Water Heater Operating instructions Installation ... · PDF fileWater Heater Operating instructions Installation instructions Thermo Top Thermo Top Thermo Top T Tele Thermo Top Thermo

Water Heater Operating instructionsInstallation instructions

Thermo TopThermo TopThermo Top TTele Thermo Top

Thermo Top SThermo Top STele Thermo Top S

BW 50 DW 50

Petrol Diesel

8/1995

Table of contents VersionsPage

Operating instructions 2Safety Information 4Operation of the Heater 6Maintenance of Heater 15Troubleshooting 18Functional Description 20Technical Data 22

Installation instructions 23Installation ExampleThermo Top 25Installation ExampleThermo Top S 26Fuel installationThermo Top S 27Fuel installationThermo Top 30Troubleshooting 43Webasto 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 Sw itch

Thermo Top Petroltype BW 50Water heater for fuel “petrol”Thermo Top Dieseltype DW 50Water heater for fuel “Diesel/fueloil EL”

Thermo Top S Petroltype BW 50Water heater for fuel “petrol” withmetering pumpThermo Top S Dieseltype DW 50Water heater for fuel “Diesel/fueloil EL” with metering pump

The water heaters Thermo Top aredesigned to operate on 12 volts.

Thermo Top

I

Installation instructionsLegal Provisions for Installation

For testing the heater in accordance with articles 19, 20 or21 of the StVZO the following regulations are primarily tobe observed (art. 22a StVZO):

Testing is performed upon presentation of the operatingand installation instructions of the manufacturer.

The year of the initial start-up (commissioning) must bedurably marked on the heater nameplate by the installer.

Extracting the combustion air from the interior of thevehicle is not permissible.

The exhaust pipe must be so mounted that its dischargeopening points downward, sideways or, in the case of rout-ing the exhaust pipes on the underside of the bottom of thevehicle, their discharge opening must be positioned nearthe lateral or rear edge of the driver’s cab or vehicle.Exhaust pipes must be routed in such a way that exhaustgases cannot penetrate the interior of the vehicle. Thefunction of any parts of the vehicle essential for its oper-ation must not be impaired.

The openings of the combustion air inlet and exhaust gasoutlet must be so designed that a spherical object of 16mm diameter cannot be introduced.

Electric lines, switchgear and controlgear of the heatermust be so arranged in the vehicle that their proper func-tion cannot be impaired under normal operating conditions.

For the routing of fuel lines and the installation of addi-tional fuel tanks articles 45 and 46 of the StVZO are to beadhered to. The most important excerpts therefrom are asfollows:Fuel lines are to be designed in such a way that they re-main unaffected by torsional stresses in the vehicle, en-gine movement and the like. They must be protected

against mechanical damage. Fuel-carrying parts are to beprotected against excessive heat and are to be arrangedsuch that any dripping or evaporating fuel can neither col-lect nor be ignited by hot components or electrical equip-ment.

The heater must not be installed in passengers areas.

The operating state of the heater at any given time - i.e. atleast an indication as to whether it is “on” or “off” - must beeasily recognizable.

When the heater has been retrofitted, this installation mustbe examined by an officially recognized expert or exam-iner (TÜV) for its compliance with article 21. A new opera-ting license for the vehicle must be applied for at the MotorVehicle Registration Office on the basis of the test report.

Use of the Water Heater

The Webasto Thermo Top water heater in conjunctionwith 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 en-gine and is connected to the cooling system, the fuel sys-tem and the electrical system of the vehicle.

Installation Location

Preferably, the heater should be installed in the enginecompartment, the splash-water protected areas of the frontfenders or at the splashboard.

Applicable to Thermo Top , Thermo Top T and Tele Thermo Top onlyIf the heater cannot be installed in the aforementioned loca-tions it may also be installed:- in upright position in front of the gearbox (partly

covered, see Fig. 1) provided the fuel supply system isnot located in front of the engine, any auxiliary equip-ment or the gearbox.

- in inclined position in front of the gearbox (see illus-tration) provided point “A” is located below the loweredge of the gearbox and at least 25 mm above point“B”. This ensures that the heater can slide under-neath the gearbox in the case of an accident.

- in accordance with vehicle-specific Webasto installationinstructions which are to be presented to the officiallyregistered expert when the installation is being in-spected.

