Webasto thermo top evo Instruction manual

Water Heaters
03/2003
Workshop Manual
Thermo Top Evo
Type Thermo Top Evo (Petrol)
Type Thermo Top Evo (Diesel)
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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.
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Thermo Top Evo Table of Contents
I
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Contents and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Meaning of signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Additional documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4.1 Statutory regulations governing installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4.2 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.5 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Combustion-air fan unit/control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2 Burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2.1 Glow plug/Flame monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.3 Heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.3.1 Temperature sensor and overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.4 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.5 Metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.6 Heater controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3 Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.1 Switching on/starting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.2 Heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.3 Restarting after fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.4 Starting after long period of non-use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.5 Switching off/Switch-off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1.1 Fault lock-out and heater lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1.2 Fault lock-out due to undervoltage or overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1.3 Fault release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.2 General fault symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
5.4 Reading out fault memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
5.5 Component fault entered in the fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
5.6 General faults entered in fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.7 Faults without fault entry in control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
6 Operating tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.2 Operating checks in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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Table of Contents Thermo Top Evo
II
7 Circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
8 Servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.1 Work on the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.2 CO2 setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.3 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.4 DP42 metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.5 Checking work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6 Heater, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6.1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.7 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.1 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.1.1 Dismantling heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.1.2 Assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.2 Burner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.2.1 Removing burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.2.2 Installing burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.3 Glow plug/Flame monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.3.1 Electrical test of glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.3.2 Removing glow plug/flame monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.3.3 Installing glow plug/flame monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
9.4 Combustion-air fan unit and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
9.5 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
9.6 Temperature sensor/Overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
9.6.1 Removing temperature sensor/overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
9.6.2 Installing temperature sensor/overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
9.6.3 Checking sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
9.7 Water connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
9.7.1 Installing water connection piece Variant A - without lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
10 Packing, Storage and Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
10.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
10.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
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Thermo Top Evo List of illustrations
III
List of illustrations
Fig. 201 Thermo Top Evo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Fig. 202 Combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 203 Burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 204 Heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 205 U4847 Econ circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 206 DP42 metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 207 Digital timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 208 Telestart T91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 209 Telestart T100 HTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 301 Functional illustration of Thermo Top Evo heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Fig. 501 Overview of component faults entered in the fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Fig. 502 Overview of general faults entered in fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Fig. 503 Overview of possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Fig. 504 Overview of functional test of heater and its components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Fig. 701 Wiring diagram of Thermo Top Evo parking heater and 12 V digital timer. . . . . . . . . . . . . . . . . . . . . . . . 702
Fig. 801 CO2 setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Fig. 802 Installation position of U4847 Econ circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Fig. 803 Pumping quantity of DP42 metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 804 Installation position of DP42 metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 901 Component illustration of Thermo Top Evo heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Fig. 902 Burner unit and combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Fig. 903 Detailed illustration of cable routing for glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 904 Petrol burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 905 Diesel burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 906 Burner unit with glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 907 Remove retaining spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 908 Remove cooling flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 909 Remove glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 910 Installing glow plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 911 Installing cooling flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 912 Installing retaining spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 913 Installing glow plug properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 914 Installing glow plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 915 Routing glow plug cable with slight bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 916 Combustion-air fan unit with illustration of connectors
(variant shown is equipped with the maximum connector assignment) . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Fig. 917 Heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Fig. 918 Moistening gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Fig. 919 Position retaining spring while watching cable routing and position of sensors W5 and W6 . . . . . . . . . . 907
Fig. 920 Mounting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Fig. 921 Tightening screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Fig. 922 Sensor resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Fig. 923 Comparison of retaining plates without (above) and with (below) lock . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Fig. 924 Retaining plate for installing water connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Fig. 1001 Preferred position for Thermo Top Evo heater for storage and transport . . . . . . . . . . . . . . . . . . . . . . . . 1001
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List of illustrations Thermo Top Evo
IV
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Thermo Top Evo 1Introduction
101
1 Introduction
1.1 Contents and purpose
This workshop manual is used to support trained personnel
which repairs the petrol and diesel models of the Thermo
Top Evo parking heater water heaters and auxiliary heaters.
