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Webasto Thermo 230 Operating Instructions Manual
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Webasto Thermo 230 Operating Instructions Manual

Webasto Thermo 230 Operating Instructions Manual

Coolant heater
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Coolant Heaters
Thermo 230
Thermo 300
Operating Instructions
Installation Instructions
Service Parts Listing

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Summary of Contents for Webasto Thermo 230

  • Page 1 Coolant Heaters Thermo 230 Thermo 300 Operating Instructions Installation Instructions Service Parts Listing...

  • Page 2: Table Of Contents

    Boost Heating for Engine and Passenger Compartment ..........202 Operation with 7-Day Digital Timer Model 1531.............. 202 7-Day Digital Timer Programming and Operating Instructions........204 3. Technical Data Thermo 230/300 Heater Data..................301 3.1.1 Thermo 230/300 Heater Dimensions..............302 Coolant Circulation Pump Data ..................303 3.2.1...
  • Page 3 8. Warranty Policy Warranty Policy........................ 801 List of Figures 101 Webasto Thermo 230/300 Heater ................... 101 201 7-Day Digital Timer – Model 1531 ................... 203 301 Thermo 230/300 Heater Dimensions ................302 302 Coolant Circulating Pump Assembly - U 4814 ..............303 303 Coolant Circulating Pump Assembly - U 4851 ..............

  • Page 4: List Of Tables

    Thermo 230/300 Contents List of Tables 201 Digital Timer Instructions ....................204 301 Thermo 230/300 Heater Data..................301 302 Coolant Circulation Pump Data ..................303 601 Operational Failure Symptoms via Fault/Flash Code............603 PART # 907 507 Rev. 11.15.98 Subject to modification...

  • Page 5: Introduction

    12 Combustion air swirler Fig. 101: Webasto Thermo 230/300 Heater The Webasto Thermo 230 and 300 Heaters for use on diesel powered transit buses and coaches are designed to: 1. Preheat Engine block of liquid cooled engines to ensure reliable starting in cold weather and to reduce cold start wear and emissions (white smoke).

  • Page 6: Legal Provisions

    Any deviations from these instructions are only permitted with written approval from Webasto Thermosystems. Installations not complying with the installation instructions will release Webasto Thermosystems from any product liability. OEM installations must be approved by Webasto Thermosystems. Meaning of Warning, Caution and Note...

  • Page 7: Operating Your Webasto Heater

    When the switch is used for switching “ON” the Webasto heater, the operation indicator integrated in the switch is illuminated. The heater motor and coolant circulating pump begin to run. After approximately 10-25 seconds the solenoid valve opens and fuel is sprayed into the combustion chamber.

  • Page 8: Switching Off

    “OFF”. The heater will begin a brief after-run (cool-down) cycle. Operation with 7-Day Digital Timer Model 1531 The “Digital Timer with 3 time settings” permits the Webasto heater to be switched on and off instantly, or automatically at 3 programmable starting times.
  • Page 9 Thermo 230/300 Operating your Webasto Heater Programmed Heater Operation Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week. Pre-selected Starting Times The pre-selected starting time is the time at which the heater switches itself on automatically.

  • Page 10: 7-Day Digital Timer Programming And Operating Instructions

    Operating your Webasto Heater Thermo 230/300 7-Day Digital Timer Programming and Operating Instructions Setting the time Press the button for more than 2 seconds. and day of the Time display flashes. week Press the button to set time of day.

  • Page 11: Technical Data

    Exhaust Gas % by Volume 10.5 ±0.5 Dimensions of Heater 610 mm (24.01 in.) 246 mm (9.69 in.) mm (inch) 220 mm (8.66 in.) 19 (41.88) Weight of Heater including Control Unit kg (lb) Table 301: Thermo 230/300 Heater Data...

  • Page 12: Thermo 230/300 Heater Dimensions

    Technical Data Thermo 230/300 Thermo 230/300 Heater Dimensions 3.1.1 Fig. 301: Thermo 230/300 Heater Dimensions...

  • Page 13: Coolant Circulation Pump Data

    Thermo 230/300 Technical Data Coolant Circulation Pump Data Circulating Pump U 4814 U 4851 Flow Rate l/hr l/h (gal/min) 5200 (22.9) against 0.2 mbar 6000 (26.4) against 0.4 mbar Rated Voltage Operating Voltage Range 20 ... 28 18 ... 32 Power Consumption 221 mm (8.7 in.)
  • Page 14 Technical Data Thermo 230/300 Fig. 303 Coolant Circulating Pump Assembly - U 4851 Fig. 304 Pump Operating Data - U 4851...

