Webasto Thermo 90 S-ADR Wartungshandbuch

Water heaters09/2005Workshop manualThermo 90 SThermo 90 S-ADR(Transport of hazardous goods)Thermo 90 STThermo 90 ST-ADR(Transport of hazardous goods)

Thermo 90 S / Thermo 90 ST 2 General description2032.3 Temperature sensorThe temperature sensor records the coolant temperature at the coolant outlet

2 General description Thermo 90 S / Thermo 90 ST204Page for notes

Thermo 90 S / Thermo 90 ST 3 Function description3013 Function description(Fig. 301)3.1 Switching onThe “operating indicator” on the digital timer lig

3 Function description Thermo 90 S / Thermo 90 ST302Fig. 301 Sequence of functions3.4 Switching offThe operating indicator on the digital timer/swit

Thermo 90 S / Thermo 90 ST 3 Function description303 A Glow plug B Metering pump C Combustion air fan D Flame monitor E Operation indicator light F Ci

3 Function description Thermo 90 S / Thermo 90 ST3043.6.2 Diagnosis after fault lock-outThermo 90 S and Thermo 90 STCheck the fuses and plug connector

Thermo 90 S / Thermo 90 ST 3 Function description305Page for notes

Thermo 90 S / Thermo 90 ST 4 Technical data4014 Technical dataExcept where limit values are specified, the technical data below refer to the usual hea

4 Technical data Thermo 90 S / Thermo 90 ST402Page for notes

Thermo 90 S / Thermo 90 ST 5 Troubleshooting5015 Troubleshooting5.1 GeneralThis section describes how to identify and remedy faults on the Thermo 90 S

Thermo 90 S / Thermo 90 ST Table of contentsITable of contents1 Introduction1.1 Contents and purpose ...

5 Troubleshooting Thermo 90 S / Thermo 90 ST5025.3 Fault indications on fault lock-outNOTEIf the system is operated with a switch, the nature of the f

Thermo 90 S / Thermo 90 ST 5 Troubleshooting503Fig. 502 Fault indications on fault lock-out (page 2 of 2)5.4 Visual check for assessingthe burnerThe

5 Troubleshooting Thermo 90 S / Thermo 90 ST5045.4.2 Back wall with metal evaporator• The pilot flame outlet opening (Fig. 504) must be clear otherwis

Thermo 90 S / Thermo 90 ST 6 Function tests6016 Function tests6.1 GeneralThis section describes the tests conducted on the heater and its settings whe

6 Function tests Thermo 90 S / Thermo 90 ST602Page for notes

Thermo 90 S / Thermo 90 ST 7 Circuit diagrams7017 Circuit diagrams7.1 GeneralThe circuit diagrams (Figs. 701 to 704) show the possible circuits for th

7 Circuit diagrams Thermo 90 S / Thermo 90 ST702Fig. 701 System circuit for Thermo 90 S, 12 and 24 V, with standard clock28111011274H3P2H1H6308586 8

Thermo 90 S / Thermo 90 ST 7 Circuit diagrams703Fig. 702 System circuit for Thermo 90 S, 12 and 24 V, with standard clock and separate circulating p

7 Circuit diagrams Thermo 90 S / Thermo 90 ST704Fig. 703 System circuit for Thermo 90 S-ADR, 24 V, with switchTemperature coding (temperature at wat

Thermo 90 S / Thermo 90 ST 7 Circuit diagrams705Fig. 704 System circuit for Thermo 90 S-ADR, 24 V, with switch without power take-offTemperature cod

Table of contents Thermo 90 S / Thermo 90 STII6 Function tests6.1 General ...

7 Circuit diagrams Thermo 90 S / Thermo 90 ST706Fig. 705 System circuit for Thermo 90 ST, 12 and 24 V, with standard clockϑϑTemperature coding (temp

Thermo 90 S / Thermo 90 ST 7 Circuit diagrams707Fig. 706 System circuit for Thermo 90 ST, 12 and 24 V, with standard clock and separate circulating

7 Circuit diagrams Thermo 90 S / Thermo 90 ST708Fig. 707 System circuit for Thermo 90 ST-ADR, 24 V, with switchϑϑTemperature coding (temperature at

Thermo 90 S / Thermo 90 ST 7 Circuit diagrams709Fig. 708 System circuit for Thermo 90 ST-ADR, 24 V, with switch without power take-offTemperature co

