Operating and servicing instructions
Thermo 230/300/350 Thermo 231/301

Webasto AG

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

The heater must not:

General information
Dear Webasto Customer, We assume that the operation and function of your new heater will have been explained to you properly and to your complete satisfaction by the installing workshop / service outlet. This owner's handbook is designed to give you a brief summary of how to use the Thermo 230 / Thermo 231 / Thermo 300 / Thermo 301 / Thermo 350 heaters.
be exposed to temperatures exceeding 110C (storage temperature). If this temperature is exceeded the electronics system may suffer permanent damage. be operated without at least 20% of a brand name antifreeze in the heating system water.

The heater must:

Servicing and safety instructions
Type approvals pursuant to Directive 2001/56/EC (Heating Systems) and 72/245/EEC (EMC) have been issued for the region covered by European Directive 70/156/EEC for the Thermo 230 / Thermo 231 / Thermo 300 / Thermo 301 / Thermo 350 water heaters. For heater models Thermo 230 / 300 /350 (not Thermo 231/Thermo 301) designed for installation in rail vehicles, a design certification acc. to 33 EBO (= Federal Railway Authority) has been issued with the following approval number: EBA 32AZ3/0141/04. The heaters must be installed as described in the attached installation instructions. The installation must be checked pursuant to the statutory regulations governing installation work. Further details are given in the installation instructions. The year in which the heater is used for the first time must be permanently marked on the heater's model plate by removing the inapplicable year numbers. Ensure that the existing shut-off devices in the fuel line return are open before the heater is used for the first time. When the coolant used in the vehicle's engine is renewed, after bleeding the vehicle's cooling system, give careful attention to bleeding the heater. Top up the coolant as described in the instructions supplied by the vehicle manufacturer. Check the openings for the combustion air intake and exhaust outlet and clean them if necessary. When the heater is operated in rail vehicles, maintenance chart / test certificate item no. 22 is to be used. Switch off the auxiliary heating system before refuelling.

2/0503

Liability claims:
be operated using the fuel type shown on the model plate and the rated voltage shown on the model plate. be shut down by removing the fuse in the event of extensive smoke development, unusual combustion noises or fuel odours. The heater must not be used again until personnel trained by Webasto have examined it. be run for 10 minutes at least once per months when the engine is cold and with the blower at its lowest setting. At the latest at the start of the cold weather the heater must be inspected by an expert.
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 compliance with all the servicing and safety instructions.
The heater must not be operated:
n at filling stations or other refuelling points. in locations where inflammable vapours or dust may form, for example near fuel, coal, wood dust or cereal storage facilities. near inflammable materials such as dry grass and leaves, cartons, paper, etc. in enclosed areas (for example garages), not even if the timer or Telestart unit is used.

Ident-Nr. 634 20D

Risk of fire, explosion and asphyxiation

Heater operation

The water heater can be switched on using either a switch or timer. Before you switch on the heater set the vehicle's heating system to Warm.

Standard Timer

Switching the heater on Switching the heater off
Setting time/ day of the week Viewing the time Programming heater starting time
Manually: by pressing the button (continuous heating mode) Automatically: by programming the heater starting time Manually: by pressing the button Automatically: after the programmed operating time has elapsed With the heater running: by programming the remaining operating time Press the button for more than 2 seconds - time of the day is flashing - and set the clock using the and buttons. Day of the week is flashing - adjust the day of the week. With the ignition switched off: press the button
day of the week time display memory location alarm indicator time program selection
heater "on" indicator
Standard Timer instant reverse heating forward
Press the button - the memory location is flashing - using the and buttons set start of the heater operating time. Day of the week is flashing - set the day of the week. By repeatedly pressing the button, memory locations 2 and 3 can be programmed or the time display mode can be reached.
Recalling/ Repeatedly press the button until the desired memory location is erasing preset displayed. To erase the preset time, press the button several times until the time of the day is displayed instead of the memory times Programming duration of operating time Setting the remaining operating time
The heater must be switched off. Press the button for 3 seconds operating time is flashing - and set the desired operating time (10 to 120 minutes) using the and buttons. Set the desired remaining operating time (1 to 120 minutes) using the and buttons. The remaining operating time refers to the time the heater still continues to remain in operation. It can only be changed while the heater is in operation and the ignition switched off. A wakeup time can only be programmed on the standard digital timer. The wakeup time is not bound to a specific day of the week. Repeatedly press the button until the bell symbol appears on the display. Set the desired wakeup time using the and buttons.The alarm clock turns off after 5 minutes or when one of the buttons is pressed.