1.2 Meaning of signal words
Throughout this manual, the signal words WARNING,
IMPORTANT and NOTE have the following meanings:
WARNING
This heading is used to highlight operating instructions or
procedures which, if not or not correctly followed, may
result in personal injury or fatal accidents.
IMPORTANT
This heading is used to highlight operating instructions or
procedures which, if not or not correctly followed, may
result in damage to the equipment or its components.
NOTE
This heading is used to direct your attention to a special fea-
ture deemed essential to highlight.
1.3 Additional documentation to be used
This workshop manual contains all necessary information
and instructions for the repair of Thermo Top Evo water
heaters.
Information from the general installation and operating
instructions and the vehicle-specific installation documents
is not contained within this workshop manual. If repairs are
necessary, these documents must also be used.
1.4 General safety precautions
In principle, the general accident prevention regulations and
current works safety instructions are applicable.
"General safety precautions" which go beyond the scope of
these regulations are listed in the following.
Any special safety regulations relevant to this instruction
manual will be highlighted in the relevant sections or text
passages of the procedures.
1.4.1 Statutory regulations governing installa-
tion
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.
For the installation, primarily the regulations of Appendix VII
of the Directive 2001/56/EC and the regulations contained
in the installation instructions must be observed.
NOTE:
The regulations of these guidelines are binding in the scope
of the EU Directive 70/156/EEC and/or EC/2007/46 (for new
vehicle models from 29/04/2009) and should also be
observed in countries in which there are no special regula-
tions!
The Thermo Top Evo water heater was designed for instal-
lation in Class M1 motor vehicles. The installation in motor
vehicles of the classes O, N2, N3 and hazardous substance
transports according to the EC Directive EEC/70/156 and/or
Basic Directive EC/2007/46 is not permissible.
The applicable regulations must be taken into account when
installing in special vehicles. Other uses are possible in con-
sultation with Webasto AG.
1.4.2 General safety precautions
The repair and commissioning of the unit may only be car-
ried out by personnel trained by Webasto. The repair and
installation of the unit may only be carried by trained experts
in accordance with the workshop manual and the installa-
tion instructions.
WARNING
The heater must not be operated:
• at filling stations and tank farms.
• at locations at which highly flammable gases or dusts
can form, and at locations at which highly flammable
liquids or solid materials are stored (e.g. near fuel, coal
and wood dust, grain warehouses, dry grass and leaves,
cardboard , paper, etc.).
• In closed rooms (e.g. garages), not even via the timer or
Telestart.
• Without at least 20 % brand name anti-freeze in the
water of the heating circuit.
There is a danger of burns, as the heater and the
attached parts may be extremely hot.
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1Introduction Thermo Top Evo
102
The heater:
• may not be subjected to temperatures of more than
120 °C (storage temperature). Otherwise the electron-
ics may suffer permanent damage.
• may only be operated with the fuel and the nominal
voltage specified on the type label.
• must be shut down by immediately switching off the
heater and removing the fuse in case of heavy smoke,
unusual combustion noises or fuel odours. The heater
must not be restarted until the unit has been checked
exclusively by personnel duly trained by Webasto.
• must be switched off during work in the engine com-
partment and may not be cleaned with high-pressure
cleaning units or compressed air.
• must be put into operation at least once a year for
10 minutes with the engine cold and the lowest fan
speed selected.
• must be checked by a professional every 2 years, at the
commencement of the heating period.
Liability:
• Non-compliance with the installation/operating instruc-
tions and the warnings contained therein will lead to
the exclusion of all liability by Webasto. The same ap-
plies 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 therefore of its homologation/EC type licence.