A

B

A

B

A

B

min 25

Fig. 1: Installation location in front of the gearbox

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The heater should be installed at a level as low as possibleso as to ensure automatic venting of heater and circulatingpump. This is of special importance since the circulatingpump is not of the self-priming type.

Note:The heater must not be installed on the support plate in ahanging 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 mount-ing position the bottom of the heater must be locatedabove the wheel center).

Caution:The openings of the water connecting branches must not,in any installation position, point in downward direction.

Nameplate

The type plate must be located at a place where it is pro-tected against damage and must be easily accessibleonce the heater has been installed (or a nameplate dupli-cate is to be used).The year not applicable is to be removed from the typeplate.

Connection to the Vehicle Cooling System

The heater is to be connected to the vehicle cooling sys-tem in accordance with Figs. 4, 5, 6 and 7. The coolantsystem capacity must be at least 4 liters.

As a rule, the water hoses (pipes) supplied by Webastoare to be used. If not, the hoses must at least conform toDIN standard 73411. The hoses are to be laid without anykinks and - for proper venting - should be pitched upward,if possible. Hose connections must be secured against slip-ping off by means of hose clamps.

NOTE:The hose clamps at the heater must be mounted betweenthe 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 cool-ant has been replaced it must be ensured that the coolingsystem is properly vented. Heater and piping should be soinstalled as to ensure static venting.

Insufficient venting can result in a failure during heatingoperation due to overheating.

Legend for Fig. 4 and 5:1 Expansion tank2 Thermostat3 Engine4 Check valve5 Heater6 Heat exchanger7 Radiator

Fig. 2: Mounting position

Fig. 3: Mounting position

1 3 5

6

27

Fig. 4: Integration into engine/cooling water circuit“Inline-Integration”

1 3 4

5

6

2

7

Fig. 5: Integration with check v alve

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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 heating11 Heat exchanger, vehicle heating system12 Vehicle heater fan13 Vehicle heater fan switch14 Fuse bank in the vehicle

15 Digital timer16 Fuel pickup17 Fuel pump (in heater)18 Exhaust muffler, as required19 Circulating pump (in heater)

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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 heating11 Heat exchanger, vehicle heating system12 Vehicle heater fan13 Vehicle heater fan switch14 Fuse bank in the vehicle

15 Digital timer16 Fuel pickup17 Intake muffler18 Exhaust muffler, as required19 Circulating pump (in heater)20 Intake extension21 Fuel metering pump

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Fuel Installation for Thermo Top S

Fuel Supply

In the case of carburetor or injection engines equippedwith return lines, the heater’s fuel system is to be inte-grated in the return line as shown in Fig. 7.

In the case of carburetor engines without return line, thefuel circuit of the heater is to be integrated in the flow linebetween the vehicle’s fuel tank and pump.

Particulars on pressure values permitted to prevail at thepoint of fuel extraction are contained in the Table below.

permissible fuelfeed 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 fuelsuction height S (m)

at max. perm.underpressure (bar) in the

fuel line

0,00 -0,10

0,50 -0,06

1,00 -0,02

ANNOTATIONA fuel flow line can usually be identified by the in-line fuelfilter.

NOTE:If the vehicle’s fuel system is equipped with a vapour sep-arator, fuel extraction is to take place upstream of same.

l1 + l2 ≤ 10 ml1 ≤ 1,2 ml2 ≤ 8,8 m

Fig. 8: Fuel Supply

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For fuel extraction from flow or return lines it is mandatorythat the special Webasto fuel pickup (see Fig. 9) beused.

The fuel pickup is to be so mounted that any air or gasbubbles that may form are automatically discharged to-ward the tank (see Fig. 9).

Air or gas bubbles in the fuel line of the vehicle can occur ifthere is a leak in the vehicle’s carburetor or fuel pump or inthe case of ambient temperatures exceeding the vaporiz-ing temperature of the fuel.

Fuel should not be extracted from within the vicinity of theengine as gas bubbles are likely to form in the lines owingto the heat radiating from the engine which may result inmalfunctions in the heating operation.

If the heater is installed in vehicles equipped with injectionsystems it is therefore to be determined whether the fuelpump is mounted inside or outside the tank.

Where the fuel pump is located inside the tank, fuel mayonly be extracted from the return line whereby it must beensured that the return line extends almost to the bottomof the tank. Failing this, the return pipe can be extended.

