Water Heater Operating instructions Installation instructions Thermo Top Thermo Top Thermo Top T Tele Thermo Top Thermo Top S Thermo Top S Tele Thermo Top S BW 50 DW 50 Petrol Diesel 8/1995
Table of contents Page Operating instructions 2 Safety Information 4 Operation of the Heater 6 Maintenance of Heater 15 Troubleshooting 18 Functional Description 20 Technical Data 22 Installation instructions 23 Installation Example Thermo Top 25 Installation Example Thermo Top S 26 Fuel installation Thermo Top S 27 Fuel installation Thermo Top 30 Troubleshooting 43 Webasto Service Telephone 47 Please mark: Installed is: Thermo Top Thermo Top T with Telestart T6 with Telestart T60 with Telestart T5 Tele Thermo Top Thermo Top S Tele Thermo Top S Summer/Winter Switch Versions Thermo Top Petrol type BW 50 Water heater for fuel petrol Thermo Top Diesel type DW 50 Water heater for fuel Diesel/fuel oil EL Thermo Top S Petrol type BW 50 Water heater for fuel petrol with metering pump Thermo Top S Diesel type DW 50 Water heater for fuel Diesel/fuel oil EL with metering pump The water heaters Thermo Top are designed to operate on 12 volts. I
Installation instructions Legal Provisions for Installation For testing the heater in accordance with articles 19, 20 or 21 of the StVZO the following regulations are primarily to be observed (art. 22a StVZO): Testing is performed upon presentation of the operating and installation instructions of the manufacturer. The year of the initial start-up (commissioning) must be durably marked on the heater nameplate by the installer. Extracting the combustion air from the interior of the vehicle is not permissible. The exhaust pipe must be so mounted that its discharge opening points downward, sideways or, in the case of routing the exhaust pipes on the underside of the bottom of the vehicle, their discharge opening must be positioned near the lateral or rear edge of the driver s cab or vehicle. Exhaust pipes must be routed in such a way that exhaust gases cannot penetrate the interior of the vehicle. The function of any parts of the vehicle essential for its operation must not be impaired. against mechanical damage. Fuel-carrying parts are to be protected against excessive heat and are to be arranged such that any dripping or evaporating fuel can neither collect nor be ignited by hot components or electrical equipment. The heater must not be installed in passengers areas. The operating state of the heater at any given time - i.e. at least an indication as to whether it is on or off - must be easily recognizable. When the heater has been retrofitted, this installation must be examined by an officially recognized expert or examiner (TÜV) for its compliance with article 21. A new operating license for the vehicle must be applied for at the Motor Vehicle Registration Office on the basis of the test report. Installation Location Preferably, the heater should be installed in the engine compartment, the splash-water protected areas of the front fenders or at the splashboard. Applicable to Thermo Top, Thermo Top T and Tele Thermo Top only If the heater cannot be installed in the aforementioned locations it may also be installed: - in upright position in front of the gearbox (partly covered, see Fig. 1) provided the fuel supply system is not located in front of the engine, any auxiliary equipment or the gearbox. - in inclined position in front of the gearbox (see illustration) provided point A is located below the lower edge of the gearbox and at least 25 mm above point B. This ensures that the heater can slide underneath the gearbox in the case of an accident. - in accordance with vehicle-specific Webasto installation instructions which are to be presented to the officially registered expert when the installation is being inspected. The openings of the combustion air inlet and exhaust gas outlet must be so designed that a spherical object of 16 mm diameter cannot be introduced. Electric lines, switchgear and controlgear of the heater must be so arranged in the vehicle that their proper function cannot be impaired under normal operating conditions. For the routing of fuel lines and the installation of additional fuel tanks articles 45 and 46 of the StVZO are to be adhered to. The most important excerpts therefrom are as follows: Fuel lines are to be designed in such a way that they remain unaffected by torsional stresses in the vehicle, engine movement and the like. They must be protected Use of the Water Heater The Webasto Thermo Top water heater in conjunction with the vehicle heating system is used for - heating the driver s cab, - defrosting the vehicle s windows as well as - preheating water-cooled engines. The water heater operates independently of the vehicle engine and is connected to the cooling system, the fuel system and the electrical system of the vehicle. Fig. 1: A A B A min 25 B B Installation location in front of the gearbox 23