  • Page 15: Installation

    General Information installations. For special applications use this manual as a general Webasto will take you step by step through the installation process to guideline only. Contact ensure successful operation for years to come. The installation must Webasto Thermosystems be performed in accordance with the installation instructions provided directly at 1-800-555-4518.

  • Page 16: Combustion Air Supply

    2 1/4" (55mm) and a length no greater than 16’ (5m). The ducting may have several bends totaling no more than 270° overall. NOTE Approved combustion air ducting can be ordered through Webasto Approved combustion air under part number 887 29A.

  • Page 17: Plumbing Into The Coolant System

    A path for coolant flow must always be maintained while the Webasto vehicle’s heating system. heater is in operation. A bypass loop will be required if an...
  • Page 18 Fig. 402: Parallel Plumbing Circuit (Shown with heater installed) A fuel fired Webasto heater used in conjunction with a high capacity coolant pump can significantly increase the available heat and coolant volume supplied to both series and parallel systems increasing interior heating efficiency.
  • Page 19 Instructions for options A, B or C (Typical installations) On typical systems, the coolant supply will originate at the engine. NOTE From there, it will travel through the supply hose to the Webasto Silicone hose requires coolant pump (or vehicle manufacturer supplied boost pump), through special hose clamps.

  • Page 20: Example Of A Heater Installation In A Bus

    Installation Thermo 230/300 Example of a Heater Installation in a Bus 4.6.3 Fig. 404: Example of Heater Installation...

  • Page 21: Fuel System

    The fuel is drawn from the vehicles fuel tank through a fuel standpipe. This standpipe can be utilized on vehicles with a spare threaded port as shown in figure 405. The Webasto heater utilizes 37° flare JIC fuel connection fittings. The fuel supply line fitting is a JIC #4 and the return line is a JIC #6.

  • Page 22: Fuel Filter

    Installation Thermo 230/300 use 1/4" or 1/2" spare port on fuel tank (if available) and install CAUTION fuel standpipe securely in fuel tank, use pipe thread sealant on Fuel line must be secured all pipe threads. every 12" and kept away from hot exhaust and 3.

  • Page 23: Wiring Connections

    The control unit is equipped with low voltage protection, therefore it is imperative to keep vehicle batteries in good condition. CAUTION Thermo 230/300 heaters are available in 24 volt configurations only. If welding is done on the vehicle, the main battery...

  • Page 24: Wiring Diagram - With Switch

    Installation Thermo 230/300 Wiring Diagram - with Switch 4.8.4 Fig. 409: Wiring Diagram with Switch...

  • Page 25: Wiring Diagram - With 7-Day Digital Timer Model 1531

    Thermo 230/300 Installation Wiring Diagram - with 7-Day Digital Timer Model 1531 4.8.5 Fig. 410: Wiring Diagram with Timer Model 1531...

  • Page 26: Initial Operation

    4. Set vehicle heater controls to maximum heat position. 5. Start the vehicle engine and run it at a fast idle for 10 minutes to purge air from the Webasto coolant heater and all of the heat exchangers. While the engine is running check: hose connections for leaks.
  • Page 27 Thermo 230/300 Installation 15. Complete the warranty card and send to Webasto Thermosystems NOTE (There is an area on the last page of this manual for recording The engine temperature information which is useful when calling for technical support). gauge may read a lower...

  • Page 28: Maintenance Of The Heater

    Thermo 230/300 Maintenance of the Heater Maintenance of the Heater Annual Maintenance The Webasto heater requires a minimum of maintenance to operate. NOTE To keep your heater in service the following maintenance procedures For major repairs and should be performed annually before each heating season:...

  • Page 29: Basic Troubleshooting

    Fault code 7X (F 07): ¤¤¤¤¤ ... ¤ ... ¤ ... ¤ ... ¤ ... ¤ ... ¤ ... ¤ The flash code sequence will be repeated during the Thermo 230/300 after run (cool down) period and will remain visible once heater stops in the lock out mode.

