Webasto CSL 31 Operating instructions

Brand: Webasto

Model: CSL 31

Type: Operating instructions

Thermosystems

CSL31-B BEVERAGE BODY

EATING SYSTEM

Operating Instructions

Table of Contents

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Topic Page

1. Safety Information 3

1.1 Warning Symbols used in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. General Information 5

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Component Identification 7

4. Functional Description 9

4.1 Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.2 System Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.3 Full Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.4 Switching to Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5. Operating Instructions 11

5.1 Indicator Lamp Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6. Technical Data 12

Table of Contents2

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Topic

7. Preventive Maintenance 14

7.1 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7.2 Check Available Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7.3 Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.4 Fuel Filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.5 Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.6 Heater Smokes White at Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8. Troubleshooting 16

8.1 Know the System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

8.2 Diagnostic Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

9. Wiring Diagrams 18

10.Overview of Sub-assemblies 21

11.Spare Parts Lists 22

12.Limited Warranty 23

Safety Information

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1. Safety Information

Read this operating instruction manual in its entirety before operating this equipment.

Failure to follow the operating instructions and the notes contained therein will lead to all liability being refused by

Webasto.

1.1 Warning Symbols used in this Manual

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series

of symbols and signal words which are intended to convey the level of importance of the safety messages. The

progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger

and are not a substitute for proper accident prevention measures.

Indicates an imminently hazardous situation which, if not avoided, WILL result in

death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in

death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, MAY result in

minor or moderate injury or property damage.

It may also be used to alert against unsafe practices.

DANGER

WARNING

CAUTION

Safety Information4

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1.2 General Safety Instructions

• While heater is in use, the product surface or surrounding air from air outlet may become hot to the

touch. Contact with skin may cause burns.

• 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.

• NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully

completed Webasto factory training and have the technical skills, technical information, tools and

equipment required to properly complete the necessary procedures. Only genuine Webasto parts may

be used.

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

personnel.

• Webasto products produce temperatures high enough to ignite surrounding combustible materials such

as inflammable liquids, gases, vapor, and other combustible matter. The heater must be switched off

when loading or unloading inflammable materials to prevent the risk of explosion.

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

DANGER

General Information

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2. General Information

Webasto Thermo & Comfort N.A., Inc. is pleased to provide this owner’s manual with the CSL31-B Heating System.

When used according to the operating instructions stated in this manual, you can expect trouble-free, enjoyable

operation for many years.

This manual represents our latest effort to produce the best documentation possible.

In our efforts towards continuous, ongoing product improvement, we encourage our customers to write to us with

their comments or criticisms concerning this manual and the CSL31-B Heating System.

Please write to us at:

Webasto Thermo & Comfort N.A., Inc.

Technical Documentation Group

15083 North Road

Fenton MI 48430

You are also invited to fill out our online questionnaire concerning our technical documentation and web site at:

www.techwebasto.com

If you have any immediate questions concerning this manual, or the product itself, please call us at:

(800) 555-4518 or send a fax to:(810) 593-6001

General Information6

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2.1 Introduction

Thank you for purchasing the Webasto CSL31-B Beverage Body Heating System. The CSL31- B

heating system is specifically engineered to provide freeze protection during overnight storage or during

in-transit operations.

Targeting the application needs of the beverage body and product environment has led development to a system

exclusive to the Beverage Market.

The CSL31-B features the Webasto Thermo 90 ST diesel-fired 31,000 Btu/hr (output) coolant heater. The Thermo 90 ST

combined with a balanced heat system, heat exchanger and powerful fan provides a safeguard to the interior

temperature.

The electronics of the CSL31-B utilize an efficient cool down cycle once the container has reached the thermostat set

point. This is accomplished with a fan “after run” time to allow transferring the developed heat from the system into

all areas of the container. This smart “after run” is designed around the container size and insulation properties.