General

The standard digital timer enables you to preset the start of the heater operation up to 7 days in advance. It is possible to program 3 different starting times, only one of which can be activated. The standard digital timer features a wakeup alarm function. When the ignition switched on, the timer displays the current time and the day of the week. When the heater is switched on, the display and the buttons are illuminated. After the power supply has been connected, all symbols on the display will flash. The current time and weekday must be set. The timer can be operated in that all flashing symbols can be adjusted by means of the and buttons. If the buttons are not pressed within 5 seconds, the time displayed will be stored. If the and buttons are pressed for more than 2 seconds, the fast timesetting mode is activated. If the ignition is switched off while the heater is operating in the continuous mode, the remaining operating time of 15 minutes is displayed and the heater continues to operate for this period of time.

Setting the wakeup time

Operation
Recalling/ erasing the wakeup time
Repeatedly press the button until the bell symbol appears on the display - read off wakeup time. To erase the wakeup time: press the button until the bell symbol is no longer visible on the display.
Remote control Possible by means of an optional external "instant heating" button Vehicles with ADR equipment
On ADR vehicles it is not possible to program a preset starting time. The remaining time is shown on the display while the heater is in operation. The clock can be set. The alarm clock function can be programmed on the standard digital timer.

Troubleshooting

In the event of a malfunction, fuses and electrical connections should be checked for condition and security. If this action fails to correct the malfunction, please consult your authorised Webasto dealer. Following a fault lock-out situation, coded flashing signals will be emitted - via the operation indicator light - during the after-run period of the heater, on all heaters equipped with control unit 1572D. These coded flashing signals allow your authorised Webasto dealer to identify the malfunction that has occurred.

Fault Code Display

On heaters equipped with control unit 1572D and standard digital timer, a fault code appears on the display of the digital timer whenever a malfunction has occurred.
Heater turns itself off automatically (=fault lock-out)
Combustion was not established during start-up

Remedy

Switch heater briefly off and on again one time Switch heater briefly off and on again one time
Fault Codes on the Display of the Combination or Standard Digital Timer
In the case of heaters operated by a switch, the particular type of malfunction that has occurred is indicated by coded flashing signals via the operation indicator light during the after-run period of the heater. After every fast pulse sequence comprising 5 signals, the long flashing signal pulses can then be counted: The coded flashing signals correspond to the numbers in the table below No start Flame failure * Undervoltage or overvoltage Stray light detection during the prestart or after-run period Defective flame detector Defective temperature sensor Defective solenoid valve Defective fan motor unused Defective temperature limiter/overheating Defective ignition spark transmitter Fault lock-out condition due to recurring malfunctions or repeated flame failure (8x no start-up or 5x flame failure) * On the Thermo 231 and 301, if the overheating thermostat trips this is saved as a flame failure (F 02) in the control module Deactivating the heater lock-out mode: Deactivation of the heater lock-out mode is effected by switching the heater on and then disrupting the power supply during the start-up procedure.
F 01 F 02 F 03 F 04 F 05 F 06
Flame extinguishes during operation
Heater is shut down due to overheating, Top up coolant and press the push-button on the temperature limiter e.g. owing to lack/loss of coolant NOTE: In the case of Thermo 231/301 heaters, resetting is performed automatically. Vehicle voltage insufficient Combustion air and/or exhaust gas ducts obstructed Charge battery Switch heater briefly off and on again one time Check combustion air and exhaust gas ducts for unobstructed passage
F 07 F 08 F 09 F 10 F 11 F 12

Subject to change

Statutory regulations governing installation. 35 Use / version. 37 Installation. 38 Installation example for the Thermo 230 / 300 / 350 heater. 45 To install the circulating pump. 46 Connection to the vehicle cooling system. 51 Fuel supply. 52 Combustion air supply. 53 Exhaust pipe. 54 Electrical connections. 55 Initial start-up. 62 Maintenance. 63 Troubleshooting. 64 Technical data. 66

