites mortelles de monoxyde de carbone pouvant

entraîner de graves lésions voire même la mort.

Pou l’installation ou la réparation des systèmes de chauffage ou de refroidissement Webasto, il est né-

cessaire d’avoir une formation Webasto, une documentation technique, des outils spécifique et des

équipements particuliers.

N’essayez JAMAIS d’installer ou de réparer un système de chauffage ou de refroidissement Webasto

si vous n’avez pas suivi avec succès la formation Webasto et obtenu ainsi les capacités techniques in-

dispensables et si vous ne disposez pas de la documentation technique, des outils et des équipements

nécessaires à une installation ou à une réparation dans les règles de l’art.

TOUJOURS suivre scrupuleusement les instructions Webasto relatives à l’installation et à laréparation

des appareils et tenir compte de toutes les MISES EN GARDE.

Webasto décline toute responsabilité en cas de problème oude dommagecausé parun système ayant

été installé par du personnel non qualifié.

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Thermo 90 S / Thermo 90 ST

Inhaltsverzeichnis

1 Gesetzliche Bestimmungen für den Einbau ´ . . . . . . . . . . . 1

2 Verwendung / Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Einbaubeispiele . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Anschluss an das Kühlsystem des Fahrzeuges . . . . . . . . 7

6 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 Abgasleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10 Schaltpläne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

11 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

12 Störungen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

13 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table of contents

1 Statutory regulations governing installation . . . . . . . . . . 35

2 Use / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Examples for installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 Connection to the vehicle cooling system . . . . . . . . . . . . 41

6 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

10 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

11 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Thermo 90 S / Thermo 90 ST Statutory regulations governing installation

1 Statutory regulations governing installation

1.1. Statutory regulations governing installation

The Thermo 90 S / Thermo 90 ST heater has been type-tested and

approved in accordance with EC Directives 72/245/EEC (EMC), 2001/

56/EC (heater) and ECE R122 with the following EC permit numbers:

e1*2001/56*2004/78*0005*--

e1*72/245*95/54*1173*--

e1*2001/56*2004/78*0019*--

E1 R122 00 0217

Primarily the regulations of Annex VII of the Directive 2001/56/EG and

Part 2 or Annex 7 of the directive ECE R122 must be observed for the

installation.

NOTE:

The provisions of these Directives are binding within the territory

governed by EU Directive 70/156/EEC and should similarly be

observed in countries without specific regulations.

IMPORTANT

Failure to follow the installation instructions and the notes contained

therein will lead to all liability being refused by Webasto. The same

applies if repairs are carried out incorrectly or with the use of parts other

than genuine spare parts. This will result in the invalidation of the type

approval for the heater and therefore of its homologation / EC type

licence.

(Extract from Directive 2001/56/EC Annex VII)

1.7.1. A clearly visible tell-tale in the operator's field of view shall inform

when the combustion heater is switched on or off.

2. Vehicle installation requirements

2.1. Scope

2.1.1.Subject to paragraph 2.1.2, combustion heaters shall be installed

according to the requirements of this Annex.

2.1.2.Vehicles of category O (trailers) having liquid fuel heaters are

deemed to comply with the requirements of this Annex.

2.2. Positioning of heater

2.2.1. Body sections and any other components in the vicinity of the

heater must be protected from excessive heat and the possibility of fuel

or oil contamination.

2.2.2. The combustion heater shall not constitute a risk of fire, even in

thecase of overheating. Thisrequirement shall be deemed tobe fulfilled

if the installation ensures an adequate distance to all parts and suitable

ventilation, by the use of fire resistant materials or by the use of heat

shields.

2.2.3. In the case of M2 and M3 vehicles, the heater must not be

positionedinthepassengercompartment.However,aninstallationinan

effectively sealed envelope which also complies with the conditions in

paragraph 2.2.2 may be used.

2.2.4.The label referred to in paragraph 1.4 (modelplate), or a duplicate

(duplicate model plate), must be positioned so that it can be easily read

when the heater is installed in the vehicle.

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Statutory regulations governing installation Thermo 90 S / Thermo 90 ST

2.2.5 Every reasonable precaution should be taken in positioning the

heater to minimise the risk of injury and damage to personal property.

2.3. Fuel supply

2.3.1. The fuel filler must not be situated in the passenger compartment

and must be provided with an effective cap to prevent fuel spillage.

2.3.2. In the case of liquid fuel heaters, where a supply separate to that

of the vehicle is provided, the type of fuel and its filler point must be

clearly labelled.

2.3.3. A notice, indicating that the heater must be shut down before

refuelling, must be affixed to the fuelling point. In addition a suitable

instruction must be included in the manufacturer's operating manual.

2.4. Exhaust system

2.4.1. The exhaust outlet must be located so as to prevent emissions

fromenteringthevehiclethroughventilators,heatedairinletsoropening

windows.

2.5. Combustion air inlet

2.5.1. The air for the combustion chamber of the heater must not be

drawn from the passenger compartment of the vehicle.

