Webasto Thermo 230/300/350 Workshop Manual

Feel the drive
Water Heaters
Workshop Manual
Thermo 230 Thermo 300 Thermo 350

with control unit 1572 model .30 and up
Thermo 230 Thermo 300 Thermo 350

with control unit 1572D model .030 and up
Thermo 231 Thermo 301

model .01 and up
02/2005
Thermo 230 / 231 / 300 / 301 / 350 List of Contents
List of Contents
Introduction 1.1 1.2 1.3 1.4 1.5 Scope and Purpose ............................................................................................................................... 101 Applicability of Manual ........................................................................................................................... 101 Meaning of Warnings, Cautions and Notes ........................................................................................... 101 Additional Documentation to be used .................................................................................................... 101 Safety Information and Regulations....................................................................................................... 101 1.5.1 General Safety Notes ................................................................................................................. 101 1.6 1.7 Legal Provisions for Installation ............................................................................................................. 102 Corrections and Improvements.............................................................................................................. 103
General Description 2.1 2.2 Combustion Air Fan ............................................................................................................................... 202 Fuel Pump ............................................................................................................................................. 202 2.2.1 Nozzle block preheater............................................................................................................... 202 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 Heat Exchanger ..................................................................................................................................... 202 Combustion Chamber............................................................................................................................ 202 Control Unit............................................................................................................................................ 203 Flame Sensor ........................................................................................................................................ 203 Igniter Box with Igniter Electrodes ......................................................................................................... 203 Temperature Sensor.............................................................................................................................. 203 Temperature Limiter .............................................................................................................................. 203 Overheat Thermostat (Thermo 231 and 301 only) ................................................................................ 204 Circulation Pump ................................................................................................................................... 204
2.11.1 Circulation Pump U 4851 and Aquavent 6000 S ........................................................................ 204 2.12 Fuel Filter............................................................................................................................................... 205 3 Functional Description 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 Switch On .............................................................................................................................................. 302 Heating Operation.................................................................................................................................. 302 Switch Off .............................................................................................................................................. 302 Power Save ........................................................................................................................................... 302 Auxiliary Heating Operation (heaters with control unit 1572D only) ...................................................... 302 Heater Lockout (heaters with control unit 1572D only).......................................................................... 302 Switch-off upon Failure (heaters with control unit 1572)........................................................................ 303 Switch-off upon Failure (heaters with control unit 1572D) ..................................................................... 304 Error Code Output (heaters with control unit 1572D) ............................................................................ 305
Technical Data Electrical components...................................................................................................................................... 401 Propellant......................................................................................................................................................... 401
List of Contents
5 Troubleshooting 5.1 5.2 5.3
Thermo 230 / 231 / 300 / 301 / 350
General ................................................................................................................................................. 501 General Fault Symptoms ...................................................................................................................... 501 Fault Symptoms during Functional Checkouts and Error Code Output or Tests with Diagnostic Computer, Components Tester or PC Heater Diagnosis .................................................... 503 5.3.1 General ...................................................................................................................................... 503 5.3.2 Fault Symptoms......................................................................................................................... 504
Functional Checkouts 6.1 6.2 General ................................................................................................................................................. 601 Adjustments .......................................................................................................................................... 601 6.2.1 Adjustment of CO2 Contents ..................................................................................................... 601 6.3 Components Testing............................................................................................................................. 602 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 Temperature Sensor Resistance Check.................................................................................... Flame Sensor Resistance Check .............................................................................................. Igniter Electrodes Check ........................................................................................................... Igniter Box Check ...................................................................................................................... Fuel Pump Check ...................................................................................................................... Fan Motor Check ....................................................................................................................... Solenoid Valve Check ............................................................................................................... Nozzle Block Preheater Check .................................................................................................. 602 602 602 603 603 604 604 604
Circuit Diagrams 7.1 General ................................................................................................................................................. 701
Servicing 8.1 8.2 8.3 8.4 8.5 General ................................................................................................................................................. Heater Servicing ................................................................................................................................... Vehicle Servicing .................................................................................................................................. Heater Test Run.................................................................................................................................... Maintenance ......................................................................................................................................... 801 801 801 801 801
8.5.1 Inspection and Attachment of the Exhaust Muffler (only heaters from year of production 1996 and up to production date 1996, calendar week 36; 3G......) .......................... 801 8.5.2 Burner Head Opening and Closing or Removal and Installation ............................................... 803 8.6 Visual Inspections and Regulations for Installation............................................................................... 804 8.6.1 8.6.2 8.6.3 8.6.4 8.7 Connection to Vehicle Cooling System ..................................................................................... Connection to Vehicle Fuel System........................................................................................... Combustion Air Supply .............................................................................................................. Exhaust Line .............................................................................................................................. 804 804 806 806
Removal and Installation....................................................................................................................... 807 8.7.1 8.7.2 8.7.3 8.7.4 Heater, Removal and Installation .............................................................................................. Temperature Limiter, Replacement ........................................................................................... Temperature Sensor, Replacement .......................................................................................... Burner, Replacement................................................................................................................. 807 807 807 807
II
Thermo 230 / 231 / 300 / 301 / 350
List of Contents
8 7.5 Igniter Box, Replacement ........................................................................................................... 807 8.7.6 Flame Sensor, Replacement ...................................................................................................... 808 8.7.7 Combustion Chamber, Replacement ......................................................................................... 808 8.8 First Operation ....................................................................................................................................... 808 8.8.1 Water Circuit, Bleeding............................................................................................................... 808 8.8.2 Fuel Supply System, Bleeding.................................................................................................... 808 9 Repair 9.1 General .................................................................................................................................................. 901 9.1.1 Work on Components after Disassembly ................................................................................... 902 9.1.2 Incorporation of Modifications..................................................................................................... 902 9.2 Disassembly and Assembly................................................................................................................... 906 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.2.9 9.2.10 9.2.11 10 Temperature Limiter, Replacement ............................................................................................ 906 Temperature Sensor, Replacement ........................................................................................... 906 Burner, Replacement.................................................................................................................. 906 Combustion Air Fan, Replacement............................................................................................. 908 Control Unit, Replacement ......................................................................................................... 910 Fuel Pump, Replacement ........................................................................................................... 910 High Pressure Nozzle, Replacement.......................................................................................... 910 Igniter Box, Replacement ........................................................................................................... 912 Flame Sensor, Replacement ...................................................................................................... 912 Heat Exchanger, Replacement................................................................................................... 914 Combustion Chamber, Replacement ......................................................................................... 914
Packaging, Storage and Shipping 10.1 General ................................................................................................................................................ 1001
Annex A Heater, Scheduled Maintenance...................................................................................................................... A-2
III
List of Contents
Thermo 230 / 231 / 300 / 301 / 350 List of Figures
301 302 501 701 702 703 704 705 706 707 708 709 710 801 802 901 902 903 904 905
Functional Sequence (heaters with control unit 1572) .................................................................................... 303 Functional Sequence (heaters with control unit 1572D) ................................................................................. 304 General Fault Symptoms ................................................................................................................................ 501 Automatic Control Circuit with Control Unit 1572 and Switch ......................................................................... Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer) .................................................... Automatic Control Circuit with Control Unit 1572D and Switch....................................................................... Automatic Control Circuit with Control Unit 1572D and Standard Timer......................................................... System Circuit Daimler Chrysler Citaro, Ident.-Nr. 67131............................................................................... System Circuit Van Hool, Ident.-Nr. 89401 ..................................................................................................... System Circuit O405 / O407 / O408, Ident.-Nr. 91292.................................................................................... System Circuit MAN, Ident.-Nr. 89404 ............................................................................................................ System Circuit SETRA, Ident.-Nr. 90972 ........................................................................................................ Automatic Control Circuit Rail with Control Unit 1572D and Standard Timer and filter heater ....................... 702 703 704 705 706 707 708 709 710 711
Swinging Burner Head open ........................................................................................................................... 803 Example of a Heater Installation in a Passenger Bus ..................................................................................... 805 Temperature Limiter, Temperature Sensor and Burner, Replacement........................................................... Combustion Air Fan, Replacement ................................................................................................................. Control Unit and Fuel Pump, Replacement..................................................................................................... Igniter Box and Flame Sensor, Replacement ................................................................................................ Heat Exchanger and Combustion Chamber, Replacement ............................................................................ 907 909 911 912 914
IV
Thermo 230 / 231 / 300 / 301 / 350 1

1.1
1 Introduction
1.4 Additional Documentation to be used
Introduction
Scope and Purpose
This repair shop manual is intended to support familiarized personnel in the repair of water heaters Thermo 230, 231, 300, 301 and 350. The water heater may only be operated with the fuel specified on the model plate and the relevant designated type of electrical connection.
This workshop manual contains all information and procedures necessary for the repair of heaters Thermo 230, 231, 300, 301 and 350. The use of additional documentation is normally not necessary. Operating instructions and installation instructions may be used as complementary information as necessary.
1.5
Safety Information and Regulations
1.2
Applicability of Manual
This manual is applicable only for heaters identified on the title page. The different appearance of control units (see 2.5) allow to distinguish between model .30 and up with control unit 1572 and the model .030 and up with control unit 1572D. In combination with control unit 1572D additionally a different type of igniter box is installed (refer to 2.7). The heaters Thermo 231 and 301 are variants for vertical installation.
The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times. "General Safety Regulations" beyond the scope of these regulations are detailed in the following. The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings, Cautions, and Notes.
1.5.1 General Safety Notes

The year of first operation must be permanently marked on the identification label by removing the relevant number of the year. The heaters are cleared for heating the vehicle engine and the passenger cabin. The use of the heater in vehicles not subject to the EU Directive 70/156/EEC (e.g. ships) is partly governed by regional regulations. For heaters designed for installation in rail vehicles, type approval has been granted (not for Thermo 231 and 301) by the Federal Railway Authority with the type approval number: EBAAZ3/0141/04. The heater may only be fitted in vehicles or in independent heating systems with a minimum coolant capacity of 10 liters. The heater may only be installed in motor vehicles or in independent heating systems with a minimum coolant capacity of 6 liters. The heater must not be installed in the passenger or driver compartments of vehicles. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior. There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 85 C in the installation box. Excessive temperatures may cause malfunctions. WARNING Due to the danger of poisoning and suffocation the heater must not be operated, not even with timed 101
1.3
Meaning of Warnings, Cautions and Notes
WARNINGS, CAUTIONS, and NOTES in this manual have the following meaning: WARNING This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents to personnel. CAUTION This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment. NOTE This heading is used to highlight and draw specific attention to information.
1 Introduction
operation, in enclosed areas such as garages or workshops not equipped with an exhaust venting facility. At filling stations and fuel depots the heater must be switched off to prevent explosions. CAUTION Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal depots, or similar installations) the heater must be switched off to prevent explosions. The heater must not be operated near flammable materials such as dry grass and leaves, cardboard boxes, paper, etc. In the vicinity of the water heater a temperature of 110 C (storage temperature) must not be exceeded under any circumstances (e.g. during body paint work). A violation of this temperature limit may cause permanent damage to the electronics. When checking the cooling water level proceed in accordance with the vehicle manufacturers instructions. The water in the heating circuit of the heater must contain a minimum of 20% of a quality brand anti-freeze. Additives in the heating circuit must not affect metals, plastics and rubber and must leave no deposits. The opening pressure in the vehicle cooling system normally indicated on the radiator filler cap - must be between 0.4 and 2.0 bar above operating pressure (also applicable to separate heating circuits).
Thermo 230 / 231 / 300 / 301 / 350

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. NOTE: For further notes and provisions relating to the installation of the heater in vehicles, refer to the installation instructions. 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. Installation Instructions for Webasto fuel tanks for the fuel supply of water heaters in vehicles: in busses and trains the installation is not permitted in the passengers or drivers compartment. the fuel filler neck must not be located in the passengers or drivers compartment of any vehicle. fuel containers must either be equipped with a vent cap or any other type of ventilation (vent line).
Only vent caps in accordance with DIN 73400 may be used.
1.6
Legal Provisions for Installation
With effect from 4/03, Type Approvals pursuant to EC Directives 72/245/EEC (EMC) and 2001/56EC (Heating Systems) were granted for the heaters Thermo 230 / Thermo 231 / Thermo 300 / Thermo 301 / Thermo 350 with the following EC Type Approval Numbers: e1*72/245*95/54*1010*-e1*2001/56*0007*-- for Thermo 230 e1*2001/56*0008*-- for Thermo 300 e1*2001/56*0009*-- for Thermo 350 e1*2001/56*0010*-- for Thermo 231 e1*2001/56*0011*-- for Thermo 301 Up to 4/03, General Design Certifications existed for these heaters. 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 102
All fuel containers offered in the Webasto Accessories Catalogue are suitable for a maximum operating pressure of 0.15 bar overpressure. All fuel containers offered in the Webasto Accessories Catalogue are subjected during manufacture to individual pressure testing with at least 0.3 bar overpressure. The operational state of the heater, i.e. at least an indication "on" or "off" must be easily and clearly visible.
For heaters in vehicles not ruled by the EU Directive but other regulations, the acceptance by the relevant authority is required as applicable.
Thermo 230 / 231 / 300 / 301 / 350