Caution: The openings of the water connecting branches must not, in any installation position, point in downward direction. Nameplate 7 1 2 3 5 The type plate must be located at a place where it is protected against damage and must be easily accessible once the heater has been installed (or a nameplate duplicate is to be used). The year not applicable is to be removed from the type plate. 6 Fig. 2: Mounting position Connection to the Vehicle Cooling System The heater is to be connected to the vehicle cooling system in accordance with Figs. 4, 5, 6 and 7. The coolant system capacity must be at least 4 liters. Fig. 4: Integration into engine/cooling water circuit Inline-Integration Fig. 3: Mounting position The heater should be installed at a level as low as possible so as to ensure automatic venting of heater and circulating pump. This is of special importance since the circulating pump is not of the self-priming type. Note: The heater must not be installed on the support plate in a hanging position. CAUTION: The heater must not be installed in the following places: - in the immediate vicinity of or above hot parts - in the direct splash water area of the wheels Applicable to Thermo Top, Thermo Top T and Tele Thermo Top only - in front of the engine block or the engine units - in engine compartments which are open at the bottom, below the wheel center (i.e. in each permissible mounting position the bottom of the heater must be located above the wheel center). As a rule, the water hoses (pipes) supplied by Webasto are to be used. If not, the hoses must at least conform to DIN standard 73411. The hoses are to be laid without any kinks and - for proper venting - should be pitched upward, if possible. Hose connections must be secured against slipping off by means of hose clamps. The hose clamps at the heater must be mounted between the flared neck of the pipe and the heater. The hose clamps must be tightened to a torque of 2,0 + 0,5 Nm. Before the heater is operated for the first time or after coolant has been replaced it must be ensured that the cooling system is properly vented. Heater and piping should be so installed as to ensure static venting. Insufficient venting can result in a failure during heating operation due to overheating. 7 Fig. 5: 1 2 3 4 Integration with check valve Legend for Fig. 4 and 5: 1 Expansion tank 2 Thermostat 3 Engine 4 Check valve 5 Heater 6 Heat exchanger 7 Radiator 5 6 24
Fig. 6: Installation example of heater Thermo Top in a passenger car 1 Radiator 2 Cooling water thermostat 3 Water pump (of car engine) 4 Standard equipment engine 5 Water heater 6 Battery 7 Fuse holder 8 Control unit (in heater) 9 Relay (for vehicle fan) 10 Regulating valve of vehicle heating 11 Heat exchanger, vehicle heating system 12 Vehicle heater fan 13 Vehicle heater fan switch 14 Fuse bank in the vehicle 15 Digital timer 16 Fuel pickup 17 Fuel pump (in heater) 18 Exhaust muffler, as required 19 Circulating pump (in heater) 25
Fig. 7: Installation example of heater Thermo Top S in a passenger car 1 Radiator 2 Cooling water thermostat 3 Water pump (of car engine) 4 Standard equipment engine 5 Water heater 6 Battery 7 Fuse holder 8 Control unit (in heater) 9 Relay (for vehicle fan) 10 Regulating valve of vehicle heating 11 Heat exchanger, vehicle heating system 12 Vehicle heater fan 13 Vehicle heater fan switch 14 Fuse bank in the vehicle 15 Digital timer 16 Fuel pickup 17 Intake muffler 18 Exhaust muffler, as required 19 Circulating pump (in heater) 20 Intake extension 21 Fuel metering pump 26
Fuel Installation for Thermo Top S Fuel Supply In the case of carburetor or injection engines equipped with return lines, the heater s fuel system is to be integrated in the return line as shown in Fig. 7. In the case of carburetor engines without return line, the fuel circuit of the heater is to be integrated in the flow line between the vehicle s fuel tank and pump. Particulars on pressure values permitted to prevail at the point of fuel extraction are contained in the Table below. permissible fuel feed height H (m) at max. perm. overpressure (bar) in the fuel line 0,00 0,2 1,00 0,11 2,00 0,03 permissible fuel suction height S (m) at max. perm. underpressure (bar) in the fuel line 0,00-0,10 0,50-0,06 1,00-0,02 ANNOTATION A fuel flow line can usually be identified by the in-line fuel filter. If the vehicle s fuel system is equipped with a vapour separator, fuel extraction is to take place upstream of same. l 1 + l2 10 m l 1 1,2 m l 2 8,8 m Fig. 8: Fuel Supply 27
