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Water heater Service Instructions

Thermo Pro 90
Thermo Pro 90 HDD

Thermo Pro 90 12 V Diesel - ADR (Transport of

dangerous goods)
Thermo Pro 90 24 V Diesel - ADR (Transport of
dangerous goods)
Thermo Pro 90 HDD 24 V Diesel - ADR (Transport of
dangerous goods)

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Improper installation or repair of Webasto heating and cooling systems can cause fire or the
leakage of deadly carbon monoxide leading to serious injury or death.

To install and repair Webasto heating and cooling systems you need to have completed a
Webasto training course and have the appropriate technical documentation, special tools
and special equipment.

Only genuine Webasto parts may be used. See also Webasto air and water heaters
accessories catalogue.

NEVER try to install or repair Webasto heating or cooling systems if you have not completed
a Webasto training course, you do not have the necessary technical skills and you do not
have the technical documentation, tools and equipment available to ensure that you can
complete the installation and repair work properly.

ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.

Webasto rejects any liability for problems and damage caused by the system being installed
by untrained personnel.

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Thermo Pro 90 Table of Contents

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.1 Contents and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

1.2 Meaning of signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.3 Additional documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4 Legal requirements and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4.1 Statutory regulations governing installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4.2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.5 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

2 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.1 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202

2.2 Overheating protection, coolant temperature sensor and heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . .202
2.3 Glow plug and burner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
2.4 Combustion chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
2.5 Exhaust gas temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
2.6 U4840 coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
2.7 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
2.8 DP42 fuel pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

3.1 Switching on and residual heat utilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

3.2 Start and control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
3.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
3.4 Heater functions in ADR vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

5 Malfunctions and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

5.1 Procedure in the case of fault, malfunction and lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

5.1.1 Fault code output at the control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
5.2 Cause of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
5.3 Deleting fault code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
5.3.1 Without Webasto Thermo Test PC Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
5.3.2 with Webasto Thermo Test computer diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
5.4 Heater lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
5.5 Fault code table (fault codes, flash codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503
5.6 Troubleshooting (fault symptoms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505

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Table of Contents Thermo Pro 90

6 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.2 Function checks in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.3 Setting CO2 content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.4 Testing individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.1 Checking resistance of the coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.2 Checking resistance of the glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.3 Checking resistance of the exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.4 Checking the combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.5 Checking the DP42 fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.6 Checking the overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.7 Checking the U4840 coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

7 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.1 Working on the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.2 Working on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
7.3 Heater test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
7.4 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
7.5 Removing and installing heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.6 Visual inspection to assess the burner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.6.1 Metal fiber evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.6.2 Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
7.7 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703

8 Repairing and replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.2 Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.3 Work on stripped down components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.5 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6 U4840 coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.7 Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.8 Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8.9 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8.10 Burner unit and glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.11 Burner head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.12 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.13 Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

9 Thermo Pro 90 HDD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.3 U4840 coolant pump with EMC suppressor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.3.1 Replacing the EMC suppressor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.4 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.5 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.6 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.7 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.8 Thermo Pro 90 HDD wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.8.1 Legend to connector VG95328R2016PN (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

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Thermo Pro 90 Table of Contents

10 Packaging/storage and shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

10.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

10.2 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

11 Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1101

11.1 Thermo Pro 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1101

11.2 Thermo Pro 90 HDD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1101
11.3 System wiring diagram for Thermo Pro 90 with MultiControl control element with battery disconnector . .1102
11.4 System wiring diagram for Thermo Pro 90 with SmartControl control element (ADR). . . . . . . . . . . . . . . . .1103
11.5 System wiring diagram for Thermo Pro 90 with on/off switch (ADR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1104
11.6 System wiring diagram for Thermo Pro 90 with ThermoCall TC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1105
11.7 System wiring diagram for Thermo Pro 90 with UniBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1106
11.8 System wiring diagram for Thermo Pro 90 with MultiControl control element (analogue connection) . . . .1107
11.9 System wiring diagram for Thermo Pro 90 HDD with MultiControl control element . . . . . . . . . . . . . . . . . .1108
11.10 System wiring diagram for Thermo Pro 90 HDD with SmartControl control element (ADR). . . . . . . . . . . . .1109
11.11 System wiring diagram for Thermo Pro 90 HDD with on/off switch (ADR) . . . . . . . . . . . . . . . . . . . . . . . . .1110
11.12 Cable cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
11.13 Cable colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
11.14 Heater connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
11.15 Plug assignments at control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
11.16 Legend to wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1112
11.17 Legend for comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1113
11.18 Legend for plug X8, 12-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1113

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Table of Illustrations Thermo Pro 90

Table of Illustrations

Fig. 201 Heater components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Fig. 202 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 203 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 204 Burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 205 Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 206 Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 207 U4840 coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 208 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 209 DP42 fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 301 Thermo Pro 90 functional sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Fig. 601 CO2 altitude correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Fig. 701 Visual check, burner back plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
Fig. 702 Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Fig. 801 Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Fig. 802 Control unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 803 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 804 Replacing the U4840 coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Fig. 805 Removing overheating protection sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Fig. 806 Coolant temperature sensor removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Fig. 807 Combustion air fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Fig. 808 Seal on combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Fig. 809 Burner unit and glow plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Fig. 810 Burner unit and glow plug, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Fig. 811 Burner head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Fig. 812 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Fig. 813 Exhaust gas temperature sensor with clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Fig. 814 Burner head and exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Fig. 815 Checking mica insulator on sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Fig. 901 Thermo Pro 90 HDD heater components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Fig. 902 U4840 coolant pump with EMC suppressor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 903 Thermo Pro 90 HDD combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 904 Thermo Pro 90 HDD control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 905 Connector VG95328R2016PN (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 1001 Preferred position of Thermo Pro 90 heater for storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . 1001
Fig. 1102 System wiring diagram Thermo Pro 90, MultiControl with battery disconnector . . . . . . . . . . . . . . . . . . 1102
Fig. 1103 System wiring diagram Thermo Pro 90, SmartControl (ADR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
Fig. 1104 System wiring diagram Thermo Pro 90, on/off switch (ADR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104
Fig. 1105 System wiring diagram Thermo Pro 90, ThermoCall TC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
Fig. 1106 System wiring diagram Thermo Pro 90, UniBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1106
Fig. 1107 System wiring diagram Thermo Pro 90, MultiControl (analogue connection) . . . . . . . . . . . . . . . . . . . . 1107
Fig. 1108 System wiring diagram Thermo Pro 90 HDD, MultiControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1108
Fig. 1109 System wiring diagram Thermo Pro 90 HDD, SmartControl (ADR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1109
Fig. 1110 System wiring diagram Thermo Pro 90 HDD, on/off switch (ADR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110
Fig. 1111 Heater connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111
Fig. 1112 Plug assignments at control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111

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Thermo Pro 90 1 Introduction

1 Introduction

1.1 Contents and purpose Stipulations of Annex 7 to the Regulation ECE-R 122 and the
requirements specified in the installation instructions must be
This workshop manual is designed to assist trained personnel observed for the installation.
in the repair of Thermo Pro 90 water heaters.
NOTE:
This workshop manual contains all the information and
instructions necessary to repair Thermo Pro 90 water heaters. The stipulations of these regulations are binding in the area
covered by EU Directive 70/156/EEC and/or 2007/46/EC (for
1.2 Meaning of signal words new vehicle models from 29/04/2009) and should also be
observed in countries where there are no specific regulations.
Throughout this manual, the signal words CAUTION, ATTEN-
TION and NOTE have the following meanings: The Thermo Pro 90 water heater has been designed for instal-
lation in commercial vehicles. If it is installed in special-pur-
CAUTION pose vehicles, the applicable regulations must be taken into
account. Alternative applications must be agreed upon with
This signal word is used to highlight operating instructions or Webasto in advance.
procedures which, if not followed or not followed correctly,
may result in personal injury or fatal accidents. 1.4.2 General safety information
ATTENTION Follow the Installation Instructions.
This signal word is used to highlight operating instructions or
The year of initial commissioning must be permanently
procedures which, if not followed or not followed correctly,
marked on the type label by removing the numbers of
may result in damage to the equipment or its components.
the inapplicable years.
NOTE The heaters are approved for heating the vehicle engine and
the cab but they are not approved for heating cargo areas
This signal word is used to draw your attention to a special
used to carry dangerous goods/hazardous substances.
feature.
The heater may only be installed in motor vehicles or in inde-
1.3 Additional documentation to be used pendent heating systems with a minimum coolant capacity of
6 litres.
Use the following documents:
The heater must not be installed in the driver's or passenger's
• Installation Instructions compartment of vehicles. If the heater is nevertheless installed
• Heater operating instructions in such a place, the casing must be tightly sealed from the
• Control element operating instructions vehicle interior. If the heater is in an enclosure, outside air ven-
• Optional (if installed) vehicle-specific installation tilation must be sufficient. Additionally, the ambient tempera-
documentation ture regarding fuel pump and fuel line, combustion air intake
and heater must be observed (see technical data). Faults may
1.4 Legal requirements and safety occur if the temperature exceeds this level.
information Follow the instructions of the vehicle manufacturer when
The general accident prevention regulations and valid opera- checking the coolant level.
tional safety instructions must be observed. Failure to follow the installation instructions and the notes
contained therein will result in a disclaimer of liability by
"General safety requirements" that extend beyond the frame-
Webasto. The same shall apply if repairs are carried out incor-
work of these regulations are specified in the following.
rectly or with the use of parts other than genuine spare parts.
The special safety requirements that pertain to this workshop This will render the general type approval of the heater and
manual are highlighted in the individual sections and proce- therefore the vehicle type approval invalid.
dural descriptions.
CAUTION
1.4.1 Statutory regulations governing Risk of burn injuries as the heater and its add-on parts
installation can become very hot.