1.7 Corrections and Improvements
1 Introduction
Deficiencies, improvements, or proposals for correction of this workshop manual are to be mailed to: Webasto AG Abt. Technische Dokumentation Bus D-82131 Stockdorf Telephone:++49 (0) 18 05 / 93 22 78 Telefax: ++49 (0) 395 7 55 92-353
103
1 Introduction
Thermo 230 / 231 / 300 / 301 / 350
Page empty for notes 104
Thermo 230 / 231 / 300 / 301 / 350 2 General Description
2 General Description
The heaters Thermo 230, 231, 300, 301 and 350 basically consist of the combustion air fan the fuel pump with nozzle block and nozzle the heat exchanger and the combustion chamber the igniter box with igniter electrodes
The water heaters Webasto Thermo 230, 231, 300, 301 and 350 are used in combination with the vehicles own heating installation to heat the passenger compartment defrost the windscreen preheat water-cooled engines
For control and monitoring the heater includes a control unit a flame sensor a temperature sensor a temperature limiter a temperature limiter without reset button for Thermo 231and301 and Thermo 230.126, 300.126 and 350.126 Rail
The heaters Thermo 231 and 301 are variants for vertical installation. The difference in appearance are the different identification label and the Z profiles on the installation interface. The water heater operates independent from the vehicle engine and is connected to the vehicle cooling system, the fuel system and the electrical system. The heater designed to the heat exchanging principle operates intermittently controlled by the temperature sensor.
An external circulating pump is installed inside the vehicle, or, in the case of compact units, directly at the heater.
4 3
6 11 7 1 2 3 4 5 6 7 8 9 10 11
Thermo 231/301 Burner Coolant inlet Temperature limiter Temperature sensor Coolant outlet Heat exchanger Exhaust outlet Fuel return Combustion air inlet Fuel delivery Splash protection cover (instead of screen) 201
8 10 9
Thermo 231/301
2.1 Combustion Air Fan
Thermo 230 / 231 / 300 / 301 / 350

2.2.1 Nozzle block preheater
NOTE For operation with PME (Bio Diesel) the installation of a nozzle block preheater is mandatory. At extremely low temperatures malfunctions may occur without a nozzle block preheater. At a temperature of < 0 C a thermostat activates the heater cartridge in the nozzle block. The heating period depends on the heat reflected within the combustion chamber. Preheating is deactivated when the thermostat ambient temperature is +8 C. If the heater is not equipped with a nozzle block preheater a retrofit is possible.
The combustion air fan supplies the air required for combustion from the combustion air inlet to the combustion chamber. Fan motor Splash protection cover
Fan wheel Screen Cap
2.3
Heat Exchanger
The fan consists of a fan motor with fan wheel. Air is taken in through a splash protection cover or a screen and the cap. The heaters Thermo 231 and 301 are provided with a splash protection cover only.
The heat exchanger transfers the heat generated by combustion to the coolant circuit.
2.4 2.2 Fuel Pump
Combustion Chamber
The fuel pump delivers the fuel and is driven by the fan motor via a clutch. The fuel is compressed in the pump to approximately 10 bar and diffused by a high pressure nozzle. A screwed on solenoid valve controls the fuel flow to the nozzle. Solenoid valve Nozzle block preheater
The fuel/air mix is dispersed in the combustion chamber for combustion to heat the heat exchanger.
Heat exchanger
Combustion chamber
Screen
O-ring
Fuel pump
202
Thermo 230 / 231 / 300 / 301 / 350

2.5 Control Unit 2.7
Igniter Box with Igniter Electrodes
The control unit 1572 or 1572D is the central component to ensure controlled operation and monitoring of combustion. If the heater has a control unit 1572 installed, a retrofit of control unit 1572D is possible (see Section 9).
The igniter box generates the high voltage for igniting the fuel/air mix by a high voltage ignition spark across the electrodes. Igniter electrodes Igniter box (black connector cover) only in combination with control unit 1572 Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572
2.8
Temperature Sensor
Control Unit 1572
The temperature sensor senses the coolant temperature at the heat exchanger outlet as an electrical resistance. This signal is supplied to the control unit for processing.
2.9
Temperature Limiter
The temperature limiter (bimetal) protects the heater against undue high operating temperatures. The temperature limiter can be reset manually. The temperature limiter responds at a temperature in excess of 125 C to switch off the heater. In the case of Thermo 231 and 301 and Thermo 230.126, 300.126 and 350.126 Rail, the temperature limiter will trip at a temperature in excess of 105C. After the temperature has dropped, an automatic reset will occur. Control Unit 1572D Temperature sensor
2.6
Flame Sensor
The flame sensor continuously monitors the flame condition during operation. The flame sensor is a photo transistor changing its resistance depending on the flame intensity. The signals are supplied to the control unit for processing. Flame sensor Temperature limiter
203
2.10 Overheat Thermostat for burner (Thermo 231 and 301 only)
The overheat thermostat is screwed onto the disk and electrically connected to the solenoid valve of the fuel pump. When the burner overheats the thermostat causes an error lockout.
Thermo 230 / 231 / 300 / 301 / 350
U 4851
Aquavent 6000 S
Overheat Thermostat
2.11 Circulation Pump

The externally mounted circulation pump ensures proper coolant circulation in the vehicle and heater circuit. The pump is activated by the control unit to operate as long as the heater is in operation. The heaters may be operated with circulation pump U 4814, Aquavent 5000 S, U 4851 or Aquavent 6000 S.
2.11.1 Circulation Pump U 4851 and Aquavent 6000 S

The circulation pump U 4851 / Aquavent 6000 S is equipped with a brushless motor. Soft start (U 4851 only) Motor run-up is slow with no stress for the material. It takes 5 seconds to reach maximum speed. Dry run protection Integrated in the motor is a dry run protection for speeds > 3300 rpm. If the motor in a time window of 1018 revolutions has a power consumption less than 4 A a dry run condition is identified. The motor is switched off by means of the failure mode (after approx. 10 seconds when in operation or approx. 15 seconds after activation).
U 4814
Aquavent 5000 S
Seizure protection When operating speed drops below 57 rpm the motor is switched off after approx. 1 seconds by means of the failure mode. If no complete revolution is achieved within 1 second with the motor powered, the motor is switched off by means of the failure mode. Overload protection After completion of the soft start an overload protection is activated to limit the power consumption and keep the speed at 5550 rpm. That means that the motor is not damaged in case of circulation pump hydraulic overpressure.
204
Thermo 230 / 231 / 300 / 301 / 350

Failure mode The failure mode stops the motor in case of malfunctions. After approx. 5 seconds the failure mode switches the motor to the power saving sleep mode. Sleep mode In the sleep mode the internal consumers of the motor electronics are switched off. The power consumption in this mode then amounts to < 2 mA. Motor reactivation The motor can be reactivated out of the sleep mode by disconnection of the power supply for approx. 2 minutes. After power reconnection the motor will again run up with a soft start. Reverse pole protection The motor is not equipped with an internal reverse pole protection. In combination with a wiring harness and a 25 A fuse the motor is protected against reverse poling.
2.12 Fuel Filter

In the case of compact units of the 230/300/350.126 Rail model range, a fuel filter is fitted that may be heated if desired. When the integrated filter heater is connected, the temperature switch will turn the filter heater on at a fuel temperature of 0.5 2.5 C and turn it off at 5.5 2.5 C.
205
Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description
3 Functional Description
Activation and deactivation is by means of a switch timer air conditioning dependent on the type of installation. For monitoring operation at least an operating indicator light is provided. Switch off releases a run-down procedure (see "Switch off"). The heaters may be operated with power save for reduced fuel consumption (see circuit diagram) equipped or retrofitted with a nozzle block preheater for extreme low temperatures. Heaters with control unit 1572D only When connecting terminal +61 the heaters may operate in the auxiliary heating mode of operation. Operating Thresholds Control Unit Ident. No. 63482E Ident. No. 97806B Bus Ident. No. 97810A Rail Standard Ident. No. 63859D Bahn J.E.S Ident. No. 67981C Bahn Vossloh
Auxiliary heating Upper operating point Lower operating point 85C 78C 85C 70C 85C 75C 80C 72C
Parking heating, normal Upper operating point Lower operating point 85C 70C 60C 45C 85C 70C 75C 60C
Parking heating, economy Upper operating point Lower operating point 70C 55C 20C 5C 70C 55C 57C 42C
Gradient evaluation Hysteresis adaptation
YES YES
YES YES
YES YES
YES YES
301
3.1 Switch On
Thermo 230 / 231 / 300 / 301 / 350

heaters with control unit 1572D). Reactivation of the heater during run-down is permitted. The burner immediately resumes operation after the run-up time.
Upon switch on the operating indicator light goes on. Combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 C nozzle block preheater is also activated). After approximately 12 seconds (run-up time) the high voltage igniter spark is available. Approximately 1 second later the solenoid valve in the fuel pump opens and the nozzle sprays fuel into the combustion chamber to be ignited by the igniter spark. A photo control circuit deactivates the igniter box after flame-up.
3.4
Power Save
With power save on the control temperatures of the heating circuit are kept low. Combustion performance is not reduced. This results in a reduced heat radiation loss when limited heating performance is required (e.g. in heat hold operation) cutting down fuel consumption.
3.2
Heating Operation
After reaching operating temperature the control unit takes over to provide controlled operation by activation and deactivation of the burner in order to maintain a nearly constant temperature of the heat exchanger (coolant). The heating operation is terminated as soon as the upper operating point is exceeded. The heater now starts the control idle period. Heater operation is resumed when the temperature drops below the lower operating point. Heaters with control unit 1572D only Gradient evaluation With a low coolant flow rate or poor venting, the temperature in the heating mode rises too quickly. If gradient evaluation is available, the control unit is able to detect any undue temperature rise and can automatically shift the upper operating point to a lower value. Any tripping of the temperature limiter due to residual heat after the combustion operation has been terminated can thus be prevented. Control idle period A rise in temperature above the upper operating point makes the solenoid valve in the fuel pump shut off the fuel supply initiating the run-down. The flame extinguishes, the combustion air fan and the circulation pump however continue their operation. After approximately 90 seconds (120 seconds for heaters with control unit 1572D) run-down is completed with deactivation of the combustion air fan. The circulation pump remains in operation during the control idle period. The operating indicator light is on.
3.5
Auxiliary Heating Operation (heaters with control unit 1572D only)
If terminal +61 (engine running) is connected and active, the heater will be operating in the auxiliary heating mode. In the auxiliary heating mode, the economy setting is deactivated automatically by the control unit. The lower temperature threshold for restarting the burner after the control idle period is here higher than in the parking heating mode and is shifted automatically up or down depending on the combustion time of the heater (hysteresis adaptation. Hysteresis adaptation (example) After the first control idle period, the lower operating point is 78C. Combustion operation is started when the temperature falls below this threshold. The length of combustion time until the upper operating point is exceeded should be 120 seconds. If combustion lasts more than 120 seconds, the lower operating point is increased by 1 Kelvin, up to max. 80C. If combustion time is less than 120 seconds, the lower operating point is lowered by 1 Kelvin, down to minimally 70C.
3.6
Heater Lockout (heaters with control unit 1572D only)
3.3
Switch Off
Switching off the heater stops combustion. The operating indicator light goes out and run-down commences. The combustion air fan and circulation pump are deactivated after approximately 90 to 120 seconds (120 seconds for 302
After the heater has performed eight consecutive start attempts due to a malfunction or after five consecutive subsequent flame-outs the heater enters a lockout and start attempts are suspended. This lockout is superior to the normal error lockout. Unlocking is performed by starting the heater and disconnection of the main power supply of the heater during error run-down.
Thermo 230 / 231 / 300 / 301 / 350
A B C H1 E1 M2 U1 M1 Y1 B1 Operating indicator light Heater cartridge Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor
7 3 1 2 5 6 8 2 3 9 6 10
D E F G
A B C D E F G
12s 12 13 11 1s 1s 14 15 12s 30s max. 90s 16 12s 12 13 1s 1s 14 15 12s 30s max. 90s 16
1 2 3 5 6 7 8 9 10 11 12 13 14 15 16
Switch on Start Combustion operation Temperature sensor upper switching threshold Flame sensor dark Control idle Temperature sensor lower switching threshold Switch off Heater off Nozzle block preheater Start-up Foreign light check Pre-ignition Safety period Run-down
Fig. 301 Functional Sequence (heaters with control unit 1572)
3.7
Switch-off upon Failure (heaters with control unit 1572)
The heater switches off automatically when detecting one of the following malfunctions. The operating indicator light goes off. Combustion air fan and circulation pump are deactivated after approximately 90 to 120 seconds. Malfunctions during switch-on short or open circuit of temperature sensor. short or open circuit of flame sensor. open circuit of solenoid valve. Malfunctions during start-up: flame detected by photo control circuit prior to high voltage igniter spark. no flame detected after approximately 25 seconds after heater start. Malfunctions during heating operation: low voltage threshold of approximately 20V violated for a duration of 12 seconds. no combustion for more than 10 seconds.
temperature sensor short or open circuit. temperature sensor short or open circuit during combustion. flame sensor short or open circuit during combustion. solenoid valve short or open circuit during combustion.
Malfunctions during run-down: Detection of a flame after more than 30 seconds after start of run-down with the circulation pump and combustion air fan maintaining operation for the following 90 seconds. Malfunctions by overheating: Overheating results in deactivation of the heater by the temperature limiter. After the heater has cooled down and the cause of overheating has been corrected, the temperature limiter must be reset by pressing the reset button. An error reset for a new start standby is achieved by switching the heater off and on again.
303
Thermo 230 / 231 / 300 / 301 / 350