7 Circuit diagrams Thermo 90 S / Thermo 90 ST710Page for notes

Thermo 90 S / Thermo 90 ST 8 Service work8018 Service work8.1 GeneralThis section describes the service work that can be carried out on the heater whe

8 Service work Thermo 90 S / Thermo 90 ST8028.4 Heater trial runThe heater must not be operated in enclosed areas such as garages and workshops withou

Thermo 90 S / Thermo 90 ST 8 Service work803Fig. 801 Specimen installations for heater in a truckNOTEThe Thermo 90 S and Thermo 90 ST heater is supp

8 Service work Thermo 90 S / Thermo 90 ST8048.6 Visual inspections and installation instructions8.6.1 Connection to the vehicle cooling systemIn therm

Thermo 90 S / Thermo 90 ST 8 Service work8058.6.2.1 Fuel extractionVehicles with diesel enginesThe fuel must be taken from the vehicle fuel tank or fr

Thermo 90 S / Thermo 90 ST Table of contentsIII9Repair9.1 General...

8 Service work Thermo 90 S / Thermo 90 ST806The fuel extractor should not be located near the engine, as gas bubbles may form in the lines on account

Thermo 90 S / Thermo 90 ST 8 Service work8078.6.3 Metering pump with damperThe metering pump is a combined delivery, metering and shut-off system and

8 Service work Thermo 90 S / Thermo 90 ST8088.6.6 Exhaust lineThe exhaust line (internal diameter 38 mm) can be installed with a length of 0.5 m to 5

Thermo 90 S / Thermo 90 ST 8 Service work8098.7.2 Changing the circulating pumpNOTEThe process for changing the circulating pump is the same irrespect

Thermo 90 S / Thermo 90 ST 9Repair9019 Repair9.1 GeneralThis section describes the repair work which is permitted on the heater when it has been remov

9Repair Thermo 90 S / Thermo 90 ST9029.2 Dismantling and assembling9.2.1 Electrical connections (Thermo 90 S)9.2.1.1 Disconnecting the electrical conn

Thermo 90 S / Thermo 90 ST 9Repair9039.2.2 Changing the circulating pump9.2.2.1 Removal1. Remove the heater (see 8.7.1.1).2. Disconnect the electrica

9Repair Thermo 90 S / Thermo 90 ST9049.2.3 Changing the temperature limiter9.2.3.1 RemovalNOTEThe temperature limiter only has to be removed if it is

Thermo 90 S / Thermo 90 ST 9Repair905Fig. 903 Changing the temperature limiter and temperature sensor6512341 Protective cap2 Clip3 Temperature limit

9Repair Thermo 90 S / Thermo 90 ST9069.2.5 Changing the combustion air fan9.2.5.1 Removal1. Remove the heater (see 8.7.1.1).2. Disconnect the electric

List of illustrations Thermo 90 S / Thermo 90 STIVList of illustrations301 Sequence of functions ...

Thermo 90 S / Thermo 90 ST 9Repair9079.2.6 Changing the burner, flame monitor and glow plug9.2.6.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove

9Repair Thermo 90 S / Thermo 90 ST908Fig. 905 Changing the burner, flame monitor and glow plug 1 Burner 2 Swirl orifice 3 Burner head 4 Washer

Thermo 90 S / Thermo 90 ST 9Repair9099.2.7 Changing the burner head9.2.7.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the combustion air fan

9Repair Thermo 90 S / Thermo 90 ST9109.2.8 Changing the heat exchanger9.2.8.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the circulating pump

Thermo 90 S / Thermo 90 ST 10 Packing / Storage / Shipment100110 Packing / Storage and Shipment10.1 GeneralIf the heater or its components are sent to

10 Packing / Storage / Shipment Thermo 90 S / Thermo 90 ST1002Page for notes

Thermo 90 S / Thermo 90 ST 1Introduction1011Introduction1.1 Contents and purposeThis workshop manual is designed to assist trained personnel with repa

1Introduction Thermo 90 S / Thermo 90 ST1021.5 Statutory regulations governing installationRefer to the installation instructions for the statutory re

Thermo 90 S / Thermo 90 ST 2 General description2012 General descriptionThermo 90 S and Thermo 90 ST water heaters operate in conjunction with the veh

2 General description Thermo 90 S / Thermo 90 ST202Thermo 90 ST heater2.1 Combustion air fanThe combustion air fan supplies the air required for the c