The Thermo Pro 90 heater has been type-tested and approved

in accordance with ECE-R 10 (EMC) and ECE-R 122 (heater).

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1 Introduction Thermo Pro 90

The heater must NOT be operated:

• at filling stations and tank facilities

• at locations where highly flammable gases or dust can
form, or at locations where highly flammable liquids or
solid materials are stored (e.g. near fuel, coal and wood
dust, grain storage areas, dry grass and leaves, cardboard
boxes, paper, etc.).
• in closed rooms (e.g. garages), nor with time pre-
selection or the Telestart function.
• unless the water in the heating circuit contains at least
33% quality antifreeze.

The heater including the control unit:

• must NOT be exposed to storage temperatures in excess

of +125 °C. The operating voltage may be applied.
Exceeding the specified temperature can result in
permanent damage to the electronics.
• may ONLY be operated with the fuel and the rated
voltage specified on the type label.
• must be shut down by switching off immediately and
removing the fuse in case of heavy smoking, unusual
combustion noises or combustion odours. Restarting
may not be carried out until after the unit has been
checked only by Webasto-trained personnel.
• must be switched off when working in the engine
compartment.
• may NOT be cleaned with high-pressure cleaners.
• may NOT be cleaned with compressed air.
• must be operated for 10 minutes with a cold engine on
the lowest blower setting at least once a year.
• must be checked by a specialist every 2 years or at the
start of the heating period at the latest.

CAUTION

Carefully read the operating instructions before operating the

heater.

1.5 Spare parts

The identity numbers of the available spare parts can be
found:

• in the Webasto spare parts catalogue

• online in the dealer portal (http://dealers.webasto.com)

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Thermo Pro 90 2 General description

2 General description
The water heater has been designed for installation in com- The heater switches off burner operation automatically
mercial vehicles. Depending on equipment, the ADR function (pause) when the setpoint is exceeded and switches it back on
is provided for the 12 V and 24 V variant. automatically when the temperature drops below the set-
point.
Parking heating Actuation of the water heater with an external regulator (e.g.
In parking heating mode, the water heater works together room thermostat) is not permitted.
with the vehicle's heating system for The Thermo Pro 90 heater mainly consists of the following
• cab and engine preheating, components:
• use of residual heat from the vehicle engine. – Combustion air fan
– Heat exchanger
The water heater works independently of the vehicle engine – Burner unit
and is integrated in the cooling system, the fuel system and – Coolant pump
the electrical system of the vehicle.
The following control and monitoring components are inte-
Auxiliary heating grated in the heater:
– Control unit
The water heater works during engine operation and provides – Exhaust gas temperature sensor
thermal assistance to the cooling system. The water heater is – Glow plug
integrated in the cooling system, the fuel system and the elec- – Coolant temperature sensor
trical system of the vehicle. – Overheating protection
When the engine is switched off, the water heater is automa- The burner motor speed is monitored by a Hall sensor inte-
tically switched off and fuel supply is interrupted within 5 se- grated in the control unit. Operation with a remote control
conds. unit is therefore not possible.
The heater operates fully automatically, controlled by the The fuel is supplied externally by a fuel pump which is con-
coolant temperature. nected to the vehicle fuel system.
The burner output is controlled within the limits between 1.8
and 7.6 kW depending on the deviation of the current coolant
temperature from the setpoint at the coolant temperature
sensor.

1 2 3 4 5 6

7 8 9
10
1 combustion air fan
2 fuel connection
11 3 coolant outlet
4 coolant temperature sensor
5 heat exchanger
6 overheating protection
7 exhaust gas temperature
sensor
8 outlet, exhaust gas
9 combustion air inlet
12
10 U4840 coolant pump
11 coolant inlet

Fig. 201 Heater components

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2 General description Thermo Pro 90

2.1 Combustion air fan 2.3 Glow plug and burner unit

Fig. 202 Combustion air fan

The combustion air fan supplies the air necessary for the com-
Fig. 204 Burner unit
bustion process to the burner unit.
The fuel is evaporated and precombusted in the burner unit.
2.2 Overheating protection, coolant
The fuel/air mixture is ignited by the glow plug when the
temperature sensor and heat heater is started. The glow plug is axially arranged in the mid-
exchanger dle of the burner unit.
2
2.4 Combustion chamber

1
Combustion chamber

Fig. 205 Combustion chamber

The combustion chamber assists combustion of the fuel/air

mixture thus heating the heat exchanger.

1 coolant temperature sensor

2 overheating protection

Fig. 203 Heat exchanger

The coolant temperature sensor registers the coolant temper-
ature at the coolant outlet of the heater as an electrical resist-
ance. This signal is sent to the control unit where it is
processed.
The heat exchanger transfers the heat generated in the com-
bustion process to the coolant circuit.
The overheating protection (bimetal strip) protects the heater
from impermissibly high operating temperatures. The over-
heating protection trips at a heat exchanger temperature in
excess of 127 ±7 °C and switches off the heater.
The overheating protection is reset automatically at tempera-
tures below 65 ±5 °C.

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Thermo Pro 90 2 General description

2.5 Exhaust gas temperature sensor 2.7 Control unit

Fig. 206 Exhaust gas temperature sensor

The exhaust gas temperature sensor detects the flame as well

as impermissible exhaust temperatures.

2.6 U4840 coolant pump Fig. 208 Control unit

The control unit controls the functional sequence and moni-

toring of burner operation.

2.8 DP42 fuel pump

Fig. 207 U4840 coolant pump

The coolant pump pumps the coolant in the vehicle and

heater circuits. The pump is switched on by the control unit
and runs continuously during heater operation (also during
the pause and afterrunning phases as well as during residual
Fig. 209 DP42 fuel pump
heat utilization).
The DP42 fuel pump supplies fuel to the heater.

ATTENTION
• The fuel pump must not be operated with the operating
voltage (12 or 24 ).
• Power must not be supplied to the pump when a control
unit is connected.

The fuel pump serves as a shut-off system when the heater is

switched off.

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3 Functional description Thermo Pro 90

3 Functional description

Glow plug

Fuel pump

Combustion air fan

Exhaust gas tempe-

rature sensor

Operation indicator
lamp

U4840 coolant pump

Vehicle blower

Possible coded control temperatures

1 Switching on 12 Afterrunning finished

2 Heater 13 Preheating 15 to 20 s
3 Preheating 40 s 14 Fuel pump / partial load (1/4)
4 Fuel pump / partial load (1/4) 15 "Flame ON" detection
5 "Flame ON" detection 16 Stabilization time
6 Stabilization time 17 Coolant temperature dropped
7 Full load 18 Full load
8 Vehicle blower "On" 19 Switching off (afterrunning period)
9 Control range 20 "Flame OFF" detection
10 Normal shutdown pause 21 Afterrunning finished
11 "Flame OFF" detection

Fig. 301 Thermo Pro 90 functional sequence

3.1 Switching on and residual heat utilization

Switching on the heater Residual heat utilization can only be activated from the "OFF"
state, i.e. the "residual heat utilization" state is not assumed
The heater is switched on with the control element. from the "fault lock-out", "ADR lock-out" and "heater lock-
Activation of residual heat utilization out" states.

Every time it is switched on, the heater checks the coolant Deactivation of residual heat utilization
temperature before the heating process. Residual heat utiliza- Conditions for deactivating residual heat utilization:
tion is activated automatically at coolant temperature above
60 °C. When residual heat utilization is activated, the coolant a) When the lower operating voltage limit has been
pump for the heater and the vehicle blower are automatically exceeded
actuated. b) When the coolant outlet temperature is lower than 60 °C
c) When the heater is switched off

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Thermo Pro 90 3 Functional description

OFF state will be assumed if the conditions a) or c) are met The disconnector (emergency off switch) may only be actu-
when activating residual heat utilization or during residual ated in the event of danger since the heater will be switched
heat utilization. off without any afterrunning period (possible overheating).

The heater will be started automatically if the condition b) is

met when activating residual heat utilization or during resi-
dual heat utilization.

3.2 Start and control mode

Automatically controlled heater operation begins when com-
bustion is initiated (start).
The boost heating capacity of 9.1 kW can be actuated for
max. 2 hours at low coolant temperatures.
The heating capacity is modulated between 1.8 kW and
7.6 kW at higher coolant temperatures. The aim is to reach
and maintain the control temperature.
The vehicle's heater fan cuts in when the coolant reaches a
temperature of approx. 30 °C.

The heater is switched to control pause mode if the coolant

temperature continues to increase beyond the control tem-
perature setpoint up to the pause threshold. The coolant
pump, the vehicle's heater fan and the operation indicator
remain in operation during the control pause phase.
The heater starts up again automatically after the coolant has
cooled down to the precoded cut-in temperature.

3.3 Switching off

The operation indicator lamp goes out when the heater is
switched off. The fuel pump stops, combustion stops and
afterrunning begins. The coolant pump, glow plug and the
combustion air fan continue to run during the afterrunning
phase in order to cool down the heater. It is possible to switch
the heater back on during the afterrunning period. The heater
restarts after the afterrunning period has elapsed.

