Ebasto eThermo Top Eco 20 P Operating instructions

Service Instructions
eThermo Top Eco 20 P | 30 P
English

Contents Webasto
2 9039398A_WSM_eThermo_Top_Eco_EN
Contents
1 Introduction .............................................................. 3
1.1 About this document ................................................3
1.2 Purpose of the document .........................................3
1.3 Using this document.................................................3
1.4 Use of symbols and highlighting ...............................3
1.5 Warranty and liability................................................3
1.6 Qualifications of installation personnel......................3
1.7 Spare parts ...............................................................3
1.8 Safety precautions ....................................................3
1.9 Statutory regulations governing installation ..............4
2 Information about the unit and external components
.................................................................................. 5
2.1 Overview ..................................................................5
2.2 Heater – general information ....................................6
2.3 12V wiring harness ..................................................6
2.3.1 Electrical connection of coolant pump and
vehicle fan................................................... 6
2.3.2 Vehicle battery (voltage stability) ................. 6
2.4 230V heater supply cable / extension cable..............6
2.5 External components ................................................6
2.5.1 Coolant pump ............................................. 6
2.5.2 Power cable................................................. 6
2.5.3 Fan relay...................................................... 6
3 Functional description ............................................... 7
4 Technical data ........................................................... 8
4.1 Dimensions...............................................................9
5 Malfunctions and troubleshooting .......................... 10
5.1 Cause of malfunctions ...........................................10
5.2 Table of causes of fault...........................................11
6 Function checks....................................................... 12
6.1 General information ...............................................12
6.2 Heater supply cable / extension cable......................12
6.3 Function check in the vehicle ..................................12
6.4 Activation of vehicle blower....................................12
6.4.1 Fan relay.................................................... 12
6.5 Checking coolant pump..........................................12
7 Servicing ................................................................. 13
7.1 Servicing ................................................................13
7.2 Working on the heater............................................13
7.3 Maintenance...........................................................13
7.3.1 Annual ...................................................... 13
8 Replacing the unit ................................................... 14
8.1 General information ...............................................14
8.2 Required tools ........................................................14
8.3 Removal .................................................................14
8.3.1 Preliminary Work ....................................... 14
8.3.2 Pinch off the coolant hoses.........................14
8.3.3 Release the hose clips.................................14
8.3.4 Removal .....................................................14
8.4 Installation...............................................................15
9 Packaging/storage and shipping ...............................16
9.1 General information ................................................16
9.2 Storage and transportation ......................................16
10 Wiring Diagram .........................................................17
10.1 Legend to wiring diagram........................................18
10.2 Legend for comments..............................................18
10.3 Pin assignments plug connection X1, 2-pin .............18
10.4 Pin assignments plug connection X2, 2-pin .............18
10.5 Pin assignments plug connection X9, 3-pin .............18
10.6 Cable colours ..........................................................18