Be sure to read the operating instructions of the heater
before commissioning.
1.5 Spare parts
The ID numbers of available spare parts can be found in the
Webasto spare parts catalogue or online in the dealer portal
at http://dealers.webasto.com.
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Thermo Top Evo 2 General description
201
2 General description
The Thermo Top Evo water heater is used to compensate
the heat deficit which results with consumption-optimised
vehicle engines.
The Thermo Top Evo parking heater is used:
– to heat the vehicle interior,
– to defrost the vehicle windows,
– to preheat water-cooled vehicle engines.
The Thermo Top Evo auxiliary heater can be upgraded to a
parking-auxiliary heater with an additional kit.
As the external appearance is identical, the heaters are
marked with "Petrol" or "Diesel on the type label; there is
no special marking for the auxiliary heater. The heaters may
only be operated with the predetermined fuel and only with
the respectively specified type of electrical connection.
NOTE
This workshop manual describes the retrofit variant of the
heater. For heaters installed directly at the vehicle manufac-
turer's plant, other control units with other connectors and
other software and other application parts may be used
which are not described in this manual. Information is only
available for these heaters via the documentation of the
vehicle manufacturer.
The heater designed according to the evaporator principle
operates in the full-load and partial-load mode, controlled
by the temperature sensor.
The heater consists of the combustion-air fan unit (G) with
the control unit, the heat exchanger (W) with the water con-
nection piece and the burner.
Fig. 201 Thermo Top Evo
G
G = Combustion air fan assembly
B = Heat exchanger assembly
W
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2 General description Thermo Top Evo
202
2.1 Combustion-air fan unit/control unit
The combustion-air fan unit contains:
• the heater type label
• the connection piece for the combustion air pipe
• the control unit with the plug-in contacts
• the engine and the impeller
The combustion air fan supplies the air required for the
combustion process from the combustion air inlet to the
combustion chamber.
NOTE
It is not permissible to dismantle the combustion-air fan
unit.
2.2 Burner unit
The fuel-air mixture is processed and the actual combustion
takes place in the burner unit. The fuel flows via the fuel
pipe to the evaporator, is distributed there and is evapo-
rated using the glow plug. The air required for combustion
is provided by the combustion-air fan unit and flows into the
combustion chamber via holes in the burner.
Fig. 202 Combustion-air fan unit
Fig. 203 Burner unit
B1
B1 = Combustion pipe
with evaporator
mount and evapora-
tor
B2 = Retaining spring for
glow plug
B3 = Cooling flag for glow
plug
B4 = Glow plug/Flame
monitor
B5 = Fuel pipe
B9 = Connector for glow
plug/flame monitor
B4
B2 B3
B5 B9
Pin 1
Pin 2
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Thermo Top Evo 2 General description
203
2.2.1 Glow plug/Flame monitor
The glow plug/flame monitor is connected to the control
unit (SG) via an electrical line with a connector (B9). The
glow plug is fastened to the evaporator mount with a
retaining spring (B2). A cooling flag (B3) provides for heat
dissipation from the glow plug, and therefore reduces the
temperature at the glow-plug connection lines.
The glow plug ignites the fuel-air mixture in the start-up
phase and is switched off after the "full load" state is
reached. From this point it is used exclusively for flame mon-
itoring. If the flame extinguishes, the electrical resistance in
the glow plug drops as the result of the missing heat appli-
cation. This is detected in the control unit.
2.3 Heat exchanger
The heat generated in the heat exchanger by combustion is
transferred to the coolant circuit.
2.3.1 Temperature sensor and overheating sensor
The temperature sensor detects the coolant temperature in
the heat exchanger of the heater as an electrical resistance.
This signal is fed to the control unit, where it is processed.
The temperature sensor (W5) and the overheating sensor
(W6) for a unit together with the cable and the connector.
