Webasto Thermo Pro 90 D Installation Manual Download Page 30

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Webasto Thermo & Comfort N.A., Inc.

Thermo Pro 90

Circuit Diagrams

12.1 Thermo Pro 90 Circuit Diagram Legend

Item Designation

Comment

Heater

Control module

Exhaust Temperature sensor

Coolant temperature sensor

Temperature limiter/ overheat sensor

Battery

Vehicle battery

Operation indicator light

Vehicle blower circuit

Terminal needs to be added to X14
Webasto P/N: 901204 Deutsch P/N:0462-209-16141

Glow plug

Fuse 5 A

ATM mini flat fuse

Fuse 20 A

ATM mini flat fuse

Fuse 30 A

ATO flat fuse

“Heating” symbol in the display

Operating indicator (in item P2)

Symbol light

Light (in item P2)

Motor

Combustion air fan

Motor

Circulating pump

SmarTemp fx

For programmed operation

Digital timer 1531

For programmed operation

Toggle switch

ON/OFF

4-pin plug connector

To item M1 (Combustion air fan motor)

Plug connector, 2-pin

To item E (igniter)

Plug connector, 2-pin

To connector X11 (Fuel pump)

Plug connector, 2-pin

To connector X12 (Circulating pump)

Plug connector, 2-pin

To item B2 (Coolant temperature sensor)

Plug connector, 2-pin

To item B1 (Exhaust temperature sensor)

Plug connector, 2-pin

To item B3 (Temperature limiter)

12-pin plug connection

To item A1 (Control unit)

X10

Plug connector, 2-pin

Diagnostics

X11

Plug connector, 2-pin

To item Y1 (Fuel pump)

X12

Plug connector, 2-pin

To item M2 (Circulating pump)

X13

Plug connector, 9-pin

To item X14

X14

Plug connector, 9-pin

To item S1 or P1

X15

Plug connector, 4-pin

To item X16

X16

Plug connector, 4-pin

To item P1

Metering pump

Fuel pump for heater

Summary of Contents for Thermo Pro 90 D

Page 1: ...ation 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 heating and cooling systems require qualified and or professional installation and repair technicians Warranty shall be void if not installed by a certified or trained installer repair techni...

Page 2: ...n Examples 10 6 Mounting the Heater to the Vehicle 11 6 1 Allowable Mounting Positions 11 7 Connection to the Vehicle Cooling System 14 7 1 General Information 14 7 2 Various Plumbing Configurations 15 8 Fuel Supply 18 8 1 General Information 18 8 2 Fuel Standpipe Installation 19 8 3 Fuel Lines 21 8 4 Fuel Metering Pump 21 8 5 Fuel Filter 22 9 Combustion Air Supply 23 10 Exhaust System 24 11 Elect...

Page 3: ...o Comfort N A Inc 14 2 Heater Interlock 37 14 2 1 Interlock Reset Procedure 37 14 3 Diagnostic after a Fault Lock out for the Thermo Pro 90 37 15 Technical Data 39 15 1 Electrical Components 39 15 2 Fuel for Thermo Pro 90 Diesel 39 15 3 Thermo Pro 90 Dimensions 40 ...

Page 4: ...These symbols are used to alert the installer to important or useful information about proper installation of the equipment 1 2 General Information Webasto Product North America Inc is pleased to provide this installation manual with the Thermo Pro 90 Heater When used according to the guidelines stated in this manual you can expect to provide years of trouble free enjoyable operation for your cust...

Page 5: ...ing the heater all reasonable precautions must be taken to minimize the risk of personal injury or damage to items in the vehicle 2 2 6 A clearly visible indicator within the user s field of vision must show when the heater is switched on or off 2 3 Fuel Supply 2 3 1 The fuel filler neck must not be located in the passenger compartment and must have a tightly fitting cap to prevent any fuel leaks ...

Page 6: ...w of water through the hoses 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 Webasto service parts This will result in the invalidation of the type approval for the heater and therefore of its homologation ...

Page 7: ...d engines to heat boats and motor homes recreational vehicles 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 Pro 90 heaters differ from each other in their component connection arrangement and in the fact that they have different control units 3 2 Versions 3 2 1 Thermo Pro 90 version T...

Page 8: ...itted in order to prevent damage to the Teflon insulation of the cable Do not pull on the cable after the exhaust temperature sensor is installed Should a sensor be dropped during maintenance work then a new sensor must be installed The proper condition of the mica disc insulation on the sensor the force free seating of the cable clips of the exhaust temperature sensor and the loose routing of the...

Page 9: ...Webasto Thermo Comfort N A Inc 10 www techwebasto com Installation Location Examples Thermo Pro 90 5 Installation Location Examples Figure 1 Installation locations ...

Page 10: ...Position 3 is not permissible Figure 3 Permitted installation positions for the Thermo Pro 90 heaters Figure 4 Thermo Pro 90 heater Inlets Outlets Dimensions Coolant Direction Fuel Connection 1 2 3 1 Fuel inlet 2 Heat exchanger outlet 3 Heat exchanger inlet 4 Exhaust outlet 5 Combustion air inlet A Height 232mm 9 13 B Width 140mm 5 5 L Length 355mm 14 L Length from control unit to inlet connection...

