Webasto Thermo Pro 50 Eco User manual

Wasserheizgerät
Water heater
Appareil de chauffage à eau
Einbauanweisung
Installation Instructions
Notice de montage
Thermo Pro 50 Eco
Thermo Pro 50 Eco 24 V Diesel - ADR
(Gefahrguttransport)
(Transport of dangerous goods)
(Transport des marchandises
dangereuses)
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Thermo Pro 50 Eco
2
12
26 2527
24
23
3
928
29
4
30
23
24
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Thermo Pro 50 Eco
3
5
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Thermo Pro 50 Eco
4
4
5
°
9
0
°
6
0
°
8
5
°
U4847 Econ
UP500
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Thermo Pro 50 Eco
5
39
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Thermo Pro 50 Eco
6
0-45°
Factory label duplicate
valid only with the original
12
4
5
8
7
9
10
3
6
X11 F1, F2, F3
K5
FZG
X4
X1
X2
X7
X10, X20
-
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Thermo Pro 50 Eco
7
20
9032657A03
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Thermo Pro 50 Eco
8
21
9032357A04
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Thermo Pro 50 Eco
9
22
9037063A01
58
15
D+/61
30
F4 F1 F2 F3
gr
sw/gr
rt
rt
sw
sw
br
br
br/gn
rt/bl
br br
31
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X10
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ge/rt
sw/rt
gr
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gn/ws
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bl
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rt
br
B4
X2
V3
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X6X5X4X3
A1
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ws
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br
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UEHS WTSUPGS ATSBM
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87a 87 86
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0123
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X5
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7
4
6
9
10
1
8
2
1
5
321421 212121 3
21
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Thermo Pro 50 Eco
10
23
9033212A02
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Thermo Pro 50 Eco
11
24
9032659A03
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Thermo Pro 50 Eco
12
25
9032644A03
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Thermo Pro 50 Eco
14
Improper installation or repair of Webasto heating and cooling systems 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 appropriate technical documentation, special tools and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
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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Thermo Pro 50 Eco
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Inhaltsverzeichnis
1 Bestimmungen für den Einbau .......................................... 20
1.1 Gesetzliche Bestimmungen für den Einbau....................................................20
1.2 Applikation von Verbrennungsheizgeräten in Fahrzeuge zur Beförderung
gefährlicher Güter.........................................................................................20
1.3 Zusätzlich zu verwendende Dokumentation ..................................................20
2 Verwendung / Ausführung ................................................ 20
2.1 Verwendung der Wasserheizgeräte...............................................................20
2.2 Ausführung .................................................................................................21
3 Einbau ............................................................................... 21
3.1 Einbauort / Einbaulage .................................................................................21
3.2 Einbau des Heizgeräts ..................................................................................21
3.3 Standardhalter..............................................................................................22
4 Typschild ........................................................................... 22
5 Einbaubeispiel ................................................................... 22
6 Integration in das Kühlmittelsystem.................................. 23
6.1 Anschluss .....................................................................................................23
6.2 Montage Kühlmittelstutzen...........................................................................23
6.3 Montage der Kühlmittelpumpe.....................................................................23
6.4 Überprüfung ................................................................................................23
7 Kraftstontegration ......................................................... 24
7.1 Allgemein.....................................................................................................24
7.2 Integration in Fahrzeugtank ..........................................................................24
7.3 Kraftstoeitung ...........................................................................................24
7.4 Kraftstoffpumpe ..........................................................................................25
7.5 Aufkleber .....................................................................................................25
7.6 Kältebeständige Kraftstoffe ..........................................................................25
8 Brennluftversorgung ......................................................... 26
8.1 Brennluftansaugschalldämpfer......................................................................26
8.2 Hinweise zum Einbau....................................................................................26
9 Abgasanlage ..................................................................... 27
9.1 Abgasleitung ................................................................................................27
9.2 Abgasschalldämpfer .....................................................................................27
9.3 Hinweise zum Einbau....................................................................................27
10 Elektrische Anschlüsse ...................................................... 28
10.1 Anschluss Steuergerät/Heizgerät ..................................................................28
10.2 Anschluss bei Einbau Thermo Pro 50 Eco-ADR in ein Fahrzeug zum Transport
gefährlicher Güter (ADR)...............................................................................28
10.3 Einbau und Anschluss der Bedienelemente ...................................................28
10.4 Fahrzeuggebläse...........................................................................................28
10.5 Einstellung der Regeltemperaturen des Heizgeräts.........................................28
11 Schaltpläne ....................................................................... 29
11.1 Leitungsquerschnitte.....................................................................................29
11.2 Leitungsfarben..............................................................................................29
11.3 Legende Schaltpläne.....................................................................................29
11.4 Legende zu Bemerkungen.............................................................................30
11.5 Legende zu Stecker X1, 10-polig...................................................................31
11.6 Legende zu Stecker X31, 10-polig.................................................................31
11.7 Erstinbetriebnahme MultiControl / SmartControl / UniControl .......................31