  • Page 30: Reading A Fault Code With 1531 "Comfort" Timer Installed

    6.2.2 Storing a Fault Code in Memory Once the Thermo 230/300 completes the after run (cool down) period initiated by a failure event, the current flash code will be downloaded (stored) in memory. The Thermo 230/300 can store up to ten fault codes.

  • Page 31: Operational Failure Symptoms Via Fault/Flash Code

    Thermo 230/300 Basic Troubleshooting Operational Failure Symptoms via Fault/Flash Code The following table lists the possible faults which can be read by flashing code or read directly off of an appropriate timer or with the PC diagnostics kit. Failure Symptom...
  • Page 32 This is achieved through the use of a diagnostic interface kit End User service facilities. connected to the Thermo 230/300 and an IBM compatible computer having the necessary software installed. The PC Diagnostic Interface Kit comes with software and instructions for use with Webasto heaters equipped with internal diagnostics capabilities such as the Thermo 230/300.
  • Page 33 SECTION 7 – THERMO 230/300 SPARE PARTS LISTING ITEM QUANTITY PART NO. DESCRIPTION REMARKS No Fig. 636 47A Thermo 230.036 Heater - Complete Replacement heater No Fig. 636 50A Thermo 300.066 Heater - Complete Replacement heater 206 49B Hood 206 41B...
  • Page 34 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 148 46B Ignition Electrodes 470 716 Fuel Nozzle For Thermo 230 470 724 Fuel Nozzle For Thermo 300 838 88A Photo Disc 148 45C Ignition Coil 197 23B Retaining Clip - Nozzle Pre-heater 839 33A...
  • Page 35 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 208 18B Splash Guard 208 19A Grill Optional to splash Guard item 1 922 22A Supply Line Fitting - #4 JIC (37° Flare) 922 21A Return Line Fitting - #6 JIC (37° Flare) 151 157 Copper Washer - 10 x 14 150 754 Banjo Bolt...
  • Page 36 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 636 49A Overheat Protection Thermostat 149 41A Temperature Sensor Mounted in water outlet pipe 213 27A Bleed Valve Mounted in water inlet pipe...
  • Page 37 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 443 25A Combustion Chamber 820 73E Heat Exchanger 150 47A Eye Bolt - 8 x 40 208 26A Nut with Washer - M8 156 74A Roll Pin - 8 x 16 131 60A Cotter Pin...
  • Page 38 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 211 524 90° Rubber Elbow - 1 1/2" ID. For coolant connection 902 428 Hose Clamp - 34-57mm 101 377 Connector For combustion air tubing item 4 887 29A Combustion Air Tubing Per meter 101 404 90°...
  • Page 39 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 881 95A 24V - 7 Day Digital Timer Model 1531 3 programmable timer settings and alarm feature. 884 36A Harness For 1531 Digital Timer 284 47A 24V - Replacement Bulb For digital timer model 1531 116 389 Label - ON/OFF 103 877...
  • Page 40 ITEM QUANTITY PART NO. DESCRIPTION REMARKS 372 69A Mounting Base For U 4814 only 139 661 Mount Clamp For U 4814 only 431 52A 24V - Coolant Pump - U 4814 427 46A Pump Parts For U 4814 and U 4851 427 47A Seal Kit For U 4814 and U 4851...
  • Page 41 PART NO. DESCRIPTION REMARKS 925 42A PC Download Diagnostic Kit (IBM) Includes software 208 65A Adapter Harness for Thermo 230/300 Heaters Order separately 647 15B Software on 3.5 Floppy Disk (IBM) Version 1.15 for item 1 (Upgrade from version 1.14)

  • Page 42: Warranty Policy

    O.E.M. installations. The warranty period may not however, exceed 36 months from the original date of delivery by Webasto. During the warranty period the EXCLUSIVE REMEDY will be for Webasto to repair or replace those parts which are demonstrated to be defective in material or workmanship.
  • Page 43 Thermo 230/300 WARRANTY POLICY Heater Information: Serial No.: Purchased From: Date Purchased: Date Installed: Installer: Your Notes:...
  • Page 44 Webasto Thermosystems Inc. North America 3333 John Conley Drive Lapeer, MI 48446 Phone (810) 245-2400 Toll-free (800) HEATER-1 (810) 664-7720 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.com Org. 11/1998 907507...

This manual is also suitable for:

Thermo 300