A C D E
3
H1 M2 U1 M1 Y1 B1
Operating indicator light Circulation pump Igniter box Combustion air fan Solenoid valve Flame sensor
7 3 1 2 5 6 8 2
F
9 6 10
A C D E F G
12s 12 13 1s 1s 14 15 max. 12s max. 30s max. 120s 16 12s 12 13 1s 1s 14 15 max. 12s max. 30s max. 120s 16
1 2 3 5 6 7 8 9 10 12 13 14 15 16
Switch on Start Flame-up, combustion operation Temperature sensor upper switching threshold Flame sensor dark Control idle Temperature sensor lower switching threshold Switch off Heater off Start-up Foreign light check Pre-ignition Safety period Run-down
Fig. 302 Functional Sequence (heaters with control unit 1572D)
3.8
Switch-off upon Failure (heaters with control unit 1572D)
The heater switches off automatically when detecting one of the following malfunctions. Several subsequent switch-offs due to a malfunction will cause the heater to enter an error lockout condition. Flash pulses are output via the operating indicator light. The combustion air fan and the circulation pump are switched off after approx. 120 seconds. Malfunctions during switch-on: Short or open circuit of temperature sensor flame sensor burner motor solenoid valve igniter box Malfunctions during start-up: short circuit of igniter box open circuit of igniter box flame detected by photo control circuit prior to high voltage igniter spark. no flame detected after approximately 25 seconds after heater start.
short/open circuit or dry run (if programmed) of circulation pump. when using the circulation pump U 4851 approximately 15 seconds after switch-on the circulation pump is automatically stopped and may only be reactivated after approximately 2 minutes should coolant be missing or the pump wheel be seized.
Malfunctions during heating operation: low voltage threshold of approximately 21 V violated for a duration of 20 seconds. no combustion for more than 10 seconds. temperature sensor short or open circuit. flame sensor short or open circuit. solenoid valve short or open circuit. Malfunctions during run-down: Detection of a flame after more than 30 seconds after start of run-down with the circulation pump and combustion air fan only maintaining operation for the following 90 seconds.
304
Thermo 230 / 231 / 300 / 301 / 350

Malfunctions by overheating: Overheating results in deactivation of the heater by the temperature limiter. Dependent on heater configuration: the reset button on the temperature limiter must be reset. the reset is performed automatically after cool down. An error reset for a new start standby is achieved by switching the heater off and on again. Malfunctions by overheating of the burner (Thermo 231 and 301): Overheating of the burner causes the overheat thermostat to initiate an error lockout at 150 C. The solenoid valve closes, the fuel supply is cut off and a run-down is launched. An auto-reset occurs after cooldown of the thermostat.
3.9 Error Code Output (heaters with control unit 1572D)
When equipped with a standard timer an error code readout appears on the display of the timer after a malfunction. NOTE When the heater is operated by means of a switch the type of error is output during heater run-down via a flash code of the operating indicator light. After five short signals the long flash pulses are counted. The flash pulses correspond to the error number in the table below: F 01 no start F 02 flame failure * F 03 low voltage or excess voltage F 04 foreign light detected during run-up and run-down F 05 flame sensor defective F 06 temperature sensor defective F 07 solenoid valve defective F 08 fan motor defective F 09 circulation pump defective F 10 temperature limiter defective / overheating F 11 igniter box defective F 12 error lockout due to repeated malfunction or repeated flame failure (8x no start-up or 5x flame failure) * A response of the overheat thermostat will be stored in the control unit as a flame-out (F 02) (Thermo 231 and 301).
305
Thermo 230 / 231 / 300 / 301 / 350
306
Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data
4 Technical Data
Where no threshold values are specified technical data are understood to include standard tolerances for heater units of 10% at ambient temperature of + 20 C and at nominal voltage.
Electrical components
Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge for nozzle block preheater and timer are 24 V components. Temperature limiter, flame sensor, temperature sensor and switches are voltage independent components. NOTE The allocation of circulation pumps to heater units must be in accordance with coolant resistances.
Propellant
The suitable propellant is the Diesel fuel specified by the vehicle manufacturer. Only the type of fuel indicated on the identification plate may be used. Also Diesel fuel with an addition of 5% PME (vegetable oil methyl ester), class EL fuel oils (not fuel oil L) or petroleum may be used if their quality is in accordance with the German standard. A bad influence caused by additives is not known. When using fuel out of the vehicle tank the information about additives of the vehicle manufacturer must be observed. When using fuel out of a separate fuel tank and at temperatures below 0 C, winter Diesel fuel must be used. The use of flow improvers is permitted. Mixing ratio for separate fuel tank and temperature below 0 C. Temperature 0 C to 20 C 20 C to 30 C Winter Diesel fuel 100 % 70 % Additive petroleum or petrol 30 %
or special low temperature Diesel fuel 30 C to 40 C special low temperature Diesel fuel or 100 % petroleum
401
4 Technical Data
Circulation pump Type Mark of conformity up to 4/03
EC type approval number e1*2001/56*
Thermo 230 / 231 / 300 / 301 / 350

Thermo 230 DW 230 ~ S230
0007*--
Thermo 231 Thermo 231 ~ S327

0010*--
Thermo 300 DW 300 ~ S229

0008*--
Thermo 301 Thermo 301 ~ S328

0011*--
Thermo 350 DW 350 ~ S228

0009*--
Heater principle Heating flow Fuel Fuel consumption Nominal voltage Operating voltage Nominal power consumption (without circulation pump) Permissible operating ambient temperature range (heater, control unit, circulation pump) Permissible storage temperature Permissible operating overpressure Heat exchanger capacity Minimum capacity of circuit CO2 in exhaust at nominal voltage Dimensions heater (tolerance 3 mm) Weight kg/h VVW 65 2.5 KW (kcal/h) 23 (20 000)
High pressure atomizer 30 (26 000) Diesel / fuel oil 3.3 24 20 ... 28 110 140 3.7 35 (30 000)
C C bar l l Vol.-% mm mm mm kg
40 ... +85 +110 max. 0.4 ... 2.0 1.8 10.00 10 0.5 related to 500 m above S.L. Length 610 Width 246 Heigh 220 19
402
Thermo 230 / 231 / 300 / 301 / 350
4 Technical Data
Circulation pump Volume flow Nominal voltage Operating voltage range Nominal power consumption Dimensions l/h VVW mm mm mm kg
U 4814
Aquavent 5000 S
U 4851 6000 (against 0.4 bar)
Aquavent 6000 S
5200 5200 (against 0.15 bar) (against 0.4 bar)
6000 (against 0.4 bar)
24 20 ... 28 104 Lenght 221 Width 100 Height 105 2.1 215 Lenght 249 Width 100 Height 105 4.75 209 Lenght 279 Width 115 Height 110 2.7 209 Lenght 284 Width 115 Height 110 2.95
Weight
Optional Fuel Filter Heater Filter Heater
Nominal power consumption W Nominal voltage

Switch-on point Switch-off point VC C
240 24 0,5 2,5 5,5 2,5
403
4 Technical Data
Thermo 230 / 231 / 300 / 301 / 350
404
Thermo 230 / 231 / 300 / 301 / 350 5

5.1
5 Troubleshooting
CAUTION Troubleshooting is normally limited to the isolation of defective components. The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunction: corrosion on connector loose contact on connector wrong crimping on connector corrosion on wiring and fuses corrosion on battery terminals After any fault correction a functional checkout in the vehicle has to be performed.
Troubleshooting
General
This section describes troubleshooting procedures for the heaters Thermo 230, 231, 300, 301 and 350. CAUTION Troubleshooting requires profound knowledge about components and their theory of operation and may only be performed by trained personnel. In case of doubt functional interrelations may be derived from Sections 2 and 3.
5.2
General Fault Symptoms
The following table (Fig. 501) lists possible fault symptoms of general nature. Symptom Fault in electrical system Operating indicator light is not on, no heater operation. no power supply fuses wiring to terminals of connector A of control unit. Probable Cause
Fuse F2 blows. Fuse F3 blows. Normal heater operation, operating indicator light is out.
Short circuit in circulation pump or in wiring to heater. Short circuit in wiring to heater/motor/nozzle block preheater (if installed). Operating indicator light defective or wiring to light open or shorted.
Fault in water system Circulation pump not operating (U 4851 and Aquavent 6000 S only) Failure mode activated
The failure mode switches the motor off in case of malfunctions. After approx. 5 sec the failure mode switches the motor to the power saving sleep mode. In the sleep mode the internal consumers of the motor electronics are switched off. The power consumption in this mode then amounts to < 2 mA. The motor can be reactivated out of the sleep mode by disconnection of the power supply for approx. 2 minutes. After power reconnection the motor will again run up with a soft start. Fig. 501 General Fault Symptoms (Sheet 1 of 3)
501
5 Troubleshooting
Symptom Heater operation stops because heat exchangers connected do not dissipate enough heat.
Thermo 230 / 231 / 300 / 301 / 350

Probable Cause Rate of flow too low, because air in heater, in heat exchangers or in system sections. cocks (flow regulator) throttled, contaminated or closed. contamination in system, e.g. in areas of restricted flow. circulation pump rate of delivery insufficient (air in pump housing). wrong sense of rotation check wiring colors (black + / brown ). not enough anti-freeze. excessive system resistance (especially high when cold). circulation pump defective. Heat exchanger dissipate not enough heat, because air in heat exchangers or in system sections. contaminated heat exchanger surfaces (external). insufficient air intake or exit. fan: rate of delivery low / wrong sense of rotation / resistance too high. too much anti-freeze. heat exchanger of too low capacity.
Rough calculation of rate of flow heat flow [kW] acc. to ident. label Rate of flow in [l/h] = temperature difference t in [K] or [C] measured between heater water inlet and outlet (e.g. with contact thermometer) x 860
Fault in fuel supply No fuel delivery to heater. fuel tank empty. kinked, closed, contaminated or leaking lines. paraffin deposits or water captured in fuel filter or fuel lines. vent in tank clogged. fuel lines interchanged. fuel filter contaminated. fuel screen in pump contaminated.
Fig. 501 General Fault Symptoms (Sheet 2 of 3)
502
Thermo 230 / 231 / 300 / 301 / 350

Symptom Wrong combustion CO2 value cannot be set to rated value, combustion irregular. Probable Cause
5 Troubleshooting
air bubbles in suction line (suction line leaking). fuel filter contaminated or leaking. fuel system integration leak (suction height, low pressure in tank); observe installation instructions. fuel pump defective (pump pressure). return line throttled. filter screen in pump contaminated. O-ring sealing on fuel pump no longer effective (ageing) nozzle jet defective. combustion air or exhaust lines throttled or closed. fan motor speed too low.
Fig. 501 General Fault Symptoms (Sheet 3 of 3)
5.3
Fault Symptoms during Functional Checkouts and Error Code Output or Tests with Diagnostic Computer, Components Tester or PC Heater Diagnosis
Operation of the diagnostic computer is menu controlled by means of four push button switches. For details refer to operating instructions for "Diagnostic Computer". Components Tester
5.3.1 General
Error Code Output NOTE Only heaters with a control unit 1572D provide an error code output. When equipped with a standard timer an error code readout is available after a malfunction on the display of the timer. When the heater is operated by means of a switch a coded flashing of the operating indicator light during run-down of the heater or until switch-off indicates the type of error (see 3.9). Diagnostic Computer NOTE Checks with the diagnostic computer may only be performed on heaters equipped with control unit 1572. By use of the diagnostic computer heaters may be checked in the vehicle. The following tests are available: indication of measured values: water temperature, control unit supply voltage, flame sensor bright/dark. indication and erasure of faults stored in the control unit. NOTE Checks with the components tester may only be performed on heaters equipped with control unit 1572. Using the components tester several types of faults and component malfunctions may be analyzed in the vehicle. The test of the individual components with the components tester is not intended. Faults like short or open circuits may be detected with the components tester but cannot be localized. For details refer to operating instructions for "Components Tester". PC Heater Diagnosis By use of the PC heater diagnosis heaters (with control unit 1572 or 1572D) may be tested in the vehicle. For details refer to operating instructions for "PC Heater Diagnosis".
503
5 Troubleshooting
5.3.2 Fault Symptoms
5.3.2.1 Fault Symptom "No Start" NOTE Heaters with control unit 1572D: If the heater performs 8 consecutive attempts to start due
Thermo 230 / 231 / 300 / 301 / 350

to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply during run-down.
NO
Switch on heater. Is combustion air fan operating? Motor and fan wheel free to move? Is fan wheel caught in cap? Is voltage present on plug contact A3? Check fuses F1/F2/F3 and relais K1, K2 and replace as required (control unit 1572 only). Does trouble persist?
YES
Check motor electrics and replace as required.
Replace cap and fan wheel.
Is voltage too low? Rated value >20,5 volts ( 0,5 volts)
Check electrical wiring and connections. Does trouble persist?
Low voltage switch off during start-up. Check battery.
Control unit defective, replace.
Is fuel free of bubbles in supply and return?
Is fuel filter contaminated?
Fuel suction line leak?
Fuel lines empty?
Are O-rings in fuel pump? Is pump mounted securely?
Replace fuel filter.
Retighten line connections, replace lines as required.
Repeat start (several times if necessary) until lines are filled.
Fuel pump defective, replace.
Is solenoid valve connected to electrics?
Connect solenoid valve.
Is gap between igniter electrodes ok?
Check gap between igniter electrodes.
Is nozzle free of foreign matter and deposits and properly secured?
Replace nozzle.
Is viewing glass of flame sensor contaminated?
Clean window and viewing glass.
504
Thermo 230 / 231 / 300 / 301 / 350