Where the fuel pump is mounted outside the tank, the con-nection to the fuel system can be accomplished betweenthe fuel tank and the fuel pump

Fuel Lines

NOTE: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 tostarting up the engine or the heater.

As fuel lines only steel, copper and plastic pipes made ofplasticized, light-resistant and temperature-stabilized PA 11or PA 12 (e.g. Mecanyl RWTL) in accordance with DIN73378 may be used.

As in the majority of cases it is not possible to route thelines in a continuous upward pitch, the inside diametermust not exceed a given dimension. With inside diametersof 4 mm and larger, air or gas bubbles accumulate whichresult in malfunctions if the lines sag or are routed in adownward pitch. When the diameters shown in Fig. 8 areused, you can be sure that no unwanted bubbles will beformed.

The lines from the metering pump to the heater should notbe routed in a downward pitch.

To prevent the lines from sagging, freely suspended fuellines must be secured. Mounting should be performed insuch a manner that the lines are protected against flyingstones and thermal influence (exhaust pipe).

Connection of 2 Pipes by Means of Hose

The proper connection of fuel lines by means of a hose isshown in Fig. 10.

Check for leakage!

to metering pump

to engine

from tank

Fig. 9: Webasto Fuel Pickup

correct

incorrect

clamp

bubblebubble

Fig. 10: Pipe/Hose Connection

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Metering Pump

The metering pump is a combined fuel supply, meteringand shutoff system and is subject to certain installationcriteria (see Figs. 8, 11 and 12).

Installation Location

Prior to installing the metering pump make sure that themaximum pressure prevailing at the fuel extraction point isless than 2.0 bar.

It is recommended that the metering pump be installed in aposition which is sufficiently cool. On no account must thepermissible ambient temperature at any given operatingstage be in excess of + 20°C.

Metering pump and fuel lines must not be installed in theradiation range of hot vehicle parts. If necessary, a radia-tion 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-dampingsuspension. The installation position is restricted in accord-ance with Fig. 11 and 12 in order to ensure sufficient self-ventilation.

Combustion Air Supply for Thermo Top S and TeleThermo 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 asplash-proof area, if possible.

If the combustion air intake opening points in the directionof travel, the existing reducer is to be exchanged for the in-take elbow, order no. 319 12A.

The reducer provided in the intake opening is to beremoved beforehand.

NOTE:The intake elbow, order no. 319 12A, is required for the ex-tension of the combustion air tube.

The combustion air line can be so routed that it featuresseveral bends (total of 270°, smallest bending radius 50mm).

On no account should the combustion air be drawn fromrooms where persons are present. If the heater is installedin an enclosed housing, a vent hole of at least 3cm2 is re-quired.

If the temperature in the installation housing exceeds thepermissible ambient temperature of the heater, the venthole must be enlarged after prior consultation with We-basto.

The combustion air intake opening is to be so located thatthe 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 vehicletank in a common installation space, combustion air intakemust be from the outside of the vehicle and the exhaustgas be discharged into the atmosphere. Appropriate cu-touts are to be splashwater-proof.

preferable15°-90°

Fig. 11: Metering Pump Wit hout Diaphragm DamperInstallation position and mounting

Unique to Diesel versions

Bild 12: Metering Pump (deli vered from 1996)Installation position horizontal

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Fuel Installation for Thermo Top , Thermo Top T andTele Thermo Top

Fuel Supply

In the case of carburettor or injection engines equippedwith return line, the heater’s fuel supply circuit must be in-tegrated in the return line as shown in Fig. 13

The direction arrows provided on the heater must be ob-served.

In the case of carburettor engines without return line, thefuel supply circuit of the heater must be integrated in theflow line between vehicle fuel tank and pump.

NOTE:If the fuel system of the vehicle is equipped with a degass-ing device, fuel extraction is to take place upstream ofsame.

Fuel Lines

Only the special hoses supplied with the heater by We-basto must be used as fuel lines between fuel connectionsand heater. When using hoses, the joints are to be se-cured using hose clamps. To prevent any sagging the fuelline must be secured with clips.

Prior to cutting the fuel line open it must be clamped off ora suitable vessel placed underneath the pipe.

Any fuel that may have leaked is to be removed from theengine or heater prior to starting up the vehicle or heater

The fuel lines - not cut to length as yet - are to be con-nected to the vehicle’s return line.