Webasto Introduction | 1
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1 Introduction
1.1 About this document
This workshop manual is designed to assist trained personnel in
resolving application queries and other issues relating to the
eThermo Top Eco 20 P | 30 P.
NOTE
Do not open the heater.
If faulty always replace the complete heater.
1.2 Purpose of the document
This workshop manual is part of the product and contains all
the information required to resolve malfunctions of the eTh-
ermo Top Eco 20 P | 30 P.
1.3 Using this document
nRead and observe this workshop manual when determining
and carrying out repairs to the application or the replace-
ment of the eThermo Top Eco 20 P | 30 P.
nThe Installation Instructions and the Operating Instructions
and the important information and legal provisions con-
tained therein should always be read and observed.
1.4 Use of symbols and highlighting
DANGER
This signal word denotes a hazard with a high degree
of risk which, if not avoided, will lead to death or seri-
ous injury.
WARNING
This signal word denotes a hazard with a moderate de-
gree of risk which, if not avoided, may lead to minor or
moderate injury.
CAUTION
This signal word denotes a hazard with a low degree of
risk which, if not avoided, will lead to minor or moder-
ate injury.
NOTE
This signal word denotes a Special Technical Feature or
(if not observed) potential damage to the product.
Refers to separate documents which are enclosed or
can be requested from Webasto.
Symbol Explanation
Requirements for the following necessary ac-
tion
Necessary action
1.5 Warranty and liability
Webasto shall not assume liability for defects or damage that
are the result of the installation and operating instructions being
disregarded. This liability exclusion particularly applies for:
nmechanical damage to the equipment
ninstallation by untrained personnel
nconversion of the unit without permission from Webasto
nimproper use
nUse of non-genuine replacement units
nRepairs or device replacement not carried out by a Webasto
service workshop
nUse of unsuitable accessories
nInsufficient coolant supply before, during and after heating
mode
1.6 Qualifications of installation
personnel
The installation personnel must have the following qualifica-
tions:
nSuccessful completion of Webasto training.
nCorresponding qualification for working on technical sys-
tems.
nInstallation and operating instructions as well as the notes
it contains must be observed.
DANGER
Any work on the eThermo Top Eco 20 P | 30 P must
only be carried out by electricians qualified to carry out
electrotechnical work on high-voltage systems in
vehicles.
1.7 Spare parts
There are no spare parts for the eThermo Top Eco 20 P | 30 P
heater; the unit can only be replaced. The components, such as
the coolant pump, are available as single parts.
You can find original spare parts:
nIn the Webasto spare parts catalogue
nIn the dealer portal http://dealers.webasto.com
1.8 Safety precautions
DANGER
To avoid electric shocks, guard against electric shocks,
risk of fire and risk of damage caused by hot, moving or
sharp objects.
uDo not adapt the heater supply cables or shorten
or lengthen them yourself.
DANGER
Before working on the heater: disconnect the power
supply to the heater, the coolant pump and the vehicle
fan.
uDisconnect the negative terminal of the vehicle bat-
tery
uRemove the power cable
DANGER
To guard against electric shocks, the heater may only
be connected when the 230V socket outlet with earth-
ing contact is protected with an RCD switch (circuit
breaker) with a rated residual current of max. 30mA. If
you have any questions, please contact an authorized
electrician.
The heater may only be connected to power grids that
are protected with a minimum current and designed ac-
cordingly (10A for eThermo Top Eco 20P, 16A for
eThermo Top Eco 30 P).
The device should be properly connected to a
230V/50Hz socket outlet with earthing contact. This
should also be checked against the data on the type la-
bel.