The overheating sensor protects the heater against imper-
missibly high operating temperatures. This reacts at a tem-
perature above 125 °C and switches off the heater.
2.4 Circulating pump
The U4847 Econ circulating pump ensures a feed rate of the
coolant in the vehicle heater and heater circuit.The pump is
switched on with the control unit and runs during the entire
operation of the heater. The circulating pump is a centrifu-
gal pump with a brushless EC motor.
The circulating pump is equipped with a 2-pin connector
output and is connected to the control unit (SG) by means
of a separate wiring harness.
2.5 Metering pump
The fuel metering pump is a combined pumping, metering
and shut-off system. This dry-primeable reciprocating piston
pump pumps the fuel from the vehicle fuel tank to the fuel
connection piece of the heater via fuel lines. Installation is
usually carried out near the fuel tank. The metering pump
contains no pulsation damper and is equally well-suited for
diesel and petrol. The metering pump is connected to the
control unit via the heater-unit wiring harness and to an
earthing point on the vehicle body.
Fig. 204 Heat exchanger
W2 W5 W4 W3
W6
W1
W1 = Heat exchanger
W2 = Cable of temperature sensors
W3 = Ejomat DG 40x10 self-tapping screw
W4 = Retaining spring for sensors
W5 = Temperature sensor
W6 = Overheating sensor
Fig. 205 U4847 Econ circulating pump
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2 General description Thermo Top Evo
204
IMPORTANT
Only the model DP42 fuel metering pump may be used for
the Thermo Top Evo heater. Observe the model designation
on the component for this purpose. When replacing the
metering pump, the CO2settings must be checked. See
Section 8.2.
2.6 Heater controls
NOTE
Additional information on the respective heater control is
contained in the specific installation and operating instruc-
tions.
Fig. 206 DP42 metering pump
Fig. 207 Digital timer
Fig. 208 Telestart T91
Fig. 209 Telestart T100 HTM
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Thermo Top Evo 3 Description of operation
301
3 Description of operation
3.1 Switching on/starting process
The heater is started with the parking heater via a switch-on
signal of the heater control. And with the auxiliary heater
when the auxiliary heating signal is present at the heater
unit inlet. The auxiliary heating signal is dependent on pre-
viously defined switch-on conditions, such as the outside
temperature (below 5 °C) and engine running.
NOTE
The Thermo Top Evo heaters described in this manual can
only be put into operation with a W-bus-capable heater
control, or with the Webasto Thermo Test PC Diagnosis.
With the Webasto Thermo Test PC Diagnosis connected, the
connection to other heater controls is disconnected.
Different configuration options are shown in the system wir-
ing diagram.
When the heater is started up, the combustion air fan, the
circulating pump and the glow plug are put into operation.
Then the metering pump is connected. The petrol heater
starts up at the highest load level. In contrast, the diesel
heater starts up at a low load level and is slowly adjusted
upward to full load in the form of a ramp.
During this start-up phase, it is checked whether a flame has
formed with the glow plug. If no flame is formed or the
flame extinguishes, then automatic restarting can be initi-
ated. If no flame is formed once again, the starting attempt
is ended. Then a fault lock-out is carried out with run-on of
the combustion air fan. The heater cannot be restarted until
after switch-off.
Depending on the coolant temperature, the control unit
decides which starting process is selected. Start-up proc-
esses are identical with regard to the sequence, however
differ in the length of the individual phases (preheating, fuel
delivery, etc.).
3.2 Heating mode
After full load is reached, the glow plug assumes the func-
tion of the flame monitor and checks the flame. The heater
switches into the energy-saving partial-load mode after a
certain temperature (around 80 °C) is reached. If the tem-
perature continues to increase, the heater switches into the
control break from a pre determined temperature (approx.
84 °C).
After the coolant has cooled down, the heater restarts in the
partial-load mode. If the temperature rises to a defined
switching temperature again, the heater switches into the
control break again.If the temperature of the coolant con-
tinues to drop due to an increased heat requirement during
partial load operation, then the heater switches over to full
load operation again.