Keeping slack to a minimum, they are then to be routedalong any obstructing vehicle parts up to the fuel connec-tions of the heater and the length thus obtained is to be

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 dis-tributed evenly. The fuel lines are to be so fastened thatthey will not be damaged by vehicle parts that may comein contact with them.

The lines must be mounted in such a way that they are pro-tected from mechanical damage (e.g. stones) and thermalinfluence (e.g. exhaust pipe). If the fuel line is damagedthere is a danger of fire.

NOTE:The hose clamps are to be tightened to a torque of 1.0 +0.4 Nm.

Combustion Air Supply for Thermo Top, ThermoTop T and Tele Thermo Top

Combustion air is to be drawn in from a location as cool aspossible and splash-proof via a combustion air line.

The combustion air line which is contained in the installa-tion kit must not be extended.

It may be shortened to a min. of 500 mm.The combustion air line may feature several bends (total of270°, smallest bending radius 50 mm).

NOTE:The combustion air line consists of an inside and outsidepart.Shorten combustion air line only at the end that is not pro-vided with a fastening clip.

fuel pump

engine

carburator

Fig. 13: Fuel Supply Circuit in the Single Line Sys-tem (Carburetor Engine without Return Line)“Inline Integration between Pump and Car-buretor”

engine

injection system

flow pipe

return pipe

Fig. 14: Fuel Supply Circuit in the Double Line Sys-tem (Carburetor or Injection Motor with Re-turn Pipe) “Inline Integration in Return Flow”

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Prior to installing the heater make sure that the combus-tion air intake connection has been mounted to the heater.

Under no circumstances must the combustion air be ex-tracted from driver’s cabs or passenger compartments. Ifthe heater is installed in an enclosed housing a vent holeof at least 3 cm2 is required.

If the temperature in the installation housing exceeds thepermissible ambient temperature of the heater the venthole must be enlarged after consulting Webasto.

The combustion air intake opening must be so positionedas to prevent any clogging due to contamination. It mustnot point in the direction of travel.

When the heater is installed in the vicinity of the vehicletank in a common installation space, combustion air intakemust be from the outside of the vehicle and the exhaustgas must be discharged to atmosphere. Appropriate cu-touts must be splash-proof.

Support Plate

The support plate must be secured to the chassis or the in-termediate support using at least 4 M6 screws.

It is mandatory that washers and spring lock washers beused.

In the case of level chassis surfaces, the washers usedmust be at least 22 mm in diameter.

No sheet-metal screws must be used to secure the heatermounting plate (support plate).

Insert Plate

The insert plate serves to connect exhaust gas and com-bustion air lines.

The heater may be fastened to the mounting plate turnedby 180° provided the insert plate has also been turned ac-cordingly.

The exhaust gas line is preassembled at the insert platewhereas the combustion air line is to be attached bymeans of a hose clamp during installation.

The insert plate is to be mounted to the bracket by meansof 2 M3 screws.

NOTE:A coding is provided on the insert plate to ensure proper at-tachment of exhaust gas and combustion air connectionsof 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 ofthe heater is to be replaced prior to each reinstal-lation.

Exhaust Gas Pipe

The exhaust gas line (inside diameter 22 mm) is permittedto have a length of up to 2 m and may feature severalbends (total of 270°, smallest bending radius 50 mm).

The exhaust gas line as a whole must not be shorter than500 mm.

The exhaust muffler should preferably be installed near theheater.

The exhaust silencer must not be mounted in the vicinity ofthe combustion air intake opening.

It is not permissible to operate the Thermo Top S heaterwithout muffler.

The discharge opening of the exhaust pipe must not point

M3 x 8 DIN695

Insert plate

Exhaust gas pipe

CAUTION:Do not use sheet-metalscrews for attaching in-sert plate.

Fig. 15: Insert plateMounting position

Fig. 16: Exhaust Gas Seal

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in the direction of travel (see Fig. 18).

Rigid pipes made of unalloyed steel with a minimum wallthickness of 1.0 mm or flexible tubes of alloyed steel are tobe used as exhaust pipes only.

NOTE:Any collection of condensation water in the exhaust pipemust be drained immediately; if required, it is permitted todrill a condensation water drain hole

Electrical Connections

Control Unit/Heater Connection

The electrical connection of the heaters is to be performedin accordance with Fig. 25, 26, 27, 28, 39 or schematic di-agram on page 45.