5.3.2.2 Fault Symptom "Flame-out" NOTE Heaters with control unit 1572D: If the heater performs 5 consecutive attempts to start due to a malfunction, the heater enters an error lockout and
5 Troubleshooting
stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply during run-down.
NO
Switch on heater. Is combustion air fan operating? Electrical power supply, fuses, plug contacts, relays o.k.? (control unit 1572 only) Replace defective electrical components.
YES
Is fuel free of bubbles in supply and return?
Is fuel filter contaminated or jellied?
Is fan wheel free to move?
Check cap, motor and fan wheel.
Replace filter and check fuel low temperature rating.
Is motor o.k.?
Replace motor.
Thermo 231/301 No fuel supply.
Is solenoid valve o.k.? (5.3.2.7)
Is viewing glass of flame sensor contaminated?
Clean window and viewing glass.
Is nozzle free of foreign matter and deposits?
Replace nozzle.
5.3.2.3 Fault Symptom "Low Voltage"
NO
Is voltage present on plug contact A3? Is electrical wiring o.k.? Make electrical connections.
Disconnect heater from battery supply. Is battery properly charged?
YES
Connect heater. Is voltage between plug contacts A3 and A6 approx. 0.5 volts less than on battery?
Is electrical power supply line to heater o.k.?
Replace power supply line.
505
5 Troubleshooting
5.3.2.4 Fault Symptom "Foreign Light Detection during Run-up or Run-down"
Thermo 230 / 231 / 300 / 301 / 350
NO
Has heater been in long time operation shortly before ? Flame sensor defective, replace. Control unit defective, replace.
Allow heater to cool down and restart (approx. 2 min.). Does same symptom show again?
Clean combustion tube. Remove coke deposits.
YES
Flame in run-down. Control unit defective, replace.
Replace solenoid valve.
5.3.2.5 Fault Symptom "Flame Sensor Defective"
NO
Flame sensor defective, replace.
YES
If replacement of flame sensor does not cure the problem, replace control unit.
5.3.2.6 Fault Symptom "Temperature Sensor Defective"
NO
Are electrical lines and contacts to and on temperature sensor o.k.? Make contacts or replace component. WARNING: loss of water!
Temperature sensor defective, replace.
YES
WARNING: Water may escape!
If replacement of temperature sensor does not cure the problem, replace control unit.
506
Thermo 230 / 231 / 300 / 301 / 350

5.3.2.7 Fault Symptom "Solenoid Valve Defective"
5 Troubleshooting
NO
Is solenoid valve supplied with electrical power ? Make electrical connections.
YES
Has safety thermostat responded ? (Thermo 231/301 only)
Safety thermostat defective, replace.
Investigate reason for response (e.g. check exhaust system)
Is components test with diagnostic computer o.k. (audible click of solenoid valve)?
Does fuel leak from nozzle in run-down?
507
5 Troubleshooting
5.3.2.8 Fault Symptom "Temperature Limiter Defective"
Thermo 230 / 231 / 300 / 301 / 350
NO
Is electrical power supply to components o.k.? Make electrical connections.
YES
Has temperature limiter responded? (Reset according to type of temperature limiter)
Determine why temperature limiter has responded, e.g.: check shut-off elements, check water circulation in system is free from bubbles, check circulation pump sense of rotation, check coolant low temperature resistance. Can no fault be detected?
Replace temperature limiter.
If symptom shows again after testing: control unit defective, replace.
508
Thermo 230 / 231 / 300 / 301 / 350 6

6.1
6 Functional Checkouts
Functional Checkouts
General
This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops with no exhaust ventilation facilities. To prevent fires do not switch heater on with burner swung open.
6.2
Adjustments
Fastening screw
6.2.1 Adjustment of CO2 Contents

It is allowed to change the manufacturers setting for combustion air quantity by rotation of the setting ring. Measurement of the CO2 value of the exhaust gas must be performed followed by an adjustment of the combustion air quantity as required in case of: repairs on the burner irregularities in combustion functional checkouts nozzle replacement Setting procedure measure control unit power supply voltage operate heater for approximately 5 min. measure CO2 contents and smoke spot number and compare with relevant diagram loosen fastening screw (refer to Fig.) and reposition setting ring with fastening screw until rated value is obtained. tighten fastening screw with 1.0 +0.5 Nm and apply screw seal varnish.
14 13 12 11 10 9
NOTE CO2 setting depends on fuel (viscosity) and on geodetic altitude (0.1 % per 100 m). If proper setting cannot be obtained or when exceeding smoke spot number, proceed as follows: check burner head air side for damage and replace if required check fuel pump pressure and replace pump if required check fuel filter and strainer in fuel pump for contamination and replace if required adjust pressure replace fuel nozzle measure burner motor speed
CO2 (Vol.-%)
8 7 6 18 20 22 24 26 28 30 32
Voltage CO2 - setting at 500 m NN 601
6.3 Components Testing
Thermo 230 / 231 / 300 / 301 / 350

6.3.3 Igniter Electrodes Check
NOTE The insulator of the igniter electrodes must show no damage. Igniter electrodes not working properly must be replaced. Check inspect insulators of igniter electrodes for damage
6.3.1 Temperature Sensor Resistance Check

When checking the temperature sensor with a digital multimeter the values of the following diagram must be obtained. Resistance checking is preferably performed at ambient temperatures between 20 C and approximately 100 C (immerse sensor in water).
R/y
10000
Resistance (Ohm)
5000
20 C 4419 ..... 4892 W
1000
100 C 319 ..... 348 W

T/C 10 50 100
Water temperature C
6.3.2 Flame Sensor Resistance Check

NOTE The glass bulb of the flame sensor and the viewing glass of the window (refer to Fig.) are to be cleaned if contaminated. In case of damage or not obtaining the rated values replace flame sensor. Check cover flame sensor glass bulb check resistance (rated value: < 20 kOhm) uncover flame sensor glass bulb and expose to light of strong lamp. check resistance (rated value: < 400 Ohm)
Viewing glass
Glass bulb
602
Thermo 230 / 231 / 300 / 301 / 350

6.3.4 Igniter Box Check
NOTE The igniter box may also be tested using the PC heater diagnosis (component test). WARNING High voltage; 20.000 volts arcing across the igniter electrodes. CAUTION Do not apply voltage to igniter box without electrodes. Check apply 24 V as shown on figure normal condition: spark between electrodes.
6.3.5 Fuel Pump Check
6.3.5.1 Fuel Pump Check on Heaters with Control Unit 1572 A test gauge is required for performing the test. Such a gauge (with a range from 0 to 15 bar) can be procured from your authorized Webasto dealer. The fuel pump and the fuel hoses must be replaced every 5 years. CAUTION The electronic ignition coil must be removed for safety reasons. Check remove igniter box (refer to 9.2.7.1). remove nozzle. screw on tester. cover flame sensor. switch on heater. after approximately 13 sec. pump pressure is indicated (refer to diagram). switch off heater. unscrew tester. CAUTION Do not damage nozzle bore. screw in nozzle and torque with 20 Nm. install igniter box (refer to 9.2.7.2).
NOTE Igniter box (black connector cover) only in combination with control unit 1572
Igniter electrodes 20.000 V
Pump pressure (bar)
Igniter electrodes 20.000 V NOTE Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also with control unit 1572
11 10,5 10 9,5 Thermo 350 9 8,5 8

2500 3000 4000 5000 6000 7000 8000 8500
Thermo 300/301 Thermo 230/231
Speed (min ) Pump pressure in relation to speed
-1
603
6.3.5.2 Fuel Pump Check on Heaters with Control Unit 1572D NOTE On heaters with control unit 1572D the fuel pump may only be checked by means of the PC heater diagnosis. The fuel pump and the fuel hoses must be replaced every 5 years.
Thermo 230 / 231 / 300 / 301 / 350

6.3.7 Solenoid Valve Check
NOTE A solenoid valve leaking valve seat shows by rather long smoke emissions during run-down. In this case fuel keeps dripping through the fuel nozzle. Short smoke emissions are normal caused by clearing the area between solenoid valve and nozzle bore. Check CAUTION Disconnect solenoid valve connector from control unit to avoid damage to the control unit. Check electrics for the following values: break voltage 17.0 Volts operating voltage 19.2 ... 28.8 Volts power consumption at nominal voltage and 20 C 10 Watts nominal current 0.42 Amps
6.3.6 Fan Motor Check

NOTE The fan motor check is performed with the burner installed. If normal conditions are not obtained the fan motor must be replaced. Check check fan motor bearing condition(binding) measure heater power supply voltage switch on heater measure speed and compare with the diagram below Thermo 230/231 4400 350 24 Volt Thermo 300/301 5200 420 24 Volt Thermo 230/301 6200 500 24 Volt
NOTE With all variants of the control unit the solenoid valve may also be checked by means of the PC heater diagnosis (component test).
8000 7500 7000 6500 6000 5500 5000 4500
Thermo 350
6.3.8 Nozzle Block Preheater Check

NOTE At a temperature of < 0 C the heater cartridge in the nozzle block is activated. The heating period depends on the heat reflected within the combustion chamber. Preheating is deactivated when the thermostat ambient temperature is +8 C. Power consumption is 130 13 Watts at 24 Volt. Check swing burner head open or remove disconnect electrical connector connect ohmmeter to connector using cooling spray cool down thermostat or bridge resistance (max. 4.5 ).
Thermo 300/301
Thermo 230/231
Speed (1/min.)
4000 3500 3000 2500 18 20 22 24 26 28 30 32
Voltage
604
Thermo 230 / 231 / 300 / 301 / 350 7

7.1
7 Circuit Diagrams
Circuit Diagrams
General
The circuit diagrams (Fig. 705 through 710) show possible variants of heater circuits for Thermo 230, 231,300, 301 and 350 with control unit 1572D.
The circuit diagrams (Fig. 701 and 702) show possible heater circuits for Thermo 230, 300 and 350 with control unit 1572 and with switch timer 1529 (triple timer)
The circuit diagrams (Fig. 703 and 704) show possible heater circuits for Thermo 230, 231, 300, 301 and 350 with control unit 1572D and with switch standard timer 1531
701
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350
A
6 1 2 3
30
30
5 4
F3
F2 C S2 S1 S4 X3
4 3 2
1
1
gn
or
S3 X1
1 5 3
br
gr
D
3 2 1 4
1 4
X1
2 5 3 6
sw or rt/ws
5 1 3
X3 X2
1 1 3 5 7
K1
4 2 6
A2
2 2 4 6 8
rt br bl br sw
4 6
M1
U1
F1/B3
B2
K2
2
B4 C
+ SE
H1 A2 B1 Y1 E1 A1
br
M2
U1 E1 U2 A1
F1 M1 Y1 B3
H2
B2 B1
X2
31
31
Wire colors bl br ge gn gr or rt sw vi ws blue brown yellow green gray orange red black violet white
Diagnostic connector
Wire gauges
< 7.5 m 0.75 mm2 1.0 mm2 1.5 mm2 2.5 mm2 4.0 mm2 7.5 - 15 m 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.0 mm2
Item A1 A2 B1 B2 B3 B4 E1 F2 F3 H1 K1 K2 M1 M2 S1 S2
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Heating cartridge Fuse 25A Fuse 25A Light Relay (in item A2) Relay (in item A2) Motor Motor Switch Continuity switch
Remark not grounded SG 1572
Item S3 S4 U1 U2
Nomenclature Switch, external trigger circulation pump Switch Igniter box Igniter electrodes Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Solenoid valve
Remark
power save operation
open at T > 8 C for nozzle preheating flat fuse SAE J 1284 flat fuse SAE J 1284 operation indicator light for circulation pump for combustion air fan / heating cartridge combustion air fan circulation pump on / off on water cock
A C D X1 X2 X3 Y1
Fig. 701 Automatic Control Circuit with Control Unit 1572 and Switch 702
Thermo 230 / 231 / 300 / 301 / 350
7 Circuit Diagrams
A
58 75(15) 30 58 75(15) 30
6 5 4 1 2 3
F3
F6
F2 C S4
S2
S3 X3
4 3 2
1
1
gn
or
2 3
8 4 6 2 5 7 3
br
gr
X1
1
D
3 2 1 4
1 4
X1
2 5 3 6
sw or rt/ws
5 1 3
P H3 H4
3 5
X3 X2
1 1 3 5 7
K1 X4
4 2 6
A2
2 2 4 6 8
rt br bl br sw
X4
6
M1
U1
F1/B3
B2
K2
2
8 7 6
5 4
3 2
B4 C
+
SE
M2 A2 B1 Y1 E1 A1
br br
U1 E1 U2 A1
F1 M1 Y1 B3
H2
B2 B1
X2
31
31
1 2 3
Diagnostic connector to vehicle terminal +75 if available, otherwise terminal 15 Timer P: with plus to connection 4 without plus to connection 4 vehicle lighting terminal 58
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Heating cartridge Fuse 25A Fuse 25A Fuse 5A Light in item P Symbol for Heating in Display Relay (in item A2) Relay (in item A2) Motor Motor Triple timing clock (1529) opens at T > 8 C for nozzle preheating flat fuse SAE J 1284 flat fuse SAE J 1284 flat fuse SAE J 1284 symbol lighting symbol lighting (in item P) for circulation pump fo combustion air fan / heating cartridge combustion air fan circulation pump for timed operation Remark not grounded SG 1572 Item S2 S3 S4 U1 U2 A C D X1 X2 X3 X4 Y1 Nomenclature Continuity switch Switch, external trigger circulation pump Switch Igniter box Igniter electrodes Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Plug connections, 8-pole Solenoid valve
Wire gauges
< 7.5 m 7.5 - 15 m 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.0 mm2 0.75 mm2 1.0 mm2 1.5 mm2 2.5 mm2 4.0 mm2
= continuous operation during immediate heating = heating period 1 hour
4
Item A1 A2 B1 B2 B3 B4 E1 F2 F3 F6 H3 H4 K1 K2 M1 M2 P
Remark on water cock
power save operation
Fig. 702 Automatic Control Circuit with Control Unit 1572 and Timer (Triple Timer) 703
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350
4 1 3 3 3 3 3 3
Wire colors
1 3 Diagnostic connector Pin assignment: Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0,75 gr 0,75 or 0,75 gn 0,75 br nicht belegt nicht belegt 7wire lead 0,75 rt 0,75 or 0,75 bl 2,0 br 2,0 sw 2,0 rt/ws
Wire gauges
4
Item A1 A2 B1 B2 B3 B4 B5 B6 E1 F1 F2 F3 H1 H2 M1 M2 S1
with connection to terminal 61 auxiliary

Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Thermostat Thermostat Heating cartridge Fuse 5 A Fuse 25 A Fuse 25 A Light Light Motor Motor Switch for nozzle preheating alternative to B3 for vertical installation (MV Y1) for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator combustion air fan circulation pump on / off external trigger circulation pump SG 1572D observe polarity polarity optional Remark Item S4 U1 U2 W1 W2 A C D F X1 X2 X3 Y1 Nomenclature Switch Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2)
bl br ge gn gr or rt sw vi ws
blue brown yellow green gray orange red black violet white
Remark power save operation
Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Solenoid valve
S3
Switch
Fig. 703 Automatic Control Circuit with Control Unit 1572D and Switch 704
Thermo 230 / 231 / 300 / 301 / 350
7 Circuit Diagrams
4 1
1 2
Wire colors
Timer P: with plus to connection 10 = continuous operating during immediate heating terminal 10 not connected = duration of heating programmable (10 min to 120 min); Pin assignment: Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0.75 gr 0.75 or 0.75 gn 0.75 br not used not used 7wire lead 0.75 rt 0.75 or 0.75 bl 2.0 br 2.0 sw 2.0 rt/ws
Wire gauges
bl br ge gn gr or rt sw vi ws
blue brown yellow green gray orange red black violet white
4
Item A1 A2 B1 B2 B3 B4 B5 B6 E1 F1 F2 F3 H1 H2 H4 M1 M2
with connection to terminal 61 auxiliary

Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Thermostat Thermostat Heating cartridge Fuse 5 A Fuse 25 A Fuse 25 A Light Light Symbol for Heating in Display Motor Motor for nozzle preheating alternative to B3 for vertical installation (MV Y1) for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator symbol lighting (in item P) combustion air fan circulation pump SG 1572D observe polarity polarity optional Remark Item P S3 S4 U1 U2 W1 W2 A C D F X1 X2 X3 X4 Y1 Nomenclature Standard timer (1531) Switch Switch Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Plug connections, 12-pole Solenoid valve Remark for timed operation external trigger circulation pump power save operation
Fig. 704 Automatic Control Circuit with Control Unit 1572D and Standard Timer 705
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350

61 30
6 5
61 30
A
1
DEUTSCH
2 3
F1
F2
F3
F S4 S3
Signal UP
6 6 7
1 2
X3
UPFA
5
1
D+ 7 SP 3 FA
1
1
K
2
BA
4
rt/sw
sw
sw
br
or
rt
bl
2 3 4
X1 S1
W1 A
1 1 3 4
3 3
sw
rt/ws rt sw
2 1
3 4
X1
2
6
2 5
br
X3
M1
U1
B3/B5
B2 X2
br
+ SE
B4
-
H1
M
H2
M2 A2
31
sw
U1 U2 A2 A1
B3 Y1
E1
B1 Y1
E1
A1 X2
M1
B2 B1
31
Wire gauges
< 7,5 m 0,75 mm2 1,0 mm2 1,5 mm2 2,0 mm2 2,5 mm2 4,0 mm2 7,5 - 15 m 1,5 mm2 1,5 mm2 2,5 mm2 ? mm2 4,0 mm2 6,0 mm2
Item A1 A2 B1 B2 B3 B4 E1 F1 F2 F3 H1 H2 M1 M2 S1
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Heating cartridge Fuse 25 A Fuse 25 A Fuse 5 A Light Light Motor Motor Switch
Remark not grounded SG 1572D observe polarity polarity optional for nozzle preheating for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator combustion air fan circulation pump on / off external trigger circulation pump power save operation
Item U2 W1 A C D F X1 X2 X3
Nomenclature Igniter electrodes Wiring harness (1+2) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 7-pole Plug connections, 2-pole Plug connections, 7-pole
Remark
S3
S4 U1
Switch
Switch Igniter box
Fig. 705 System Circuit Daimler Chrysler Citaro, Ident.-Nr. 67131 706
Thermo 230 / 231 / 300 / 301 / 350
7 Circuit Diagrams
30
30
6
A
1
DEUTSCH
F3
F2
5 4
2 3
C S2 S1 S4
9
8 6
1
5
gn
or
S3
X1 A
2 3 1
br
gr
2 3 4
sw or rt/ws
5 1
9 3
A
6 5 1 4 2 8 7
X1
3
10
K1
15 7 10 16
4
A
16 14 13 12 15 11
rt br sw bl
rt
4 6 2
K2
1 4 2
X2
M1
U1
F1/B3
B2 B5 H1 M2
M
rt
3
W1
C B4
+
SE
br sw
A2
U1 U2 A1
B3 Y1
H2 B2 B1
E1
M1
A2
B1 Y1
-31
E1
A1
X2
-31
Fuse acc. to SAE J 1284 / DIN 72581

DW 230 25A / 16A 25A / 16A DW 300 25A / 16A 25A / 16A DW 350 25A / 16A 25A / 16A
Wire gauges
Item A1 A2 B1 B2 B3 B4 B5 E1 F2 F3 H1 H2 K1 K2 M1 M2 S1 S2
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Fire sensor Heating cartridge Fuse Fuse Light Light Relay (in item A2) Relay (in item A2) Motor Motor Switch Continuity switch
Remark not grounded SG 1572 observe polarity polarity optional alternative to F1 for nozzle preheating Van Hool see table see table operation indicator light flame indicator for circulation pump motor for combustion air fan combustion air fan circulation pump on / off on water cock
Item S3 S4 U1 U2 W1 A C D X1 X2 Y1
Nomenclature Switch, external trigger circulation pump Switch Igniter box Igniter electrodes Wiring harness Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 16-pole Plug connections, 4-pole Solenoid valve
Remark required, if S2 not installed power save operation
Van Hool
Fig. 706 System Circuit Van Hool, Ident.-Nr. 89401 707
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350
30
30
6
A
1
DEUTSCH
F3
F2
5 4
2 3
S2 S1
C S4
X3
4 3 2
1
1
gn
or
S3 X1
1 5 3
W2 W1 A D
3 2 1 4
1 2 3 4
sw or rt/ws
5 1
br
gr
X1
1 2 5 3 6 4
K1
4 2 6
X2
1 2
rt br bl br
4 6
K2
2
1
X3
3 5 7
M1
U1
F1/B3
B2
1
H1
B4 M2
M
sw
+ SE
U1 U2 A2 A1
F1 Y1 B3
H2
E1
M1
B2 B1
A2
-31
B1 Y1
E1
A1
X2
-31
Fuse acc. to SAE J 1284 / DIN 72581

DW 230 25A / 16A 25A / 16A DW 300 25A / 16A 25A / 16A DW 350 25A / 16A 25A / 16A
Wire gauges
Item A1 A2 B1 B2 B3 B4 E1 F2 F3 H1 H2 K1 K2 M1 M2 S1 S2
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Heating cartridge Fuse Fuse Light Light Relay Relay Motor Motor Switch Continuity switch
Remark not grounded SG 1572D observe polarity polarity optional alternative to F1 for nozzle preheating for nozzle preheating see table see table operation indicator light flame indicator for circulation pump motor for combustion air fan combustion air fan circulation pump on / off on water cock
Item S3 S4 U1 U2 W1 W2 A C D X1 X2 X3 Y1
Nomenclature Switch, external trigger circulation pump Switch Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Solenoid valve
Fig. 707 System Circuit O405 / O407 / O408, Ident.-Nr. 91292 708
Thermo 230 / 231 / 300 / 301 / 350
7 Circuit Diagrams
61 30
61 30
6 5
A
1
DEUTSCH
2 3
F1
F2
C S2 S1
S4
D+
1
L
5
1
SP 4 FA 3 K
2
M
1
D
X3
1
X2
rt/sw
sw
or
br
bl
rt
S3 X1
1 5 3 4
W2 W1 A F D
2 1 3 3 2 1 4
2 3 4
F
1 2
sw or rt/ws rt
5 1 2 1
3
3 8
X1
2
7
2
1 7
4 5 7
br bl
X2
M1
U1
B3/B5
B2
C
1
H1
M
B4
+
SE -
X3
M
A2
B1 Y1
E1
A1
sw
M2 A2 U2 A1
U1
B3 Y1
H2 B2 B1 A
31
2 4 3 1 5
E1
M1
31
Wire gauges
Item A1 A2 B1 B2 B3 B4 E1 F2 F3 H1 H2 M1 M2 S1 S2 S3 S4
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Heating cartridge Fuse 25 A Fuse 25 A Light Light Motor Motor Switch Continuity switch Switch, external trigger circulation pump Switch
Remark not grounded SG 1572D observe polarity polarity optional for nozzle preheating for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator combustion air fan circulation pump on / off on water cock required, if S2 not installed power save operation
Item U1 U2 W1 W2 A C D F X1 X2 X3 Y1
Nomenclature Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 6-pole Plug connections, 2-pole Plug connections, 8-pole Solenoid valve
Remark
Fig. 708 System Circuit MAN, Ident.-Nr. 89404 709
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350
Wire gauges
Item A1 A2 B1 B2 B3 B4 B5 B6 E1 F1 F2 F3 H1 H2 M1 M2 S1 S2
Nomenclature Heater Control unit Flame sensor Temperature sensor Temperature limiter Thermostat Temperature sensor extern Thermostat Heating cartridge Fuse 25 A Fuse 25 A Fuse 5 A Light Light Motor Motor Switch Continuity switch
Remark not grounded SG 1572D observe polarity polarity optional for nozzle preheating observe polarity alternative to B3 for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator combustion air fan circulation pump on / off on water cock
Pos. S3 S4 U1 U2 W1 W2 A C D F X1 X2 X3 X4 X5 Y1 Y2
Nomenclature Switch, external trigger circulation pump Switch Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 10-pole Plug connections, 2-pole Plug connections, 8-pole Plug connections, 4-pole Plug connections, 4-pole Solenoid valve Shut-off valve with filter
Fig. 709 System Circuit SETRA, Ident.-Nr. 90972 710
Thermo 230 / 231 / 300 / 301 / 350
7 Circuit Diagrams
1 3
Diagnostic connector Timer P: with plus to connection 4 = continuous operation during immediate heating without plus to connection 4= heating period 1 hour Pin assignment: Pin assignment D1 D2 D3 D4 F1 F2 4wire lead 0.75 gr 0.75 or 0.75 gn 0.75 br not used not used 7wire lead 0.75 rt 0.75 or 0.75 bl 2.0 br 2.0 sw 2.0 rt/ws
Wire gauges
5
Item A1 A2 B1 B2 B3 B4 B5 B6 E E1 F1 F2 F3 F4 F5 F6 F7 H1 H2 H4 K4 M1 M2
Option
Nomenclature Heater Control unit 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 Remark SG 1572D observe polarity polarity optional for nozzle preheating alternative to B3 for vertical installation (MV Y1) for nozzle preheating flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 flat fuse DIN 72581 part 3 operation indicator light flame indicator Power-on indicator (in item P) combustion air fan circulation pump Item P S1 S3 S4 S5 S6 T U1 U2 W1 W2 W3 A C D F O Q X2 X4 X5 X6 X7 Y1
Nomenclature Digital timer, standard (1531) Switch Switch Switch Switch Switch Temperature switch Igniter box Igniter electrodes Wiring harness (1) Wiring harness (2) Wiring harness (3) Plug connections, 6-pole Plug connections, 1-pole Plug connections, 4-pole Plug connections, 2-pole Plug connections, 2-pole Plug connections, 2-pole Plug connections, 2-pole Plug connections, 12-pole Plug connections, 4-pole Plug connections, 4-pole Plug connections, 7-pole Solenoid valve
Remark For programmed operation on / off external trigger circulation pump power save operation Auxiliary heating mode Filter heater on Filter heater
Fig. 710 Automatic Control Circuit Rail with Control Unit 1572D and Standard Timer and filter heater 711
7 Circuit Diagrams
Thermo 230 / 231 / 300 / 301 / 350
712
Thermo 230 / 231 / 300 / 301 / 350 8