12 Erstinbetriebnahme........................................................... 32
13 Störungen ........................................................................ 32
14 Technische Daten .............................................................. 33
14.1 Elektrische Bauteile .......................................................................................33
14.2 Kraftstoff......................................................................................................33
14.3 Technische Daten Kühlmittelpumpe ..............................................................33
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Table of Contents
1 Regulations governing installation .................................... 36
1.1 Statutory regulations governing installation...................................................36
1.2 Application of combustion heaters in vehicles for the transportation of dange-
rous goods. ..................................................................................................36
1.3 Additional documentation to be used...........................................................36
2 Use / variants .................................................................... 36
2.1 Use of the water heater................................................................................36
2.2 Variants .......................................................................................................37
3 Installation ........................................................................ 37
3.1 Installation location/installation position .......................................................37
3.2 Installing the heater .....................................................................................37
3.3 Standard bracket ..........................................................................................38
4 Type label.......................................................................... 38
5 Installation example.......................................................... 38
6 Integration in the coolant system...................................... 39
6.1 Connection...................................................................................................39
6.2 Installing the coolant connection piece .........................................................39
6.3 Installing the coolant pump ..........................................................................39
6.4 Inspection ....................................................................................................39
7 Fuel integration................................................................. 40
7.1 General .......................................................................................................40
7.2 Integration in vehicle tank.............................................................................40
7.3 Fuel line........................................................................................................40
7.4 Fuel pump ....................................................................................................41
7.5 Labels...........................................................................................................41
7.6 Cold-resistant fuels ......................................................................................41
8 Combustion air supply....................................................... 42
8.1 Combustion air intake silencer ......................................................................42
8.2 Notes on installation.....................................................................................42
9 Exhaust system ................................................................. 43
9.1 Exhaust pipe.................................................................................................43
9.2 Exhaust silencer ............................................................................................43
9.3 Notes on installation.....................................................................................43
10 Electrical Connections ...................................................... 44
10.1 Connecting control unit/heater ....................................................................44
10.2 Connection when installing Thermo Pro 50 Eco-ADR in a vehicle for transpor-
ting dangerous goods (ADR).........................................................................44
10.3 Installing and connecting the control elements ............................................44
10.4 Vehicle blower..............................................................................................44
10.5 Setting the control temperatures for the heater ............................................44
11 Wiring diagrams................................................................ 45
11.1 Cable cross-sections......................................................................................45
11.2 Cable colours................................................................................................45
11.3 Legend to wiring diagrams ...........................................................................45
11.4 Legend for comments...................................................................................46
11.5 Legend for X1 connector, 10-pin ..................................................................47
11.6 Legend for X31 connector, 10-pin ................................................................47
11.7 MultiControl / SmartControl / UniControl initial start-up ................................47
12 Initial start-up ................................................................... 48
13 Malfunctions .................................................................... 48
14 Technical data .................................................................. 49
14.1 Electrical components...................................................................................49
14.2 Fuel ..............................................................................................................49
14.3 Technical data for coolant pump...................................................................49
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Index
1 Dispositions concernant le montage ................................. 52
1.1 Dispositions légales concernant le montage ..................................................52
1.2 Application concernant des appareils de chauffage à combustion dans des
véhicules destinés au transport de marchandises dangereuses par route........52
1.3 Autre documentation à utiliser .....................................................................52
2 Utilisation/version ............................................................. 52
2.1 Utilisation des appareils de chauffage à eau..................................................52
2.2 Version .........................................................................................................53
3 Montage ........................................................................... 53
3.1 Emplacement/position de montage...............................................................53
3.2 Montage de l’appareil de chauffage ............................................................54
3.3 Support standard..........................................................................................54
4 Plaque signalétique ........................................................... 54
5 Exemple de montage ........................................................ 54
6 Intégration dans le système de liquide de refroidissement 56