The temperature of the switching points is programmed in
the control unit.
If a flame out occurs during normal combustion operation,
a restart is automatically initiated.
Fig. 301 Functional illustration of Thermo Top Evo heater
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3 Description of operation Thermo Top Evo
302
3.3 Restarting after fault lock-out
After the fault cause has been eliminated, the heater must
be switched on again with the normal switch-on signals.
This does not apply after overheating or if a fault occurs sev-
eral times without intermediate combustion operation.
3.4 Starting after long period of non-use
Longer periods of non-use have no effect on the starting
function of the heater. However, limitations must be made
here with regard to filling of the fuel lines. Especially with
petrol heaters, the fuel evaporates from the fuel line in the
summer months. As a result, it must be expected that sev-
eral complete starting attempts will be required for initial
starting. Commissioning must them be carried out with the
Webasto Thermo Test PC Diagnosis.
Prime the heater with fuel using the Webasto Thermo Test
PC Diagnosis:
Press the fill line button and fill the lines until fuel is present
at the heater.
3.5 Switching off/Switch-off function
When a switch-off signal is received, when the burn-out
temperature is reached, when the set heating time is
reached or if faults occur, combustion operation is ended
and a burn-out is initiated. In the process, the control of the
fuel metering pump is immediately interrupted and the fan
speed is decreased. After the burn-out is complete the fan
speed is increased to cool the combustion chamber.
NOTE
The run-on time and the combustion-air fan speed are
dependent on the heater model and operating mode from
which the heater is switched off.
Switch-off or new switch-on signals are processed accord-
ing to the following rules:
1. A switch-off signal on a heater control always as priority
irrespective of the heater operating state.
2. If the original switch-on signal is no longer active, or if
the included heating duration has expired, then this is
interpreted as a switch-off signal.
3. New switch-on signals are ignored until the original
switch-on signal is no longer active.
4. It is therefore not possible to change the heating time
during operation. The heater must be switched off and
then on again with the changed heating duration.
5. If the heater has been started as an auxiliary heater, then
switching off the vehicle engine must be interpreted as
a switch-off signal (legal requirement).
6. A restart of the heater is not possible until after the burn-
out has completed and the first cooling phase (forced
run-on) has been ended. New switch-on signals are tem-
porarily stored and are not followed until then.
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Thermo Top Evo 4 Technical data
401
4Technicaldata
The technical data is contained in the installation instructions.
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4 Technical data Thermo Top Evo
402
Page for notes
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Thermo Top Evo 5 Troubleshooting
501
5 Troubleshooting
5.1 Faults
5.1.1 Fault lock-out and heater lock-out
Faults which occur are assigned to various categories:
Fault
1) A fault which occurs has no effect on the current
combustion operation; an fault message is stored.
2) A fault which occurs causes automatic restarting or a
restart; a fault message is stored.
Fault lock-out
3) A fault which occurs in the power supply or in the
control unit results in an immediate heater switch-off
without burn-out. No fault is entered.
4) A fault which occurs results in a heater switch-off (burn-
out) or prevents heater start-up; a fault message is
stored. Restarting requires a switch-off signal and a
repeat switch-on signal.
Permanent heater lock-out due to multiple repetitions of
an fault
5) If a fault from 4) occurs 6 times consecutively without
the full load state being reached, then the heater is
locked out and a fault message is stored.
The lock-out can only be cancelled at the workshop.
If the fault is an undervoltage switch-off due to a weak
battery, then no lock-out occurs.
Overheating lock-out (heater is overheated)
6) The heater overheats and is locked out; a fault message
is stored.
The lock-out can only be cancelled at the workshop.
NOTE
If a fault lock-out and a subsequent heater lock-out occurs,
then no display occurs on the heater controls. A start-up of
the heater is permitted; a fault is no longer present.
