Webasto Thermo Pro 90 User manual

Wasserheizgerät
Water heater
Appareil de chauffage
Einbauanweisung
Installation Instructions
Notice de montage
Thermo Pro 90
Thermo Pro 90 12 V Diesel - ADR
(Gefahrguttransport)
(Transport of dangerous goods)
(Transport des marchandises dangereuses)
Thermo Pro 90 24 V Diesel - ADR
(Gefahrguttransport)
(Transport of dangerous goods)
(Transport des marchandises dangereuses)
Thermo Pro 90 High Altitude 24 V Diesel

Thermo Pro 90
Thermo Pro 90 High Altitude
Thermo Pro 90
219 mm
L= 385 mm
B= 139 mm
H=
2

Thermo Pro 90
3

Thermo Pro 90
Ø
Ø
Ø
4

Thermo Pro 90
28
5

Thermo Pro 90
6

Thermo Pro 90
7

Thermo Pro 90
17
9032679A03
8

Thermo Pro 90
18
9032353A04
9

Thermo Pro 90
19
9037064A01
10

Thermo Pro 90
20
9033213A02
11

Thermo Pro 90
21
9032413A03
12

Thermo Pro 90
22
9032678A03
13

Thermo Pro 90
The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide. This can
lead to serious injury or death.
To install and repair Webasto heating and cooling systems, you must have completed a Webasto training course and have the appropriate
technical documentation, special tools and special equipment.
Only use genuine Webasto parts. See also the Webasto air and water heaters accessories catalogue for this purpose.
NEVER try to install or repair Webasto heating or cooling systems if you have not successfully completed a Webasto training course and have
not acquired the necessary technical skills, or if you do not have the technical documentation, tools and equipment available necessary for
correct installation and repair.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
Webasto does not accept any liability for defects and damage due to installation by untrained personnel.
15

Thermo Pro 90
TR
Table of Contents
1 Regulations governing installation 40
1.1 Statutory regulations governing installation ................................... 40
1.2 Application of combustion heaters in vehicles for the transportation of
dangerous goods........................................................................... 40
2 Use / variants 41
2.1 Intended use.................................................................................. 41
2.2 Variants ........................................................................................ 41
3 Installation 42
3.1 Installation location/installation position ....................................... 42
3.2 Installing the heater ...................................................................... 42
4 Type label 43
5 Installation example 44
6 Integration in the coolant system 45
6.1 Connection.................................................................................... 45
6.2 Inspection ..................................................................................... 45
7 Fuel integration 46
7.1 General ......................................................................................... 46
7.2 Integration in vehicle tank.............................................................. 46
7.3 Integration in motor return line ..................................................... 47
7.4 Fuel line ........................................................................................ 47
7.5 DP42 fuel pump............................................................................. 48
7.6 Fuel filter ...................................................................................... 48
7.7 Sticker .......................................................................................... 48
7.8 Cold-resistant fuels ....................................................................... 48
8 Combustion air supply 49
9 Exhaust system 50
9.1 Exhaust pipe .................................................................................. 50
9.2 Exhaust silencer ............................................................................. 50
9.3 Notes on installation...................................................................... 50
10 Electrical Connections 51
10.1 Connecting control unit/heater ..................................................... 51
10.2 Connection when installing Thermo Pro 90-ADR in a vehicle for
transporting dangerous goods (ADR) ............................................. 51
10.3 Installing and connecting the control elements ............................. 51
10.4 Vehicle blower............................................................................... 51
10.5 Electrical connection of the wiring harness .................................... 52
10.6 Setting the control temperatures for the heater ............................. 52
11 Wiring diagrams 52
11.1 Cable cross-sections....................................................................... 53
11.2 Cable colours................................................................................. 53
11.3 Legend to wiring diagrams ............................................................ 53
11.4 Legend for comments.................................................................... 54
11.5 Legend for X8 connector, 12-pin ................................................... 54
11.6 SmartControl/ MultiControl/ UniControl initial start-up................. 54
12 Initial start-up 55
13 Malfunctions 55
14 Technical data 56
14.1 Electrical components .................................................................... 56
14.2 Fuel ............................................................................................... 56

About This Document
To enable quick reference to the individual procedures you will find a descrip-
tive symbol on the top outer edge of each page.
Mechanical system Combustion air
Electrical system Technical Information
Coolant circuit Attention
Fuel Note
Exhaust gas

Thermo Pro 90
Technical Information
40
1 Regulations governing installation
1.1 Statutory regulations governing installation
The Thermo Pro 90 heater has been type-tested and approved in accordance
with ECE-R10 (EMC) and ECE-R122 (heater).
For approval number see Section 14 Technical data (page 56).
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 a leak in the fuel line, the fuel must 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 must have
a clearance of 100 mm or be protected by a heat 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.
Additional documentation to be used
These installation instructions contain all the information and instructions
necessary to install a Thermo Pro 90 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.

Thermo Pro 90 Technical Information
41
2 Use / variants
2.1 Intended use
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.
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.
Depending on equipment, the ADR function is provided for the 12V and 24V
variant.
The water heater works independently of the vehicle engine and is integrated
in the cooling system, the fuel system and the electrical system of the vehicle.
Auxiliary heating
The water heater works during engine operation and provides thermal as-
sistance to the cooling system. The water heater is integrated in the cooling
system, the fuel system and the electrical system of the vehicle.
When the engine is switched off, the water heater is automatically switched
off and fuel supply is interrupted within 5 seconds.
2.2 Variants
-Thermo Pro 90 12 V diesel - ADR
Water heater for diesel fuel.The water heater is designed for 12 volts.
-Thermo Pro 90 24 V diesel - ADR
Water heater for diesel fuel.The water heater is designed for 24 volts.
-Thermo Pro 90 High Altitude 24 V Diesel
Water heater for diesel fuel, variant for high altitudes of up to 4500m
above sea level. Depending on the altitude, the heating capacity may be
reduced.
The water heater without ADR approval is designed for 24volts.
This variant is an alternative to the two standard units mentioned above.
For technical information see Chapter 14 Technical data (page 56).

Thermo Pro 90
Technical Information
42
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
For Thermo Pro 90 High Altitude:
Only install the Thermo Pro 90 High Altitude vertically. See Fig. 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.
(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 56).
Legend for Fig. 2:
23) Heat exchanger inlet
24) Heat exchanger outlet
25) Combustion air inlet
26) Fuel inlet
27) Exhaust outlet
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).

Thermo Pro 90 Technical Information
43
FL vehicles:
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 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).
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.
The non-applicable years should be removed from the type label, retaining the
current year.
For an example, see also Fig. 16.