8.1
8 Servicing
in case of leakage the fuel pump and the fuel lines must be replaced immediately, otherwise every 5 years. the heater should be checked in regular intervals by a Webasto service agent, the latest before the beginning of the heating season (refer to Annex A "Scheduled Maintenance"). When the heater is operated in rail vehicles, maintenance chart / test certificate item no. 90 087 22B is to be used.
Servicing
General
This section describes the servicing procedures allowed on the heater when installed.
8.2
Heater Servicing
As long as the heater is in operation or in run-down the battery main power supply must not be disconnected to prevent the heater from overheating by response of the overheat protection. When performing long time repairs on the heater its removal is appropriate. After working on the heating circuit replenish with a coolant mix prepared with water and anti-freeze and bleed circuit afterwards according to manufacturers instructions.
8.5.1 Inspection and Attachment of the Exhaust Muffler (only heaters from year of production 1996 and up to production date 1996, calendar week 36; 3G......)
NOTE If the exhaust muffler is already secured with a sheet metal screw, the following procedure need not be performed. General The exhaust muffler of heaters manufactured from the beginning of 1996 up to a manufacturing date of 1998 (calendar week 36; 3G.......) (for year or date of production refer to identification label) the exhaust muffler may get loose or lost under certain circumstances. Therefore an inspection for proper attachment of the muffler should be performed. Heaters manufactured from beginning of 1996 Identification up to 1998, calendar label week 36; 3G......)
8.3
Vehicle Servicing
CAUTION In the vicinity of the heater a temperature of 110 C must under no circumstances be exceeded (e.g. during paint work on the vehicle).
8.4
Heater Test Run
The heater must not be operated, not even with the timer, in enclosed areas like garages or workshops not equipped with exhaust ventilation facilities.
8.5
Maintenance
To ensure functional reliability of the heater the following maintenance must be performed: check combustion air inlet and exhaust outlet for contamination and clean as required. outside the heating season the heater should be operated with the vehicle engine cold approximately every four weeks for 10 minutes setting the heating system to "warm". This avoids difficulties in the start-up. at least once a year, in case of contaminated fuel more often, the fuel filter or filter cartridge as well as the filter screen of the fuel pump must be replaced to avoid malfunctions. at least once a year the heat exchanger must be cleaned inside. Exhaust muffler
801
8 Servicing
Inspection and Attachment NOTE The exhaust muffler must always be secured with a sheet metal screw. Drill a hole with a diameter of 2.5 mm into the exhaust end pipe and muffler and arrest muffler with a sheet metal screw B 3.9 x 25 (see figure). 1. Check exhaust end pipe for presence of muffler. For checking remove exhaust end pipe as required. 2. If muffler is found in exhaust end pipe fasten as described in NOTE. Slot or drill exhaust end pipe and refit.
Thermo 230 / 231 / 300 / 301 / 350

3. If no muffler is found in exhaust end pipe check if muffler is upstream in exhaust pipe. If muffler is dislocated in the exhaust pipe, arrest muffler as described in NOTE. Slot or drill exhaust pipe and refit. 4. If the exhaust muffler has been lost it may be ordered free of charge from Webasto (ident. no. 206 91C). Fasten muffler according to NOTE. Slot or drill exhaust pipe and refit. 5. If heater is operated without exhaust pipe, fasten muffler according to NOTE. An exhaust deflector (ident. no. 849 70A) must be additionally fitted.
Exhaust end pipe
Exhaust end pipe
Sheet metal screw B 3.9 x 25 Hole 2.5 mm
Sheet metal screw B 3.9 x 25
Hole 2.5 mm
Exhaust muffler (ident. no. 206 91C)
Exhaust muffler (ident. no. 206 91C)
Slot exhaust pipe
Exhaust deflector (ident. no. 849 70A)
Exhaust pipe
Heater without exhaust pipe
Heater with exhaust pipe
802
Thermo 230 / 231 / 300 / 301 / 350

8.5.2 Burner Head Opening and Closing or Removal and Installation
WARNING The igniter box operates with high voltage. Prior to opening the burner head the connectors of the cable harness in the vehicle have to be disconnected to prevent lethal injuries. After closing and fixing burner head, reconnect connectors in the vehicle. NOTE Maintenance on the heater is easy. By swinging the burner head open the following components become accessible: fuel pump and fuel nozzle solenoid valve igniter box igniter electrodes flame sensor combustion chamber nozzle block preheater (if installed) In order to obtain a convenient burner head opening angle it is required to disconnect the electrical connection(s) to the temperature limiter and temperature sensor.
8 Servicing
Opening or removal 1. Disconnect electrical connections to temperature limiter and temperature sensor. 2. Loosen nuts (3, Fig. 801) enough to release hinge bolts (2). 3. Swing hinge bolts (2) out. 4. Swing burner head (4) open. 5. Remove cotter pin (1) as required to remove burner head. Closing or installation 1. As required fasten burner head (4, Fig. 801) in position using cotter pin (1). 2. Swing burner head (4) closed and locate for assembly. 3. Swing hinge bolts (2) into lock position and secure with nuts (3). 4. Torque nuts (3) with 7.5 Nm + 1 Nm. 5. Reconnect electrical connections to the temperature limiter and temperature sensor. NOTE When making electrical connections observe wiring color codes.
1 2 3 4
Cotter pin Screw (2) Nut (2) Burner head
3 NOTE Depending on the burner head direction of swing the cotter pin may be located on the opposite side.
Fig. 801 Swinging Burner Head open 803
8 Servicing
8.6 Visual Inspections and Regulations for Installation
Thermo 230 / 231 / 300 / 301 / 350

8.6.2 Connection to Vehicle Fuel System
Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel tank. 8.6.2.1 Fuel Lines In order to avoid air from being captured in fuel lines, they should only be installed with an incline. The fuel line joints are to be secured against slipping with hose clamps should no screwed mechanical unions be in use. Should fuel hoses be installed always use the hoses supplied or offered by Webasto. If other hoses are used they must at least meet the specifications of DIN733791C; type 3. Fuel hoses must not be kinked or twisted and must be secured with clamps every 25 cm. For routing fuel also fuel lines may be used consisting of materials standard in the manufacturing of vehicles, e.g. steel or plastic lines made of unhardened, light and temperature stabilized PA11 or PA12 (e.g. Mecanyl RWTL) according to DIN 73378 observing the applicable jointing instructions. Basic rules for the routing of fuel lines are: Protect against undue temperatures. WARNING In overheat condition the heater outer shell may reach Diesel fuel inflammation temperature! Protect lines from stone strike. Dripping or evaporating fuel may neither accumulate nor ignite on hot components or electrical equipment.
8.6.1 Connection to Vehicle Cooling System

The installation of the heater should be in a location as low as possible to ensure self-venting of the heater and circulation pump. This applies in particular for the circulation pump because it is not self-sucking. The heater is to be connected to the vehicle cooling system according to Fig. 802. The cooling system coolant capacity must be at least 10 liters. The vehicle cooling system or the separate heating circuit must use only pressure relief valves with an opening pressure of at least 0.4 bar and of max. 2.0 bar. It is a basic requirement to use the coolant hoses supplied by Webasto, otherwise the hoses must at least meet the specifications of DIN 73411. The hoses have to be installed free of kinks and for proper venting in an inclination. Hose connections must be secured against slippage with hose clamps. NOTE The specified tightening torques of the hose clamps used must be complied with. Prior to the heaters first operation or after replacement of the coolant, attention must be paid to carefully bleed the cooling system. Heater and lines must be installed so that static venting is guaranteed. Improper venting may cause malfunctions by overheating in equipment operation. Proper venting may be identified by a circulation pump almost noiseless in operation. When using a circulation pump U 4851 or Aquavent 6000 S the circulation pump automatically switches off approx. 15 seconds after switch-on should coolant be missing or the pump wheel be seized. After 2 minutes be pump may be reactivated. In combination with control unit 1572D (Thermo label colored) and with programmed circulation pump check the heater also switches off when coolant is missing.
804
Thermo 230 / 231 / 300 / 301 / 350
8 Servicing
Water heating circuit Sidewall radiators and roof duct heating
6 7
1 2
9 8 Vorlauf Supply R cklauf Return
1 2 3 4 5 6 7 8
Sidewall radiator with fan Heat exchanger, entrance Heater unit Circulation pump Heat exchanger, roof Vehicle engine Cockpit heating Control element
Fig. 802 Example of a Heater Installation in a Passenger Bus 805
8 Servicing
When installing a shut-off device in the return line a clearly visible information label must be provided. CAUTION Operation with the return line shut off causes damage to the fuel pump. Fuel may escape. Danger of fire.
Thermo 230 / 231 / 300 / 301 / 350

It must be located so that no clogging by contamination, impact of snow, or intake of splash water is to be expected. The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle. Permissible dimensions of combustion air intake line: inner diameter: 55 mm max. length: 5 m without the exhaust extension max. bend: 270 The combustion air inlet must be located so that no exhaust fumes can enter. NOTE If the combustion air intake line cannot be routed upwards to the heater, a water drain hole 4 mm is to be provided at the lowest point. If the heater is located near the fuel tank in a common installation compartment, combustion air must be taken in from and the exhaust routed to the exterior. The feedthroughs must be sealed against splash water. If the heater is located in a closed installation box, a vent port is required: Thermo 230, 231, 300 and 301 Thermo 350 30 cm2 35 cm2
Information label Loose fuel lines must be secured in order to avoid sagging. The installation of an additional fuel pump is not allowed. Fuel lines permissible dimensions: inner diameter for suction and return line: 6 mm (other diameters upon request). max. permissible length for each suction and return line: 10 m Max. permissible suction height: 2 m Max. permissible priming pressure: 0.3 bar for suction and return line. 8.6.2.2 Fuel Filter A fuel filter supplied as deliverable item or cleared for use by Webasto is to be fitted. Installation position possibly vertical with horizontal direction of flow. To avoid operating malfunctions replace filter or filter cartridge once a year or more often if fuel is contaminated.
If the temperature in the installation box exceeds the permitted ambient temperature of the heater (see Technical Data), the vent port must be enlarged consulting Webasto.
8.6.4 Exhaust Line

CAUTION Observe official regulations concerning the installation (see 1.6). The exhaust pipe outlet opening must not point in the direction of motion. The exhaust pipe outlet opening must be located so as not to expect clogging by snow or mud. The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle.
8.6.3 Combustion Air Supply

CAUTION Observe official regulations concerning the installation (see 1.6). Combustion air must under no circumstances be extracted from rooms with persons. The combustion air inlet must not point towards the forward direction of motion. 806
Thermo 230 / 231 / 300 / 301 / 350

Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only. The exhaust pipe is secured to the air heater e.g. with a clamp. Permissible exhaust line dimensions: inner diameter: 70 mm max. length: 5 m without the exhaust extension max. bend: 270 As an alternative an exhaust deflector must be installed cleared by Webasto.
8 Servicing
5. Secure combustion air inlet line on heater as applicable. 6. Connect electrical connectors of cable harness in vehicle and to circulation pump. 7. Bleed fuel supply system. 8. Bleed coolant circuit.
8.7.2 Temperature Limiter, Replacement

NOTE The replacement procedure for the temperature limiter is identical with the heater installed or removed. Perform replacement in accordance with 9.2.1.
8.7
Removal and Installation
8.7.3 Temperature Sensor, Replacement

NOTE The replacement procedure for the temperature sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.2. WARNING Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by opening the cooling circuit sealing element. If required also allow heater to cool down and have collector vessel ready to collect escaping coolant.
CAUTION In installed condition only the following disassembly or removal procedures are permitted should enough space for removal allow such action: replacement of temperature limiter replacement of temperature sensor replacement of combustion air fan replacement of burner replacement of igniter box replacement of flame sensor replacement of combustion chamber
8.7.4 Burner, Replacement 8.7.1 Heater, Removal and Installation

8.7.1.1 Removal 1. Disconnect connectors of cable harness in vehicle and of circulation pump. 2. Disconnect combustion air intake on heater if required. 3. Loosen clamp on exhaust outlet. 4. Loosen fuel supply and return line connections and fit dummy plugs. Close water cocks as applicable. 5. Loosen hose clamps on coolant hoses, disconnect hoses and fit dummy plugs. 6. Remove 3 screws and washers or 4 screws and washers. 7. Remove heater. 8.7.1.2 Installation 1. Locate heater for installation and secure with 3 screws and washers or 4 screws and washers. 2. Secure line on exhaust outlet using clamp. 3. Slide on coolant hoses and fasten with hose clamps. Torque clamps with 1.5 Nm. Open water cocks. 4. Connect fuel supply and return lines and tighten connections or screw tight with banjo bolt and new gaskets. NOTE The replacement procedure for the burner is identical with the heater installed or removed. Perform replacement in accordance with 9.2.3. WARNING The igniter box operates on high voltage. Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.
8 7.5 Igniter Box, Replacement

NOTE The replacement procedure for the igniter box is identical with the heater installed or removed. Perform replacement in accordance with 9.2.7. WARNING The igniter box operates on high voltage. Prior to replacement of igniter box disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.
807
8 Servicing
8.7.6 Flame Sensor, Replacement
NOTE The replacement procedure for the flame sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.8. WARNING The igniter box operates on high voltage. Prior to replacement of flame sensor disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.
Thermo 230 / 231 / 300 / 301 / 350

8.8.1 Water Circuit, Bleeding
NOTE Bleeding must always be performed in accordance with manufacturers instructions. For bleeding the circulation pump must not be switched on. Set vehicle own heating system to "warm" and replenish coolant which must consist of at least 20 % anti-freeze (on glycol base) (protection against corrosion). When using pure water there will be no protection against corrosion and due to the lower boiling point of the water when overheating loss of cooling water may result requiring continuous replenishment. Additives in the coolant must not affect metals, plastics or rubber and leave no deposits. Then operate engine at increased idle until radiator thermostat opens. Shut down engine, check coolant level and replenish as required. Switch on heater and vehicle heating fan with engine shut down. After a certain cool-down period the heater must automatically switch on and control to off. In case of no restart attempt the temperature limiter on the heater has responded because the heater has not been bled properly. Reset temperature limiter (push button on temperature limiter) and repeat complete bleeding procedure. NOTE The heater may be equipped with an automatically resetting temperature limiter. The manual reset is not necessary.
8.7.7 Combustion Chamber, Replacement