Secure cable harness to the burner cover using a retainingclamp (strain relief clamp).

CAUTION:Unique to heaters with a diaphragm in the control unitcoverPrior to treating the connector strip with anticorrosive waxspray (e.g. Tectyl 100K, order no. 111 329) to protect itfrom moisture, the following must be observed:A cardboard strip is provided between control unit coverand connector strip. The cardboard serves to prevent themembrane provided in the cover from coming into contactwith the spray. The membrane inside the cover must retainits air permeability to prevent the condensation of waterfrom occurring. The cardboard strip protects the membrane during thespraying procedure. After spraying has been completed,remove the cardboard strip to ensure proper functioning ofthe membrane.

Press rubber seal of cable harness into central cover andfasten central cover using countersunk screws.

Connection of the Controls

The heater can be switched on and off by means of the fol-lowing Webasto control devices- Digital timer, see wiring diagram Fig. 25, 27 and 28- Digital timer and Telestart T6/T60, see wiring diag-

ram 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

Installation and Connection of Digital Timer

Installation of the digital timer is to be performed in accord-ance with Fig. 19. A drilling template is part of the scope ofdelivery!

Connection of the digital timer is to be performed in accord-ance with wiring diagram Fig. 25, 27 and 28.

NOTE:Do not press on the display panel during installation!

Vehicle Fan

The vehicle fan is activated via the vehicle fan relay fittedto the fuse holder, see wiring diagram Fig. 25, 26, 27, 28and 29.

NOTE:The connection terminal in the control unit (heater) is de-signed for one fan relay.

Fig. 17: Exhaust muffler Direction of flow (not specified)

preferreed direction of discharge 90° ± 10°

Fig. 18: Exhaust pipe discharge openingMounting position

Fig. 19: Installation of Digital Timer

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Connection of Summer/Winter Switch

Connection of the summer/winter switch is to be performedin accordance with Figs. 20 and 25.

Tuning of Te lestart T6 Handheld Transmitter and Receiver

NOTE:Each receiver can be assigned 2 handheld transmitters.

CautionDo not pull out antenna on the hand-held transmitter whenin near field (less than 3m)

- Interrupt the voltage supply for at least 10 seconds byremoving 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 slidethe switch in the handheld transmitter briefly to the “Off”position (1 second).

- Wait for 3 seconds

- Thereafter, within another 5 seconds, slide the switchbriefly 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 nolonger 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 re-peated from the beginning.

Follow the same procedure for tuning and thus allocating asecond handheld transmitter.

Off

03

Start

0

5

wait 3 seconds

wait 10 seconds

wait 3 seconds

S5

br

plugtimer

vi

insulate

Fig. 20: Connection of Summer/Winter Switch

Fig. 21: Tuning of Te lestart T6 Handheld Transmitterand Receiver

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Tuning of Te lestart T60 Handheld Transmitter and Receiver

NOTE:Each receiver can be assigned 2 handheld transmitters.

CautionDo not pull out antenna on the hand-held transmitter whenin near field (less than 3m)

- Interrupt the voltage supply for at least 10 seconds byremoving 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 pushthe switch in the handheld transmitter briefly to the “Off”position (1 second).

- Wait for 3 seconds

- Thereafter, within another 5 seconds, push the switchbriefly 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 nolonger 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 re-peated from the beginning.

Follow the same procedure for tuning and thus allocating asecond handheld transmitter.

Retrofitting the T6/T60 Telestart Rece iver

NOTE:All Thermo Top heaters can be retrofitted with the TelestartT6/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 We-basto service workshop.

CAUTION:The receiver must be installed in the interior of the vehicle. It is not permitted to extend the cable harness (approx. 70cm long) provided on the receiver.

- Determine suitable installation location for receiver T6 inthe interior of the vehicle, in the vicinity of the digitaltimer.

- Attach receiver using the sheet-metal screws (containedin the kit).

- Sever existing cable harness leading to digital timer.Place aside cut-off end together with connector (seeFig. 23).

- Strip cables (rt, sw and br) at the other end of the cableharness.Fig. 22: Tuning of Te lestart T60 Handheld Transmit-

ter and Receiver

Off

03

Start0

5

wait 3 seconds

wait 10 seconds

wait 3 seconds

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34

- Crimp on push-on receptacles. Install tab connector andpush-on receptacles in housing observing color coding.

- Establish plug connection. Re-establish plug connectionwith digital timer.