In case of a heater lock-out, the heater is locked out and
cannot be switched on.
5.1.2 Fault lock-out due to undervoltage or
overvoltage
In case of an undervoltage of 11.5 V for a certain period
(20 sec.), a fault lock-out with a run-on occurs. The specified
undervoltage is software-dependent and is measured at the
control unit input.
In case of an overvoltage of 16.0 V (measured on the
heater) for a certain period (5 sec.), a fault lock-out with
run-on also occurs.
5.1.3 Fault release
After the fault cause is eliminated, the fault release is carried
out by switching the heater off and then on again.
IMPORTANT
A permanent heater lock-out/overheating lock-out can only
be cancelled with the Webasto Thermo Test PC Diagnosis.
The heater faults stored in the fault memory must be read
out and printed with the Webasto Thermo Test PC Diagno-
sis. To delete the heater lock-out without clearing the fault
memory, select the menu command Fault memory/Delete
heater lock-out.
In exceptional cases, the heater lock-out can be cancelled by
disconnecting the power supply of the control unit (e.g. by
removing the fuse F1, 20 A for at least 10 seconds). The
fault must be eliminated beforehand. (See Section 5.3). The
fuse must be pulled within 10 sec. after switching on the
heater.
5.2 General fault symptoms
The following chapter contains a general overview of the
fault symptoms with the heater installed.
IMPORTANT
Troubleshooting work demands precise knowledge of the
structure and theory of operation of the various compo-
nents and must be carried out by trained personnel only.
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5 Troubleshooting Thermo Top Evo
502
5.3 Troubleshooting
Possible fault during heater operation are sorted in this
chapter according to the following criteria:
1) Component faults entered in the fault memory (see
Section 5.5).
A specific component which is defective is contained in
the control-unit fault memory. The component or next-
highest assembly must be replaced.
2) General faults entered in the fault memory (see
Section 5.6).
The heater has detected a problem (e.g. no starting),
however cannot identify the specific cause.
Troubleshooting is structured so that the periphery of
the heater is checked (e.g. the fuel supply) before the
heater or a sub-component is replaced.
3) Fault without fault entry in the control unit (see
Section 5.7).
Troubleshooting is structured so that first the periphery
of the heater is checked (e.g. the fuel supply) before the
heater or a sub-component is replaced.
5.4 Reading out fault memory
The fault memory of the heater can be read out with the
Webasto Thermo Test PC Diagnosis.
The fault memory displays up to 8 different faults. The older
an fault is, the higher its number. The current operating
duration and the current start-up number are entered in the
control unit summary.
If a fault is entered as "current" then the control unit has
discovered this fault since the last switch-on.
The fault message "Initial starting attempt failed" remains
current until either full-load combustion operation is
achieved in the restart or the second start-up also fails. In
this case, the fault message "Initial starting attempt failed"
is deleted and replaced with "No start".
The fault message "Flame abort" remains current until the
heater is switched off or several flame aborts lead to the
heating mode being aborted. In this case, the fault message
"Flame abort" is deleted and replaced with "Flame failure".
NOTE
The operation of the diagnostic unit is explained in the oper-
ating instructions. W bus must be entered under Heater
model.
It is recommended that the operating and fault data and the
extended fault environment conditions be printed out.
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Thermo Top Evo 5 Troubleshooting
503
5.5 Component fault entered in the fault memory
Fault
code
(HEX)
Fault
code
(DEZ)
WTT* fault message Fault details with double-
click in WTT*
Recommended workshop
action
00 - No fault No fault No activity required
01 1 Defective control unit Defective control unit, off-line
programming is not per-
formed\or water temperature
sensor defective
Delete fault, carry out fault
release/heater lock-out on
heater (see Section 5.1.1),
restart heater
08 8 Metering pump short cir-
cuit
Metering pump has short cir-
cuit to ground
Conduct electrical test of fuel
system (see Section 5.7, Fig.