3.4 Heater functions in ADR vehicles

The Thermo Pro 90 heater is switched on and off manually by
means of a switch. Automatic controllers are prohibited. In
vehicles of the type FL, the operation of these heaters is pro-
hibited during loading and unloading and at the loading
points. The generator signal and auxiliary drive signal are
requested for this purpose.

In vehicles of type FL, the heaters are automatically switched

off and the maximum ADR afterrunning time is 40 s in accor-
dance with the legal specifications.

An ADR afterrunning period takes place if:

• the generator signal (D+) is discontinued or

• the auxiliary drive signal (e.g. pumping device) is present.
After the end of the ADR afterrunning period, the control unit
is in ADR locking mode.

Before the restarting, the ON/OFF switch must be set to "OFF"

and the auxiliary drive signal must no longer be applied.

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4 Technical data Thermo Pro 90

4 Technical data

Thermo Pro 90 Diesel

Heater
12 V 24 V
Approval mark ECE R122 (heating) E1 00 0320
ECE R10 (EMC) E1 04 6196
Design Water heater
Heat flow Max. 9.1 kW
Control range 1.8 to 7.6 kW
Fuel Diesel DIN EN 590
PME DIN EN 14214
Fuel consumption Maximum (+/- 10%) 1.1 l/h
Fuel consumption over control range Control range (+/- 10%) 0.2 to 0.9 l/h
Rated voltage 12 Volt 24 Volt
Operating voltage range 10.5 to 15.5 Volt 20 to 31.5 Volt
Rated power consumption without coolant < 90 W
pump
and vehicle blower over control range [W] 37 to 83 W
(max.)
Permissible ambient temperature:
Heater (incl. control unit):
- Operation -40 to +80 °C
- Storage -40 to +125 °C
(heater off, operating voltage may be applied)
Fuel pump:
- Operation -40 to +30 °C
- Storage -40 to +85 °C
Permissible working pressure of coolant 2.0 bar
Capacity of the heat exchanger 0.15 l
Max. combustion air intake temperature +40°C
Minimum volume in coolant circuit 6.0 l
Specific volumetric coolant flow against 0.15 bar 1650 l/h
DP42: fuel pump:
specific volumetric fuel flow Diesel: 115 ml/(stroke*Hz)
DP42 fuel pump:
rated voltage 7 - 10 V (PWM actuation)
CO2 in exhaust gas (permitted function range) 9 to 12 Vol.-%
CO2 setting (at 20 °C and 1010mbar) 10.1 Vol.-%
Heater dimensions Length/length* (length
(tolerance ± 3 mm) of control unit as far as L = length: 355 (381*) mm
intake connection to W = width: 131 mm
coolant pump) H = height: 232 mm
Weight 4.9 kg

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Thermo Pro 90 5 Malfunctions and troubleshooting

5 Malfunctions and troubleshooting

General information NOTE
Select W-Bus under "Diagnostics" => "Device Selection" in
This chapter describes how to identify and remedy faults in Webasto Thermo Test PC Diagnostics. It is recommended to
the Thermo Pro 90 heater. print out the operating and fault data as well as the extended
fault conditions.
ATTENTION
Troubleshooting assumes detailed knowledge of the design
and functional principle of the individual heater components 5.1.1 Fault code output at the control element
and must only be carried out by specifically trained personnel.
• Control element (On/Off)
On control elements without a display (analogue), the fault
If in doubt, refer to Section 2 and 3 for information on how code is indicated in the form of a flash pulse.
the functions interact.
Error code output:
ATTENTION After 5 fast flash pulses, the fault code is output by a sequence
Troubleshooting is generally restricted to locating faulty com- of long flash pulses. The long flash pulses must be counted.
ponents. The following potential sources of malfunction are This number (fault code) provides information for the work-
not taken into account as they should always be checked to shop about the type of heater malfunction.
rule them out as the cause of fault:
• MultiControl / SmartControl element
• Corroded connector In the case of control elements with a display (analogue or W-
bus), the malfunction is shown on the display in the form of a
• Loose plug connector
fault code.
• Crimping defect at connector
Error code output:
• Corroded cables and fuses The fault code is indicated by a letter (F) followed by a 2-digit
combination (FXX).
• Corroded battery terminals

• Impermissibly high ambient temperature

NOTE
Carry out a function check in the vehicle after rectifying each • See Chapter "5.5 Fault code table (fault codes, flash
fault. codes)" on page 503.
• The fault code for the heater begins with F (FXX). Other
fault codes do not stem from the heater (e.g. TXX for
5.1 Procedure in the case of fault, MultiControl/SmartControl, see MultiControl/
SmartControl installation instructions).
malfunction and lock-out

ATTENTION 5.2 Cause of malfunctions

Always determine the cause of the lock-out first before recti- A malfunction is caused when there is one or more faults
fying the lock-out! occur. Possible faults are:

Overvoltage / Undervoltage,
The control unit recognises faults in the heater as malfunc-
– malfunctions of all components, e.g. due to short-circuit
tions. Afterrunning may be initiated depending on the type
or break,
and severity of the fault. If afterrunning is initiated in the case
– overheating of heater,
of fault, the heater remains in the lock-out state. A fault code
– impermissible exhaust temperature,
is also output after detecting a malfunction during the fault
– unsuccessful starts,
switch-off.
– flame failure.
The fault code is shown on the control element either by the
indicator lamp flashing of letter combination on the display
(depending on the type of control element).
The fault code assists the workshop or Webasto Technical
Service in determining the fault.

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5 Malfunctions and troubleshooting Thermo Pro 90

5.3 Deleting fault code

5.3.1 Without Webasto Thermo Test PC Determine cause of fault by reading out the fault code
Diagnostics memory.
Click on the "Fault List" button to read out the fault code
Switching on the heater (via control element) memory.
NOTE
Print out or note down fault code memory
There is a fault and it is detected by the control unit as a
relevant malfunction
Rectify fault

Heater shuts down due to the fault, i.e.

fault switch-off followed by fault lock-out. Clear fault code memory with the command "Clear Fault
The fault code is shown on the control element. Code Memory/Heater Lock-Out" in the "Fault Code
Memory" menu.

Determine cause of fault (e.g. with or without fault code

output, visual inspection of fuses and plug connections, ...) Switch on the heater
See Chapter "5.5 Fault code table (fault codes, flash
codes)" on page 503.
Reset fault lock-out

Switch off the heater Certain faults add to the fault count in the fault code memory.
The heater assumes heater lock-out mode when the number
of faults in the fault code memory exceeds a limit value. The
Rectify fault maximum number of fault in the fault code memory and the
limit value of the fault code memory is defined by the soft-
ware.
Switch on the heater
5.4 Heater lock-out
Reset fault lock-out The heater can be unlocked:

Without Webasto Thermo Test computer diagnostics:

5.3.2 with Webasto Thermo Test computer
diagnostics 1. Switching on the heater (via control element)
2. Remove fuse F3 for at least 10 s within 10 s after swit-
Connect diagnostic cable to the heater diagnostic plug ching on.
(next to fuses). 3. Reinsert fuse F3
4. Switching off the heater (via control element)

Switch on the heater (via control element) With Webasto Thermo Test computer diagnostics:

See Chapter "5.3.1 Without Webasto Thermo Test PC Diag-

nostics" on page 502.
There is a fault and it is detected by the control unit as a
relevant malfunction

Heater shuts down due to the fault, i.e. fault switch-off

followed by fault lock-out.

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Thermo Pro 90 5 Malfunctions and troubleshooting

5.5 Fault code table (fault codes, flash codes)

*: Indicator lamp of control element flashing: Number of long flash pulses after 5 short flash pulses
Fault Fault
code code Error message Possible causes Recommended action in workshop
(ana- (hexa-
logue) decimal)
F00 F01 No error Fuses Check fuses F1, F2 and F3
or F81
Electrical wiring • Check battery connections:
0* F91
+ at 12 / - at 9 / + at 3 (switch-on signal),
F92
connector X8
F2C
• Check control element
FA3 • Check contacts of W-bus cable (yellow cable)
F07
FAC Heater lock-out Delete heater lock-out
Control unit defective Replace control unit
F01 F02 No start Fuel system Check fuel level
or F82
Check fuel filter
1* F4E
F32 Checking tank extracting device and fuel line for
leaks
Bleed fuel system
Combustion air / exhaust Check combustion air/exhaust line for foreign
line objects and clean if necessary
Burner unit • Clean burner unit or replace if necessary
• Check glow plug
F02 F03 Flame abort Fuel system Check fuel level
or F83
Check fuel filter
2*
Checking tank extracting device and fuel line for
leaks
Bleed fuel system
Burner unit Clean burner unit or replace if necessary
F03 F04 Supply voltage too high Power supply Check battery
or F84 Check electrical connections
3*
F04 F05 Flame was detected Exhaust gas temperature • Check operation of exhaust gas temperature
or prior to combustion sensor defective sensor, replacing if necessary
4* • Check prepressure in fuel system to fuel pump
• Check delivery rate of fuel pump
F06 F14 Temperature sensor Wiring • Check wiring for damage
or F94 short circuit • Check resistance
6*
Coolant temperature sen- Check operation of coolant temperature sensor,
sor defective replacing if necessary
F07 F08 Fuel pump short circuit Wiring Check wiring for damage, break and short-circuit
or F88
DP42 fuel pump defective Check operation of fuel pump, replacing if
7*
necessary
F08 F09 Combustion air fan Wiring Check wiring for damage, break and short-circuit
or F89 short circuit
Combustion air fan blocked Check operation of combustion air fan, replacing
8* F2D
if necessary
Combustion air fan defec- Replace combustion air fan
tive