Page 11: ...s 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 via back wall Vertical or horizontal mounting CAUTION 80mm 3 5 32 70mm 2 3 4 310mm 12 13 64 80mm 3 5 32 70mm 2 3 4 150mm 5 29 32 23mm 29 32 50mm 1 31 32 ...

Page 12: ...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 ...

Page 13: ...inutes monthly during the off season Ensure any shut off valves are open before operating the coolant heater Use 1 2 or larger NPT pipe fittings for hose connections at engine Use good quality heavy duty 3 4 ID coolant hose for the coolant heater circuit Hoses must be installed without kinks and bends which may restrict coolant flow To ensure proper bleeding of air keep hoses rising if possible Av...

Page 14: ...ost heat configuration Figures 10 through 13 illustrate configurations for bunk heat and engine preheat boost heat Figure 14 illustrates a system for vehicles with continuous fan operation or high amperage heat exchanger fan designs In this case the addition of a low amperage draw auxiliary heat exchanger system is recommended Figure 9 System configured for engine pre heating and boost heating Fig...

Page 15: ...event the valve is closed during heater operation 1 2 2 3 4 5 6 7 1 Coolant supply connection 2 Vehicle heat exchangers 3 Coolant pump 4 Thermo Pro 90 heater 5 Coolant return connection 6 Engine coolant pump 7 Thermostat 1 2 2 3 4 5 6 7 1 Coolant supply connection 2 Vehicle heat exchangers 3 Coolant pump 4 Thermo Pro 90 heater 5 Coolant return connection 6 Engine coolant pump 7 Thermostat 4 way ba...

Page 16: ...nal 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 connection 2 Vehicle heat exchangers 3 Coolant pump 4 Thermo Pro 90 heater 5 Coolant return connection 6 Engine coolant pump 7 Thermostat 8 Automated control valve 9 Wye connectors 10 N A 11 Auxiliary heat exchanger ...

Page 17: ...arning that the heater must be switched off before refuelling Figure 15 Fuel system components Figure 16 Fuel system parameters Intake Side Pressure Side D1 Inside diameter of fuel line 2 mm D2 Inside diameter of fuel line 2 mm H1 Dimension for fuel tank over metering pump m H2 Dimension for heater over metering pump m S1 Dimension for fuel tank under metering pump m S2 Dimension for heater under ...

Page 18: ...arp burrs and smooth edges with emery cloth 3 determine length of standpipe when installed End should sit at least 25mm 1 above tank bottom Cut off excess standpipe at a 45 degree angle Remove burrs 4 loosely assemble items C D E and F Figure 17 5 place sealing compound on threads of item B and thread into item F Tighten item B completely 6 slide standpipe into hole at angle Slip one shoulder of i...

Page 19: ...ole See Figure 19 Figure 19 Standpipe installation illustration 2 8 center standpipe in tank hole See Figure 20 Figure 20 Standpipe installation illustration 3 9 pull up on standpipe and tighten in place with the clamping nut item A in Figure 21 Do not over tighten causing rubber washer to squeeze out Figure 21 Standpipe installation illustration 3 A Fuel Tank ...

Page 20: ...t be damaged by flying road debris and high temperatures i e close to the exhaust line The fuel lines must be secure at the connections using hose clips to prevent their slipping IMPORTANT Cut lines without burr and do not crush them Do not cut fuel line with side cutting pliers 8 3 1 Connecting two fuel lines with a coupler hose The correct procedure for connecting fuel lines with hosing is shown...

Page 21: ...isk of corrosion only genuine Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness 8 5 Fuel Filter Only a Webasto filter is allowed to be used if the fuel is expected to be contaminated Install vertically if possible however at least horizontally check flow direction IMPORTANT Do not substitute the Webasto supplied fuel filter with a non...

Page 22: ...lling 360 The minimum bending radius is 45 mm 1 75 inches The combustion air intake must not be routed in the vicinity of the exhaust discharge IMPORTANT A minimum of 0 5m of the combustion air tube must be installed on every application IMPORTANT If the combustion air intake tube cannot be installed so that it slopes downwards a water drain hole with a diameter of 4 mm 5 32 is to be made at its l...

Page 23: ...located so that it cannot become clogged with snow and mud Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1 0 mm or flexible piping of alloyed steel only must be used as exhaust tube The exhaust pipe is secured to the muffler using an approved muffler clamp See Figure 27 for details See the regulations section 2 for other requirements Figure 26 Exhaust muffler installat...

Page 24: ...hat 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 point to allow condensate to drain 10 10 The exhaust pipe must be securely attached no further than 150 mm 6 in from the end of the exhaust pipe to ensure that the angle of 90 10 vertical down is maintained Discharge direction almost vertical 90 10 ...

Page 25: ...lied with the power control harness Figure 28 Power and control harness assembly A Route item 1 into the vehicle cab in the area where the switch or timer is to be installed B Route item 4 to vehicle battery box and connect to batteries as shown in Figure 28 Brown wire to ground red wire with fuse holder to positive Ensure battery connections are clean and protected with an anti corrosive compound...