6.1 Raccordement ..............................................................................................56
6.2 Montage des tubulures du liquide de refroidissement....................................56
6.3 Montage de la pompe de liquide de refroidissement.....................................56
6.4 Contrôle .......................................................................................................57
7 Intégration du carburant ................................................... 58
7.1 Généralités ..................................................................................................58
7.2 Intégration dans le réservoir du véhicule .......................................................58
7.3 Conduite de carburant..................................................................................59
7.4 Pompe à combustible ...................................................................................60
7.5 Autocollant...................................................................................................60
7.6 Carburants résistant au froid .........................................................................60
8 Alimentation en combustible ............................................ 61
8.1 Silencieux d’aspiration d’air de combustion...................................................61
8.2 Remarques concernant le montage...............................................................61
9 Système d’échappement ................................................... 62
9.1 Tuyau d’échappement ..................................................................................62
9.2 Silencieux .....................................................................................................62
9.3 Remarques concernant le montage...............................................................62
10 Branchements électriques ................................................. 63
10.1 Branchement du module de commande/appareil de chauffage.....................63
10.2 Branchement en cas de montage du Thermo Pro 50 Eco-ADR sur un véhicule
de transport de matières dangereuses (ADR) .................................................63
10.3 Montage et branchement des éléments de commande.................................63
10.4 Ventilateur du véhicule ................................................................................63
10.5 Paramétrage des températures de régulation de l’appareil de chauffage........64
11 Schémas électriques ......................................................... 64
11.1 Sections des câbles ......................................................................................64
11.2 Couleurs des câbles ......................................................................................64
11.3 Légende des schémas électriques..................................................................64
11.4 Légende relative aux remarques....................................................................66
11.5 Légende fiche X1, 10 pôles...........................................................................66
11.6 Légende fiche X31, 10 pôles.........................................................................66
11.7 Première mise en service MultiControl / SmartControl / UniControl................66
12 Première mise en service ................................................... 68
13 Pannes .............................................................................. 68
14 Caractéristiques techniques............................................... 69
14.1 Composants électriques................................................................................69
14.2 Carburant .....................................................................................................69
14.3 Caractéristiques techniques pompe de liquide de refroidissement..................69
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About This Document
To enable quick reference to the individual procedures you will find a descriptive symbol on the top outer edge of each page.
Sections presented in italics contain excerpts from the Regulation ECE-R 122.
Mechanical system Combustion air
Electrical system
Technical Information
Coolant circuit Attention
Fuel Note
Exhaust gas
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Thermo Pro 50 Eco
Technical Information
36
1 Regulations governing installation
1.1 Statutory regulations governing installation
The Thermo Pro 50 Eco heater has been type-tested and approved in accord-
ance with ECE-R10 (EMC) and ECE-R122 (heater).
For approval number see Section 14 Technical data (page 49).
The stipulations of these regulations are binding in the area
covered by EU Directive 70/156/EEC and/or 2007/46/EC (for new
vehicle models from 29/04/2009) and should also be observed in
countries where there are no specific regulations.
Failure to follow the installation instructions and the notes con-
tained 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.
1.2 Application of combustion heaters in vehicles for the transpor-
tation of dangerous goods.
Vehicles used for the purpose of transporting dangerous goods are type
approval tested in accordance with ECE-R 105. The following measures are
derived for our combustion heaters.
• The electrical cable/wiring harness must be suciently dimensioned to
prevent overheating. The electrical cable/wiring harness must be suf-
ficiently insulated. All electrical circuits must be protected by fuses or
automatic circuit breakers.
• The cables must be installed and firmly secured such that the wirings are
adequately protected against mechanical and thermal stress.
• The combustion heaters must be type-tested in accordance with ECE-R
122 and comply with Annex 9 - Additional regulations for vehicles used
for transporting dangerous goods.
• The combustion heaters and their exhaust gas piping system must be de-
signed, arranged, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load.
• In the event of any fuel line leakage, the fuel shall drain to the ground
without coming into contact with hot parts of the vehicle or the load.
• 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 shall have
a clearance of 100 mm or be protected by a thermal shield.
• It must only be possible to switch the combustion heater on manually.
Programming devices shall be prohibited. The combustion heater may be
switched back on manually after switching off the vehicle engine.
Requirements relating to the basic unit:
When switched off, it is permissible for combustion heaters to continue run-
ning for max. 40 seconds. Only combustion heaters are to be used with heat
exchangers that are not damaged during their standard operating period by
the reduced afterrunning time of 40seconds.
1.3 Additional documentation to be used
These installation instructions contain all the information and instructions
necessary to install a Thermo Pro 50 Eco heater.
The following must additionally be observed:
• The Operating Instructions for the heater,
• The Operating and Installation Instructions for the control element
Detailed technical information is provided in the service manual for the heater.
2 Use / variants
2.1 Use of the water heater
The water heater has been designed for installation in commercial vehicles.
If it is installed in special-purpose vehicles, the applicable regulations must be
taken into account. Alternative applications are possible in agreement with
Webasto.
2.1.1 Parking heating
In parking heating mode, the water heater works together with the vehicle's
heating system for
- cab and engine preheating,
- use of residual heat from the vehicle engine.