NOTE The replacement procedure for the combustion chamber is identical with the heater installed or removed. Perform replacement in accordance with 9.2.10. WARNING The heater operates on high voltage. Prior to replacement of combustion chamber disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents.
8.8
First Operation
After heater installation the coolant circuit and the fuel supply system must be thoroughly bled observing the vehicle manufacturers instructions. During test runs all coolant and fuel line connections have to be checked for security and no leakage. Should the heater in operation enter a fault condition, perform troubleshooting (refer to Section 5). NOTE Heaters with control unit 1572D: If the heater performs 8 subsequent attempts to start due to a malfunction, the heater enters an error lockout and stops any further attempts to start. This error lockout is superior to the normal error lockout condition. The error lockout reset is achieved by switching the heater on and disconnection of the heater power supply within 120 sec. during run-down.
8.8.2 Fuel Supply System, Bleeding

When switching the heater on the fuel pump sucks fuel to prime the complete fuel supply system. Should no combustion be achieved with the first start attempt, switch the heater off and on again.
808
Thermo 230 / 231 / 300 / 301 / 350 9

9.1
9 Repair
Repair
General
This section describes the repairs that may be performed on the heaters Thermo 230, 231, 300, 301 and 350 when removed. Any further disassembly will void the warranty. For re-assembly only components of the proper spare part kits are to be used. WARNING The igniter box operates on high voltage. The following components may also be replaced with the heater installed unless restricted space prevents access: temperature limiter temperature sensor combustion air fan burner igniter box flame sensor combustion chamber
Prior to replacement disconnect connectors of cable harness in vehicle to avoid lethal accidents. WARNING Hot coolant may escape during the replacement of the temperature sensor. Before replacing the temperature sensor also release pressure from cooling system by opening sealing element. If required also allow heater to cool down.
901
9 Repair
9.1.1 Work on Components after Disassembly
CAUTION All gaskets located between disassembled components must always be replaced and discarded. 9.1.1.1 Visual Inspection, General Examine all components for damages (cracks, deformation, wear, etc.) and replace as necessary. Examine connectors and wiring for corrosion, loose contacts, wrong crimping, etc. and repair as necessary. Check terminals for corrosion and contacts for security. Repair as required.
Thermo 230 / 231 / 300 / 301 / 350

9.1.2 Incorporation of Modifications
NOTE Continuous enhancement of heater design is for optimizing performance and avoiding failures and malfunctions. Normally equipment in use may be retrofitted using available modification kits The following modifications may be incorporated during repair procedures: installation of control unit 1572D as substitute for control unit 1572 (see 9.1.2.1) installation of circulation pump U 4851 or Aquavent 6000 S as substitute for circulation pump U 4814 or U 4816 (see 9.1.2.2) installation of circulation pump Aquavent 5000 S as substitute for circulation pump U 4814
9.1.1.2 Combustion Chamber, Visual Inspection Check swirl ring for security. Inspect combustion chamber for oxidizing and coke deposits and remove as required. Check welding seem for cracks.
NOTE Longitudinal cracks up to 80 mm are allowed. 9.1.1.3 Heat Exchanger, Visual Inspection Inspect exhaust ducting in heat exchanger for sooting, deposits, damage and corrosion.
NOTE Deposits are to be removed with water jet and brush. Inspect heat exchanger for exterior damage, deformation, etc.
NOTE Heavy deformation may cause restricted flow of coolant. CAUTION When replacing the combustion chamber on heaters installed vertically, remove deposits in heat exchanger using a suitable tool. 9.1.1.4 Combustion Air Fan Wheel, Visual Inspection Check fan wheel for contamination and cracks. Check cover plate for security. Check slide lock for proper seating.
902
Thermo 230 / 231 / 300 / 301 / 350

9.1.2.1 Installation of Control Unit 1572D as Substitute for Control Unit 1572 General Due to the progress in the development of processors control unit 1572 can no longer be supplied. The retrofit of control unit 1572D is performed according to the following procedure: The modification kit consists of: control unit 1572D igniter box thermo identification label Procedure
9 Repair
CAUTION Control unit 1572D may only be used in combination with the igniter box delivered (green connector cover). The electrical connector is coded. 1. Remove control unit according to 9.2.5.1 and discard. 2. Remove igniter box according to 9.2.7.1 and discard. 3. Install new igniter box according to 9.2.7.2. 4. Install new control unit according to 9.2.5.2. 5. Apply new thermo label onto existing label to indicate retrofit.
Previous igniter box (black connector cover)
Thermo label
New igniter box (green connector cover) Control unit 1572
Control unit 1572D
903
9 Repair
9.1.2.2 Installation of Circulation Pump U 4851 / Aquavent 6000 S or 5000 S as Substitute for Circulation Pump U 4814 or U 4816 General The circulation pumps U 4814 and U 4816 may be substituted by circulation pump U 4851 or Aquavent 6000 S respectively 5000 S as required. When exchanging circulation pump U 4816 the attachment parts (mount and hose clamp) may be re-used. An adaptation of the water connection is not necessary. The same applies for compact units. When exchanging circulation pump U 4814 observe the following: The existing mount and hose clamp must be removed and discarded. Installation must be performed using a new mount and hose clamp. When mounting the circulation pump near to a wall the new mount must be attached so that there is a clearance of 60 mm to the wall (reference line: circulation pump centerline). If required the new mount must be relocated in relation to the old mount. Hose connections must be adapted. If the circulation pump is mounted into a compact unit, the exchange procedure is difficult and must be checked if practicable. The modification cannot be performed when water stations Starliner and Cityliner and involved.
Thermo 230 / 231 / 300 / 301 / 350

Procedure, circulation pump U 4851 CAUTION When installing circulation pump U 4851 the following information must be strictly observed to avoid loss of warranty. NOTE The circulation pump is not self-venting. Therefore the pump has to be installed at the lowest point of the water circuit observing the permitted pump orientation (see Fig.). The hoses must be installed routed upwards free of kinks. Hose connections must be secured against slippage with hose clamps. The specified tightening torques of the hose clamps used must be complied with. On the water inlet side of the pump no solenoid valves or other shut-off devices must be installed allowing closure during pump operation. The same applies for filters which may clog. Prior to first operation of the circulation pump the vehicle cooling system and the pump body must be bled.
Permitted installation position CAUTION Improper bleeding or a dry run of the pump causes damage to the slip ring gasket. Proper venting is indicated by the pump operating almost noiseless.
U 4851
Water inlet side
904
Thermo 230 / 231 / 300 / 301 / 350

Procedure, circulation pump Aquavent 6000 S CAUTION When installing circulation pump Aquavent 6000 S the following information must be strictly observed to avoid loss of warranty. NOTE Different to pump U 8451, Aquavent 6000 S is to be installed in a vertical position, so that the pump head is located above the motor. The circulation pump is not self-venting. Therefore the pump has to be installed at the lowest point of the water circuit observing the permitted pump orientation (see Fig.). The hoses must be installed routed upwards free of kinks. Hose connections must be secured against slippage with hose clamps. The specified tightening torques of the hose clamps used must be complied with. On the water inlet side of the pump no solenoid valves or other shut-off devices must be installed allowing closure during pump operation.
9 Repair
The same applies for filters which may clog. Prior to first operation of the circulation pump the vehicle cooling system and the pump body must be bled. The ciculation pump includes no parts subject to wear. A motor replacement in some cases is also possible without removal of the pump head.
Permitted installation position CAUTION A dry run of the circulation pump is permitted up to 15 minutes. Proper bleeding may be verified by almost noiseless operation of the pump.
Aquavent 6000 S
Water inlet side
905
9 Repair
9.2 Disassembly and Assembly
Thermo 230 / 231 / 300 / 301 / 350

9.2.2.2 Installation 1. Manually screw temperature sensor (2, Fig. 901) into coolant outlet (4). 2. Torque temperature sensor to 20 Nm +5 Nm. 3. Restore electrical connections. NOTE Observe electrical wiring color coding when making connections to temperature sensor.
9.2.1 Temperature Limiter, Replacement

9.2.1.1 Removal 1. Disconnect electrical connection to temperature limiter. 2. Withdraw rubber cap. Using screw driver lever off retaining spring and remove temperature limiter (1, Fig. 901). 9.2.1.2 Installation 1. Slide rubber cap of temperature limiter (1, Fig. 901) back until temperature limiter can be located for installation. 2. Position temperature limiter (1) in connector (3) and push in retaining clip. WARNING The retaining spring must be located in the groove of the housing and must be latched in position both perceptibly and audibly (twice) at the collar of the locating socket. Only then will the temperature limiter be in proper contact with the heat exchanger jacket. 3. Fit rubber cap. After the rubber cap has been placed in position, the cable must be aligned in the cable sleeve, free from strain. Connection cables must not be routed over reset button. NOTE Observe electrical wiring color coding when making connections to temperature limiter. 4. Make electrical connections.
9.2.3 Burner, Replacement

9.2.3.1 Removal 1. Disconnect electrical connections on burner and loosen fuel lines. 2. Loosen nuts (6, Fig. 901) until hinge bolts are free. 3. Swing hinge bolts (7) open and remove cotter pin (5). 4. Remove burner (8). 5. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.3.2 Installation 1. Position burner (8, Fig. 901) for installation, swing hinge bolts closed and secure temporarily using screws (6). 2. Insert cotter pin (5) according to the intended opening swing direction. 3. Tighten nuts (6) with 7.5 Nm + 1 Nm. 4. Connect fuel lines. 5. Restore electrical connections. NOTE Observe electrical wiring color coding when making connections to temperature limiter and temperature sensor.
9.2.2 Temperature Sensor, Replacement

9.2.2.1 Removal 1. Disconnect electrical connection to temperature sensor. WARNING Prior to replacement of temperature sensor in installed condition relief overpressure in cooling system by opening the cooling circuit sealing element. If required also allow heater to cool down and have collector vessel ready to collect escaping coolant. 2. Unscrew temperature sensor (2, Fig. 901) and remove.
906
Thermo 230 / 231 / 300 / 301 / 350
9 Repair
1 2 3 4 5 6 7 8
Temperature limiter Temperature sensor Connector Coolant outlet Cotter pin Nut (2) Hinge bolt (2) Burner
Rubber cap Temperature limiter Retaining clip
3 2 4
6 8 7 NOTE Cotter pin (5) may be fitted on other side as required for burner head to swing open in opposite direction.
Fig. 901 Temperature Limiter, Temperature Sensor and Burner, Replacement 907
9 Repair
9.2.4 Combustion Air Fan, Replacement
NOTE For replacement of the combustion air fan the burner may be left installed. In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged. 9.2.4.1 Removal 1. Loosen screws (3, Fig. 902) and withdraw cap (2) from burner. 2. Using suitable tool (e.g. mandrel 3 mm) open slide lock (5) until fan wheel can be pulled off. 3. Disconnect electrical connector (9). 4. Remove screws (6) with lock washers and withdraw fan motor (7). 5. Perform procedures on components after disassembly (refer to 9.1.1).
Thermo 230 / 231 / 300 / 301 / 350

9.2.4.2 Installation NOTE Fan motor (7, Fig. 902) to be aligned with control unit (recess in mounting flange) and with clutch (by rotating drive shaft). 1. 2. 3. 4. 5. Align fan motor (7) and position for installation. Attach fan motor using screws (6) and lock washers. Tighten screws with 5 Nm + 1 Nm. Connect electrical connector (9). Bring slide lock (5) on fan wheel in installation position. 6. Slide fan wheel onto drive shaft and using suitable tool (e.g. mandrel 3 mm or pliers) close slide lock until fan wheel is locked. 7. Locate cap (2) and secure with screws (3). 8. Tighten screws with 2 Nm.
Opening slide lock
Closing slide lock
908
Thermo 230 / 231 / 300 / 301 / 350
9 Repair
5 4 2
6 8
7 1 2 3 4 5 6 7 8 9
Splash protection cover Cap Screw (2) Fan wheel Slide lock Screw (3) Fan motor Clutch Electrical connector
Fig. 902 Combustion Air Fan, Replacement 909
9 Repair
9.2.5 Control Unit, Replacement
NOTE For replacement of the control unit the burner head may be left installed and must only be swung open for disconnection of electrical connector (8, Fig. 903). In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged. If a control unit 1572 is substituted with a control unit 1572D, perform procedure according to 9.1.2.1. 9.2.5.1 Removal 1. Disconnect all electrical connections from control unit (23, Fig. 903). 2. Swing burner head open (refer to 8.5.1) and disconnect electrical connector (8). 3. Remove flame sensor (refer to 9.2.8.1). 4. Remove combustion air fan (refer to 9.2.4.1). 5. Carefully withdraw control unit (23) in axial direction from burner head (17) and remove. 6. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.5.2 Installation 1. Carefully push control unit (23, Fig. 903) in axial direction against stop into burner head (17). 2. Install combustion air fan (refer to 9.2.4.2). 3. Make all electrical connections on control unit (23). 4. Install flame sensor (refer to 9.2.8.2). 5. Connect electrical connector (8).
Thermo 230 / 231 / 300 / 301 / 350