Installation of Antenna

NOTE:Preferably, the antenna should be installed on the right onthe inside of the windshield, with the cable leading to theright.

The clearance to the A-column and the roof edge must be7 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.

NOTE:Do neither shorten nor sharply bend antenna cable.Smallest diameter of any bend: 50 mm

- Route antenna cable to receiver.- Establish plug connection at receiver and tighten con-

nector hand-tight.- Secure plug connection using cable ties.

Installation of Telestart T5

NOTE:Only use Telestart T5 ident.no. 14869.The receiver antenna must not touch the vehicle windowpane. Any condensation water that may be present on thewindow can result in damage to the receiver.

It is recommended that the Telestart receiver be installedon or underneath the vehicle’s rear shelf. To ensure goodreception the aerial should be installed in a position as ver-tical as possible in the center of the vehicle and must beeasily seen from the outside. Connection of the Telestartunit is to be performed in accordance with wiring diagramFig. 29.

NOTE: Installation of Digital Timer and Telestart is to be performedas shown on the schematic diagram on page 45.

CAUTION:When a Telestart is fitted no optical indication occurs in thecase of a shutdown due to excessive heat.

To deactivate the interlock the slide switch provided on theTelestart receiver must be moved to the OFF and sub-sequently to the ON position again.

In order to ensure that the operator is fully aware ofdeactivating the interlock, the Law requires that theTelestart receiver be located o utside the operator’sarm’s reach.

The requirement calling for “unambiguous recognizabilityof overheating” specified in the StVZO is thus fulfilled bythis deliberate action.

From/tofuse holder

Connection with push-on receptacles (contained in the kit)

Connectionof antenna

rt to rtsw to swbr to br

Fig. 23: Connection of Rece iver T6

distance ≥ 4cm

Fig. 24: Antenna installation

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Item Designation Remark A1 Heater Thermo TopA2 Control unitA3 Terminal boxA4 Telestart receiver T5A4 Telestart receiver T6, refer to *B1 Flame detectorB2 Temperature sensorB3 Overheating thermostatE Glow plugF1 Fuse 15 amp blade-type acc. to SAE J 1284F2 Fuse 1 amp blade-type acc. to SAE J 1284F3 Fuse 25 amp blade-type acc. to SAE J 1284H1 LED (in item P) operation indicator lampH2 Light operation indicator lampK3 Relay (in item A3) vehicle fan

M1 Motor supply unitM2 Motor circulating pumpM3 Motor vehicle fanP Digital timer for timer-activated operationS1 Switch for vehicle fan S1 or S2 depending on vehicleS2 Switch for vehicle fan S1 or S2 depending on vehicleS3 Instant heat button for item A4S4 Switch slide switch

Item Designation Remark S5 Switch summer/winter switchS6 Switch ON / OFF switchX1 Connector, 2-poleX2 Connector, 2-poleX3 Connector, 2-poleX4 Connector, 3-poleX5 Connector, 3-poleX6 Connector, 2-poleX7 Connector, 2-poleX8 Connector, 2-poleX9 Connector, 4-poleX10 Connector, 6-poleX11 Connector, 2-pole refer to *X13 Connector, 2-poleX14 Connector, 6-pole water-resistant

X15 Connector, 2-pole water-resistantX16 Connector, 2-pole water-resistantX17 Connector, 2-pole water-resistantX18 Connector, 2-pole water-resistantX19 Connector, 2-pole water-resistantY Solenoid valveY1 Metering pump

Cable cross sections

< 7.5 m 7.5 - 15 m

0.5 mm2

0.75 mm2

0.75 mm2

1.5 mm2

1.5 mm2

2.5 mm2

2.5 mm2

4.0 mm2

4.0 mm2

6.0 mm2

Cable colours

blbrgegngrorrtswviws

bluebrownyellowgreengreyorangeredblackvioletwhite

Legend for wiring diagrams:

* Tele Thermo Top and Tele Thermo Top S only

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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)

Thermo Top

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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)

Thermo Top

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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)

Thermo Top

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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)

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Fig. 29: Automatic Control for Thermo Top and Thermo Top T , 12V Telestart T5 (Legend see page 36)

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Initial Operation

After the heater has been installed, the water circuit andthe fuel supply system are to be thoroughly bled. In sodoing the vehicle manufacturer’s instructions are to be ad-hered to.