Sommaire

Dispositions lgales concernant le montage. 69 Utilisation / version. 71 Installation. 72 Exemple d'installation pour le Thermo 230/300/350. 79 Installation de la pompe de circulation. 80 Raccordement au circuit de refroidissement du vhicule 85 Alimentation en carburant. 86 Alimentation en air de combustion. 87 Conduite d'chappement. 88 Branchements lectriques. 89 Premire mise en service. 96 Entretien. 97 Dysfonctionnements. 98 Caractristiques techniques. 100
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1 Statutory regulations governing installation
Statutory regulations governing installation
1.1. Statutory regulations governing installation The Thermo 230 / Thermo 231 / Thermo 300 / Thermo 301 / Thermo 350 heater has been type-tested and approved in accordance with EC Directives 72/245/EEC (EMC) and 2001/56/EC (heater) with the following EC permit numbers: e1*72/245*95/54*1010*XX e1*2001/56*0007*00 for Thermo 230 e1*2001/56*0008*00 for Thermo 300 e1*2001/56*0009*00 for Thermo 350 e1*2001/56*0010*00 for Thermo 231 e1*2001/56*0011*00 for Thermo 301 Installation is governed above all by the provisions in Annex VII of Directive 2001/56/EC. NOTE: The provisions of these Directives are binding within the territory governed by EU Directive 70/156/EEC and should similarly be observed in countries without specific regulations. (Extract from Directive 2001/56/EC Annex VII) 1.7.1. A clearly visible indicator within the user's field of vision must show when the heater is switched on or off. 2. Regulations for installation in the vehicle 2.1. Scope 2.1.1.Subject to the provisions of paragraph 2.1.2, internal combustion heaters must be installed in accordance with the requirements contained in this Annex. 2.1.2.In the case of class O vehicles of class O (trailers) with heaters for liquid fuel, it is presumed that these vehicles comply with the requirements in this Annex.
2.2. Position of the heater 2.2.1.Parts of the vehicle body and other components in the immediate vicinity of the heater must be protected against excessive heat and the danger of contamination by fuel or oil. 2.2.2.The internal combustion heater must not pose a fire hazard even when overheated. This requirement is deemed to have been met if care is taken during installation to ensure an adequate distance from all parts, as well as adequate ventilation and if fire-resistant materials or heat shields are used. 2.2.3.In class M2 and M3 vehicles the heater must not be installed in the passenger cabin. A device in a sealed cover, which also meets the requirements set out in paragraph 2.2.2, may be used, however. 2.2.4.The plate mentioned in paragraph 1.4 (model plate) or a duplicate thereof ( duplicate model plate ) must be fitted in such a way that it is still clearly legible when the heater has been installed in the vehicle. 2.2.5. When positioning the heater, all reasonable precautions must be taken to minimise the risk of personal injury or damage to items in the vehicle. 2.3. Fuel supply 2.3.1.The fuel filler neck must not be located in the passenger compartment and must have a tightly fitting cap to prevent any fuel leaks. 2.3.2.The type of fuel and the fuel filler neck must be clearly identified on heaters for liquid fuel, for which the fuel supply is separate from the fuel supply for the vehicle. 2.3.3.A sign must be affixed to the fuel filler neck warning that the heater must be switched off before refuelling. An identical warning must also be included in the manufacturer's operating instructions.

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2.4. Exhaust system 2.4.1.The exhaust outlet must be positioned in such a way that exhaust fumes cannot get into the interior of the vehicle through ventilation devices, hot-air inlets or open windows. 2.5. Combustion air inlet 2.5.1.The air for the combustion chamber of the heater must not be extracted from the passenger cabin of the vehicle. 2.5.2.The air inlet must be positioned in such a way that it cannot be obstructed by other objects. 2.6. Hot air inlet 2.6.1.The supply of heating air must consist of either fresh air or recirculated air and must be taken from a clean area which cannot be contaminated by exhaust fumes from the engine, the internal combustion heater or any other source in the vehicle. 2.6.2.The inlet line must be protected by a grating or other suitable means. 2.7. Hot air outlet 2.7.1.Hot air lines within the vehicle must be positioned or protected in such a way as to exclude all risk of injury or damage caused by direct contact. 2.7.2.The air outlet must be positioned or protected so that it cannot be obstructed by other objects. 2.8. Automatic control of the heating system When the engine stops, the heating system must cut out automatically and the fuel supply must be stopped within 5 seconds. The heating system may remain in operation if a manual unit has already been activated.
IMPORTANT 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 invalidation of the type approval for the heater and therefore of its homologation / EC type licence.
1.2. Provisions relating to the installation in rail vehicles For heater models Thermo 230 / 300 /350 Rail designed for installation in rail vehicles, a design certification acc. to 33 EBO (= Federal Railway Authority) has been issued with the following approval number: EBA 32AZ3/0141/04. Particular attention must be given to incidental provision 1.6 of the design certification: Should the manufacturer, operator or service technician gain knowledge of any accidents and damage (caused by fire, explosion, escape of Diesel fuel or heating oil EL) that may have occurred despite proper use of the heater, he is required to immediately notify the certifying body thereof.