9.2.6.2 Installation 1. Install solenoid valve (7, Fig. 903) on fuel pump (10) if required. 2. Fit new O-ring (12) and filter screen (11) on fuel pump (10). 3. Position fuel pump (10) for installation and secure with screws (9) and lock washers. 4. Tighten screws with 5 Nm + 1 Nm. 5. Connect electrical connector (8). 6. Plug on disk (6) and mount heating cartridge. 7. Plug on igniter electrodes (3, Fig. 904). 8. Install burner (refer to 9.2.3.2).
9.2.7 High Pressure Nozzle, Replacement

9.2.7.1 Removal 1. Remove burner (refer to 9.2.3.1). 2. Using screwdriver lever off igniter electrodes (3, Fig. 903) from igniter box (1) and remove. 3. Remove disk (6, Fig. 903) with heating cartridge (if installed). 4. Disconnect electrical connector (8) of the heating cartridge. 5. Unscrew high pressure nozzle (4). NOTE Ensure cleanliness is maintained when installing the nozzle. Only touch the nozzle at its hexagon surface. 9.2.7.2 Installation
9.2.6 Fuel Pump, Replacement

9.2.6.1 Removal 1. Remove burner (refer to 9.2.3.1). 2. Using screwdriver lever off igniter electrodes (3, Fig. 903) from igniter box (1) and remove. 3. Remove disk (6, Fig. 903) with heating cartridge (if installed). 4. Disconnect electrical connector (8). NOTE During the following step ensure that escaping fuel is immediately neutralized and properly disposed of. 5. Remove screws (9) with lock washers. 6. Withdraw fuel pump (10) together with solenoid valve (7) and remove. 7. Remove and discard O-rings (12) and filter screen (11). 8. Remove solenoid valve (7) from fuel pump (10) as required. 9. Perform procedures on components after disassembly (refer to 9.1.1). 910
1. Screw in high pressure nozzle (4, Fig. 903) and tighten with 20 Nm. 2. Connect electrical connector (8) of the heating cartridge. 3. Plug on disk (6) and mount heating cartridge. 4. Plug on igniter electrodes (3, Fig. 903). 5. Install burner (refer to 9.2.3.2).
Thermo 230 / 231 / 300 / 301 / 350
9 Repair
23
Control unit 1572D
Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572
Overheat thermostat (Thermo 231 / 301 only) 26 5
1 Igniter box (black connector cover) only in combination with control unit 1572
3 9
6 8
5 25 10 11 6
12 13 Control unit 1572 15 16 14
24
17 18 23 19 22 21 20 1 Igniter box 2 Screw (2) 3 Igniter electrodes 4 High pressure nozzle 5 Viewing glass 6 Disk 7 Solenoid valve 8 Electrical connector 9 Screw (3) 10 Fuel pump 11 Filter screen 12 O-ring (2) 13 Rotating ring 14 Screw 15 16 17 18 19 20 21 22 23 24 Flame sensor Screw Burner housing Strain relief clamp (2) Screw (2) Base plate for relays Relay Relay Control unit Heating cartridge with thermostat 25 Clip 26 Overheat thermostat 26 (Thermo Top 231 / 301 only)
Fig. 903 Control Unit and Fuel Pump, Replacement 911
9 Repair
9.2.8 Igniter Box, Replacement
9.2.8.1 Removal 1. Remove burner if required (refer to 9.2.3.1). 2. Using screw driver lever off igniter electrodes (Fig. 904) from igniter box and remove. 3. Remove disk (6). 4. Remove screws (2) with lock washers. 5. Withdraw igniter box (1) and remove. 6. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.8.2 Installation 1. Locate igniter box (1, Fig. 904) for installation, plug on making correct electrical connections and secure with screws (2) and lock washers. 2. Tighten screws (2) with 5 Nm + 1 Nm. 3. Plug on disk (6) and align. 4. Plug on igniter electrodes (3). 5. Install burner (refer to 9.2.3.2).
Thermo 230 / 231 / 300 / 301 / 350

9.2.9 Flame Sensor, Replacement
9.2.9.1 Removal 1. Remove burner if required (refer to 9.2.3.1). 2. If required lever off igniter electrodes (Fig. 904) from igniter box using screw driver and remove. 3. Remove disk (6). 4. Remove screw (14) and lock washer. 5. Withdraw flame sensor (15) and remove. 6. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.9.2 Installation 1. Position flame sensor (15, Fig. 904) for installation, plug on to make correct electrical connections and secure with screw (14) and lock washer. 2. Tighten screw (14) with 5 Nm + 1 Nm. 3. Plug on disk (6) and align. 4. Plug on igniter electrodes (3). 5. Install burner (refer to 9.2.3.2).
Igniter box Igniter electrodes
Removal and installation of igniter electrodes
Flame sensor
Fig. 904 Igniter Box and Flame Sensor, Replacement (Sheet 1 of 2) 912
Thermo 230 / 231 / 300 / 301 / 350
9 Repair
23
Control unit 1572D
Igniter box (green connector cover; mechanically coded) in combination with control unit 1572D and also control unit 1572
Overheat thermostat (Thermo 231 / 301 only) 26 5
1 Igniter box (black connector cover) only in combination with control unit 1572
3 9
6 8
5 25 10 11 6
12 13 Control unit 1572 15 16 14
24
17 18 23 19 22 21 20 1 Igniter box 2 Screw (2) 3 Igniter electrodes 4 High pressure nozzle 5 Viewing glass 6 Disk 7 Solenoid valve 8 Electrical connector 9 Screw (3) 10 Fuel pump 11 Filter screen 12 O-ring (2) 13 Rotating ring 14 Screw 15 16 17 18 19 20 21 22 23 24 Flame sensor Screw Burner housing Strain relief clamp (2) Screw (2) Base plate for relays Relay Relay Control unit Heating cartridge with thermostat 25 Clip 26 Overheat thermostat 26 (Thermo Top 231 / 301 only)
Fig. 904 Igniter Box and Flame Sensor, Replacement (Sheet 2 of 2) 913
9 Repair
9.2.10 Heat Exchanger, Replacement
9.2.10.1 Removal 1. 2. 3. 4. Remove temperature limiter (refer to 9.2.1.1). Remove temperature sensor (refer to 9.2.2.1). Remove burner (refer to 9.2.3.1). Withdraw combustion chamber (1, Fig. 905) from heat exchanger (2). 5. Remove heat exchanger (2). 6. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.10.2 Installation 1. Slide combustion chamber (1, Fig. 905) fully into heat exchanger (2) against stop. 2. Install burner (refer to 9.2.3.2). 3. Install temperature limiter (refer to 9.2.1.2). 4. Install temperature sensor (refer to 9.2.2.2).
Thermo 230 / 231 / 300 / 301 / 350

9.2.11 Combustion Chamber, Replacement
9.2.11.1 Removal 1. Disconnect electrical connections to temperature limiter and temperature sensor. 2. Swing burner open (refer to 8.5.2). 3. Withdraw combustion chamber (1, Fig. 905) from heat exchanger (2) and remove. 4. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.11.2 Installation 1. Slide combustion chamber (1, Fig. 905) fully into heat exchanger (2) against stop. 2. Swing burner closed (refer to 8.5.2). NOTE Observe electrical wiring color coding when making connections. 3. Make electrical connections to temperature limiter and to temperature sensor.
1 Combustion chamber 2 Heat exchanger
Fig. 905 Heat Exchanger and Combustion Chamber, Replacement 914
Thermo 230 / 231 / 300 / 301 / 350 10 Packaging, Storage and Shipping
10 Packaging / Storage / Shipping
10.1 General
The heater or its components shipped to Webasto AG for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage. CAUTION When shipping a complete heater assembly it must be drained completely. No coolant is allowed to escape when packaging or shipping. Dummy plugs must be fitted to the coolant inlet and outlet as well as to the fuel lines. In storage the ambient temperatures specified in Section 4 must not be exceeded.
1001
10 Packaging / Storage / Shipping
Thermo 230 / 231 / 300 / 301 / 350
Thermo 230 / 231 / 300 / 301 / 350 Annex A

Scheduled Maintenance
Annex A
A-1
Annex A
Heater, Scheduled Maintenance
The heater should be checked in regular intervals at least at the beginning of the heating season (point of time when weather conditions cause increased use of heater).
Thermo 230 / 231 / 300 / 301 / 350

The maintenance intervals indicated below apply to applications and requirements typical of busses. Should the heaters be used in other vehicles or applications, these intervals may have to be adapted, i.e. shortened or extended. In these cases, please contact your Webasto partner charge.
Important Notes Check Result o.k. not o.k. Measured Values, Maintenance / Repair performed
Check / Maintenance
1. Electrical connections a) Disconnect electrical connectors to cable harness, inspect for oxidation, spray and reconnect after performing step 5. b) Inspect fuses for oxidation and/or check transition resistances. 2. Heat exchanger a) Inspect paint for dark stains of burn (local overheating). b) Check for signs of leakage. c) Clean heater exterior and interior.
Use suitable contact spray, e.g. special contact spray (order no. 101322).
If necessary investigate reason for overheating (e.g. water circuit). Check temperature limiter.
3. Fuel system a) Check fuel lines and connections for leaks. b) Replace fuel filter cartridge with gasket. c) If existing, open fuel shut-off cocks. Check for tight connections in fuel supply and return! Retighten joints and hose clamps. Replace pump and lines every 5 years.
d) Fuel pump and fuel lines. e) Replace fuel filter screen with gaskets in pump. 4. Burner head a) Check combustion air inlet for contamination. Swing burner head open: b) Check cover for damage c) Check housing interior for accumulation of fuel caused by leaks. d) Clean viewing glass of flame sensor. e) Check igniter electrodes for condition. f) Replace nozzle.
Replace damaged cover
Replace bent electrodes. When coked reduce replacement interval for fuel filter.
5. Exhaust system a) Check exhaust line for contamination and clean as required. b) Remove combustion chamber from heat exchanger, inspect both components for damage and contamination and clean or replace as required. c) Insert combustion chamber and mount burner head. Check for secure connection to heat exchanger. d) Restore electrical connections. 6. Water system a) If installed, clean water filter. b) If installed, open water shut-off cocks. 7. Functional checks a) If installed, open shut-off cock in return line. b) Check heater function. c) Check for smoke emissions in run-down; replace nozzle if required. after at least 10 min. of heating operation.
A-2
Hotline (0 18 05) 93 22 78 Hotfax (03 95) 55 92-353 http://www.webasto.de Subject to modification
IDENT.-NR. 9003656B
Webasto AG Postfach 80 D-82131 Stockdorf
Printed in Germany
0.1/0505
Druck: Druckerei Steffen Friedland/Meckl.

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Thermo 230 / 231 / 300 / 301 / 350 List of Contents

Thermo 230 / 231 / 300 / 301 / 350

Circuit Diagrams 7.1 General ................................................................................................................................................. 701

Thermo 230 / 231 / 300 / 301 / 350

Packaging, Storage and Shipping 10.1 General ................................................................................................................................................ 1001

Annex A Heater, Scheduled Maintenance...................................................................................................................... A-2

Thermo 230 / 231 / 300 / 301 / 350 List of Figures

Thermo 230 / 231 / 300 / 301 / 350 1

Safety Information and Regulations

1.5.1 General Safety Notes

Meaning of Warnings, Cautions and Notes

Thermo 230 / 231 / 300 / 301 / 350

Only vent caps in accordance with DIN 73400 may be used.

Legal Provisions for Installation

Thermo 230 / 231 / 300 / 301 / 350

Thermo 230 / 231 / 300 / 301 / 350

Page empty for notes 104

Thermo 230 / 231 / 300 / 301 / 350 2 General Description

Thermo 230 / 231 / 300 / 301 / 350

Fan wheel Screen Cap

2.4 2.2 Fuel Pump

Thermo 230 / 231 / 300 / 301 / 350

Control Unit 1572

Thermo 230 / 231 / 300 / 301 / 350

2.11 Circulation Pump

2.11.1 Circulation Pump U 4851 and Aquavent 6000 S

Thermo 230 / 231 / 300 / 301 / 350

2.12 Fuel Filter

Thermo 230 / 231 / 300 / 301 / 350

Page empty for notes 206

Thermo 230 / 231 / 300 / 301 / 350 3 Functional Description

Gradient evaluation Hysteresis adaptation

Thermo 230 / 231 / 300 / 301 / 350

Auxiliary Heating Operation (heaters with control unit 1572D only)

Heater Lockout (heaters with control unit 1572D only)

Thermo 230 / 231 / 300 / 301 / 350

Fig. 301 Functional Sequence (heaters with control unit 1572)

Switch-off upon Failure (heaters with control unit 1572)

Thermo 230 / 231 / 300 / 301 / 350

Fig. 302 Functional Sequence (heaters with control unit 1572D)

Switch-off upon Failure (heaters with control unit 1572D)

Thermo 230 / 231 / 300 / 301 / 350

Thermo 230 / 231 / 300 / 301 / 350

Thermo 230 / 231 / 300 / 301 / 350 4 Technical Data

Thermo 230 / 231 / 300 / 301 / 350

Thermo 231 Thermo 231 ~ S327

Thermo 300 DW 300 ~ S229

Thermo 301 Thermo 301 ~ S328

Thermo 350 DW 350 ~ S228

Thermo 230 / 231 / 300 / 301 / 350

U 4851 6000 (against 0.4 bar)

5200 5200 (against 0.15 bar) (against 0.4 bar)

6000 (against 0.4 bar)

Nominal power consumption W Nominal voltage

240 24 0,5 2,5 5,5 2,5

Thermo 230 / 231 / 300 / 301 / 350