Webasto Thermo Top Evo - B User manual

Wasserheizgerät
Water heater
Einbauanweisung
Installation Instructions
Thermo Top Evo
Thermo Top Evo - B (Benzin / Petrol)
Thermo Top Evo - D (Diesel)

Thermo Top Evo
12
24 2325
22
21
3
10 26
27
4
28 29
4
710
14
1
5
30
21
22

Thermo Top Evo
6

Thermo Top Evo

Thermo Top Evo
M6 x 16
0 - 5°

Thermo Top Evo
18

Thermo Top Evo
Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious
injury or death.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and have the appropriate technical
documentation, special tools and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary
technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and
repair work properly.
ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS.
Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.

Table of Contents
II
Table of Contents
1 Regulations governing installation...................................................20
1.1. Statutory regulations governing installation ....................20
1.2. Additional documentation to be used.............................20
2 Use / version ...................................................................................21
2.1. Use of the water heaters ................................................21
2.1.1. Additional heater.........................................21
2.1.2. Auxiliary heater............................................21
2.2. Version...........................................................................21
3 Installation location and installation position ...................................22
4 Type label .......................................................................................23
5 Standard bracket ............................................................................23
6 Example for installation in a passenger car ......................................23
7 Integration in coolant system ..........................................................24
7.1. Connection ....................................................................24
7.2. Installing coolant connection pieces................................24
7.3. Installing coolant hoses ..................................................25
7.4. Installing circulation pump..............................................25
7.5. Checking........................................................................25
8 Fuel integration...............................................................................26
8.1. Integration in engine supply or return line ......................26
8.2. Integration via fuel removal unit .....................................26
8.3. Fuel line .........................................................................26
8.3.1. Line installation............................................27
8.3.2. Line design ..................................................27
8.3.3. Connecting two lines with a hose ................27
8.3.4. Metering pump............................................27
8.3.5. Installation location......................................27
8.3.6. Installation and attachment..........................27
8.4. Label ..............................................................................28
8.5. Cold-resistant fuels.........................................................28
9 Combustion air supply ....................................................................29
9.1. Combustion air pipe.......................................................29
9.2. Intake silencer ................................................................29
9.3. Recommendations for installation...................................29
10 Exhaust System .............................................................................. 30
10.1. Exhaust pipe.................................................................. 30
10.2. Exhaust silencer ............................................................. 30
10.3. Recommendations for installation.................................. 30
11 Electrical connections ..................................................................... 31
11.1. Connection of control unit / heater................................ 31
11.2. Installation and connection of the timer......................... 31
11.3. Installation of other heater controls ............................... 31
11.4. Vehicle fan .................................................................... 31
12 Circuit diagrams............................................................................. 31
13 Initial start-up................................................................................. 33
14 Faults............................................................................................. 33
15 Technical data................................................................................ 34
15.1. Technical data for Thermo Top Evo................................ 34
15.2. Technical data of circulation pump ................................ 34

Thermo Top Evo
19
Note
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Caution
Technical information
Explanatory Notes on Document
To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in
question.
Sections in italics contain an excerpt from the Directive 2001/56/EC and ECE R122.

Technical Information
20
1 Regulations governing installation
1.1. Statutory regulations governing installation
Homologation approvals according to the EC Directives 72/245/EEC (EMC),
ECE-R 10 (EMC), 2001/56/EC (Heating) and ECE R-122 (Heating) and ECE
R-10 03 (EMC) exist for the Thermo Top Evo heater.
See chapter 15, "Technical data" for the approval number.
The provisions of these Directives are binding within the territory
governed by EU Directive 70/156/EEC and/or EC/2007/46 (bind-
ing for new vehicle types as of 29/04/2009) and should also be
observed in countries in which there are no special regulations!
Failure to follow the installation instructions and the notes con-
tained therein will lead to all liability being refused by Webasto.
The same applies if repairs are carried out incorrectly or with the
use of parts other than genuine spare parts. This will result in
the invalidation of the type approval for the heater and there-
fore of its homologation / EC type licence.
1.2. Additional documentation to be used
These installation instructions do not contain all necessary information and
instructions with regard to the installation of Thermo Top Evo water heat-
ers.
In addition, the operating instructions and the vehicle-specific installation
instructions must also be used.