For fuel extraction from flow or return lines it is mandatory that the special Webasto fuel pickup (see Fig. 9) be used. The fuel pickup is to be so mounted that any air or gas bubbles that may form are automatically discharged toward the tank (see Fig. 9). Air or gas bubbles in the fuel line of the vehicle can occur if there is a leak in the vehicle s carburetor or fuel pump or in the case of ambient temperatures exceeding the vaporizing temperature of the fuel. To prevent the lines from sagging, freely suspended fuel lines must be secured. Mounting should be performed in such a manner that the lines are protected against flying stones and thermal influence (exhaust pipe). Connection of 2 Pipes by Means of Hose The proper connection of fuel lines by means of a hose is shown in Fig. 10. Check for leakage! Fuel should not be extracted from within the vicinity of the engine as gas bubbles are likely to form in the lines owing to the heat radiating from the engine which may result in malfunctions in the heating operation. If the heater is installed in vehicles equipped with injection systems it is therefore to be determined whether the fuel pump is mounted inside or outside the tank. from tank to engine correct incorrect clamp Where the fuel pump is located inside the tank, fuel may only be extracted from the return line whereby it must be ensured that the return line extends almost to the bottom of the tank. Failing this, the return pipe can be extended. Fig. 9: to metering pump Webasto Fuel Pickup bubble bubble Where the fuel pump is mounted outside the tank, the connection to the fuel system can be accomplished between the fuel tank and the fuel pump As fuel lines only steel, copper and plastic pipes made of plasticized, light-resistant and temperature-stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) in accordance with DIN 73378 may be used. Fig. 10: Pipe/Hose Connection Fuel Lines The hose clamps are to be tightened to a torque of 1.0 + 0.4 Nm. Any fuel that may have leaked is to be removed prior to starting up the engine or the heater. As in the majority of cases it is not possible to route the lines in a continuous upward pitch, the inside diameter must not exceed a given dimension. With inside diameters of 4 mm and larger, air or gas bubbles accumulate which result in malfunctions if the lines sag or are routed in a downward pitch. When the diameters shown in Fig. 8 are used, you can be sure that no unwanted bubbles will be formed. The lines from the metering pump to the heater should not be routed in a downward pitch. 28
Metering Pump The metering pump is a combined fuel supply, metering and shutoff system and is subject to certain installation criteria (see Figs. 8, 11 and 12). Fig. 11: preferable 15-90 Metering Pump Without Diaphragm Damper Installation position and mounting Unique to Diesel versions Bild 12: Metering Pump (delivered from 1996) Installation position horizontal Installation Location Prior to installing the metering pump make sure that the maximum pressure prevailing at the fuel extraction point is less than 2.0 bar. It is recommended that the metering pump be installed in a position which is sufficiently cool. On no account must the permissible ambient temperature at any given operating stage be in excess of + 20 C. Metering pump and fuel lines must not be installed in the radiation range of hot vehicle parts. If necessary, a radiation protection is to be provided. The preferred installation position is near the tank. Installation and Mounting The metering pump is to be attached by vibration-damping suspension. The installation position is restricted in accordance with Fig. 11 and 12 in order to ensure sufficient selfventilation. Combustion Air Supply for Thermo Top S and Tele Thermo Top S A combustion air intake line needs not to be provided if - the temperature of the intake air is below 60 C - the air intake point location is not affected by splash water. The combustion air intake point must be located in a splash-proof area, if possible. If the combustion air intake opening points in the direction of travel, the existing reducer is to be exchanged for the intake elbow, order no. 319 12A. The reducer provided in the intake opening is to be removed beforehand. The intake elbow, order no. 319 12A, is required for the extension of the combustion air tube. The combustion air line can be so routed