1 | Introduction Webasto
4 / 19 9039398A_WSM_eThermo_Top_Eco_EN
DANGER
If the 230V heater supply cable(s) mounted in the
vehicle is (are) accidentally overextended, you MUST
check whether the 230V heater supply cable(s), the
connector or other parts of the vehicle heating system
have been damaged. A damaged heater supply cable
MUST be replaced by a Webasto service workshop.
DANGER
Before each use, check the power cable and 230V
socket outlet with earthing contact for defects. If you
find any defects, you must not operate the heater until
the defects have been fixed by a Webasto service work-
shop.
Before starting up the vehicle, the power cable must be
removed from the 230V socket outlet with earthing
contact and from the vehicle. Do not use the power
cable to pull the connector out of the 230V socket out-
let with earthing contact; always use the connector it-
self.
The power cable must not be connected to the 230V
power grid while coiled.
DANGER
If maintenance is not carried out, there will be insuffi-
cient or no protection from electric shocks, and this can
result in corresponding injuries. In the event of non-
compliance, Webasto is released from any liability, inso-
far as this is legally permissible.
NOTE
Observe data on type label.
NOTE
Maximum continuous operating duration of the heater:
120min.
NOTE
Make sure that the female connector of the power
cable can be plugged in without difficulty.
NOTE
Protect the connector and power cable from damage.
NOTE
At low temperatures the power cable may feel a little
more rigid; this is a characteristic of the product.
NOTE
Function of timer:
A commercially available timer switch can be used for
this purpose (230V). For outdoor use, the timer must
have protection class IP44.
If a timer switch is used, ensure there is sufficient
switching power (10A / 16A).
eThermo Top Eco 20 P : min. 10 A
eThermo Top Eco 30 P : min. 16 A
1.9 Statutory regulations governing
installation
This document is a supplement to the Operating and Installation
Instructions, which are available on the Webasto dealer portal
at https://dealers.webasto.com. The regulations of these
guidelines are binding in the scope of the Directive 70/156/EEC
and/or 2007/46/EC (for new vehicle models from 29/04/2009)
and should also be observed in countries in which there are no
special regulations. Failure to follow the installation instructions
will result in the invalidation of the type approval for the heater
and therefore invalidation of the general homologation of the
vehicle. For vehicles with an EU type approval, an entry is not
required in accordance with § 19 section 4 of appendix VIII b of
German StVZO. Country-specific registration regulations must
be complied with. The noise emissions from the Webasto eTh-
ermo Top Eco 20 P | 30 P heater are below the threshold spe-
cified in section 1.7.4.2. u) of the Machinery Directive 2006/42/
EC.
WEEE directive
This product must not be disposed of with normal
household rubbish. Dispose of this product accord-
ing to the applicable rules and regulations. Inform-
ation about proper disposal is provided by the mu-
nicipal authorities, the responsible household
waste recycling centre and/or your local distribu-
tion partner.

Webasto Information about the unit and external components | 2
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2 Information about the unit and external components
2.1 Overview
1 2 3 4 5 6
7
8
9
10
11
12
13
14
15
16
17
18
Fig.1: Overview
Relay bracket eThermo Top Eco 20 P | 30 P Coolant inlet
Vehicle blower relay X1 (connection for coolant pump and vehicle
fan relay)
Coolant outlet
Installation cable X2 (voltage compensation for battery and
fuses)
Earth connection 12V
Earth connection 230 V Coolant pump connector 12V wiring harness
Connector bracket Coolant pump adapter cable Fuse holder
Power cable Coolant pump Vehicle fan wiring harness

2 | Information about the unit and external components Webasto
6 / 19 9039398A_WSM_eThermo_Top_Eco_EN
2.2 Heater – general information
The eThermo Top Eco 20 P | 30 P works together with the
vehicle heating system to preheat the cab and engine in parking
heating mode.
The water heater eThermo Top Eco 20 P | 30 P is available in
two variants:
neThermo Top Eco 20 P with 2kW heating capacity
neThermo Top Eco 30 P with 3kW heating capacity
The eThermo Top Eco 20 P | 30 P operates independently from
the vehicle engine.
The heater is integrated in the cooling system and the electrical
system of the vehicle.
A power pack is built into the heater to supply the coolant
pump and assist the vehicle battery.
2.3 12V wiring harness
See also Fig. 12.
2.3.1 Electrical connection of coolant pump and
vehicle fan
The coolant pump is supplied with 12V voltage by the heater
(connector X1). If the heater is switched on and in operation,
the coolant pump also starts up and remains switched on dur-
ing operation.
The fan relay for switching on the vehicle fan is also supplied
with 12V voltage at the same connection. The fan relay also re-
mains switched on during operation.
2.3.2 Vehicle battery (voltage stability)
The heater wiring harness is connected to the vehicle battery.
During operation of the heater, the charge state of the vehicle
battery is maintained to the extent possible. The power con-
sumption of the coolant pump and of the vehicle battery cause
only a slight reduction in the charge state of the vehicle battery.
2.4 230V heater supply cable /
extension cable
In the vehicle:
The 230V power supply to the heater is provided via a special
cable (installation cable with earth connection) on the heater. If
the distance between the heater and the integrated connector
is larger than the length of the installation cable, an extension
cable is installed. When the installation cable is connected to
the extension cable, the safety interlock is fitted.
2.5 External components
2.5.1 Coolant pump
The coolant pump U4847 Econ ensures a flow rate of the
coolant in the heater and heater circuit of the vehicle. The
pump is switched on by the control unit and runs continuously
during heater operation. The coolant pump is a circulating
pump.
The coolant pump has a 2-pin connector socket and is connec-
ted to the heater wiring harness.
The coolant pump must not be used again if it has been
dropped or knocked over.
Fig.2: Coolant pump installation position
2.5.2 Power cable
The power cable supplies the eThermo Top Eco 20 P | 30 P with
230V domestic electricity. To do this, the cable is connected to
the plug on the vehicle and then to the domestic earthing con-
nector.
2.5.3 Fan relay
The vehicle fan is switched on or off via the fan relay.
See also Fig. 12.