Advantages of the CSL31B include:

• 22° C (72° F) fixed thermostat utilizing the heating

system only when necessary

• Independently operated low temperature red

warning light

• Low heat outlet-operating temperatures to

• avoid damaging product or packaging

• Two levels of heating; Maintenance and Recovery

heating

• System Efficiency 84%

• Diagnostic code at switch indicator light

• Maintenance on/off switch at heater

• No fuel or coolant within the product area

• Upward exhaust

• Simple access to heating system

• Manufactured to ISO 9002 and QS 9000

• Weather Resistant Electrical Connections

Component Identification

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3. Component Identification

Figure 1. CSL31-B Assembly

Thermo 90 ST

Coolant

Hoses

Exhaust

Control

Module

Coolant

Tank

Fuses/Relay

Electrical

Connectors

Heat

Exchanger

Enclosure

Diagnostic

Connector

Combustion

Air Intake

Low Temp.

Indicator

Operation/

Diag.

Indicator

Component Identification8

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Figure 2. Thermo 90 ST Heater

Fuel Pump

Combustion

Air Inlet

Control

Unit

Exhaust

Coolant Pump

Coolant

Inlet

Combustion

Chamber

Water Jacket

(Heat Exchanger)

Overheat

Thermostat

Coolant

Outlet

Burner

Assembly

Fuel

Inlet

Functional Description

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4. Functional Description

4.1 Standby Mode

Upon switching the system on, power is supplied to the interior regulation thermostat and to the operation status relay

(K1 page 12 and 13) inside the heating system enclosure. When the interior regulation thermostat is open, not

requiring heat.The operation status relay will illuminate the green LED and remain in this state until the interior

thermostat closes and commences the system start.

4.2 System Start

Temperature within the container drops and switches the interior regulation thermostat closed at 10º C (50° F). The12

Volt output from the thermostat energizes the operation status relay and also supplies the on signal to begin the

Thermo 90 ST operation. The Thermo 90 ST will perform a brief self-diagnostic check, indicated by the combustion fan

motor powering on high speed momentarily and then reducing to start (low) speed. The ceramic igniter circuit begins a

20-30 second pre-heat followed by the fuel-metering pump beginning the fuel supply/pulse. The Thermo 90 ST will

begin to increase fan/air speed as well the fuel pump will increase pulse/fuel delivery. A start mode flame is established

and sensed by the flame detector and electronic control unit. Once this initial flame is sensed the combustion air fan

and fuel increase to the full heat mode.

Approximately one minute after the Thermo 90 ST has started the air delivery fan will commence via a coolant

temperature thermostat located near the coolant outlet connection. The heating system is now in the Full Heat Mode.

Functional Description10

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4.3 Full Heat

The Thermo 90 ST and Air Delivery Fan will continue operation until the interior regulation thermostat within the

container opens/senses 22° C (72° F).

4.4 Switching to Standby

Once the interior is heated, the regulation thermostat opens which disconnects the on signal to the Thermo 90 ST and

operation status relay. A cool down sequence will begin by stopping fuel delivery, the combustion air fan motor

continues on high speed until the flame detector has sensed the flame being extinguished.At which time a cool down

period of 2-3 minutes begins. The cool down period will allow the combustion air fan and circulation pump to operate

and cool down the system.

The forced air delivery fan will continue operation until the coolant system has cooled, allowing additional air

circulation and heat distribution within the container

Operating Instructions

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5. Operating Instructions

Product loading will require a minimum of one pallet to separate the product from the floor to providing warm air

distribution. To insure of adequate airflow the loaded product should not exceed the height of the bay walls.

The heater on/off switch with green indicator light is located at the exterior front wall on the driver side of vehicle. This

provides visible identification of the heaters Operation State to the vehicle operator.

An additional red light is located on the heater enclosure. The red light indicates that the temperature within the

container has dropped to a level where the product has the potential of freezing. To operate the heating system simply

push rocker switch top position.

5.1 Indicator Lamp Description

Green Indicator Lamp:

1. On - Heater System On or in Stand By Mode (not requiring heat)

2. Blinking - System Fault. Notify maintenance personnel.

3. Off - System Fault. Switch heater off and then back on again, one time only permitted. Notify maintenance

personnel if heater fails to turn On.

Red Indicator Lamp On with Green Indicator Lamp Off:

System Fault. Switch heater off and then back on again, one time only permitted. If unit starts and the green light

remains on, allow 10 minutes for red light to go out. Notify maintenance personnel.