that it features several bends (total of 270, smallest bending radius 50 mm). On no account should the combustion air be drawn from rooms where persons are present. If the heater is installed in an enclosed housing, a vent hole of at least 3cm 2 is required. If the temperature in the installation housing exceeds the permissible ambient temperature of the heater, the vent hole must be enlarged after prior consultation with Webasto. The combustion air intake opening is to be so located that the possibility of clogging due to contamination is remote. It must not point in the direction of travel. When the heater is installed in the vicinity of the vehicle tank in a common installation space, combustion air intake must be from the outside of the vehicle and the exhaust gas be discharged into the atmosphere. Appropriate cutouts are to be splashwater-proof. 29
Fuel Installation for Thermo Top, Thermo Top T and Tele Thermo Top Fuel Supply In the case of carburettor or injection engines equipped with return line, the heater s fuel supply circuit must be integrated in the return line as shown in Fig. 13 carburator engine marked. The fuel lines are to be cut off 35 cm longer than marked. The excess length of the fuel lines of 35 cm is to be distributed evenly. The fuel lines are to be so fastened that they will not be damaged by vehicle parts that may come in contact with them. The direction arrows provided on the heater must be observed. In the case of carburettor engines without return line, the fuel supply circuit of the heater must be integrated in the flow line between vehicle fuel tank and pump. If the fuel system of the vehicle is equipped with a degassing device, fuel extraction is to take place upstream of same. Fig. 13: fuel pump Fuel Supply Circuit in the Single Line System (Carburetor Engine without Return Line) Inline Integration between Pump and Carburetor The lines must be mounted in such a way that they are protected from mechanical damage (e.g. stones) and thermal influence (e.g. exhaust pipe). If the fuel line is damaged there is a danger of fire. The hose clamps are to be tightened to a torque of 1.0 + 0.4 Nm. Fuel Lines Only the special hoses supplied with the heater by Webasto must be used as fuel lines between fuel connections and heater. When using hoses, the joints are to be secured using hose clamps. To prevent any sagging the fuel line must be secured with clips. Prior to cutting the fuel line open it must be clamped off or a suitable vessel placed underneath the pipe. Any fuel that may have leaked is to be removed from the engine or heater prior to starting up the vehicle or heater The fuel lines - not cut to length as yet - are to be connected to the vehicle s return line. Keeping slack to a minimum, they are then to be routed along any obstructing vehicle parts up to the fuel connections of the heater and the length thus obtained is to be injection system Fig. 14: engine flow pipe return pipe Fuel Supply Circuit in the Double Line System (Carburetor or Injection Motor with Return Pipe) Inline Integration in Return Flow Combustion Air Supply for Thermo Top, Thermo Top T and Tele Thermo Top Combustion air is to be drawn in from a location as cool as possible and splash-proof via a combustion air line. The combustion air line which is contained in the installation kit must not be extended. It may be shortened to a min. of 500 mm. The combustion air line may feature several bends (total of 270, smallest bending radius 50 mm). The combustion air line consists of an inside and outside part. Shorten combustion air line only at the end that is not provided with a fastening clip. 30
Prior to installing the heater make sure that the combustion air intake connection has been mounted to the heater. Under no circumstances must the combustion air be extracted from driver s cabs or passenger compartments. If the heater is installed in an enclosed housing a vent hole of at least 3 cm 2 is required. If the temperature in the installation housing exceeds the permissible ambient temperature of the heater the vent hole must be enlarged after consulting Webasto. The combustion air intake opening must be so positioned as to prevent any clogging due to contamination. It must not point in the direction of travel. The heater may be fastened to the mounting plate turned by 180 provided the insert plate has also been turned accordingly. The exhaust gas line is preassembled at the insert plate whereas the combustion air line is to be attached by means of a hose clamp during installation. The insert plate is to be mounted to the bracket by means of 2 M3 