504, Point 5)
0B 11 Circulating pump short
circuit
The connected line of the
water pump has a short circuit
to earth\nor the engine is over-
loaded
Conduct electrical test of
coolant system (see
Section 5.7, Fig. 504, Point 9)
10 16 Coolant changeover valve
short circuit
The coolant changeover valve
has a short circuit to earth
Conduct electrical test of
coolant changeover valve (see
Section 5.7, Fig. 504,
Point 16)
13 19 Vehicle fan power circuit
short circuit
The vehicle fan power circuit
has a short circuit to earth
Conduct troubleshooting in
area of vehicle fan (see
Section 5.7, Fig. 504,
Point 13)
15 21 Combustion air fan
blocked
Combustion air fan is blocked 1 Conduct troubleshooting
in combustion air fan (see
Section 5.7, Fig. 504,
Point 8)
2 Conduct troubleshooting
in intake air system (for-
eign body) (see
Section 5.7, Fig. 504,
Point 12)
19 25 Glow/ignition element
power circuit short circuit
Glow plug / electronic ignition
unit has short circuit to ground
Conduct electrical test of
glow plug (see Section 5.7,
Fig. 504, Point 6)
1B 27 Overheat sensor short cir-
cuit
The connected line of the ele-
ment has a short circuit to earth
Conduct electrical test of
temperature sensors (see
Section 5.7, Fig. 504, Point 7)
2D 45 The combustion-air fan
power circuit is defective
Fan motor speed is below value
to be expected
Delete fault, carry out fault
release/heater lock-out on
heater (see Section 5.1.1),
restart heater
Fig. 501 Overview of component faults entered in the fault memory
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5 Troubleshooting Thermo Top Evo
504
2E 46 The glow/ignition-ele-
ment power circuit is
defective
Glow plug resistance is outside
the value range
In case of multiple occur-
rences (> 3):
1) Troubleshooting in air
intake or in exhaust sys-
tem (see Section 5.7, Fig.
504, Point 12)
2) Conduct electrical test of
glow plug (see
Section 5.7, Fig. 504,
Point 6)
3A 58 W-bus/LIN-bus short cir-
cuit to earth
No additional information
available
Troubleshooting in area of W
bus communication (see
Section 5.7, Fig. 504, Point 2
and 3)
3C 60 Internal control unit fault
60
No additional information
available
Delete fault, carry out fault
release/heater lock-out on
heater (see Section 5.1.1),
restart heater
3D 61 Internal control unit error
61
No additional information
available
Delete fault, fault release/
carry out heater lock-out on
heater (see Section 5.1.1),
restart heater
3E 62 Internal control unit error
62
No additional information
available
Delete fault, fault release/
carry out heater lock-out on
heater (see Section 5.1.1),
restart heater
3F 63 Wrong version dataset
loaded
No additional information
available
Delete fault, fault release/
carry out heater lock-out on
heater (see Section 5.1.1),
restart heater
81 129 EOL checksum error Checksum of EOL dataset is
wrong
Delete fault, fault release/
carry out heater lock-out on
heater (see Section 5.1.1),
restart heater
88 136 Metering pump interrup-
tion
Metering pump interrupted or
short circuit to supply voltage
+Ub
Conduct electrical test of fuel
system (see Section 5.7, Fig.
504, Point 5)
89 137 Combustion air fan inter-
ruption
Combustion air fan interrupted
or short circuit to supply volt-
age +Ub
Troubleshooting in combus-
tion air fan (see Section 5.7,
Fig. 504, Point 8)
8B 139 Circulating pump inter-
ruption
Circulating pump interrupted
or short circuit to supply volt-
age +Ub
Conduct electrical test of
coolant system (see
Section 5.7, Fig. 504, Point 9)
Fault
code
(HEX)
Fault
code
(DEZ)
WTT* fault message Fault details with double-
click in WTT*
Recommended workshop
action
Fig. 501 Overview of component faults entered in the fault memory
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