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2 Use / version

2.2. Versions

Use / version

2.1. Use of the water heaters The Webasto Thermo 230/231/300/301/350 water heaters are used in connection with the vehicle's own heating system to heat the passenger cabin, to defrost the vehicle windows and to preheat water-cooled engines. The water heaters operate independently of the engine and are connected to the cooling system, the fuel system and the electrical system of the vehicle. The heater is approved for heating the passenger cabin or the drivers cab, but not to heat a cargo space used to transport hazardous substances. NOTE: The Thermo 230/300/350 heaters are only licensed for horizontal installation.The Thermo 231/301 heaters are licensed for vertical and horizontal installation.
Thermo 230 Water heater for diesel with 23 kW heat current (20000 kcal/h) Thermo 231 Water heater for diesel with 23 kW heat current (20000 kcal/h) Thermo 300 Water heater for diesel with 30 kW heat current (26000 kcal/h) Thermo 301 Water heater for diesel with 30 kW heat current (26000 kcal/h) Thermo 350 Water heater for "diesel" fuel with 35 kW heat current (30000 kcal/h)
The water heaters are designed for 24 V. On request, and depending on the configuration, the heater may be equipped with a nozzle holder preheating system.
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Installation

3 Installation
IMPORTANT The statutory regulations governing installation on pages 35 and 36 must be adhered to. If the water heater is to be operated in a separately installed heating system, prior to installation an installation planning report must always be submitted to Webasto for approval. If this approval is not obtained, all warranty and liability claims will be void. The water heater has been designed, tested and approved for specific bus requirements. NOTE: Check the installation situation of the relevant vehicle type. 3.1. Installation location The heater and circulating pump are to be integrated into the cooling system (or in a separate heating system). The heater must be installed in as low a position as possible to allow the heater and circulating pump to be bled automatically. This is particularly important as the circulating pump is not self-priming. If it is not possible to install the heater in the vehicles engine bay it may be installed in a box. The installation box must have sufficient external ventilation to ensure that the maximum temperature of 85C is not exceeded in the box. Bear in mind the space required for servicing accessibility (for example for removing the combustion chamber) (see Figures 1, 2, 5, and 10) when installing the heater.

3.1.1. Installation Location in Rail Vehicles When the heater is to be installed in rail vehicles, it should be installed either in the engine room (e.g. locomotive) or underfloor in an installation box at the wagon body (e.g. railcar). Other installation locations require Webasto's approval in writing. NOTE No antivibration mounts must be used for securing the heater in rail vehicles.
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CO2 setting Combustion air intake Exhaust fume outlet Fuel intake Fuel discharge Space required to remove the burner chamber Coolant intake Temperature limiter Swivel range, at least approx. 25 Max. swivelled burner Coolant outlet Temperature sensor
10 Fig. 1: Dimensions of the Thermo 230 / 300 / 350 heater (horizontal installation)
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ca 226

ca.440

26,5 302,5 382

ca.160 70,3

ca.145 200

ca. 25 ca.440

Fig. 2:

Dimensions of the Thermo 230 / 300 / 350 Rail heater
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3.2. To install the Thermo 230 / 300 / 350 heater The heater may be secured either with four screws M8 (Figure 4/1) or with four screws and nuts (Figure 4/2).

Fig. 3:

Horizontal installation position 2 2

Fig. 4: 1 D 1

Hole pattern for Thermo 230 / 300 / 350 heater 4.5 mm diameter for using M4 screws, 2.9 mm diameter for using B3.9 self-tapping screws
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Fig. 5:

Dimensions of the Thermo 231 / 301 heater (vertical installation)
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3.3. To install the Thermo 231 / 301 heater The heater is to be secured with four M8 screws (Figure 7), body washers and nuts. IMPORTANT The heat transfer base must be supported on a stable surface connected to the floor of the car. The securing screws are designed to fix the heater in position, not to suspend it.

Fig. 7:

Hole pattern for the Thermo 231 / 301 heater

Fig. 6:

Vertical installation position
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3.4. Model plate The model plate must be protected from damage and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used).
3.5. Additional Type Plate Heaters approved for use in rail vehicles are additionally identified by the type plate illustrated below:

Feel the drive

Eisenbahn-BundesamtBauartzulassung Nr: EBA 32AZ3/0141/04

Fig. 8:

Model plate for Thermo 230 Fig. 9: Additional Type Plate
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Installation example for the Thermo 230 / 300 / 350 heater
Water heating circuit wall heater and roof duct heating system Wall heater with blower Heat exchanger at entry point Heater Circulating pump Roof heat exchanger Vehicle engine Drivers position heating system Control element
Vorlauf Supply Rcklauf Return
Fig. 10: Installation example for the Thermo 230 / 300 / 350 heater
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To install the circulating pump
5 To install the circulating pump
The circulating pump must be installed as shown in Figures 11 and 12, Figure 14 and 15, Figure 17 and 18 or Figures 20 and 21. Note the installation position. NOTE: The pump ports and connection lines from the water intake and water outlet must be flush (no stress). 5.1. U 4814 circulating pump
Fig. 12: Hole pattern for the stand for U 4814 circulating pump
Delivery rate (with water at 20C)
Flow resistance (with the pump stopped)
Fig. 11: U 4814 circulating pump Installation position
Fig. 13: Delivery rate and flow resistance U 4814 circulating pump
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5.2. Aquavent 5000 S circulating pump

131,5 99,32

225 Br- Sw+ 0-90 90
Fig. 15: Hole pattern for the stand for Aquavent 5000 S circulating pump Delivery rate (with water at 20C) Flow resistance (with the pump stopped)
Fig. 14: Aquavent 5000 S circulating pump Installation position
Fig. 16: Delivery rate and flow resistance Aquavent 5000 S circulating pump
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5.3. U 4851 circulating pump

500 38

6,97,5

Br- Sw+

Fig. 18: Hole pattern for the stand for U 4851 circulating pump
* Clamping area of the stand clamp
Fig. 17: U 4851 circulating pump Installation position
Delivery rate (with water at 20C) Flow resistance (with the pump stopped)
Fig. 19: Delivery rate and flow resistance U 4851 circulating pump
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5.4. Aquavent 6000 S circulating pump

97,5 122,5

Fig. 21: Hole pattern for the stand for the Aquavent 6000 S circulating pump

Fig. 20: Aquavent 6000 S circulating pump Installation position
NOTE: When connecting the circulating pump is must be ensured that the volume flow does not drop below 1800 l/h !
Fig. 22: Delivery rate and flow resistance Aquavent 6000 S circulating pump
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5.5. Motor for the U 4851 / Aquavent 6000 S circulating pump The U 4851 / Aquavent 6000 S circulating motor is fitted with a brushless motor. 5.5.1. Soft start The motor starts slowly to protect its material. It does not reach its maximum speed for approx. 5 seconds. 5.5.2. Dry running protection (U 4851 only) A dry running protection is integrated in the motor for speeds >3300 rpm. If the motor consumes less than 4 A of current in a timeframe of 1018 revolutions, it assumes that it is running dry. The motor is switched off by the error motor (after approx. 10 seconds of operation or approx. 15 seconds after it was switched on). 5.5.3. Blocking protection If the speed falls to below 57 rpm the motor is switched off after approx. 1 second by the error mode. If the motor does not complete a full revolution in 1 seconds despite the medium flow, it is also switched off by the error mode. 5.5.4. Error mode The error mode switches off the motor in the event of faults. The motor is switched to power-saving sleep mode by the error mode after approx. 5 seconds. 5.5.5. Sleep mode In sleep mode the internal consumers of the motors electronics are switched off. The current consumption in this mode is then < 2 mA.
5.5.6. To reactivate the motor The motor can be reactivated from sleep mode. This is done by disconnecting it from the power supply for approx. 2 minutes. When the voltage supply is reconnected the motor will restart in soft start mode. 5.5.7. Reverse polarity protection The motor does not have polarity reversal protection. The motor is protected from polarity reversal by the wiring harness and a 25 A fuse.
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6 Connection to the vehicle cooling system
Connection to the vehicle cooling system
The heater is connected to the vehicle cooling system as shown in Figures 1, 2, 5 and 10. The system must contain at least 10 litres of coolant. A minimum of 20% of a good quality antifreeze should be maintained in the heating circuit of the heater at all times. The water hoses supplied by Webasto must always be used. If you do not use these hoses, the hoses that you do use must comply with DIN 73411. The hoses must be installed without kinks and (to ensure perfect bleeding of the heater) rising if possible. Hose connections must be supported by hose clips to prevent them slipping. NOTE: The specified tightening torques of the hose clamps used must be complied with. Only pressure valves with an opening pressure of min. 0.4 bar and max. 2.0 bar may be used in the vehicles cooling system or in a separate heating system. The cooling system must be bled carefully before using the heater for the first time or after replacing the coolant. The heater and lines should be installed in such a way as to ensure static bleeding. Perfect ventilation can be identified by the circulating pump operating almost silently. Poor bleeding may cause the resetting temperature limiter to trip whilst the heater is operating. When using circulating pump U 4851, approximately 15 seconds after switch-on the circulating pump is automatically switched off when there is a lack of coolant or the pump impeller is obstructed; it may be restarted after approximately 2 minutes. When using Aquavent 6000 S circulating pump, approximately 45 seconds after switch-on the circulating pump is automatically switched

off when there is a lack of coolant or the pump impeller is obstructed; it may be restarted after approximately 2 minutes. Also in the case of Thermo 230/231/300/301/350 heaters featuring control unit SG 1572 D in combination with a programmed check of the circulating pump, will the heater be switched off when there is a lack of coolant.
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Fuel supply

