Webasto Thermo 90 S - User Manual

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Operation

In the case of a severe build-up of smoke, unusual

combustion noises or fuel smell, the heater is to be put out

of operation by removing the fuse and may only be

restarted after being inspected by Webasto-trained

personnel.

be operated at least once a month for 10 minutes, with the

vehicle engine cold and at the lowest fan setting. The

heater should be checked annually by a qualified expert,

preferably prior to the heating season commencing.

be operated using the fuel specified on the name plate and

the rated voltage specified on the name plate.

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 revocation of the type

licence for the heater and therefore the General operating

licence / EC type licence.

Liability claims can only be made if the claimant can verify

that he has complied with the servicing and safety

instructions.

The heater :must

Liability claims:

Before switching the heater on, set the vehicle heating system to the "warm" position

and the vehicle heater fan to the lowest setting (less power consumption)!

Thereafter, the electronic control unit is in the "fault lock-out" state. Before the heater can

be restarted, the On/Off switch must be set to "Off".

The disconnect switch (Emergency Stop switch) may only be actuated in an emergency

situation since this will shut the heater down without any after-run being performed

(danger of overheating).

For ADR vehicles only:

The Thermo 90 S and Thermo 90 ST heaters are switched on and off by hand using a

switch. Automatic controllers must not be used. These heaters must not be used in FL

type vehicles during loading and unloading and at loading bays. In FL type vehicles the

heaters are switched off automatically and the supply of combustion air is stopped after

a maximum of 40 seconds in the following circumstances:

The vehicle engine is at a standstill; in this case the heater may be switched on again

by hand

-A transport device on the vehicle is started in which case the brief slow-down time is

stopped after 20 seconds (Thermo 90 ST after 40 seconds).

Ident-Nr. 1301489B 3/0402

Operating and

maintenance instructions

General Information

Maintenance and Safety Information

Dear Webasto Customer !

We assume that the workshop / service center that carried out the installion explained to

you the operation and principle of functioning of your new heater to your complete

satisfaction.This owner's handbook is designed to give you a brief summary of how to

use the Thermo 90 S / Thermo 90 ST heaters.

General type approvals have been issued in the region covered by the European

Directive 70/156/EEC for the Thermo 90 S and Thermo 90 ST heaters, which comply

with Directives 2001/56/EC (Heating systems) and 72/245/EEC (EMC).

In addition to the Road Traffic Act, the requirements of the latest version of the ADR must

also be observed for the installing the Thermo 90 S / Thermo 90 ST heater into vehicles

used to transport hazardous substances.

The installation of the units must be carried out in accordance with the enclosed

installation instructions. The installation must be checked in accordance with the Legal

Provisions for Installation. For details refer to the installation instructions.

The year of the initial operation must be durably marked on the heater's nameplate by

removing the non-applicable years.

at filling stations and tank farms.

in locations where flammable vapours or dust may

accumulate (e.g. in the vicinity of fuel-, coal-, sawdust or

grain depots).

in enclosed spaces (e.g. garages). This should also be

considered when pre-setting heater operating times or

using the Telestart remote control.

exposed to temperatures greater than +85°C. Exposure

to such temperatures may cause damage to the

electronic components.

operated without a minimum level of 20% of good quality

antifreeze in the water of the heating circuit.

The heater must be switched :off

Danger of explosions

and asphyxiation

The heater must benot

Webasto Thermosysteme International GmbH

Postfach 80 - D-82132 Stockdorf - http://www.webasto.de

Thermo 90 S/ 90 ST

Visit www.butlertechnik.com for more technical information & downloads.

www.butlertechnik.com

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Installation Instructions40 pages

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Summary

Maintenance and Safety Information

Liability Claims

Webasto's liability is refused if installation instructions or repairs are incorrect or use non-genuine parts.

Standard Timer Operation

Switching Heater On;Off

Manual and automatic methods for switching the heater on and off using the timer.