Technical Information
21
2Use/version
2.1. Use of the water heaters
2.1.1. Additional heater
The Thermo Top Evo water heater was designed for installation in Class M1
motor vehicles. Installation in Class O, N 2, N3 motor vehicles and vehicles
for transporting hazardous substances is not permissible. When installing
in special vehicles, the applicable regulations must be taken into account.
Other uses are possible in consultation with Webasto AG.
The Webasto Thermo Top Evo water heater is used in conjunction with the
original vehicle heating system
– to heat the passenger compartment,
– to defrost the vehicle windows,
– to preheat water-cooled engines (if technically possible).
The water heater operates independently of the vehicle engine and is inte-
grated in the vehicle's cooling system, fuel system and electrical system.
Other uses must be clarified with Webasto AG in advance.
2.1.2. Auxiliary heater
The Webasto Thermo Top Evo water heater operated in dependence on the
vehicle engine and is integrated in the vehicle's cooling system, fuel system
and electrical system.
When the engine is switched off, the water heater unit is automatically also
switched off and the fuel supply is cut off within 5 seconds.
2.2. Version
Thermo Top Evo - D
Water heater for "diesel" fuel.
Thermo Top Evo - B
Water heater for "petrol" fuel.
The Thermo Top Evo water heater is designed for a 12 V power supply.
See chapter 15, "Technical data" for the technical design.
5 KW heater versions must not be used for island-coolant sys-
tem applications.

Technical Information
22
3 Installation location and installation position
Body sections and any other components in the vicinity of the heater must
be protected from excessive heat and the possibility of fuel or oil contami-
nation. (Requirement from 2001/56/EC, Appendix VII, Point 2.2.1. and ECE
R122, Point 5.3.2.1.).
The combustion heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be fulfilled if the instal-
lation ensures an adequate distance to all parts and suitable ventilation, by
the use of fire resistant materials or by the use of heat shields. (Requirement
from 2001/56/EC, Appendix VII, Point 2.2.2. and ECE R122, Point 5.3.2.2.).
The heater is preferably installed in the engine compartment, i.e. in the area
between the wheel well and the front bumper.
Installation should be carried out as low as possible to ensure automatic
bleeding of the heater and circulation pump.
The openings of the heat exchanger may not face downward in
any installation position.
Fig. 1 shows the permissible installation position of the heater.
For the position of the heat exchanger opening of the heater, see fig. 2.
For dimensions of heater, see chapter 15, "Technical data".
Legend fig. 2:
21) Heat exchanger inlet
22) Heat exchange outlet
23) Combustion air inlet
24) Fuel inlet
25) Exhaust outlet
L) Length
B) Width
H) Height
The heater may not be installed:
– in the direct area of radiation of exhaust systems
– below the wading line of the vehicle.
– above the coolant expansion tank.

Technical Information
23
4Typelabel
The label referred to in paragraph 1.4 or a duplicate (duplicate model
plate), must be positioned so that it can be easily read when the heater is
installed in the vehicle. (Requirement from 2001/56/EC, Appendix VII, Point
2.2.4. and ECE R122, Point 5.3.2.4.).
Inapplicable years must be erased from the model plate and the current
year must be retained.
Example see also fig. 16.
5 Standard bracket
The heater must be fastened on the bracket with at least 3x M5 bolts with
8Nm.
The heater fastening screws are approved for bracket metal thickness of
1.5 to 3.0 mm.
The standard bracket must be secured to the car body or an intermediate
bracket with at least four M6 screws.
The bracket must not be secured to the car body with self-tapping screws.
If necessary, the bracket must be properly machined in accordance with the
rules of technology.
See also fig. 3: Example of a Thermo Top Evo bracket.
Legend:
10) Water heater
26) Bracket for heater
27) Body
6 Example for installation in a passenger car
Fig. 6 shows an installation example of the heater in the vehicle.
Legend:
1) Radiator
2) Coolant thermostat
3) Coolant pump
4) Internal combustion engine
5) Exhaust silencer
6) Intake silencer, combustion-air intake pipe
7) Circulation pump
8) Battery
9) Fuse holder
10) Water heater
11) Control unit (in heater unit)
12) Mechanical shut-off valve
13) Fan of vehicle heater
14) Heat exchanger for vehicle heater
15) Switch for fan of vehicle heater
16) Fuse block in vehicle
17) Relay (for vehicle fan)
18) Heater control
19) Fuel metering pump
20) Fuel removal