screws. A coding is provided on the insert plate to ensure proper attachment of exhaust gas and combustion air connections of the heater relative to the insert plate. Gasket at Exhaust Gas Outlet Make sure that the gasket is fitted. The gasket provided at the exhaust gas outlet of the heater is to be replaced prior to each reinstallation. When the heater is installed in the vicinity of the vehicle tank in a common installation space, combustion air intake must be from the outside of the vehicle and the exhaust gas must be discharged to atmosphere. Appropriate cutouts must be splash-proof. M3 x 8 DIN695 Fig. 16: Exhaust Gas Seal Support Plate The support plate must be secured to the chassis or the intermediate support using at least 4 M6 screws. It is mandatory that washers and spring lock washers be used. In the case of level chassis surfaces, the washers used must be at least 22 mm in diameter. No sheet-metal screws must be used to secure the heater mounting plate (support plate). Insert Plate The insert plate serves to connect exhaust gas and combustion air lines. CAUTION: Do not use sheet-metal screws for attaching insert plate. Fig. 15: Insert plate Mounting position Insert plate Exhaust gas pipe Exhaust Gas Pipe The exhaust gas line (inside diameter 22 mm) is permitted to have a length of up to 2 m and may feature several bends (total of 270, smallest bending radius 50 mm). The exhaust gas line as a whole must not be shorter than 500 mm. The exhaust muffler should preferably be installed near the heater. The exhaust silencer must not be mounted in the vicinity of the combustion air intake opening. It is not permissible to operate the Thermo Top S heater without muffler. The discharge opening of the exhaust pipe must not point 31
in the direction of travel (see Fig. 18). Rigid pipes made of unalloyed steel with a minimum wall thickness of 1.0 mm or flexible tubes of alloyed steel are to be used as exhaust pipes only. Any collection of condensation water in the exhaust pipe must be drained immediately; if required, it is permitted to drill a condensation water drain hole Fig. 17: Exhaust muffler Direction of flow (not specified) Electrical Connections Control Unit/Heater Connection The electrical connection of the heaters is to be performed in accordance with Fig. 25, 26, 27, 28, 39 or schematic diagram on page 45. Secure cable harness to the burner cover using a retaining clamp (strain relief clamp). CAUTION: Unique to heaters with a diaphragm in the control unit cover Prior to treating the connector strip with anticorrosive wax spray (e.g. Tectyl 100K, order no. 111 329) to protect it from moisture, the following must be observed: A cardboard strip is provided between control unit cover and connector strip. The cardboard serves to prevent the membrane provided in the cover from coming into contact with the spray. The membrane inside the cover must retain its air permeability to prevent the condensation of water from occurring. The cardboard strip protects the membrane during the spraying procedure. After spraying has been completed, remove the cardboard strip to ensure proper functioning of the membrane. Installation and Connection of Digital Timer Installation of the digital timer is to be performed in accordance with Fig. 19. A drilling template is part of the scope of delivery! Connection of the digital timer is to be performed in accordance with wiring diagram Fig. 25, 27 and 28. Do not press on the display panel during installation! Press rubber seal of cable harness into central cover and fasten central cover using countersunk screws. Connection of the Controls Fig. 19: Installation of Digital Timer preferreed direction of discharge 90 ± 10 Fig. 18: Exhaust pipe discharge opening Mounting position The heater can be switched on and off by means of the following Webasto control devices - Digital timer, see wiring diagram Fig. 25, 27 and 28 - Digital timer and Telestart T6/T60, see wiring diagram Fig. 25, 27 and 28 - Digital timer and Telestart T5, see schematic diagram on page 45 - Telestart T6/T60, see wiring diagram Fig. 25, 26, 27 and 28 - Telestart T5, see wiring diagram Fig. 29 Vehicle Fan The vehicle fan is activated via the vehicle fan relay fitted to the fuse holder, see wiring diagram Fig. 25, 26, 27, 28 and 29. The connection terminal in the control unit (heater) is designed for one fan relay. 32