Webasto Functional description | 3
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3 Functional description
The eThermo Top Eco 20 P or the eThermo Top Eco 30 P is an
electric water heater with coolant temperature control and in-
tegrated power pack.
The necessary, continuous coolant flow is provided by a coolant
pump. The heater is connected to the 220V to 230V domestic
power grid.
Heating mode starts as soon as the power supply is established.
This happens as soon as the power cable connected to the
vehicle connection is inserted into the socket.
To switch off, the power cable is first removed from the socket
outlet with earthing contact and then from the vehicle connec-
tion.
Once the heater is activated, heating mode is controlled auto-
matically as a function of the temperature. To generate heat,
the heating coil in the heater housing is heated by electrical
means (immersion heater principle).
Standard temperature range (standard values) in °C
nSwitches off at T > 70°C
nSwitches back on at T < 55°C
The coolant temperature is monitored by the sensor system in
order to protect the heater from overheating.

4 | Technical data Webasto
8 / 19 9039398A_WSM_eThermo_Top_Eco_EN
4 Technical data
Heater eThermo Top Eco 20 P eThermo Top Eco 30 P
Design Water heater (electrical operation)
Power connection [V] (50Hz) 220 - 230
Heater output (kW) 2 3
Operating voltage [V] (50Hz) 220 - 230
Output voltage [V] 12.0 - 14.0
Rated power consumption over control range [kW] 2 3
Permissible ambient temperature (operation) [°C] –40 to +80
Permissible ambient temperature (storage) [°C] –40 to +120
Permissible working pressure [bar] < 2.5
Capacity of the heat exchanger [I] 0.25
Heater dimensions [mm] 181x133x91
Heater weight, empty [kg] 1.4
IP class Heater IP 5K4K, IPX9K
Coolant pump (12 V)
Volume flow against 0.14bar [l/h] 450
Rated voltage [V] 12
Operating voltage range [V] 10.5 -17
Rated power consumption [W] 14
Dimensions of coolant pump (length) [mm] 109
Diameter Ø [mm] 48.5
Weight [kg] 0.3
NOTE
The technical data apply under following conditions:
Rated voltage: 12V / 230V
Air pressure: 1013 hPa
Relative humidity: 50%,
Ambient temperature: +20 °C
Geodetic height: 0 m above sea level
The standard tolerances of ±10 % for heaters shall apply if no limits are specified.

Webasto Technical data | 4
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4.1 Dimensions
181
133
Fig.3: side
91
133
Fig.4: Front

5 | Malfunctions and troubleshooting Webasto
10 / 19 9039398A_WSM_eThermo_Top_Eco_EN
5 Malfunctions and troubleshooting
5.1 Cause of malfunctions
A malfunction is caused when there is one or more faults occur.
Possible faults are:
nOvervoltage / Undervoltage
nmalfunctions of all components, e.g. due to short-circuit or
break,
noverheating of heater,
nIncorrect installation position of the heater, see Fig. 5
91
133
Fig.5: Check installation position
nIncorrect installation of the coolant pump, see
„chapter2.5.1.