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Thermo Pro 90 Series
Webasto Thermo Pro 90 Series User Manual
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Water heater
Service Installations
Thermo Pro 90
Thermo Pro 90 HDD
Thermo Pro 90 12
V Diesel - ADR (Transport of
dangerous goods)
Thermo Pro 90 24
V Diesel - ADR (Transport of
dangerous goods)
Thermo Pro 90 HDD 24
V Diesel - ADR (Transport of
dangerous goods)
2
Table of Contents
Table of Contents
3
1 Introduction
7
Spare Parts
8
Fig. 201 Heater Components
9
2 General Description
9
Fig. 202
10
Fig. 203
10
Fig. 204
10
Fig. 205 Combustion Chamber
10
Fig. 206
11
Fig. 207
11
Fig. 208
11
Fig. 209 DP42 Fuel Pump
11
Fig. 301 Thermo Pro 90 Functional Sequence
12
3 Functional Description
12
Start and Control Mode
13
Technical Data
14
5 Malfunctions and Troubleshooting
15
Deleting Fault Code
16
Fault Code Table (Fault Codes, Flash Codes)
17
General Information
23
Fig. 601
24
Testing Individual Components
25
7 Servicing
27
Fig. 701 Visual Check, Burner Back Plate
28
Removing and Installing Heater
28
Fig. 702 Combustion Chamber
29
8 Repairing and Replacing Components 8 Repairing and Replacing Components
30
8 Repairing and Replacing Components
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Fig. 801 Component Layout
30
Fig. 802 Control Unit Cover
31
Fig. 803
31
Work on Stripped down Components
31
Fig. 804 Replacing the U4840 Coolant Pump
32
Fig. 805 Removing Overheating Protection Sensor
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Fig. 806 Coolant Temperature Sensor Removal
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Fig. 807 Combustion Air Fan Removal
33
Fig. 808 Seal on Combustion Air Fan
33
Fig. 809 Burner Unit and Glow Plug
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Fig. 810 Burner Unit and Glow Plug, Front
34
Fig. 811 Burner Head
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8.11 Burner Head
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Fig. 812 Heat Exchanger
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Fig. 813 Exhaust Gas Temperature Sensor with Clip
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Fig. 814 Burner Head and Exhaust Gas Temperature Sensor
36
Fig. 815 Checking Mica Insulator on Sensor
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Fig. 901 Thermo Pro 90 HDD Heater Components
37
Coolant Temperature Sensor
37
Overheating Protection
37
Heat Exchanger
37
10 U4840 Coolant Pump
37
13 Control Unit
37
Combustion Air Fan
37
Exhaust Gas Temperature Sensor
37
General Information
37
Technical Data
38
Fig. 902 U4840 Coolant Pump with EMC Suppressor Module
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Fig. 903 Thermo Pro 90 HDD Combustion Air Fan
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Fig. 904 Thermo Pro 90 HDD Control Unit
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Fig. 905 Connector VG95328R2016PN (if Installed)
40
Fig. 1001 Preferred Position of Thermo Pro 90 Heater for Storage and Transportation
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10 Packaging/Storage and Shipping
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11 Wiring Diagrams
42
Fig. 1102 System Wiring Diagram Thermo Pro 90, Multicontrol with Battery Disconnector
43
Fig. 1103 System Wiring Diagram Thermo Pro 90, Smartcontrol (ADR)
44
System Wiring Diagram for Thermo Pro 90 with Smartcontrol Control Element (ADR)
44
Fig. 1104 System Wiring Diagram Thermo Pro 90, On/Off Switch (ADR)
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Fig. 1105 System Wiring Diagram Thermo Pro 90, Thermocall TC4
46
Fig. 1106 System Wiring Diagram Thermo Pro 90, Unibox
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Fig. 1107 System Wiring Diagram Thermo Pro 90, Multicontrol (Analogue Connection)
48
System Wiring Diagram for Thermo Pro 90 with Multicontrol Control Element (Analogue Connection)
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Fig. 1108 System Wiring Diagram Thermo Pro 90 HDD, Multicontrol
49
System Wiring Diagram for Thermo Pro 90 HDD with Multicontrol Control Element
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Fig. 1109 System Wiring Diagram Thermo Pro 90 HDD, Smartcontrol (ADR)
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System Wiring Diagram for Thermo Pro 90 HDD with Smartcontrol Control Element (ADR)
50
Fig. 1110 System Wiring Diagram Thermo Pro 90 HDD, On/Off Switch (ADR)
51
Fig. 1111 Heater Connections
52
Fig. 1112 Plug Assignments at Control Unit
52
Cable Cross-Sections
52
Legend to Wiring Diagrams
53
Legend for Comments
54
4
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Webasto Thermo Pro 90 Series Specifications
General
Fuel
Diesel
Operating Temperature Range
-40°C to +60°C
Fuel Consumption
1.14 l/h
Voltage
12V or 24V
Efficiency
Up to 90%
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