7 Fuel supply
The fuel is taken from the vehicle fuel tank or from a separate fuel tank. 7.1. Fuel lines Fuel lines are to be installed with a gradient wherever possible to prevent air inclusions. Connections within the line are to be secured with hose clips if no mechanical screw connectors are used. If fuel hoses are used, the hoses supplied by or available from Webasto must generally be used. If you do not use these hoses, the fuel hoses that you do use must comply with DIN 73379. Fuel hoses must not be kinked or twisted and must be secured with clips approx. every 25 cm. Materials commonly used in automobile manufacture, e.g. steel and plastic lines made of plasticized, light-resistant and temperaturestabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) as per DIN 73378 may also be used for fuel lines taking into account the suitable connection system in each case. The following must be observed for the installation of fuel lines: The lines must be protected from the effects of high temperatures. IMPORTANT! The external casing on the heater may reach the ignition temperature of diesel if it is operated without coolant. The lines must be protected from stone damage. Dripping or evaporating fuel must not be allowed either to accumulate or to ignition hot parts or electrical equipment It is not permissible to install a shut-off device in the return line! IMPORTANT Operation with a closed return line will damage the fuel pump. Fuel may escape. Danger of fire!
Unsupported fuel lines must be secured to prevent them sagging. Do not install an additional fuel pump. See pages 35 and 36 for the statutory regulations. 7.1.1. Maximum dimensions of the fuel lines: Internal diameter for intake and return line: 6 mm (other diameters to order). Maximum line length for each intake and return line: 10 m Maximum intake height: 2 m (we recommend the installation of a foot valve if the max. intake height is used) Max. permissible suction height: 2 m Max. permissible pressure in flow and return lines: 0.3. bar 7.2. Fuel filter A fuel filter supplied or approved by Webasto must be used (check the flow direction). To avoid malfunctions the filter or filter insert is to be replaced before the start of the cold weather.

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8 Combustion air supply

Combustion air supply
Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt or snow and cannot suck in splashing water. Maximum dimensions of the air intake line: Internal diameter: 55 mm Maximum line length: 5 m without the exhaust extension Maximum bends: 270 Total length of air intake line and exhaust pipe max. 5m The combustion air intake must not be routed above the exhaust outlet. NOTE: If the combustion air intake line cannot be installed so that it slopes downwards, a water drain hole with a diameter of 4 mm is to be made at its lowest point. If the heater is installed in a general installation space near the vehicles fuel tank, the combustion air must be taken in from the outside and the exhaust fumes discharged into the atmosphere. The openings must be splash-proof. A ventilation opening is required if the heater is installed in an enclosed box. Thermo 230 / Thermo 231 / Thermo 300 / Thermo cm2 Thermo cm2
The size of the ventilation opening must be increased subject to consultation with Webasto if the temperature in the box exceeds the permitted ambient temperature of the heater (see Technical data).
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Exhaust pipe

9 Exhaust pipe
The opening of the exhaust pipe must not point towards the front of the vehicle. The exhaust pipe opening must be located so that it cannot become clogged with snow and mud. Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm or flexible piping of alloyed steel only must be used as exhaust line. The exhaust pipe is secured to the heater using a clamping collar, for example. See the statutory regulations for other requirements. Maximum dimensions of the exhaust pipe: Internal diameter: 70 mm Maximum line length: 5 m without the combustion air intake extension Total length of air intake line and exhaust pipe max. 5m Maximum bend: 270 NOTE: If the exhaust line is installed near heat-sensitive parts, it must be insulated.
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10 Electrical connections

Electrical connections

10.1. Heater connection IMPORTANT HIGH VOLTAGE: Danger of death. Disconnect the plug connection to the vehicle before you open the heater. Make the electrical connections to the heater as shown in Figure 23: Automatic circuit diagram for water heaters type Thermo 230, Thermo 231, Thermo 300, Thermo 301 and Thermo 350 Any plug designs that differ from the standard versions (Figures 23 and 24) are to be requested separately from Webasto. Use the specified cable cross-sections. Connect the negative and positive terminals of the heater controller direct to the battery. 10.2. Connecting the controls The heater can be switched on and off using the following Webasto controls: Switch, see automatic circuit diagram Figure 23 Timer, see circuit diagram Figure 24 10.3. Control module The control module is installed in the heater. 10.4. Economy mode The connection of the switch for economy mode is shown in the automatic circuit diagram, Figures 23 and 24.