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5 Malfunctions and troubleshooting Thermo Pro 90

*: Indicator lamp of control element flashing: Number of long flash pulses after 5 short flash pulses
Fault Fault
code code Error message Possible causes Recommended action in workshop
(ana- (hexa-
logue) decimal)
F09 F8A Glow plug / flame mo- Wiring Check wiring for damage, break and short-circuit
or F19 nitor short circuit
Glow plug defective Check operation of glow plug, replacing if
9* F99
necessary
F10 F06 Heating unit over- Heating unit overheated Check coolant level, bleed coolant circuit
or F07 heated
Check operation of coolant pump
10* F86
Overheating protection Check wiring for damage, break and short-circuit
defective
Check operation of overheating protection,
replacing if necessary
F11 F0B Coolant pump short Wiring Check wiring for damage, break and short-circuit
or F8B circuit
U4840 coolant pump Replace coolant pump
11*
defective
F12 F16 Battery disconnector or Wiring Check wiring for damage, break and short-circuit
or electronic battery Electronic battery switch Check power intake of battery disconnector
12* switch short-circuit
defective
F13 F13 Vehicle fan power cir- Wiring Check wiring for damage, break and short-circuit
or F30 cuit short circuit
Vehicle fan relay Check wiring for damage, break and short-circuit
13*
Check operation of vehicle fan relay (K5, see
Section 11), replacing if necessary
F14 F1B Overheat sensor short Wiring Check wiring for damage, break and short-circuit
or FAB circuit
Overheating protection Check operation of overheating protection sensor,
14*
sensor defective replacing if necessary
F15 F2E The glow/ignition-ele- Wiring Check glow plug wiring for damage, break and
or ment power circuit is short-circuit
15* defective Glow plug defective Check operation of glow plug, replacing if
necessary
F16 F4F Exhaust gas tempera- Exhaust gas temperature Check wiring for damage, break and short-circuit
or F3B ture too high sensor defective Check operation of exhaust gas temperature
16* sensor, replacing if necessary
Heater fouled • Check burner
Visual inspection with cleaning, replacing
burner if necessary
• Visual inspection with cleaning and replacing
burner head if necessary
• Visual inspection with cleaning of inner
surface of heat exchanger (replace if
necessary)
F17 F31 Exhaust-gas tempera- Wiring Check wiring for damage, break and short-circuit
or F4D ture sensor: open or Exhaust gas temperature Check operation of exhaust gas temperature
17* short circuit sensor defective sensor, replacing if necessary

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Thermo Pro 90 5 Malfunctions and troubleshooting

5.6 Troubleshooting (fault symptoms)

Symptom Possible cause Corrective measures

A Heater does not Operating voltage – Check fuses (F2, F3)
respond, no component – Check power supply: measure supply voltage at heater connector X8,
running, operation indi- Pin 12 (see Fig. 1112)
cator remains off (VG connector, See Chapter "9.8.1 Legend to connector
VG95328R2016PN (if installed)" on page 904.
Operation indicator Operating indicator control element
(control element or ON/ – Measure supply voltage at connector X9, Pin 11
OFF switch) – Check continuity at connector X9, Pin 12 to ground
Operation indicator, switch:
– Measure supply voltage at switch S4, Pin A
– Check continuity at switch S4, Pin F to ground
B Heater will not start, DP42 fuel pump ATTENTION
briefly starts up then Always operate the fuel pump via the heater. Never connect directly to
switches immediately to 12V or 24V supply.
afterrunning, operating – Check fuel line connection at fuel pump DP42
indicator flashing (fault – Connect Webasto Thermo Test and evaluate.
code output, See Chap- – Ensure clear passage and seating of the flat spring contacts of the fuel
ter "5.5 Fault code table pump line.
(fault codes, flash – Measure cold resistance of fuel pump DP42 at 25 °, see Section 6.4.5
codes)" on page 503. Setpoints: 4.95 to 5.45 ohm, test current: < 1 mA
Combustion air fan – Check exhaust system and air intake system (see 'Excess smoke from
heater during start-up phase')
– Connect Webasto Thermo Test and evaluate.
• Set speed of 5500 rpm
• Listen for grinding noise and start-up noise.
Start up to the specified speed must be heard.
• The error message "Fan motor stiff" must not be activated
– Short-circuit or break. Check fan wiring
U4840 coolant pump – Check coolant level
– Connect Webasto Thermo Test and evaluate.
Switch on component test via Webasto Thermo Test, touch pump
with your hand, the pump is operating if slight vibration can be felt
– Check wiring
– Check self-bleeding position, see Section 7.5.2
Coolant temperature – Check coolant level
sensor – Connect Webasto Thermo Test and evaluate.
– Check cold resistance of coolant temperature sensor, see Section
6.4.1.
Setpoints (at 25 °C): 990 to 1010 ohm, test current < 1 mA
Glow plug See symptom A, glow plug

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5 Malfunctions and troubleshooting Thermo Pro 90

Symptom Possible cause Corrective measures

C Excessive smoke from Glow plug – Connect Webasto Thermo Test and evaluate.
heater during start-up – Measure glow plug resistance at glow plug connector X2, see Section
phase 6.4.2. Measured values: (cold resistance at 25 °C):
• 0.235 to 0.305 ohm, 12 V version
• 0.670 to 0.870 ohm, 24 V version (green mark on glow plug)
DP42 fuel pump See symptom B, DP42 fuel pump
Combustion air fan See symptom B, combustion air fan
Fuel integration – Check fuel level and fuel take-off from fuel tank
– Check integration in the vehicle's fuel system
– Check fuel lines for leaks, kinks and clogging, especially in the area of
line connectors on the intake side
– Disconnect fuel line from heater, hold hose in a collection container
and operate the fuel pump with Webasto Thermo Test PC
Diagnostics. (Measured fuel delivery rate 115 ml/h*Hz) Fuel should be
free of bubbles
– The fuel pipe of the burner unit is clogged if fuel flows out of the line
when it is disconnected from the heater, replace burner unit
Exhaust system and air – Check that the lines are not clogged
intake system – Rectify any leaks in the intake line and exhaust pipe (no CO2 in intake
air)
– Exhaust pipe outlet is not located under the intake line inlet.
– Check that intake line and exhaust pipe are installed in accordance
with installation instructions
– Check that there is sufficient distance from the interior fresh air intake
to the vehicle
Burner unit – Removal and visual inspection
– Replace the burner unit if the fuel pipe is clogged
Heater goes out prema- Undervoltage detection – Check fuses (F2, F3)
D turely – Webasto Thermo Test PC Diagnostics, check supply voltage
– Without Webasto Thermo Test: measure supply voltage at heater
connector X8, Pin 12 (see Fig. 1112). Setpoints:
• 12 V version:
The voltage must not drop below 10.5 V for more than 10 s
• 24 V version:
The voltage must not drop below 20.0 V for more than 10 s
DP42 fuel pump See symptom B, DP42 fuel pump
Combustion air fan See symptom B, combustion air fan
moves stiffly
Fuel integration See symptom C, fuel integration
Coolant circuit – Check integration in vehicle's coolant circuit in accordance with
general installation instructions. Remove kinks and chafing points.
– Check heater, water connection, coolant pump and hoses for leaks,
rectifying if necessary
– Check that coolant circuit is bled correctly
– Check circulation in coolant circuit
Exhaust system and air See symptom C, exhaust system and air intake system
intake system
Burner unit See symptom C, burner unit
E Irregular DP42 fuel pump See symptom B, DP42 fuel pump
combustion noise
Burner unit See symptom C, burner unit

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Thermo Pro 90 5 Malfunctions and troubleshooting

Symptom Possible cause Corrective measures

F Excessive smoke from DP42 fuel pump See symptom B, DP42 fuel pump
heater during heating
Fuel See symptom C, fuel integration
phase
integration
Exhaust system and air See symptom C, exhaust system and air intake system
intake system
Burner unit See symptom C, burner unit
G Heater running, vehicle Vehicle blower – Check fuse F1
interior cold – Check coolant temperature (K5 switches at approx. 30 °C)
– Check switching signal at relay K5, ground at Pin 85 and positive at
Pin 86, (audible, see wiring diagram in general installation
instructions)
– Check coolant temperature signal line (green/white, gr/ws), Pin 86 at
K5
H Excessive smoke from Exhaust system and air See symptom C, exhaust system and air intake system
heater during afterrun- intake system
ning phase
I Fuel odour Fuel See symptom C, fuel integration
integration
DP42 fuel pump See symptom B, DP42 fuel pump
Glow plug See symptom A, glow plug
J Smell of exhaust in vehi- Exhaust system and air See symptom C, exhaust system and air intake system
cle interior intake system
K Coolant loss U4840 coolant pump See symptom B, coolant pump
Coolant circuit See symptom D, coolant circuit

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5 Malfunctions and troubleshooting Thermo Pro 90

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Thermo Pro 90 6 Function checks

6 Function checks

6.1 General information 6.3 Setting CO2 content

This section describes the checks and settings carried out on
NOTE
the heater and its components in installed and uninstalled
state. After repairing the heater it will be necessary to check the
CO2 setting.
CAUTION
ATTENTION
Even if you use the timer, the heater must not be operated in
enclosed spaces such as garages and workshops without an It is recommended to check or reset the CO2 content after
emissions extraction system. replacing the burner unit, combustion air fan or the control
unit.