Connection of Summer/Winter Switch Connection of the summer/winter switch is to be performed in accordance with Figs. 20 and 25. Tuning of Telestart T6 Handheld Transmitter and Receiver Each receiver can be assigned 2 handheld transmitters. plug timer br vi insulate Caution Do not pull out antenna on the hand-held transmitter when in near field (less than 3m) - Interrupt the voltage supply for at least 10 seconds by removing the 15A flat fuse (blue), or the 1A flat fuse (black) if the Telestart was retrofitted. wait 10 seconds Fig. 20: S5 Connection of Summer/Winter Switch - Within 3 seconds after reinstallation of the flat fuse slide the switch in the handheld transmitter briefly to the Off position (1 second). 0 3 - Wait for 3 seconds Off - Thereafter, within another 5 seconds, slide the switch briefly to the Start position (1 second). wait 3 seconds - Wait for 3 seconds 0 - Slide switch briefly to the Off position (1 second). Operation indicator on the handheld transmitter no longer flashes. 5 Start - The tuning operation is terminated. If any specified time period is exceeded or fallen short of, tuning is not successful and the procedure is to be repeated from the beginning. wait 3 seconds Follow the same procedure for tuning and thus allocating a second handheld transmitter. Fig. 21: Tuning of Telestart T6 Handheld Transmitter and Receiver 33
Tuning of Telestart T60 Handheld Transmitter and Receiver Each receiver can be assigned 2 handheld transmitters. Caution Do not pull out antenna on the hand-held transmitter when in near field (less than 3m) - Interrupt the voltage supply for at least 10 seconds by removing the 15A flat fuse (blue), or the 1A flat fuse (black) if the Telestart was retrofitted. - Within 3 seconds after reinstallation of the flat fuse push the switch in the handheld transmitter briefly to the Off position (1 second). - Wait for 3 seconds - Thereafter, within another 5 seconds, push the switch briefly to the Start position (1 second). - Wait for 3 seconds - Slide switch briefly to the Off position (1 second). Operation indicator on the handheld transmitter no longer flashes. - The tuning operation is terminated. If any specified time period is exceeded or fallen short of, tuning is not successful and the procedure is to be repeated from the beginning. Follow the same procedure for tuning and thus allocating a second handheld transmitter. Fig. 22: 0 0 3 5 wait 10 seconds wait 3 seconds Start wait 3 seconds Off Tuning of Telestart T60 Handheld Transmitter and Receiver Retrofitting the T6/T60 Telestart Receiver All Thermo Top heaters can be retrofitted with the Telestart T6/T60 remote control. The T6 retrofit kit includes the following parts: - Transmitter T6 with 2 lithium batteries - Standard antenna T6 - Receiver T6 - Mounting hardware (bag) includes 2 sheet-metal screws 1 receptacle housing 1 tab connector housing 3 push-on receptacles The T60 retrofit kit includes the following parts: - T60 transmitter with 2 LR1 alcaline batteries (1.5V) - Standard antenna T6 - Receiver T6 - Mounting hardware (bag) includes 2 sheet-metal screws 1 receptacle housing 1 tab connector housing 3 push-on receptacles Installation may be only carried out by an authorized Webasto service workshop. CAUTION: The receiver must be installed in the interior of the vehicle. It is not permitted to extend the cable harness (approx. 70 cm long) provided on the receiver. - Determine suitable installation location for receiver T6 in the interior of the vehicle, in the vicinity of the digital timer. - Attach receiver using the sheet-metal screws (contained in the kit). - Sever existing cable harness leading to digital timer. Place aside cut-off end together with connector (see Fig. 23). - Strip cables (rt, sw and br) at the other end of the cable harness. 34
- Crimp on push-on receptacles. Install tab connector and push-on receptacles in housing observing color coding. - Establish plug connection. Re-establish plug connection with digital timer. - Route antenna cable to receiver. - Establish plug connection at receiver and tighten connector hand-tight. - Secure plug connection using cable ties. Installation of Antenna Installation of Telestart T5 Preferably, the antenna should be installed on the right on the inside of the windshield, with the cable leading to the right. Only use Telestart T5 ident.no. 14869. The receiver antenna must not touch the vehicle window pane. Any condensation water that may be present on the window can result in damage to the receiver. Connection of antenna The clearance to the A-column and the roof edge must be 7 cm. Distance from the windshield edge must be at least 4 cm. - Clean windshield using grease-dissolving cleaner (e.g. methylated spirits) - Peel off protective foil from antenna and glue antenna in place. It is recommended that the Telestart