The water heater operates independently of the vehicle engine and is inte-
grated into the cooling system, the fuel system and the electrical system of the
vehicle.
2.1.2 Auxiliary heating
The water heater works during engine operation and provides thermal as-
sistance to the cooling system. The water heater is integrated into the cooling
system, the fuel system and the electrical system of the vehicle.
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Thermo Pro 50 Eco Technical Information
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When the engine is switched off, the water heater is automatically switched
off and fuel supply is interrupted within 25 seconds.
2.2 Variants
-Thermo Pro 50 Eco 24 V diesel - ADR
Water heater for "diesel" fuel. The water heater is designed for 24 volts.
For technical information see Chapter 14 Technical data (page 49).
3 Installation
- The water heater may only be installed outside the passenger
compartment.
- The requirements stipulated in the current version of the
ADR must be additionally observed when installing the cor-
responding heater in vehicles used to transport dangerous
goods.
Where there are specifications from the vehicle manufacturer,
these must be observed.
The water heater must not be installed:
- In the direct radiated heat range of exhaust systems
- Below the wading line of the vehicle
- Above the coolant expansion tank.
3.1 Installation location/installation position
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.
(Requirement from ECE-R 122, point 5.3.2.1.).
The heater shall not constitute a risk of fire, even in the case of overheating.
This requirement shall be deemed to be met if the installation ensures an ad-
equate distance to all parts and suitable ventilation, by the use of fire resistant
materials or by the use of heat shields.
(Requirement from ECE-R 122, point 5.3.2.2.).
It should be installed as low as possible in order to ensure automatic bleeding
of the heater and coolant pump.
This is particularly relevant for the coolant pump which is not self-priming.
Permissible installation positions for the heater:
See Fig. 1
Connection positions for the heater:
See Fig. 2
Dimensions of heater:
See Fig. 2 and Chapter 14 Technical data (page 49).
Legend for Fig. 2:
23) Heat exchanger inlet
24) Heat exchanger outlet
25) Combustion air inlet
26) Fuel inlet
27) Exhaust gas outlet
L = Length
W = Width
H = Height
3.2 Installing the heater
Every reasonable precaution should be taken in positioning the heater to mini-
mize the risk of injury and damage to personal property.
(Requirement from ECE-R 122, point 5.3.2.5.).
For ADR only:
EX/II, EX/III, AT, FL and OX vehicles:
The combustion heaters and their exhaust gas routing shall be designed, lo-
cated, 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 following
provisions:
- Each fuel tank for supplying the heater must comply with the following
regulations:
a) In the event of a leak, the fuel must drain to the ground without com-
ing into contact with hot parts of the vehicle or the load;
[...]
- 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.
Compliance with this paragraph shall be verified on the completed vehicle.
(Requirement from ECE-R 122, Annex 9, point 3.1.1).
FL vehicles:
The combustion heaters shall be put out of operation by at least the following
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Thermo Pro 50 Eco
Technical Information
38
methods:
a ) Intentional manual switching off from the driver’s cab;
b) Stopping of the vehicle engine; in this case the heater may be restarted
manually by the driver;
c) Start up of a feed pump on the motor vehicle for the dangerous goods
carried.
[...]
(Requirement from ECE-R 122, Annex 9, point 3.3.1).
3.3 Standard bracket
The heater must be fastened to the bracket using at least 3 screws M5 with
8Nm torque.
The heater mounting screws are approved for bracket plate thicknesses of 1.5
to 3.0mm.
See also Fig. 3: Example of a bracket.
Legend for Fig. 3:
9) Water heater
28) Bracket for heater
29) Vehicle body
4 Type label
The label referred to in Annex 7, paragraph 4, or a duplicate, must be posi-
tioned so that it can be easily read when the combustion heater is installed in
the vehicle.
(Requirement from ECE-R 122, point 5.3.2.4.).
The type label must be positioned in a location where it is protected from
damage.
(Requirement from ECE-R 122, Annex 9, point 3.3.1).
The non-applicable years should be removed from the type label, retaining the
current year.
For an example, see also Fig. 18.
5 Installation example
Fig. 5 shows two installation examples of the heater in a vehicle.
Legend for Fig. 5:
1. Heat exchanger for vehicle heating system
2. Switch for fan of the vehicle heating system
3. Relay for vehicle blower
4. Control element
5. Fuse block in vehicle
6. Non-return valve with seepage hole
7. T piece
8. Motor vehicle engine
9. Water heater
10. Coolant pump
11. Coolant pump in vehicle
12. Radiator
13. Regulating valve
14. Exhaust silencer
15. Fuel pump
16. Combustion air intake line
17. Thermostat
18. Control unit
19. Wiring harness
20. Fuel line
21. Exhaust pipe
22. Coolant circuit
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