Coolant circuit
24
7 Integration in coolant system
7.1. Connection
The heater is connected to the vehicle cooling system as shown in Fig. 4, 6
and 7. The coolant quantity present must at least be equivalent to the vol-
ume specified in Kapitel 15, "Technical data".
Legend fig. 4:
1) Radiator
4) Internal combustion engine
7) Circulation pump
10) Water heater
14) Heat exchanger for vehicle heater
28) Expansion tank
29) Thermostat
It is preferable to integrate the heater in the coolant system at the heat ex-
changer inlet.
Any coolant running off should be collected using an appropri-
ate container.
The coolant hoses supplied by Webasto must always be used. If other hoses
are used, they must at least comply with the standard DIN 73411, material
class B. The hoses must be routed without kinking and preferably uphill
from the heater to ensure perfect bleeding.
Only hoses with an inside diameter of 18 mm may be chosen.
Hose connections must be secured against slipping off with clips.
7.2. Installing coolant connection pieces
Never mount the retaining plate and the water connection
pieces when the heater has been installed.
The contact surfaces of the O-rings in the heat exchanger must be clean
and must not have any damage.
The O-rings must be wetted with water before being mounted in the heat
exchanger.
Lay the O-rings in the openings of the heat exchanger. Mount the water
connection pieces in the retaining plate. Move the connection pieces into
the required installation position.
Fasten the retaining plate with the coolant connection pieces on the heat
exchanger. DG 5X15 mm self-tapping screw, torque 7 Nm.
To ensure the self-bleeding of the heater, the water-outlet connection piece
must be positioned pointing 0° to 90° upward if possible.
See fig. 8: Installing water connection pieces.
Ensure proper positioning of the sensor cable!
See fig. 5: Position of sensor cable.

Coolant circuit
25
Legend Fig. 5:
21) Heat exchanger inlet
22) Heat exchanger outlet
30) Sensor cable
7.3. Installing coolant hoses
The clamps on the heat-exchanger connection pieces must be mounted be-
tween the bead and the hose shoulder.
Care must be taken to bleed the cooling system before the heater is taken
into service for the first time or after refilling with fresh coolant. Heater and
lines should be installed in such a way as to ensure static bleeding.
Malfunctions due to overheating may occur during operation if the heater
and lines have not been bled correctly.
Only spring band clamps approved by Webasto may be used for
the installation of the coolant hoses.
7.4. Installing circulation pump
The circulation pump must be installed in the coolant circuit on the pressure
side on the heater heat-exchanger inlet (see fig. 4).
Ensure the correct direction of flow of the circulation pump to the vehicle
coolant circuit. The installation position of the circulation pump must be
chosen so that the circulation pump is self-bleeding. It must be possible for
the air volume trapped in the circulation pump to automatically escape up-
ward via the connection piece. Incorrect installation can result in malfunc-
tions of the circulation pump.
See fig. 7: Installation positions of U4847 Econ circulation pump.
7.5. Checking
After the heater and all coolant-carrying components have been installed,
the entire coolant system must be checked for leaks with the system pres-
sure specified by the vehicle manufacturer.