Red Indicator Lamp On with Green Indicator Lamp On:

System Fault. Low Temperature Warning Light On / Heating System Operational. Ensure there are no obstructions

to airflow above bay wall height. Check that all bay doors are closed properly. During overnight product storage

operation, check that the power cord 110 VAC is plugged in. Notify maintenance personnel.

Technical Data12

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6. Technical Data

6.1 CSL31- B Specifications

Specifications CSL31- B Thermo 90 ST

Heating Capacities Btu/hr (kW)

– Recovery /Boost Mode

– Maintaining Regulation Temperature

17,000 Btu (5 kWh)

Btu/ hr Output = 31,000 (9.1)

Btu/ hr Output = 28,500 (8.4)

Air Flow 700 cfm (1120 m3h)

Fuel Consumption

– Recovery /Boost Mode

– Maintaining Regulation Temperature

0.28 gal/ hr (1.06 L/ hr)

0.26 gal/ hr (0.98 L/ hr)

Rated Voltage 12 Vdc

Operating Voltage 11 to 15 Vdc

Power Consumption Including Fan 11 Amps/132 Watt in boost/ recovery mode -10 Amps/120 Watt in maintenance mode

Permissible Fuels (Winter Operation) Diesel #2 to 32° F (0° C) / Winter Blend Diesel #1 to 0° F (-17.7 C) /

Below 0° F (-17.7 C) Use arctic fuel W/ anti-gelling additives

Permissible Additives All types with manufactures instructions followed -Do not over concentrate!

Operating Temperature Range - 40° F to 72° F (- 40° C to 22.2° C)

CO2 Content in Exhaust 10.5%

Enclosure Dimensions L 42.75 in x W14.25 in x H 12.25 in (L 108.5 cm x W36.1 cm x H 31.1 cm)

Weight 60 lbs (27.24 kg)

Coolant Capacity 0.84 Gallon (3.2 Liters)

Technical Data

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CSL31- B Specifications Continued

CSL31- B Kit Contents Assembled CSL31- B Enclosure

Straight Truck Chassis Harness

– Connection from enclosure to batteries = 21 ft. (640 cm)

– Connection from enclosure to exterior mount switch box = 12 ft. (365.7 cm)

Thermostat Harness = 26 ft. (792.4 cm)

Thermostats with Mounting Hardware

Fuel System Complete = 17 ft. (518 cm)

Exterior Switch with Hour Meter

Preventive Maintenance14

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7. Preventive Maintenance

7.1 Visual Checks

Inspect the following components for corrosion, damage, loose connections, leakage, and dirt build up:

•Enclosure

• Thermo 90 ST Heater

•Fuel Pump

• Batteries

• Switches and Thermostats

7.2 Check Available Power

1. Measure battery voltage (with no110 VAC plug in)

2. Measure available voltage at Fuse #1

a. Connect volt meter between enclosure ground lug and Fuse #1

b. Switch heater On with mechanics switch

c. Read volt meter -available voltage must be no less than 0.8 VDC from battery voltage

3. Turn Off mechanics switch

4. If voltage drop measures greater than 0.8 VDC:

a. Replace battery ring terminals

b. Inspect batteries per manufactures recommended test

c. Inspect electrical connections in heater enclosure for corrosion or damage

Preventive Maintenance

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7.3 Coolant Level Check

Ensure coolant recovery container is filled to proper level.

A 50% water to 50% glycol solution must be used.

7.4 Fuel Filter Check

The fuel filter must be changed at the start of each heating season.

a. Fuel filter must be changed mid season in regions of -10° F

and lower.

b. A fuel filter in new condition will fill approximately 25% with

fuel.

c. Fuel filters found with 50% or more fuel must be replaced.

7.5 Operational Test

Switch On mechanics switch in enclosure, when air delivery

fan switches on, switch mechanics switch to the Off

position.

7.6 Heater Smokes White at Start Up

Inspect air hole located in the burner assembly for obstructions if

the heater smokes white at start up, and a no start is experienced.

Remove the burner and ceramic ignitor for complete cleaning (See

Figure 3).