The fuel intermediate reservoir is to be filled by allowingthe engine to run for at least 2 minutes.

Perform a test run of the heater thereby checking all waterand fuel connections for leakage and secure attachment.Should the heater fail during operation troubleshooting isto 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 formax. 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 after-run period of 120 seconds will follow if the system is shutdown on account of malfunctions.

CAUTION:No indication occurs in the case of overheating.

Shut-Down Due to Under voltage or Overvoltage

In the case of an undervoltage of 10 ± 0.3 V (measured atcable harness input) occurring over a period of 20 second-s, the unit will be shut down and an after-run period of 120seconds will follow.

In the case of an overvoltage of 15,5 + 0.5 V(measured at the heater) occurring over a period ofmore than 6 seconds, the unit will also be shut downand 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, reset-ting is to be performed by switching the heater off andback 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, inter-lock deactivation is to be performed by switching theheater off and back on again. If an overheating conditionhas occurred the interlock has to be deactivated by press-ing the “Set” button on the timer.

Interlock deactivation if equipped with “TelestartT6/T60"After the cause of malfunction has been eliminated, reset-ting is to be performed by switching the heater off andback on again by means of the slide switch provided onthe transmitter. If an overheating condition has occurred, the interlock hasto be deactivated by removing fuse F1, 15A and putting itback in.The fuse is not destroyed in the case of an overheatingcondition.

Interlock deactivation if equipped with “Telestart T5"Switch summer/winter switch on Telestart receiver off andback on again.

This deliberate action thus fulfills the requirement laiddown in the StVZO demanding that any “overheating mustbe ascertainable beyond doubt”.

Self-Diagnosis After Shut -Down on Account of Mal-functions(unique to heaters from serial no. 20,000 onwards)

A coded flashing signal at terminal X6 of the heating unit’sconnector strip (pencil-type glow plug terminal) occurringafter the after-run period is used to indicate the cause of amalfunction.

If a test lamp of 12 volts and max. 3 watts is connected inparallel to the pencil-type glow plug, the flashing pulsescan be counted.

The flashing pulses are also audible and can be heardas operating noise of the clocked glow plug relay andcan thus be counted.

NOTE:Only the pulses that are generated before the cut-off relayhas switched are to be counted.

Number ofpulses

Cause of malfunction

1 pulse short circuit in flame-sensing control orbroken 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-upattempt)

no pulse e.g. burner defective solenoid valve defective no fuel pencil-type glow plug defective burner fan defective

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Troubleshooting

Heater is switched on water temp. < 50°C

Repair heater

Replace timer

Check fuse F2 and el. lines

Excessive heat on exhaust gas pipe

Is glow plug relay working properly

Fuse F1 o.k.

Is battery voltage o.k.

Voltage present at black control line of timer

Is indicator lamp illu-minated on display of timer

Repair heater

Check intake opening

Replace timer

Excessive temperature

Measure battery voltage of heater

Repair heater

Check el. line for earth contact

Is fuel intermediate reservoir filled

Check exhaust gas pipe

Allow motor to run for 30 sec.

Is heater working properly

Repair heater

Heater cuts out

NO

YES Charge battery

Thermo Top S only Check metering pump

Heater fails to operate also after start repetition

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Heater is switched on

Repair heater

Correct integration

Unobstructed flow in water circuit

Is vehicle fan running

Integration in water circuit o.k.

Repair heater

Switch on vehicle fan

Move heating lever to “warm” setting

NO

YES

Check el. lines/relays check fan

Vent water circuit

Water circuit o.k. Open

shut-off device

Vent water circuit

Deactivate “over- heating" interlock

Repair heater

Function of heater o.k.

Insufficient heating although heater is functioning properly

Heater exhibiting “overheating” co ndition

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Terminal Connection Diagram of Digital Timer and Telestart T5

76

5 43

2 1

1 Battery “+” red2 Battery “-” brown3 Vehicle fan motor (black)4 Vehicle fan motor terminal

+15 (red)5 F1 heater fuse 15 amp6 F2 clock fuse 1 amp7 F3 fan fuse 25 amp

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subject of modification

Ident. Nr 776 685

Webasto Thermosysteme GmbH82131 Stockdorf . Kraillinger Str. 5 .Telefon (089) 8 57 94-0Telefax (089) 8 57 94-448 . Telex 5 23 647 webas d