Fuel
26
8 Fuel integration
The fuel filler must not be situated in the passenger compartment and must
be provided with an effective cap to prevent fuel spillage. (Requirement
from 2001/56/EC, Appendix VII, Point 2.3.1. and ECE R122, Point 5.3.3.1.).
In the case of liquid fuel heaters, where a supply separate to that of the ve-
hicle is provided, the type of fuel and its filler point must be clearly labelled.
(Requirement from 2001/56/EC, Appendix VII, Point 2.3.2. and ECE R122,
Point 5.3.3.2.).
8.1. Integration in engine supply or return line
The fuel integration is carried out either in the supply or return line, or with
a special fuel standpipe. On vehicles with a fuel pump, the fuel may not be
removed from the fuel supply line!
– If the vehicle has a check valve to the fuel tank, fuel may not be removed
from the return line.
– It must be ensured that no zero balance results in the vehicle system due
to the fuel removal.
– If fuel is removed from the swirl pot, it must be ensured that this pot is
not completely drained.
Proper installation is carried out as shown in fig. 9: Example of a fuel stand-
pipe.
Legend:
33) from fuel tank
34) to metering pump
35) to engine
8.2. Integration via fuel removal unit
Also see chapter 6, "Example for installation in a passenger car"
The fuel standpipe is installed in the fuel removal unit of the fuel tank.
See fig. 12.
Legend fig. 12:
31) Fuel standpipe
32) Fuel removal unit with hole
The installation surface of the fuel standpipe must be clean, flat and burr-
free. When mounting the fuel standpipe in the fuel removal unit, ensure
careful routing of the standpipe. This may not impair the operation of the
parts of the fuel removal unit including the fuel gauge in any operating
mode. The length of the standpipe must be chosen so that a minimum dis-
tance of 10 mm over the fuel tank bottom or 20 mm over the bottom of
the fuel removal unit is ensured.
The specified securing measures of the vehicle manufacturer and the cor-
responding torques must be complied with.
Under no circumstances whatsoever may the fuel standpipe be
installed in the fuel tank body, but instead only in the fuel re-
moval unit.
8.3. Fuel line
The fuel line is divided into the intake and the delivery line. As a result, the
intake line is a connection between the fuel tank and the metering pump,
while the delivery line produces the connection between the metering
pump and the heater.

Fuel
27
8.3.1. Line installation
When installing the fuel line, it must be kept as short as possible.
The line must be installed protected against damage (e.g. stone impact) in
all areas.
The fuel line must always be routed in cool areas to prevent the formation
of bubbles due to warming.
High fuel temperatures can cause heater malfunctions. As a result, the line
may not be routed either past strong heat sources (e.g. exhaust gas) or near
stored heat zones.
In addition, the steepest possible routing of the fuel line must be ensured
from the fuel tank to the heater.
Fuel lines must be fastened in accordance with the latest technology so
that, for example, line sag is avoided.
Rub protection must be installed at sharp-edged transitions.
Do not route fuel lines through the vehicle interior.
8.3.2. Line design
Only lines approved by Webasto may be used as fuel lines.
8.3.3. Connecting two lines with a hose
The correct connection of fuel lines with a hose is shown in fig. 10.
Legend fig. 10:
41) Hose clamp
42) Air bubble
Ensure that there are no leaks.
8.3.4. Metering pump
The metering pump is a combined delivery, metering and shut-off system
and is subject to specific installation criteria (see fig. 11).
The Thermo Top Evo heater may only be operated together with the DP 42
metering pump.
8.3.5. Installation location
The metering pump may not be installed in the radiation area of hot vehicle
parts. A heat shield must be used if necessary. The pump should preferably
be installed near the tank.
The permissible ambient temperature is dependent on the fuel used, see
chapter 15, "Technical data".
8.3.6. Installation and attachment
The metering pump must be secured with a vibration-damping mounting.
The installation position is restricted as shown in fig. 11 (maximum inclina-
tion of metering pump, axial installation position of metering pump) to en-
sure good self-bleeding.
The arrow indicates the direction of flow of the fuel.
Intake line length [m] max. 3.0 m
Intake height [m]
(Height difference
between fuel tank and
metering pump)
max. 1.0 m
Delivery line length [m] max. 9.0 m

Fuel
28
8.4. Label
A notice, indicating that the heater must be shut down before refuelling,
must be affixed to the fuelling point. (Requirement from 2001/56/EC, Ap-
pendix VII, Point 2.3.3. and ECE R122, Point 5.3.3.3.).
Use the stickers provided (see fig. 17 for an example).
The sticker "Switch off heater when refuelling“ must be applied near the
filler neck.
8.5. Cold-resistant fuels
If you change to low-temperature fuel, the heater must be operated for ap-
prox. 15 minutes so that fuel line and fuel pump are also filled with the new
fuel.
We know of no negative influences due to additives.