Figure 3. Burner Rear Wall

Starting

Air Hole

Ceramic

Ignitor

Burner

Assembly

Troubleshooting16

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8. Troubleshooting

8.1 Know the System and Components

Effective troubleshooting requires knowledge of the complete system and its normal operation sequence. The

Functional Description beginning on page 9 must be read and understood before beginning any diagnosis to the

system. Preventive Maintenance beginning on page 14 must be completed when performing troubleshooting

inspections. The fault alert code are the five fast flashes (not counted) followed by the slower (counted) flashes.

Begin Troubleshooting by placing the Mechanics Switch to ON position (the mechanics switch will by-pass the cargo/

interior thermostat)

8.2 Diagnostic Table

Failure Symptom Probable Cause Check and Correct

No Function Electrical wiring, fuses

Control unit

Fuses

Battery connections: + 12Vdc at Relay (K1) pin 86 (yellow wire)

Replace control unit

0x Flash

Fault Lockout

3 start-up attempts with faults Turn switch to ON position. Pull main fuse, wait 20 seconds.

Turn heater switch off. Reinsert main fuse. Rectify the cause of

the fault.

1x Flash

No Start

Fuel delivery Correct fuel type for ambient conditions

Check condition of fuel filter

Clean or replace burner assembly

2x Flashes

Flame Outage During Operation

Fuel delivery

Combustion air/exhaust

Burner assembly

Correct fuel type for ambient conditions

Check combustion air/exhaust

Clean or replace burner assembly

3 x Flashes - Undervoltage Electrical power supply Check battery and electrical connections

Troubleshooting

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4 x Flashes

Flame Monitor Continuously Hot

Flame monitor defective Replace flame monitor

5 x Flashes

Flame Monitor Defective

Wiring

Flame monitor defective

Inspect wiring at heater

Replace flame monitor

6 x Flashes

Temperature Sensor Defective

Wiring

Defective

temperature sensor

Inspect wiring at heater

Replace temperature sensor

7 x Flashes

Fuel Pump

Wiring

Fuel pump open circuit

Inspect wiring for open circuit

Replace Fuel Pump

8 x Flashes

Combustion Air Fan

Wiring

Combustion air fan defective

Inspect wiring at heater

Replace combustion air fan motor

9 x Flashes

Glow Plug Defective

Wiring

Glow plug defective

Inspect wiring

Replace glow plug

10 x Flashes

Overheat

Coolant system Inspect for restrictions in coolant circuit

Check for proper coolant level

Reset overheat sensor

11 x Flashes

Coolant Pump

Wiring

Coolant pump open circuit

Inspect wiring

Replace coolant pump

Failure Symptom Probable Cause Check and Correct

Wiring Diagrams18

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9. Wiring Diagrams

Wiring Diagram - Enclosure and Chassis Harness

86 87 85 87a 30

2 1

1 2 3 4

3 4 2 1

16 GA BROWN

14 GA BROWN

16 GA YELLOW

16 GA GREEN

16 GA BROWN

14 GA RED

18 GA GREEN

18 GA YELLOW

18 GA RED

16 GA BROWN

14 GA BROWN

18 GA RED

18 GA GREEN

18 GA BLACK

18 GA ORANGE

18 GA BROWN

18 GA BLUE

16 GA BROWN

18 GA BLUE

16 GA BLUE

18 GA BLUE

18 GA BROWN

18 GA ORANGE

18 GA GREEN

18 GA BLACK

18 GA YELLOW

18 GA GREEN

87a

(MATING END SHOWN)

GROUND

18 GA

BLACK

FUSE BLOCK

BATTERY +

14 GA RED

Item Designation

F1 Fuse 20A

F2 Fuse 7.5A

F3 Fuse 20A

S1 Toggle switch

X1 12-pin Thermo 90 S/ST

X2 2-pin Diagnostic Link

X3 2-pin Fan Motor

X4 3-pin Mechanic Switch

X5 6-pin Chassis Harness

X6 4-pin Cargo Thermostats

X7 4-pin Indicator Lights

X8 5-pin Relay - Indicator Lights

T8 1-pin x 2 Fan Thermostat

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Webasto CSL 31 Operating instructions

Webasto CSL 31 Operating instructions

Webasto CSL 31 Operating instructions

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