6.2 Function checks in the vehicle

The Thermo Pro 90 features automatic altitude compensation.
1. Set vehicle fan to level 1 - 2 or to the level recommended The permissible operating altitude of the heater is therefore
in the vehicle Owner's Operating instructions. between 0 and 3500 m above sea level.
2. Ensure that the fresh air inlet is free of foreign objects It is possible to change the level of combustion air by chang-
(snow, leaves, etc.) and the pollen and dust filters are ing the CO2 setting with Webasto Thermo Test PC diagnostics.
clear.
Checking and setting the CO2 content
3. Make sure that the coolant circuit and fuel system have
been carefully bled according to the vehicle manufac- • Using the Webasto Thermo Test PC diagnostics, set the
turer's regulations. heater to "CO2 Setting" mode. The heater start up
automatically and then switches to "burner operation".
4. Switch on heater at the control element. It runs at a heating output level of 7.6 kW which is used
solely for the purpose of setting the CO2 content, i.e. the
The coolant pump and combustion air fan start up when heating capacity must remain at 7.6 kW for several
the heater is switched on. Check that they can be heard. minutes (approx. 10 minutes) as per Webasto Thermo
The heater switches on the vehicle fan when the coolant Test PC diagnostics.
reaches a temperature of 30 °C. The coolant temperature should be kept as low as
After max. 240 s the exhaust can be heard flowing out of possible. The greatest amount of heat is dissipated by
the exhaust silencer or connection socket. the vehicle fan (fan and interior temperature set to
5. Run heater in heating mode. Check heating effect at the maximum).
outlet nozzles of the vehicle fan.
• Set the CO2 value as shown in Fig. 601 on Page 602.
NOTE When setting:
– Increasing CO2 content => combustion air fan delivers
The heating function depends on several factors: more air => measured CO2 level should drop.
The outside temperature, type of vehicle, engine temperature, – Decreasing CO2 content => combustion air fan
type of integration in the vehicle's cooling system, quantity of delivers less air => measured CO2 level should rise.
coolant to be heated and the time since start-up must be
taken into account for the assessment. The coolant tempera- ATTENTION
ture determined by the heater and the coolant or engine tem-
perature displayed by the vehicle may differ significantly as the Due to the automatic altitude compensation by the heater,
corresponding sensors are fitted in different positions and the CO2 content should be set only with Webasto Thermo Test
may evaluate different temperatures. PC diagnostics in "CO2 Setting" mode.

6. Switch off the heater again at the control element.

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6 Function checks Thermo Pro 90

2500 = 7,6 kW 747 mbar

= 9,1 kW

2000 795 mbar

H 1500 845 mbar

[m]

1000 899 mbar

500 954 mbar

0 1013 mbar
9,5 10 10,5 11 11,5 12 12,5 13 13,5 14 14,5

CO2 [%]

Fig. 601 CO2 altitude correction

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Thermo Pro 90 6 Function checks

6.4 Testing individual components

6.4.1 Checking resistance of the coolant 6.4.5 Checking the DP42 fuel pump
temperature sensor
ATTENTION
When testing with a digital multimeter, the temperature sen- • The fuel pump must not be operated with the operating
sor should show the following values: voltage (12 or 24 ).
• Power must not be supplied to the pump when a control
Resistance at 25 °C: 990 to 1010 Ohm unit is connected.
Test current: < 1 mA When testing with a digital multimeter, the DP42 should show
the following values:
6.4.2 Checking resistance of the glow plug
Resistance at 25 °C: 4.95 to 5.45 Ohm
When testing with a digital multimeter, the glow plug should Test current: < 1 mA
show the following values:
Diesel delivery rate:
Glow plug: 12 Volt (red) 24 Volt (green) See “Technische Daten” on Page 401.

Resistance at
6.4.6 Checking the overheating protection
25 °C: 270 ± 35 mOhm 770 ± 100 mOhm
NOTE
6.4.3 Checking resistance of the exhaust gas
temperature sensor The overheating protection should only be removed when it is
to be renewed. It must be checked in installed state.
When testing with a digital multimeter, the exhaust gas tem-
perature sensor should show the following values:
Check continuity of overheating protection at room tempera-
Resistance at 25 °C: 2195 ± 4 Ohm ture, the electrical resistance must go towards 0 ohm.

Test current: < 5 mA 6.4.7 Checking the U4840 coolant pump

6.4.4 Checking the combustion air fan The coolant pump should be checked with the component
test function in Webasto Thermo Test PC diagnostics. The
The combustion air fan speed must be checked in the permis- coolant pump can also be checked by touching it with your
sible operating voltage range. Check for scraping noise. hand. Constant vibration of the coolant pump should be felt.

NOTE Technical data :

see Page 401
The combustion air fan is always checked in installed state, i.e.
the control unit must be mounted on the fan housing. This is
due to the sensors in the control unit that are required for
speed control.

The test is performed with the Webasto Thermo Test PC diag-

nostics.

Specified speed 5500 rpm

Listen for grinding noise and start-up noise. Start up to the

specified speed must be heard. The error message "Fan motor
stiff" must not be activated.

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6 Function checks Thermo Pro 90

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Thermo Pro 90 7 Servicing

7 Servicing

This section describes the servicing jobs that can be carried 7.4 Checks
out on the heater and its components when installed.
To maintain the functional reliability of the heater, the follo-
wing servicing jobs should be carried out before and after
7.1 Working on the heater each heating period:
• Read out fault code memory.
Always disconnect the power supply at the vehicle battery
and remove fuses F2 and F3 before carrying out any work on • Cleaning heater exterior (make sure no water gets in).
the heater. The main battery power must not be discon-
• Check the electrical connections for contact corrosion
nected whilst the heater is operating or afterrunning due the
and firm seating.
risk of the heater overheating and consequently the over-
heating safeguard tripping. Completely remove the heater to • Checking exhaust gas and combustion air line for dam-
carry out repairs. age and ensuring they are clear.
Once the heater and all coolant-carrying components have
• Checking fuel line and strainer for leaks.
been installed, the entire coolant system should be filled, bled
and checked for leaks at the system pressure as specified by • Check coolant circuit and coolant pump for leaks.
the vehicle manufacturer (see Technical Data).
• Check hoses for cracks.
Refer to the general installation instructions and the vehicle-
specific installation instructions for repairs that require the • Replacing fuel filter, if fitted.
heater to be installed in a different position.
• Check heater operation as described under section 6.2.
NOTE
Coolant running out of the system should be collected in a
suitable container.

7.2 Working on the vehicle

ATTENTION
With the operating voltage applied and the heater is
switched off, on no account must a temperature of 125 °C be
exceeded in the vicinity of the heater (e.g. vehicle paintwork)
(see Technical Data).

7.3 Heater test run

CAUTION
Even if you use the timer, the heater must not be operated in
enclosed spaces such as garages and workshops without an
emissions extraction system.

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7 Servicing Thermo Pro 90

7.5 Removing and installing heater 7.6 Visual inspection to assess the burner
unit
CAUTION
Hot coolant leaking out can cause burn injuries. Pay attention to the specific features of the burner unit when
it needs to be replaced or is faulty.
7.5.1 Removal The criteria for a thorough check are listed in the following.
To remove and install the burner unit: See “Burner unit and
1. Disconnect vehicle battery. glow plug” on Page 805.
2. Remove heater fuses. First check that the burner unit is complete and not damaged.

3. It is not necessary to release the control unit cover to 1 2 3 4

remove the vehicle-specific wiring harness.
4. Unplug the wiring harness connector at the heater (do
not pull the cables).
5. Depressurise coolant system.

NOTE
Protect all open plugs and connectors from moisture and dirt.

6. Release hose clips and detach the coolant hoses from the
water connection pieces on the heater. Prevent coolant
from dripping out of the coolant hoses.
5 1 1
7. Release and detach combustion air line and exhaust pipe
1 Retainer (3x)
at heater.
2 Glow plug
8. Release hose clips, detach fuel line. Close off fuel connec- 3 Metal fiber evaporator
tion socket at heater and fuel line with suitable plugs or 4 Combustion chamber
similar. 5 Fuel pipe with back plate
9. Remove the three screws and washers from the heater Fig. 701 Visual check, burner back plate
mounting bracket.
7.6.1 Metal fiber evaporator
10. Remove the heater.
• Cracks, flaking as well as black or other discoloration of
7.5.2 Installation the metal fiber evaporator (3, Fig. 701) will not cause the
1. Place heater in installation position and secure with the 3 burner to fail and do not impair operation.
screws and washers. • Carbon deposits on the evaporator surface are normal;
2. Connect fuel line and secure with hose clip. the burner unit normally cleans itself when changing
from full load/partial load and partial load/full load.
3. Connect coolant hoses and tighten hose clips to 8 Nm.
• The burner unit must be replaced when the metal fiber
4. Reestablish all electrical connections. evaporator is partially burnt through.
The 12-pin vehicle-specific wiring harness connector and
• The burner unit must be replaced when the retaining ring
the 2-pin fuel pump connector must audibly snap in.
is deformed such that the metal fiber evaporator is not
5. Connect combustion air line and exhaust pipe. pressed down correctly.
6. Connect vehicle battery.
7. Bleed coolant circuit.
8. Bleed the vehicle fuel system if necessary.

ATTENTION
Reversing the polarity of the power supply can damage the
control unit. Ensure correct polarity of the connection cables.
Direct connection to the power supply without an intermedi-
ate fuse is not permitted.

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Thermo Pro 90 7 Servicing

7.6.2 Combustion chamber 7.7 Restarting

Combustion chamber Carefully bleed the coolant circuit and the fuel supply system
after installing the heater. Follow the vehicle manufacturer's
specifications. During the test run, check all coolant and fuel
connections for leaks and that they are firmly fitted. If the
heater encounters a fault during operation, perform the trou-
bleshooting procedure to locate the malfunction (see Section
5).