receiver be installed on or underneath the vehicle s rear shelf. To ensure good reception the aerial should be installed in a position as vertical as possible in the center of the vehicle and must be easily seen from the outside. Connection of the Telestart unit is to be performed in accordance with wiring diagram Fig. 29. rt to rt sw to sw br to br Connection with push-on receptacles (contained in the kit) Do neither shorten nor sharply bend antenna cable. Smallest diameter of any bend: 50 mm Installation of Digital Timer and Telestart is to be performed as shown on the schematic diagram on page 45. CAUTION: When a Telestart is fitted no optical indication occurs in the case of a shutdown due to excessive heat. From/to fuse holder distance 4cm To deactivate the interlock the slide switch provided on the Telestart receiver must be moved to the OFF and subsequently to the ON position again. In order to ensure that the operator is fully aware of deactivating the interlock, the Law requires that the Telestart receiver be located outside the operator s arm s reach. Fig. 23: Connection of Receiver T6 Fig. 24: Antenna installation The requirement calling for unambiguous recognizability of overheating specified in the StVZO is thus fulfilled by this deliberate action. 35
Legend for wiring diagrams: Item Designation Remark A1 Heater Thermo Top A2 Control unit A3 Terminal box A4 Telestart receiver T5 A4 Telestart receiver T6, refer to * B1 Flame detector B2 Temperature sensor B3 Overheating thermostat E Glow plug F1 Fuse 15 amp blade-type acc. to SAE J 1284 F2 Fuse 1 amp blade-type acc. to SAE J 1284 F3 Fuse 25 amp blade-type acc. to SAE J 1284 H1 LED (in item P) operation indicator lamp H2 Light operation indicator lamp K3 Relay (in item A3) vehicle fan M1 Motor supply unit M2 Motor circulating pump M3 Motor vehicle fan P Digital timer for timer-activated operation S1 Switch for vehicle fan S1 or S2 depending on vehicle S2 Switch for vehicle fan S1 or S2 depending on vehicle S3 Instant heat button for item A4 S4 Switch slide switch Item Designation Remark S5 Switch summer/winter switch S6 Switch ON / OFF switch X1 Connector, 2-pole X2 Connector, 2-pole X3 Connector, 2-pole X4 Connector, 3-pole X5 Connector, 3-pole X6 Connector, 2-pole X7 Connector, 2-pole X8 Connector, 2-pole X9 Connector, 4-pole X10 Connector, 6-pole X11 Connector, 2-pole refer to * X13 Connector, 2-pole X14 Connector, 6-pole water-resistant X15 Connector, 2-pole water-resistant X16 Connector, 2-pole water-resistant X17 Connector, 2-pole water-resistant X18 Connector, 2-pole water-resistant X19 Connector, 2-pole water-resistant Y Solenoid valve Y1 Metering pump bl br ge gn gr or rt sw vi ws Cable cross sections < 7.5 m 7.5-15 m 0.5 mm 2 0.75 mm 2 Cable colours 0.75 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 blue brown yellow green grey orange red black violet white * Tele Thermo Top and Tele Thermo Top S only 36
ϑ ϑ ϑ Fig. 25: Automatic Control for Thermo Top S and Tele Thermo Top S, 12V Digital Timer and Teletstart T6/T60 (Legend see page 36) 37
ϑ ϑ ϑ Fig. 26: Automatic Control for Thermo Top S and Tele Thermo Top S, 12V, Switch and Teletstart T6/T60 (Legend see page 36) 38
ϑ ϑ ϑ Fig. 27: Automatic Control for Thermo Top S and Tele Thermo Top S, 12V Digital Timer and Teletstart T6/T60 (Legend see page 36) 39
ϑ ϑ ϑ Fig. 28: Automatic Control for Thermo Top, Thermo Top T and Tele Thermo Top, 12V Digital Timer and Teletstart T6/T60 (Legend see page 36) 40
Fig. 29: Automatic Control for Thermo Top and Thermo Top T, 12V Telestart T5 (Legend see page 36) 41
Initial Operation After the heater has been installed, the water circuit and the fuel supply system are to be thoroughly bled. In so doing the vehicle manufacturer s instructions are to be adhered to. The fuel intermediate reservoir is to be filled by allowing the engine to run for at least 2 minutes. Perform a test run of the heater thereby checking all water and fuel connections for leakage and secure attachment. Should the heater fail during operation troubleshooting is to be carried out. Malfunctions Shut-Down Due to Malfunctions of the Heater If no flame forms fuel is delivered for max. 170 seconds. If the flame goes out during operation fuel is delivered for max. 85 seconds. In the event of overheating (tripping of safety thermostat), fuel supply is immediately stopped. In all cases (except of combustion air fan defects) an afterrun period of 120 seconds will follow if the system is shut down on account of malfunctions. CAUTION: No indication occurs in the case of overheating. In the case of an overvoltage of 15,5 + 