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10.5. Water Temperature Control Thresholds:: Heater Auxiliary heating 0->1 1->control idle period Parking heating 0->1 1->control idle period Economy setting 0->1 1->control idle period 55 70

Comment

Thermo 230.032 Thermo 300.031 Thermo 350.032 Thermo 230.126 Rail Thermo 300.126 Rail Thermo 350.126 Rail 10.5.1.
Standard data record Engine start-up (>+60C) Preheat + heat preservation (>+40C) Freeze protection (>+0C)
Pin Assignment of Cable Harness for Control Thresholds, Models Thermo 230 / Thermo 300 / Thermo 350 (Standard):: on/off on on on volts Connector 24 V XV XV X3 Pin 4 Comment only in conjunction with parking heater switch connecting wire to control unit only in conjunction with parking heater
Control unit function Auxiliary heating Parking heating Economy setting
NOTE: Auxiliary heating has priority over the economy setting! 10.5.2. Pin Assignment of Cable Harness for Control Thresholds, Models Thermo 230.126 / Thermo 300.126 / Thermo 350.126 (Rail):: on/off on on on volts 24 V 24 V 24 V Connector X3 X3 X3 Pin 2 Comment only in conjunction with parking heater switch connecting wire to control unit only in conjunction with parking heater
NOTE: Auxiliary heating has priority over the economy setting!
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10.6. Legend for circuit diagrams Diagnostic connector Cable cross-sections < 7.5 m 0.75 mm2 1.0 mm2 1.5 mm2 2.5 mm2 4.0 mm2
Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white
Digital timer P: with positive at connection 10= Continuous operation with immediate heating Connection 10 open = Variable heating duration can be programmed (10 min to 120 min); Default setting 120 min Plug assignment: 4-core cable 0.75 gr 0.75 or 0.75 gn 0.75 br Not occupied Not occupied 7-core cable 0.75 rt 0.75 or 0.75 bl 2.0 br 2.0 sw 2.0 rt/ws
7.5 - 15 m 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.0 mm2
Plug assignment D1 D2 D3 D4 F1 F2
with connection to terminal 61 heating mode Option
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Item Designation A1 A2 B1 B2 B3 B4 B5 B6 E E1 F1 F2 F3 F4 F5 F6 F7 H1 H2 H4 K4 M1 M2 P S1 Heater Control module Flame sensor Temperature sensor Temperature limiter Thermostat Thermostat Thermostat Filter heater Heating cartridge Fuse 25 A Fuse 25 A Fuse 5 A Fuse 25 A Fuse 5 A Fuse 5 A Fuse 5 A Light Light Heating symbol on the display Relay Motor Motor Switch Combustion air fan Circulating pump ON/OFF For nozzle preheating Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Blade-type fuse DIN 72581 Part 3 Indicator Flame indicator Power-on indicator (in item P) For nozzle preheating Alternative to B3 For vertical installation (MV Y1) SG 1572 D Check polarity Any polarity S4 S5 S6 T U1 U2 W1 W2 W3 A C D F O Q X1 X2 X3 X4 X5 X6 X7 Y1 Switch Switch Switch Comment Item Designation S3 Switch

Comment External activation Circulating pump Economy mode Auxiliary heating mode Filter heater on Filter heater
Temperature switch Ignition spark generator Ignition electrodes Wiring harness (1) Wiring harness (2) Wiring harness (3) Plug connector, 6-pin Plug connector, 1-pin Plug connector, 4-pin Plug connector, 2-pin Plug connector, 2-pin Plug connector, 2-pin Plug connector, 6-pin Plug connector, 2-pin Plug connector, 8-pin Plug connector, 12-pin Plug connector, 4-pin Plug connector, 4-pin Plug connector, 7-pin Solenoid valve
Digital timer, standard (1531) For programmed operation
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(15) 61 30

W2 X1 S1 S3

sw or 2,0 mm rt/ws

2,0 mm rt

2,0 mm br

U1 B6 B3/B5 B2

X2 A2 B4

A2 B1 Y1

B6 M1 Y1

H2 B1 A1

2,0 mm sw

Fig. 23: System circuit for Thermo 230 / 231 / 300 / 301 / 350 24V with control module 1572 D, with switch, for legend see page 57 and 58
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P H4 H1