To assist the coolant circuit bleeding procedure, operate the

coolant pump with the "component test" function in
Webasto Thermo Test PC diagnostics.

ATTENTION
The coolant temperature must be < 60 °C before the heater
starts up otherwise burner operation may not take place. The
Air holes heater is to be placed into operation with Webasto Thermo
Test PC diagnostics. If completely empty, the fuel line should
be filled by means of Webasto Thermo Test PC diagnostics:
Cover press the "Fill Line" button and pump fuel up to the heater.
During the heater test run, check all coolant and fuel connec-
Fig. 702 Combustion chamber tions for leaks and that they are firmly fitted.

• The cover and the combustion chamber (Fig. 702) must

be firmly secured and have no play (check by lightly
moving). The burner unit must otherwise be replaced.

• The burner unit must be replaced if there is a radial gap

between the combustion chamber and cover.

• The fuel pipe must be firmly secured to the back plate

and must have no play (check by lightly moving the fuel
pipe).
Replace the burner unit if there is play between the fuel
pipe and back plate.
The combustion chamber (Fig. 702) should not be
damaged (e.g. dented). A dented combustion chamber
can cause poor combustion or coking of the heater. The
burner unit should be replaced in this case.

• The air holes (Fig. 702) in the burner unit should not be
clogged. Clogged air holes can result in the burner not
starting or poor combustion.
Carefully scrape the air holes clear.

• The metal fiber evaporator will not fit correctly if the

retainers (3x) are deformed or missing.
The burner unit should be replaced in this case.

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8 Repairing and replacing components Thermo Pro 90

8 Repairing and replacing components

8.1 General information

This section describes the repair jobs that can be carried out on the heater after it has been removed from the vehicle. Any
further dismantling will invalidate the warranty. For assembling the heater only use the spare parts from the corresponding
spare parts kits.

8.2 Component layout

1 2 3

11
10 5
9

8
7

1 Burner head 7 Combustion air fan

2 Coolant temperature sensor 8 Gasket
3 Overheating protection 9 Glow plug
4 Heat exchanger 10 Burner unit
5 U4840 coolant pump 11 Exhaust gas temperature sensor
6 Control unit

Fig. 801 Component layout

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Thermo Pro 90 8 Repairing and replacing components

8.3 Work on stripped down components 8.5 Control unit

NOTE
Seals should generally be renewed before reassembling the
heater.

Cleaning

Clean all stripped down components.

Visual inspection
Fig. 802 Control unit cover
• Check all components for damage (cracks, deformation,
wear, etc.) and replace as required.
• Inspect the connectors and cables for corrosion, loose
contacts, crimping faults, etc. and repair as required.
• Check plug contacts for corrosion and contacts to ensure
they are secure, repairing if necessary.

8.4 Electrical connections

All electrical connections are connected separately with indi-

vidual connectors in the control unit. Before removing a com-
ponent first unplug the corresponding electrical connection.
See Chapter 11.15 "Plug assignments at control unit" on
page 1111.

Fig. 803 Control unit

Removal
1. Remove control unit cover (see Fig. 802)
2. Unplug electrical connections (see section 8.4).
3. Release control unit and detach from the cap of the com-
bustion air fan.

Installation
1. Slide control unit onto the cap of the combustion air fan
until the clip snaps in.
2. Reestablish electrical connections (see section 8.4).
3. Close control unit cover so that it snaps in.

ATTENTION
It is important to follow the correct procedure when plugging
in the individual connectors at the control unit.
This means, all connectors are pushed by hand as far as they
will go into the respective position in the control unit. The
control unit cover is then locked.
The control unit cover is not a plug insertion aid.
It only prevents the connectors from falling out.

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8 Repairing and replacing components Thermo Pro 90

8.6 U4840 coolant pump 8.7 Overheating protection

Fig. 805 Removing overheating protection sensor

Removal
NOTE
• The overheating protection should only be removed
when it is to be renewed.
• It must be checked in installed state.

Fig. 804 Replacing the U4840 coolant pump

1. Remove heater (see section 7.5)
(depending on space requirements).
Removal 2. Unplug electrical connections (see section 8.4).
3. Remove clip and detach protective cap.
1. Remove heater (see section 7.5).
4. Lever off retaining spring with a screwdriver and remove
2. Disconnect plug connections (see section 8.4).
overheating protection.
3. Undo screws (2x).
5. Complete work on stripped down components (see sec-
4. Remove clip and coolant pump.
tion 8.3).
5. Complete work on stripped down components (see sec-
tion 8.3).
Installation
ATTENTION
Installation
Incorrect installation can cause the heat exchanger to burn
1. Lubricate seal (between coolant pump and heat through.
exchanger) with acid-free grease (Vaseline).
2. Place coolant pump in assembly position and secure with 1. Fit new overheating protection in heat exchanger and
clip and screws. press in retaining spring.
3. Tighten screws (2x) to 3 Nm ± 10%.
NOTE
4. Plug in connector at control unit (see section 8.4).
The spring must be heard and felt to snap into the
groove.
This ensures that the overheating protection is installed
in the correct position.
If the spring cannot be heard and felt to snap in:
• Clean contact surface of overheating protection on
the heat exchanger
• Clean the groove in the heat exchanger
• Make sure that there are locking lugs on both sides
of the spring. Replace overheating protection if
necessary.
2. Fit protective cap and secure with clip.
3. Tighten clip to 0.5 Nm ± 20%.
4. Plug in connector at control unit (see section 8.4).
5. If removed, install heater (see section 7.5).

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Thermo Pro 90 8 Repairing and replacing components

8.8 Coolant temperature sensor 8.9 Combustion air fan

Fig. 807 Combustion air fan removal

Fig. 806 Coolant temperature sensor removal

Removal
1. Remove heater (see section 7.5), depending on space
Removal requirements.
1. Remove heater (see section 7.5). 2. Unplug electrical connections (see section 8.4).
2. Unplug electrical connections (see section 8.4). 3. Remove screws (2x). Detach control unit if necessary.
3. Unscrew coolant temperature sensor (Fig. 806) (13 mm 4. Pull the combustion air fan off the burner head and
hexagon) and remove together with O-ring. remove.
4. Complete work on stripped down components (see sec- 5. Complete work on stripped down components (see sec-
tion 8.3). tion 8.3).

Installation
1. Lubricate O-ring (Fig. 904) with acid-free grease (Vase-
line).
2. Screw coolant temperature sensor with O-ring into the
heat exchanger and tighten to 1.5 Nm ±10%.
3. Make electrical connections (see section 8.4).
4. If removed, install heater (see section 7.5).

Fig. 808 Seal on combustion air fan

NOTE
Make sure that the seal on the combustion air fan is intact
(both sides).

Installation
1. Place the combustion air fan in the assembly position and
secure with screws.
2. Tighten screws (2x) to 3 Nm ± 10%.
3. Fit control unit and reestablish electrical connections (see
section 8.4).
4. If removed, install heater (see section 7.5).

804
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8 Repairing and replacing components Thermo Pro 90

8.10 Burner unit and glow plug 8.11 Burner head

1 2 3

7 6 54
Fig. 809 Burner unit and glow plug Fig. 811 Burner head

Removal
3 1. Remove heater (see section 7.5).
2. Remove combustion air fan (see section 8.9).
3. Remove burner unit with glow plug (see section 8.10).
4. Remove retaining screw of V-clip and detach V-clip.
5. Pull burner head out of heat exchanger and remove.
2 6. Complete work on stripped down components (see sec-
5 tion 8.3).
1 4, 6
NOTE
When replacing the burner head, the exhaust gas tempera-
ture sensor must be removed from the old burner head and
Fig. 810 Burner unit and glow plug, front fitted in the new burner head. See to section 8.13.

Removal Installation
1. Remove heater (see section 7.5), depending on space
requirements. NOTE
2. Remove combustion air fan (see section 8.9). The burner head and exhaust gas outlet socket can still be
3. Remove screw (2, Fig. 809/Fig. 809). aligned after installation in the vehicle.
4. Remove burner unit (1) with glow plug socket (3).
5. Remove glow plug: 1. Fit burner head in heat exchanger, align if necessary and
Detach retaining tab (6) by removing screw (4), detach secure with V-clip.
glow plug socket from fuel line. 2. Tighten retaining screw of V-clip to 3 Nm ±10% .
6. Complete work on stripped down components (see sec- 3. Install burner unit with glow plug (see section 8.10).
tion 8.3). 4. Install combustion air fan (see section 8.9).
Installation 5. Install heater (see section 7.5).
1. Carefully insert the glow plug as far as it will go into the
burner unit.
2. Secure retaining tab for glow plug with screw (4)
(tightening torque 2.5 Nm ±10%).
3. Fit glow plug socket on fuel line.
4. Fit burner unit and glow plug socket in the burner head
(7).
5. Secure burner unit with screw (2). Tighten screw to
3 Nm ±10%.
6. Install combustion air fan (see section 8.9).
7. Make electrical connections (see section 8.4).
8. If removed, install heater (see section 7.5).