0.5 V (measured at the heater) occurring over a period of more than 6 seconds, the unit will also be shut down and an after-run period follows. Interlock deactivation if equipped with Digital Timer (Thermo Top S, Tele Thermo Top) After the cause of malfunction has been eliminated, resetting is to be performed by switching the heater off and back on again. If an overheating condition has occurred, the interlock has to be deactivated by removing fuse F1, 15A. Interlock deactivation if equipped with Digital Timer (Thermo Top S, Tele Thermo Top) After the cause of malfunction has been eliminated, interlock deactivation is to be performed by switching the heater off and back on again. If an overheating condition has occurred the interlock has to be deactivated by pressing the Set button on the timer. Interlock deactivation if equipped with Telestart T6/T60" After the cause of malfunction has been eliminated, resetting is to be performed by switching the heater off and back on again by means of the slide switch provided on the transmitter. If an overheating condition has occurred, the interlock has to be deactivated by removing fuse F1, 15A and putting it back in. The fuse is not destroyed in the case of an overheating condition. Interlock deactivation if equipped with Telestart T5" Switch summer/winter switch on Telestart receiver off and back on again. Self-Diagnosis After Shut-Down on Account of Malfunctions (unique to heaters from serial no. 20,000 onwards) A coded flashing signal at terminal X6 of the heating unit s connector strip (pencil-type glow plug terminal) occurring after the after-run period is used to indicate the cause of a malfunction. If a test lamp of 12 volts and max. 3 watts is connected in parallel to the pencil-type glow plug, the flashing pulses can be counted. The flashing pulses are also audible and can be heard as operating noise of the clocked glow plug relay and can thus be counted. Only the pulses that are generated before the cut-off relay has switched are to be counted. Number of Cause of malfunction pulses 1 pulse short circuit in flame-sensing control or broken cable 2 pulses overvoltage or undervoltage at heater 3 pulses short circuit in temperature sensor 4 pulses flame-sensing controller defective (fails to detect flame) 5 pulses flame-sensing controller defective (detects a flame prior to first start-up attempt) Shut-Down Due to Undervoltage or Overvoltage In the case of an undervoltage of 10 ± 0.3 V (measured at cable harness input) occurring over a period of 20 seconds, the unit will be shut down and an after-run period of 120 seconds will follow. This deliberate action thus fulfills the requirement laid down in the StVZO demanding that any overheating must be ascertainable beyond doubt. no pulse e.g. burner defective solenoid valve defective no fuel pencil-type glow plug defective burner fan defective 42
Troubleshooting Heater fails to operate also after start repetition NO Heater is switched on water temp. < 50 C Is indicator lamp illuminated on display of timer Check fuse F2 and el. lines Replace timer Voltage present at black control line of timer Excessive temperature Replace timer YES Is battery voltage o.k. Measure battery voltage of heater Charge battery Fuse F1 o.k. Check el. line for earth contact Repair heater Is glow plug relay working properly Repair heater Excessive heat on exhaust gas pipe Is fuel intermediate reservoir filled Allow motor to run for 30 sec. Repair heater Is heater working properly Check intake opening Heater cuts out Check exhaust gas pipe Repair heater Thermo Top S only Check metering pump 43
Insufficient heating although heater is functioning properly Heater is switched on NO Integration in water circuit o.k. Correct integration Is vehicle fan running Switch on vehicle fan Check el. lines/relays check fan Repair heater YES Unobstructed flow in water circuit Move heating lever to warm setting Vent water circuit Repair heater Heater exhibiting overheating condition Vent water circuit Water circuit o.k. Open shut-off device Deactivate overheating" interlock Function of heater o.k. Repair heater 44
7 6 5 4 Thermo Top Terminal Connection Diagram of Digital Timer and Telestart T5 1 Battery + red 2 Battery - brown 3 Vehicle fan motor (black) 4 Vehicle fan motor terminal +15 (red) 5 F1 heater fuse 15 amp 6 F2 clock fuse 1 amp 7 F3 fan fuse 25 amp 3 2 1 45
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subject of modification Ident. Nr 776 685 Webasto Thermosysteme GmbH 82131 Stockdorf. Kraillinger Str. 5. Telefon (089) 8 57 94-0 Telefax (089) 8 57 94-448. Telex 5 23 647 webas d