Combustion air
29
9 Combustion air supply
The air inlet must be so positioned or guarded that blocking by rubbish or
luggage is unlikely. (Requirement from 2001/56/EC, Appendix VII, Point
2.5.2. and ECE R122, Point 5.3.5.2.).
9.1. Combustion air pipe
The intake opening for combustion air must be located so that it cannot
become clogged with dirt. It must not point in the direction of travel.
An intake line is required for combustion air.
The withdrawal point for the combustion air must be located in a cool place
where it is protected from splashing water and above the fording line of the
vehicle.
A ventilation opening measuring at least 3 cm2is required if the intake
opening is installed in an enclosed installation space.
9.2. Intake silencer
The air intake silencer must be installed in a position between 0° and 90°
pointing downwards.
See fig. 13.
Legend fig. 13:
36) Combustion-air intake pipe
37) Combustion-air intake silencer
38) Mounting clip
9.3. Recommendations for installation
Screw a combustion-air intake pipe with a maximum length of 400 mm
onto the combustion-air intake connection piece of the heater.
Screw the combustion-air intake silencer as far as possible into the combus-
tion-air intake pipe.
Leaks can result in a higher noise level. Ensure an adequate dis-
tance from the exhaust system to prevent the intake of exhaust
gas!
Depending on the installation, the combustion air intake silencer can be lo-
cated in a suitable location and secured with the included mounting clip or
other installation materials which utilise the latest technology.

Exhaust gas
30
10 Exhaust System
10.1. Exhaust pipe
The exhaust pipe (inside diameter 22 mm) can be routed with several bends
(270° altogether, minimum bending radius 50 mm).
The total line length must be between 500 and 1000 mm.
10.2. Exhaust silencer
It is not permissible to operate the Thermo Top Evo heater without exhaust
silencers.
The exhaust silencer must not be installed near the intake opening for the
combustion air.
The exhaust silencer must be installed at least 200 mm from the heater.
Drill a ø 2 mm condensed-water drain hole at the lowest point
of the exhaust silencer.
Fig. 15 shows the exhaust silencer.
10.3. Recommendations for installation
The exhaust silencer and the exhaust pipe may not be fastened to temper-
ature-sensitive vehicle parts (e.g. brake line, electr. lines, vehicle control
units, headlights, underbody protection, plastic parts, etc.) and must be a
sufficient distance of at least 20 mm from them.
Only approved Webasto spacer brackets may be used with this application.
The exhaust pipes are sufficiently fixed in place to ensure the minimum dis-
tances even during driving. Lines approved by Webasto must be used as ex-
haust pipes. It is recommended that the exhaust application be installed
splash-water protected.
Collections of condensed water in the exhaust pipe must be
drained off directly. If necessary, a condensed-water drain hole
may be drilled at the lowest point.
Condensed-water drain holes may not blow onto temperature-sensitive ve-
hicle parts.
The exhaust outlet must be located so as to prevent emissions from enter-
ing the vehicle through ventilators, heated air inlets or opening windows.
(Requirement from 2001/56/EC, Appendix VII, Point 2.4.1. and ECE R122,
Point 5.3.4.1.).
The exhaust outlet must be unobstructed. It must not be directed at vehicle
parts. The exhaust outlet may not be located within the range of throw of
the wheels.
Watch the maximum steering angle of the front wheels. It must be ensured
that the exhaust outlet is not clogged and cannot be damaged under any
operating conditions.
The opening of the exhaust pipe must not point in the direction of travel.
Point the direction of outflow vertically downward or a maximum of 20°
opposite the direction of travel.
After passing through the underbody cover, the exhaust pipe must be ex-
tended by another 10 mm.
Fig. 14: Exhaust outlet
Legend:
39) Engine under tray
40) Exhaust outlet