805
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Thermo Pro 90 8 Repairing and replacing components

8.12 Heat exchanger 8.13 Exhaust gas temperature sensor

Fig. 812 Heat exchanger

Fig. 813 Exhaust gas temperature sensor with clip

Removal Removal
1. Remove heater (see section 7.5).
1. Unplug electrical connections (see section 8.4).
2. Remove coolant pump (see section 8.6).
2. Lever cable clip from rib on burner head (make a sketch
3. Remove overheating protection (see section 8.7).
of the position of the clip if necessary).
4. Remove coolant temperature sensor (see section 8.8).
3. Release screw connection of holder and pull out exhaust
5. Remove burner head and combustion air fan (see section
gas temperature sensor.
8.11).
6. Complete work on stripped down components (see sec-
Installation
tion 8.3), check for damage (cracks, deformation etc.)
and replace if necessary. 1. Fit exhaust gas temperature sensor in burner head.
Clean soot from inner jacket of heat exchanger. 2. Secure the exhaust gas temperature sensor to the burner
head with the holder and screw. Tighten the holder
Installation screw to 2.5 Nm ±10%.
3. Press down the clip to secure the exhaust gas tempera-
1. Install burner head and combustion air fan (see section
ture sensor cable to the rib on the burner head. Make
8.11).
sure that the cable is fitted free of stress between the
2. Install coolant temperature sensor (see section 8.8).
exhaust gas temperature sensor and clip.
3. Install overheating protection (see section 8.7).
4. Install coolant pump (see section 8.6).
NOTE
5. Install heater (see section 7.5).
If the exhaust gas temperature sensor suffers external
mechanical damage, this component can be replaced with-
out the need for additional work.
Additional work will, however, be necessary if an obvious
thermal defect is incurred or no mechanical defect is found
despite an error message. This means it is necessary to visu-
ally inspect the burner unit, exhaust pipes, the combustion
chamber as well as the heat exchanger fins (inner surface).
Check for abnormal quantities of soot, fuel residue as well as
coking. If this is the case, clean all affected parts. The burner
unit should be additionally checked by a specialist technician
for thermal damage and replaced if necessary.

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8 Repairing and replacing components Thermo Pro 90

ATTENTION
• Take particular care when handling the exhaust gas
temperature sensor - as it is a sensitive electronic/ceramic
component!
Avoid pulling the cable of the exhaust gas temperature
sensor at the sensor head during installation and while
the heater is in operation.
Avoid sharp kinks in the cable at the sensor head to
prevent damage to the Teflon cable insulation.
Do not pull the cable after fitting the exhaust gas
temperature sensor!
Replace the sensor if it is dropped while carrying out
maintenance work.
When fitting the sensor, make sure the mica insulator on
the sensor is okay, the cable clip of the exhaust gas
temperature sensor is fitted without stress and the cable
from the exhaust gas temperature sensor is installed
loosely to the control unit.
• The cable of the exhaust gas temperature sensor is
designed as a high temperature resistant cable with
Teflon insulation.
The material can withstand permanent temperatures of
up to 185 °C but is sensitive to external mechanical
impact.
Before finally determining the installation location of the
heater we recommend that you assess the possible risk of
damage to the cable as the result of stone impact. If
stone impact cannot be ruled out in the place the heater
is installed, precautions should be taken to protect the
cable of the exhaust gas temperature sensor, e.g. fitting
suitable cover.

< 10 N
(single con-
ductor)
< 30°

Fig. 814 Burner head and exhaust gas temperature sensor

Fig. 815 Checking mica insulator on sensor

807
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Thermo Pro 90 9 Thermo Pro 90 HDD

9 Thermo Pro 90 HDD

9.1 General information

This section describes the differences between the Thermo Pro 90 HDD and the Thermo Pro 90. Refer to the Thermo Pro 90
specifications in this document for specifications that are not referred to in this section.

5
1 2 3 4

1 combustion air fan

7
2 fuel connection
3 coolant outlet
4 coolant temperature sensor
8
5 EMC interference suppression
module
6 exhaust gas temperature sensor
7 overheating protection
9 8 heat exchanger
9 coolant inlet
13 12 11 10 10 U4840 coolant pump
11 outlet, exhaust gas
12 combustion air inlet
13 control unit
Fig. 901 Thermo Pro 90 HDD heater components

901
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9 Thermo Pro 90 HDD Thermo Pro 90

9.2 Technical data

Thermo Pro 90 HDD*1

Heater
24 V
Approval mark ECE R122 (heating) 00 0443
ECE R10 (EMC) 04 7225
Design Water heater
Heat flow Max. 9.1 kW
Control range 1.8 to 7.6 kW
Fuel Diesel DIN EN 590
PME DIN EN 14214
NATO Codes: F34, F35, F63, F44 and F75
Fuel consumption Maximum (+/- 10%) 1.1 l/h
Fuel consumption over control range Control range (+/- 10%) 0.2 to 0.9 l/h
Rated voltage 24 Volt
Operating voltage range 19 to 33 Volt
Rated power consumption without coolant
pump
37 to 83 W
and vehicle blower over control range [W]
(max.)
Permissible ambient temperature:
Heater (incl. control unit):
- Operation -40 to +80 °C
- Storage -40 to +125 °C
(heater off, operating voltage may be applied)
Fuel pump:
- Operation -40 to +30 °C
- Storage -40 to +85 °C
Permissible working pressure of coolant 2.0 bar
Capacity of the heat exchanger 0.15 l
Max. combustion air intake temperature +40°C
Minimum volume in coolant circuit 6.0 l
Specific volumetric coolant flow against 0.15 bar 1650 l/h
DP42: fuel pump:
specific volumetric fuel flow 115 ml/(stroke*Hz)
DP42 fuel pump:
rated voltage 7 - 10 V (PWM actuation)
CO2 in exhaust gas (permitted function range) 9 to 12 Vol.-%
CO2 setting (at 20 °C and 1010mbar) 10.1 Vol.-%
Heater dimensions L = length: 355 (381)*2 mm
(tolerance ± 3 mm) W = width: 131 mm
H = height: 232 mm
Weight 5.0 kg

*1: The Thermo Pro 90 HDD water heater complies with the requirements of the United States Department of Defence con-
cerning the electromagnetic compatibility of products in accordance with the standard MIL-STD-461F.

*2: Length (length of control unit as far as intake connection to coolant pump)

902
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Thermo Pro 90 9 Thermo Pro 90 HDD

9.3 U4840 coolant pump with EMC 9.4 Combustion air fan
suppressor module

Fig. 903 Thermo Pro 90 HDD combustion air fan

Fig. 902 U4840 coolant pump with EMC suppressor
module NOTE
The Thermo Pro 90 HDD has a special combustion air fan (mo-
tor connected to ground).
NOTE
– Ensure sufficient pull relief of the wiring harness when
connecting to the coolant pump.
– After connecting to the control unit, bundle the coolant 9.5 Fuel
pump wiring harness together with the other component
cables with a cable tie near the control unit. The diesel fuel in accordance with DIN EN 590 specified by
the vehicle manufacturer must be used.
In terms of compatibility the fuels additionally comply with
9.3.1 Replacing the EMC suppressor module the corresponding NATO Codes F34, F35, F63, F44 and F75.
The fuel properties according to the manufacturer's data-
Removal sheet must be taken into account.
1. Unplug electrical connections (see section 9.3).

2. Cut through cable tie.

3. Undo holder mountings screws, including ground con-

nection of the EMC suppressor module.

Installation
1. Secure holder and cable lug for ground connection of
EMC suppressor module with screws to the heat
exchanger housing (tightening torque 6 Nm +/-10%).

NOTE
Make sure the cable lug is seated correctly when tightening
the screw connection. Avoid twisting the cable lug when
screwing down.

2. Secure the EMC suppressor module to the inside of the

holder with cable ties.

NOTE
The heads of the cable ties should face inwards to facilitate
installation of the heater.

3. Establish electrical connections.

903
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9 Thermo Pro 90 HDD Thermo Pro 90

9.6 Control unit

CAN-Offboard diagnostics
Use similar to W-bus diagnostics with SAEJ1939-compliant
diagnostic tools as per Webasto specification.

9.7 Electrical components

NOTE
A minimum bending radius of 110 mm must not be exceeded
when using the WDT wiring harness (ID: 9029629_). Avoid
mechanical stress at the connection areas.

ATTENTION
The heater must not be operated in systems with system vol-
tages stipulated in the standard MIL-STD-1275D 5.3.2.4
(generator-supported systems with voltage peaks up to 100
V).

Fig. 904 Thermo Pro 90 HDD control unit

NOTE
For Thermo Pro 90 HDD control unit with retaining spring.
The retaining spring must not be removed when replacing/in-
stalling the control unit and should be fitted as an assembly
with the control unit on the heater.

9.8 Thermo Pro 90 HDD wiring diagrams

See “11 Wiring diagrams” on Page 1101.

9.8.1 Legend to connector VG95328R2016PN (if installed)

VG Remarks VG Remarks
A Output, vehicle fan relay J Auxiliary drive
B Operating indicator/error code K Input switch-on signal (ON/OFF)
output
L Output, battery disconnector
C W-bus afterrunning signal
D Power supply (terminal 30) M CAN GND
E Power supply (terminal 30) N CAN LOW
F Power supply (terminal 31) P CAN HIGH
G Power supply (terminal 31) R Not used
H Terminal D+ S Not used

Fig. 905 Connector VG95328R2016PN (if installed)

904
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Thermo Pro 90 10 Packaging/storage and shipping

10 Packaging/storage and shipping

10.1 General information Heaters should always be stored in the original or similar
packaging in closed rooms!
The heater or its components to be sent to Webasto for tes-
ting or repair, must be cleaned and packed in such a way that After removing the delivery packaging, the heaters should
they are protected from mechanical damage, soiling and en- only make contact at the aluminium parts. The type label and
vironmental influences during handling, transportation and the surface of the heaters should be protected from damage
storage. by placing suitable material under them (e.g. cardboard).
The heater should be covered during storage and protected
The temperatures during transportation and storage must from dust, dirt and moisture.
not drop below or exceed the ambient temperatures defined The heater must not come in contact with chemicals or their
in the technical data in the installation instructions. vapours, e.g. fuels, battery fluids or brake fluids.
During storage, dirt, water or chemicals must not get into the
heater through the openings, see above.
NOTE The fuel pipe must be protected from lateral impact that
When sending in a complete heater, the unit must be com- could cause deformation.
pletely drained of fuel. Steps must be taken to ensure that re-
sidual fuel or coolant cannot leak out while packing the unit The heater can be transported in any position in suitable
and during shipping. packaging.
The coolant connection sockets and fuel connection should The electrical contacts and the fuel pipe must be protected
be closed off with dummy plugs. from mechanical damage.