Fig. 24: System circuit for Thermo 230/231/300/301/350 24V with control module 1572 D, with standard timer, for legend see page 57 and 58
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Fig. 25: System circuit for Thermo 230 / 300 / 350 Rail 24V with control module 1572 D, with standard timer, for legend see page 57 and 58
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Starting the heater for the first time
11 Starting the heater for the first time
NOTE: Refer to the safety instructions in the operating and maintenance instructions. The operating and maintenance instructions must be read through without fail before starting the heater. After you have installed the heater, bleed the water system and the fuel supply system carefully. Follow the instructions supplied by the vehicle manufacturer for this purpose. Conduct a trial of the heater to check all the water and fuel connections for leaks and to ensure that they are secure. If the heater suffers a fault during operation, the fault must be located and remedied.
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12 Maintenance

Maintenance
Periodic service activities have to be performed in accordance with Chapter 8 and Appendix A of the Workshop Manual. When the heater is operated in rail vehicles, maintenance chart / test certificate item no. 22 is to be used.

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Troubleshooting

13 Troubleshooting
13.1. Fault lock-out If it recognises one of the following fault features, the heater will conduct a fault lock-out. If several fault lock-outs occur in sequence, the heater will be disabled. Flashing pulse signals are output by the operation indicator light for heaters with control module 1572D. The combustion air blower and the circulating pump will be shut down after approx. 120 seconds. 13.1.1. Faults when the heater is switched on: Short-circuit or break Water temperature sensor Flame sensor Burner motor Solenoid valve 13.1.2. Faults during the start procedure: A flame is detected by the photo-electric controller before the high tension ignition spark is triggered. No flame identified approx. 25 seconds after the heater is started. Short-circuit / Break or dry operation (if programmed) of the circulating pump. If you use the U 4851 circulating pump, the pump will cut out automatically approx. 15 seconds after it is switched on if there is insufficient coolant or the pump impeller is blocked automatically and can be restarted after approx. 2 minutes.
13.1.3. Faults whilst the heater is operating: The voltage level falls below the lower threshold of approx. 21 V for a period of 20 seconds. Break in combustion for longer than 10 seconds. Short-circuit in the water temperature sensor. Break in the water temperature sensor. Short-circuit in the flame detector. Break in the flame detector. Short-circuit in the solenoid valve. 13.1.4. Faults whilst the heater is shutting down: Detection of a flame over than 30 seconds after the start of the shutdown cycle, with only the circulating pump operating during the following 90 seconds. 13.1.5. Faults due to overheating: If the heater overheats the temperature limiter/thermostat will complete a fault lock-out. Depending on the heater equipment: The button on the temperature limiter must be reset. The thermostat will be reset automatically when the heater has cooled down. The fault lock-out can be cancelled by switching the heater off and on again.
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13.2. Fault code output on heaters with control module 1572D If the system is equipped with a standard timer, a fault message appears on the display of the timer after a fault occurs. NOTE If the system is operated with a switch, the nature of the fault is indicated by a flashing code on an indicator light during the run-on time of the heater. After five short signals, count the long flashes. The flashes correspond to the number in the table below: F 01 F 02 F 03 F 04 F 05 F 06 F 07 F 08 F 09 F 10 F 11 F 12 No start Flame failure * Undervoltage or overvoltage Flame simulation identified during start-up or shut-down Flame detector defective Temperature sensor defective Solenoid valve defective Blower motor defective unused Temperature limiter defective / Overheating Ignition spark generator defective Fault lock-out due to repeated malfunction or repeated flame failure (8x no start-up or 5x flame failure) On the Thermo 231 and 301, if the overheating thermostat trips this is saved as a flame failure (F 02) in the control module

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Circulating pump Delivery rate Rated voltage Operating voltage range Rated power consumption Dimensions (Tolerance 3 mm) Weight Optional Fuel Filter Heater Filter heater Rated power consumption Rated voltage Switch-on point Switch-off point W VC C 0,5 2,5 5,5 2,5 U (against 0.15 bar) 24 20.Length 228.5 Width 100 Height 105 2,1 Aquavent 5000 S 5200 (against 0.15 bar) 24 20.Length 249 Width 100 Height 105 2,2
U (against 0.4 bar) 24 18.Length 279 Width 115 Height 110 2,7 Aquavent 6000 S 6000 (against 0.4 bar) 24 18.Length 284 Width 115 Height 110 2,95

I/h VVW mm mm mm kg