Setting Time and Day

Instructions for setting the current time and day of the week on the timer display.

Programming Heater Start Times

Details on programming up to three different start times for the heater operation.

Recalling and Erasing Preset Times

How to view, select, or delete previously programmed start times.

Setting Operating Duration

Instructions for setting the desired duration of the heater's operation.

Setting Wakeup Time

Procedure to program a specific wakeup time using the timer's alarm function.

Recalling and Erasing Wakeup Time

Methods for viewing or deleting the programmed wakeup time.

ADR Vehicle Equipment

Notes on timer operation for vehicles equipped for transporting hazardous substances.

Troubleshooting

Heater Auto Shut-off (Fault Lock-out)

Heater shuts off due to failed start-up, flame loss, voltage drop, or overheating issues.

Fault Code Display

Displays fault codes on the digital timer for malfunctions like no start-up, flame issues, or sensor errors.

Summary

Maintenance and Safety Information

Liability Claims

Webasto's liability is refused if installation instructions or repairs are incorrect or use non-genuine parts.

Standard Timer Operation

Switching Heater On;Off

Manual and automatic methods for switching the heater on and off using the timer.

Setting Time and Day

Instructions for setting the current time and day of the week on the timer display.

Programming Heater Start Times

Details on programming up to three different start times for the heater operation.

Recalling and Erasing Preset Times

How to view, select, or delete previously programmed start times.

Setting Operating Duration

Instructions for setting the desired duration of the heater's operation.

Setting Wakeup Time

Procedure to program a specific wakeup time using the timer's alarm function.

Recalling and Erasing Wakeup Time

Methods for viewing or deleting the programmed wakeup time.

ADR Vehicle Equipment

Notes on timer operation for vehicles equipped for transporting hazardous substances.

Troubleshooting

Heater Auto Shut-off (Fault Lock-out)

Heater shuts off due to failed start-up, flame loss, voltage drop, or overheating issues.

Fault Code Display

Displays fault codes on the digital timer for malfunctions like no start-up, flame issues, or sensor errors.

This document provides operating and maintenance instructions for the Webasto Thermo 90 S and Thermo 90 ST heaters. These are auxiliary heating systems designed for vehicles, offering both general heating functions and specific features for vehicles transporting hazardous substances (ADR vehicles).

Function Description

The Webasto Thermo 90 S and Thermo 90 ST heaters are designed to pre-heat the vehicle's engine and passenger compartment. They operate independently of the vehicle's engine, using fuel from the vehicle's tank to generate heat. This pre-heating function helps to ensure a comfortable cabin temperature before starting the engine and can also aid in easier engine starts in cold weather by pre-warming the engine's coolant. The heaters comply with European Directives 2001/56/EC (Heating systems) and 72/245/EEC (EMC), indicating their adherence to safety and electromagnetic compatibility standards.

The heaters are controlled via a standard digital timer, which allows for programming of start times up to 7 days in advance. This timer can store up to three different starting times, though only one can be active at a time. It also includes a wakeup alarm function. For ADR vehicles, specific operational limitations apply, such as manual control only (no automatic controllers) and automatic shutdown under certain conditions to enhance safety.

Important Technical Specifications

The heaters must be operated with the specific fuel and rated voltage indicated on their nameplate. They require a minimum level of 20% good quality antifreeze in the heating circuit water for proper operation and to prevent damage. The electronic components are sensitive to high temperatures and should not be exposed to temperatures exceeding +85°C.

In ADR vehicles, the heaters are designed to shut off automatically and stop the supply of combustion air within a maximum of 40 seconds under specific circumstances:

When the vehicle engine is at a standstill (though manual restart is possible).
When a transport device on the vehicle is started, with a brief slow-down time of 20 seconds (Thermo 90 ST after 40 seconds). After these events, the electronic control unit enters a "fault lock-out" state, requiring the On/Off switch to be set to "Off" before restarting. The disconnect switch (Emergency Stop switch) should only be used in emergencies, as it shuts down the heater without an after-run cycle, which could lead to overheating.