10.2 Storage and transportation

The heater can be stored in any position. There are no restric-

tions.

Fig. 1001 Preferred position of Thermo Pro 90 heater for storage and transportation

1001
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11 Wiring diagrams Thermo Pro 90

11 Wiring diagrams
The wiring diagrams show the possible connections for 12 or 24 volt heaters.

11.1 Thermo Pro 90

System wiring diagram for Thermo Pro 90 and control ele- Legend to wiring diagrams:
ment:
See:
• MultiControl (battery disconnector): see Fig. 1102 Section 11.12 "Cable cross-sections"
• SmartControl ADR: see Fig. 1103 Section 11.13 "Cable colours"
• ADR on/off switch: see Fig. 1104 Section 11.15 "Plug assignments at control unit"
• ThermoCall TC4: see Fig. 1105 Section 11.16 "Legend to wiring diagrams"
• UniBox: see Fig. 1106 Section 11.17 "Legend for comments"
• MultiControl (analogue connection): see Fig. 1107 Section 11.18 "Legend for plug X8, 12-pin"

11.2 Thermo Pro 90 HDD

System wiring diagram for Thermo Pro 90 HDD and control

element:

• MultiControl: see Fig. 1108

• SmartControl ADR: see Fig. 1109
• with ADR on/off switch: see Fig. 1110

Thermo Pro 90 HDD VG connector pin assignments:

See Section 9.8 "Thermo Pro 90 HDD wiring diagrams"

1101
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Thermo Pro 90 11 Wiring diagrams

11.3 System wiring diagram for Thermo Pro 90 with MultiControl control element with battery disconnector

9032679A03

Fig. 1102 System wiring diagram Thermo Pro 90, MultiControl with battery disconnector

1102
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11 Wiring diagrams Thermo Pro 90

11.4 System wiring diagram for Thermo Pro 90 with SmartControl control element (ADR)

9032413A03

Fig. 1103 System wiring diagram Thermo Pro 90, SmartControl (ADR)

1103
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Thermo Pro 90 11 Wiring diagrams

11.5 System wiring diagram for Thermo Pro 90 with on/off switch (ADR)

9032678A03

Fig. 1104 System wiring diagram Thermo Pro 90, on/off switch (ADR)

1104
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11 Wiring diagrams Thermo Pro 90

11.6 System wiring diagram for Thermo Pro 90 with ThermoCall TC4

9033213A02

Fig. 1105 System wiring diagram Thermo Pro 90, ThermoCall TC4

1105
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Thermo Pro 90 11 Wiring diagrams

11.7 System wiring diagram for Thermo Pro 90 with UniBox

9032352A04

Fig. 1106 System wiring diagram Thermo Pro 90, UniBox

1106
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11 Wiring diagrams Thermo Pro 90

11.8 System wiring diagram for Thermo Pro 90 with MultiControl control element (analogue connection)

9032353A04

Fig. 1107 System wiring diagram Thermo Pro 90, MultiControl (analogue connection)

1107
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Thermo Pro 90 11 Wiring diagrams

11.9 System wiring diagram for Thermo Pro 90 HDD with MultiControl control element

9032792A03

Fig. 1108 System wiring diagram Thermo Pro 90 HDD, MultiControl

1108
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11 Wiring diagrams Thermo Pro 90

11.10 System wiring diagram for Thermo Pro 90 HDD with SmartControl control element (ADR)

9032791A02

Fig. 1109 System wiring diagram Thermo Pro 90 HDD, SmartControl (ADR)

1109
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Thermo Pro 90 11 Wiring diagrams

11.11 System wiring diagram for Thermo Pro 90 HDD with on/off switch (ADR)

9032351A03

Fig. 1110 System wiring diagram Thermo Pro 90 HDD, on/off switch (ADR)

1110
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11 Wiring diagrams Thermo Pro 90

11.12 Cable cross-sections 11.15 Plug assignments at control unit

Cable < 7.5 m 7.5 - 15 m X6 X4 X7 X8

2 2
0.75 mm 1.0 mm

1.0 mm2 1.5 mm2

1.5 mm2 2.5 mm2 X5

X2
2.5 mm2 4.0 mm2 X3
X1
2 2
4.0 mm 6.0 mm

11.13 Cable colours

Abbreviation Colour
bl blue
br brown
ge yellow
gn green
gr grey
or orange
rt red
Fig. 1112 Plug assignments at control unit
sw black
vi violet
ws white

11.14 Heater connections

GS ÜHS

BM

UP
WTS

ATS

Fig. 1111 Heater connections

1111
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Thermo Pro 90 11 Wiring diagrams

11.16 Legend to wiring diagrams

Item Description Remarks
A1 Heater Thermo Pro 90 / Thermo Pro 90 HDD
A2 Control unit –
ATS Exhaust gas temperature sensor PT2000
B4 Room thermostat Optional
BA Operating indicator Light 0.15 W to max 2 W
BM Burner motor Combustion air fan
DP Fuel pump Fuel pump for heater
F1 Fuse 20A
F2 Fuse 1 A Blade fuse DIN 72581-3
F3 Fuse 20 A
FZG Vehicle blower –
GS Glow plug –
H1 Symbol on display –
(green, blue, white, red) Operating indicator, ready indicator,
H2 LED
ON indicator, fault list
H5 Bulb/LED ON indicator, pumping device (max. 500 mA)
K5 Relay with free-wheeling diode Vehicle blower
P MultiControl / SmartControl (W-bus)
P1 SmartControl (W-bus)
S4 Switch On/Off (min. 500 mA)
S5 Switch Auxiliary drive / pumping device
S6 Switch, 1 or 2-pin ADR
S7 Battery disconnector Electronically controlled disconnector (max. 500 mA)
S10 Electronic battery disconnect switch –
ÜHS Overheating protection Sensor on heat exchanger
UP Coolant pump U4840 coolant pump
V1 / V2 Diode Min. 500 mA (optional, not included in wiring harness)
WTS Coolant temperature sensor Coolant temperature in coolant circuit
X1 4-pin plug connection Item BM to item A2
X2 Item GS to item A2
X3 Item DP to item A2
X4 Item UP to item A2
2-pin plug connection
X5 Item WTS to item A2
X6 Item ATS to item A2
X7 Item ÜHS to item A2
X8 12-pin plug connection Vehicle-specific wiring harness

1112
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11 Wiring diagrams Thermo Pro 90

Item Description Remarks

X9 4-pin plug connection To item P or P1
W-bus, MultiControl / SmartControl connection, Telestart (12 V
X10 4-pin plug connection
only), ThermoCall or diagnosis
X11 2-pin plug connection To item DP
X12 2-pin plug connection To item UP
Y2 Solenoid valve / pump Auxiliary drive / pumping device

11.17 Legend for comments 11.18 Legend for plug X8, 12-pin

No. Remarks No. Remarks

 D+ signal (vehicle motor ON/OFF) for deter-

mining the control temperature
1
Output, battery disconnector afterrunning
signal

 When connecting MultiControl/SmartCon-

trol (W-bus), the black wire must be
2 Output, vehicle fan relay

removed from plug connection X10 (pin 2) 3 Input switch-on signal (ON/OFF)
and isolated (if not already done).
4 Operating indicator/error code output
 Fuse for vehicle blower (fuse present in vehi-
cle) 5 Auxiliary drive

6 W-bus
 Switch for vehicle blower
7 Terminal D+
 EMC interference suppression module (HDD
version only) CAN GND as per SAE J1939 (HDD version
8
only)
 Wiring harness
9 Power supply (terminal 31)
 Fuse for vehicle blower (fuse present in vehi-
cle) 10
CAN LOW as per SAE J1939 (HDD version
only)
 -
11
CAN HIGH as per SAE J1939 (HDD version
only)
 Optional extension available (connection to
plug connection X10) 12 Power supply (terminal 30)

 CAN module; as per SAW J1939 for diag-

nostics function (optional, HDD version
only)

 Mating connector on vehicle conforms to

VG95328R2016P (optional, HDD version
only)

 VG95328R2016PN connector (optional,

HDD version only)

1113
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Webasto Thermo & Comfort SE Ident-Nr. 1317201B •04/16 • Errors and omissions excepted • Printed in Germany • © Webasto Thermo & Comfort SE, 2016
Postfach 1410
82199 Gilching
Germany

Visiting adress:
Friedrichshafener Str. 9
82205 Gilching
Germany

Internet: www.webasto.com

Technical Extranet: http://dealers.webasto.com

The telephone number of each country can be found in the

Webasto service centre leaflet or the website of the respective
Webasto representative of your country.

In multilingual versions the German language is binding.

www.butlertechnik.com