Page 26: ...29 Toggle switch 11 2 2 Control Element SmarTemp Timer Connection Figure 30 7 Day 4 Program SmarTemp Control fx Timer All the cables and wires that are not required must be insulated against accidental shorting or grounding 1 2 3 4 Heater Control Harness Connection Using a 24 Volt Switch 1 White Ground 2 Red Power 3 Black On signal 4 Green Operation indication Heater Control Harness Connection Usi...

Page 27: ...sure to push harness through the hole before installing terminals into connector housing Secure the SmarTemp Control using the two supplied 4 screws Apply the supplied Heater Off warning sticker in a highly visible location to the drivers area Observe the installation operating manual supplied for proper menu setup NOTES Always make sure there are no obstacles behind the mounting location prior to...

Page 28: ...1 4 Setting Control Temperatures of Thermo Pro 90 When the ignition signal is connected to the control unit connector X8 contact 7 different control thresholds are effective If the terminal D signal is not applied the temperatures are the same as those at Engine off Nominal Temperature on Sensor Regulation Temperature Switch on Again After Regulation Temperature Engine ON 65 C 149 F 75 C 167 F 60 ...

Page 29: ...Webasto Thermo Comfort N A Inc 30 www techwebasto com Circuit Diagrams Thermo Pro 90 12 Circuit Diagrams Cable Cross Sections Cable Colors Legend ...

Page 30: ...g pump P1 SmarTemp fx For programmed operation P2 Digital timer 1531 For programmed operation S1 Toggle switch ON OFF X1 4 pin plug connector To item M1 Combustion air fan motor X2 Plug connector 2 pin To item E igniter X3 Plug connector 2 pin To connector X11 Fuel pump X4 Plug connector 2 pin To connector X12 Circulating pump X5 Plug connector 2 pin To item B2 Coolant temperature sensor X6 Plug c...

Page 31: ...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 ...

Page 32: ...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 ...

Page 33: ...ation manual 5 Is the heater installed in a protected location from road debris and splash water or items stored in the same area 6 Is there a sufficient amount clearance between the heater and the ground Coolant heaters only COOLANT SYSTEM Complete Yes No Comments 1 Is there a safe clearance min 4 in from heat generating components exhaust etc 2 Is there a safe clearance from sharp edges objects ...

Page 34: ...rly mounted in the fuel tank sealed structural integrity maintained 2 Validate the standpipe does not interfere with function of sending unit by checking fuel gauge for proper operation before completing installation of tank 3 Verify that all fuel lines are properly secured and are a safe distance min 4 in from exhaust systems and or moving components 4 Check all fuel lines for leaks or kinks 5 Ch...

Page 35: ...rection of travel 2 Ensure air intake system is securely fastened HEATER FUNCTION Complete Yes No Comments 1 Ensure heater starts and runs for a minimum of 20 minutes 2 Ensure vehicle blower turns ON 3 Ensure warm air is blown out of interior vents after blower is activated 4 Ensure timer control device is functioning 5 Check and Modify CO2 setting as needed based on altitude will the heater live ...

Page 36: ...itch back ON The heater will need to be switched OFF and back ON to re start after a fault 14 2 1 Heater Lock out Reset Procedure Heater Lock out Reset Procedure 1 Using switch or standard timer control turn heater on 2 Remove the main power connection to heater from battery or pull fuse for a minimum of 20 seconds 3 Using switch or standard timer control turn the heater off 4 Reinstall main heate...

Page 37: ...or defective 14 3 2 Version with timer If the system is equipped with a digital timer a fault message appears on the display of the timer after a fault occurs F 01 No start after 2 attempts to start F 02 Flame failure F 03 Under voltage or over voltage F 04 Premature flame recognition F 05 N A F 06 Coolant temperature sensor interrupt or temperature sensor short circuit F 07 Metering pump interrup...

Page 38: ... PME bio diesel which complies with DIN EN 14214 Table 1 Technical Data Heater Operation Thermo Pro 90 Approval symbol E1 122R 00 0320 Heater E1 10R 03 6196 EMC Model Water heater with evaporative type burner Heat output Max regulating range 9 1 kW 31 000 BTU 1 8 kW 7 6 kW 6 000 BTU hr 26 000 BTU hr Fuel Diesel PME Bio diesel Fuel consumption Max regulating range 1 1 l h 29 Gal hr 0 21 0 92 l h 0 ...

Page 39: ...rmo 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 9 13 B 140mm 5 5 ...

Page 40: ...www webasto us 41 Webasto Thermo Comfort N A Inc Thermo Pro 90 Technical Data NOTES ...

Page 41: ...Webasto Thermo Comfort N A Inc 42 www techwebasto com Technical Data Thermo Pro 90 ...

Page 42: ...www webasto us 43 Webasto Thermo Comfort N A Inc Thermo Pro 90 Technical Data ...

Page 43: ...Webasto Thermo Comfort N A Inc 44 www techwebasto com Technical Data Thermo Pro 90 ...

Page 44: ...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 ...

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