Usage Features

Standard Digital Timer:

Switching the heater on: Manually by pressing button 3 (continuous heating mode) or automatically by programming a start time.
Switching the heater off: Manually by pressing the button, or automatically after the programmed operating time elapses. When the heater is running, the remaining operating time can be programmed.
Setting time/day of the week: Press the button for over 2 seconds to set the time and day using the and buttons.
Viewing the time: With the ignition off, press the button.
Programming heater starting time: Press the button, then use the and buttons to set the start time and day. Up to three memory locations can be programmed.
Recalling/erasing preset times: Repeatedly press the P button to display desired memory locations. To erase, press the p button several times until the time of day is displayed.
Programming duration of operating time: With the heater off, press the button for 3 seconds to set the desired operating time (10 to 120 minutes) using the and buttons.
Setting the remaining operating time: While the heater is in operation and the ignition is off, use the and buttons to set the remaining operating time (1 to 120 minutes).
Setting the wakeup time: Repeatedly press the P button until the bell symbol appears. Set the desired wakeup time using the and buttons. The alarm turns off after 5 minutes or when a button is pressed.
Recalling/erasing the wakeup time: Repeatedly press the P button until the bell symbol appears to view the wakeup time. To erase, press the button until the bell symbol is no longer visible.
Remote control: Possible via an optional external "instant heating" button.
Vehicles with ADR equipment: Preset starting times are not possible. The remaining time is shown during operation. The clock and alarm function can be programmed.

General Operation: Before switching on, the vehicle heating system should be set to "warm" and the vehicle heater fan to the lowest setting to minimize power consumption. If the ignition is switched off while the heater is in continuous mode, it will continue to operate for 15 minutes.

Maintenance Features

General Maintenance:

The heater should be operated at least once a month for 10 minutes, with the vehicle engine cold and the lowest fan setting.
An annual check by a qualified expert is recommended, preferably before the heating season.
The year of initial operation must be marked on the heater's nameplate by removing non-applicable years.

Safety Information:

The heater must be switched off at filling stations, tank farms, and in locations where flammable vapors or dust may accumulate (e.g., near fuel, coal, sawdust, or grain depots).
It must not be operated in enclosed spaces (e.g., garages), which also applies when pre-setting operating times or using remote control.
In case of severe smoke, unusual combustion noises, or fuel smell, the heater must be shut down by removing the fuse and only restarted after inspection by Webasto-trained personnel.

Troubleshooting and Fault Codes:

In case of a malfunction, fuses and electrical connections should be checked. If the issue persists, consult an authorized Webasto dealer.
After a fault lock-out, a coded flashing signal is emitted via the operation indicator during the after-run cycle to assist in fault isolation.
If the heater is equipped with a standard digital timer, fault codes are displayed on the timer's screen.
Common Fault Codes:
- F 01: No start-up (after 2 attempts)
- F 02: Flame extinguished
- F 03: Undervoltage or overvoltage
- F 04: Premature flame detection
- F 05: Flame detector interruption or short-circuit
- F 06: Temperature sensor interruption or short-circuit
- F 07: Metering pump interruption or short-circuit
- F 08: Fan motor interruption, short-circuit, or incorrect speed
- F 09: Pencil-type glow plug interruption or short-circuit
- F 10: Overheating
- F 11: Circulating pump interruption or short-circuit

Remedies for common issues:

No combustion during start-up/repetition or flame goes out: Switch heater off and on again. If it fails, consult a Webasto dealer.
Voltage drop (>20 seconds): Check fuses, electrical connections, and battery.
Overheating due to lack/loss of coolant: Top up coolant according to vehicle manufacturer instructions.

Liability:

Failure to follow installation instructions and notes will result in Webasto refusing liability.
Incorrect repairs or use of non-genuine spare parts will revoke the type license and general operating license.
Liability claims require verification of compliance with servicing and safety instructions.