2.5.2. The air inlet must be so positioned or guarded that blocking by

rubbish or luggage is unlikely.

2.6. Heating air inlet

2.6.1. The heating air supply may be fresh or recirculated air and must

be drawn from a clean area not likely to be contaminated by exhaust

fumes emitted either by the propulsion engine, the combustion heater or

any other vehicle source.

2.6.2. The inlet duct must be protected by mesh or other suitable means.

2.7. Heating air outlet

2.7.1. Any ducting used to route the hot air through the vehicle must be

so positioned or protected that no injury or damage could be caused if it

were to be touched.

2.7.2. The air outlet must be so positioned or guarded that blocking by

rubbish or luggage is unlikely.

2.8. Automatic control of the heating system

The heating system must be switched off automatically and the supply

of fuel must be stopped within five seconds when the vehicle's engine

stops running.

If a manual device is already activated, the heating system can stay in

operation.

NOTE:

Contrary to point 2.2.3 the heater must also not be installed in the

passenger cabin of class M1 and N vehicles. However, an installation in

an effectively sealed envelope which also complies with the conditions

in paragraph 2.2.2 may be used.

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Thermo 90 S / Thermo 90 ST Statutory regulations governing installation

(Extract from Directive 2001/56/EC Annex IX)

3. Technical specifications for heater units for installation in

dangerous goods transporters (Annex 9)

3.1. General (EX/II, EX/III, AT, FL and OX vehicles)

3.1.1. The combustion heaters and their exhaust gas routing shall be

designed, located, protected or covered so as to prevent any

unacceptable risk of heating or ignition of the load. This requirement

shall be considered as fulfilled if the fuel tank and the exhaust system of

the appliance conform to the provisions set out in the points 3.1.1.1 and

3.1.1.2. Compliance with those provisions shall be verified on the

completed vehicle.

3.1.1.1. Any fuel tanks for supplying the appliance shall meet the

following requirements:

a)in the event of any leakage, the fuel shall drain to the ground

without coming into contact with hot parts of the vehicle or the

load;

b)fuel tanks containing petrol shall be equipped with an

effective flame trap at the filler opening or with a closure

enabling the opening to be kept hermetically sealed.

3.1.1.2. The exhaust system as well as the exhaust pipes shall be so

directed or protected to avoid any danger to the load through heating or

ignition. Parts of the exhaust system situated directly below the fuel tank

(diesel) shall have a clearance of at least 100 mm or be protected by a

thermal shield.

3.1.2. The combustion heater shall be switched on manually.

Programming devices shall be prohibited.

3.2. EX/II and EX/III vehicles

Combustion heaters using gaseous fuels are not permitted.

3.3. FL vehicles

3.3.1. The combustion heaters shall be put out of operation by at least

the following methods:

a)intentional manual switching off from the driver’s cab;

b)stopping of thevehicle engine; in this case the heating device

may be restarted manually by the driver;

c) start-up of a feed pump on the motor vehicle for the

dangerous goods carried.

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Use / version Thermo 90 S / Thermo 90 ST

2 Use / version

2.1. Use of the water heaters

The Webasto water heater is used in connection with the vehicle's own

heating system

– to heat the cab,

– to defrost the vehicle windows and

– to preheat water-cooled engines.

The water heater operates independently of the engine and is

connected to the cooling system, the fuel system and the electrical

system of the vehicle.

The Thermo 90 S and Thermo 90 ST heaters differ from each other in

their component plug and in the fact that they have different control

modules.

2.2. Versions

2.2.1. Thermo 90 S version

Thermo 90 S petrol

Water heater for "petrol" fuel

Thermo 90 S diesel

Water heater for "diesel" fuel

The water heaters are designed for 12 V (Thermo 90 S petrol) and for

12 or 24 V (Thermo 90 S diesel).

2.2.2. Thermo 90 ST version

Thermo 90 ST petrol

Water heater for "petrol" fuel

Thermo 90 ST diesel

Water heater for "diesel" fuel

The water heaters are designed for 12 V (Thermo 90 ST petrol) and for

12 or 24 V (Thermo 90 ST diesel).

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Thermo 90 S / Thermo 90 ST Installation

3 Installation

IMPORTANT

– The water heater must be installed outside the passenger cabin.

– The requirements of the latest version of the ADR must also be

observed for the installing the heater into vehicles used to transport

hazardous substances.

NOTE:

If the vehicle manufacturer has issued instructions, they must be

followed.

3.1. Installation site / Installation position

The heater must be installed in as low a position as possible to allow the

heater and circulating pump to be bled automatically. This is particularly

important as the circulating pump is not self-priming.

3.2. To install the heater

The heater must be secured with at least three M8 screws. The screws

must be tightened with a torque of 18 Nm.

3.3. Model plate

The model plate must be positioned so that it cannot be damaged

and must be clearly legible when the heater is installed (otherwise a

duplicate model plate must be used).

Inapplicable years must be erased from the model plate.

Fig. 1: Permitted installation positions for the Thermo 90 S /

Thermo 90 ST

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Andere Handbücher für Thermo 90

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

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