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Thermo Pro 90
Webasto Thermo Pro 90 User Manual
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Water Heaters
Workshop Manual
Therm
o Pro 90
Th
ermo Pro 90 12
V Diesel - ADR
Thermo Pro 90 24
V Diesel - ADR
Visit www.butlertechnik.com for more technical information and downloads.
www.butlertechnik.com
2
Table of Contents
Default Chapter
4
Table of Contents
4
1 Introduction
7
Spare Parts
8
Fig. 201
9
2 General Description
9
Fig. 202 Combustion Air Fan
10
Fig. 203 Heat Exchanger
10
Fig. 204 Burner Unit
10
Fig. 205 Burner Head with Combustion Pipe
11
Fig. 206 Exhaust Temperature Sensor
11
Fig. 207
11
Fig. 301
12
3 Description of Operation
12
Starting and Control Mode
13
4 Technical Data
14
5 Faults, Troubleshooting
15
Fig. 501 Overview of Possible Faults
17
Fig. 502 Overview of Functional Test of Heater and Its Components
17
Troubleshooting Without Error Code Output
17
Fig. 503 Error Code Output by Standard Timer/Switch
21
Error Code Output with Webasto Thermo Test PC Diagnosis
21
Fig. 504 Visual Inspection, Rear Wall of Burner
24
Metal Fibre Evaporator
24
Fig. 505 Visual Inspection, Entire Burner Unit
25
6 Operating Tests
26
Checking Individual Components
27
Testing DP42 Metering Pump
28
Fig. 701 Connector Assignment on Control Unit
29
Fig. 702 Positioning of Electrical Components on Heater
29
7 Circuit Diagrams
29
Fig. 703 Wiring Diagram for Thermo Pro 90, Parking Heater with Standard Timer Without ADR
31
Fig. 704 Circuit Diagram for Thermo Pro 90, Parking Heater with On/Off Switch Without ADR
32
Fig. 705 Circuit Diagram for Thermo Pro 90, Parking Heater with On/Off Switch with ADR with Auxiliary Drive
33
8 Servicing Work
35
Work on Vehicle
35
Installation
36
9 Maintaining and Replacing Components
37
Fig. 901 Replacing Circulation Pump
38
Measures on Components When Dismantled
38
Replacing Overheating Protection
39
Fig. 902 Replacing Overheating Protection and Coolant Temperature Sensor
40
Fig. 903 Replacing Combustion Air Fan
41
Replacing Burner Unit and Glow Plug
42
Fig. 904 Replacing Burner Unit, Glow Plug, Burner Head and Exhaust Temperature Sensor
43
Replacing Heat Exchanger
44
Fig. 905 Permissible Bending Angle and Permissible Load
45
Fig. 906 Testing Mica Disc (Insulation) on Sensor
45
Fig. 1001 Preferred Position of Thermo Pro 90 Heater for Storage and Transport
46
10 Packing, Storage and Shipping
46
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Webasto Thermo Pro 90 Specifications
General
Fuel Type
Diesel
Voltage
12V/24V
Fuel Consumption
1.14 l/h
Operating Temperature Range
-40°C to +70°C
Efficiency
85%
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