Webasto thermo top evo User manual

Wasserheizgerät
Water Heater
水暖式加热器
Einbauanweisung
Installation Instructions
安装指导
Thermo Top Evo
Thermo Top Evo - B (Benzin / Petrol / 汽油 )
Thermo Top Evo - D (Diesel / 柴油 )
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12
24 2325
22
21
3
10 26
27
4
28 29
4
710
14
1
5
30
22
21
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M6 x 16
0 - 5°
13 14
≥200 mm
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9031781A03C
X14
X11/X13/X17/X19/X25
X10/X12/X20/X18/X24
X9
X8
X7
X4/X16
X22
5
2
3
1
4
4
6
6
7
61
12
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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 person-
nel.
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Table of Contents Thermo Top Evo
II
Table of Contents
1 Regulations governing installation................................................... 2
1.1. Statutory regulations governing installation ................... 2
1.2. Additional documentation to be used ............................ 2
2 Use / version ................................................................................... 3
2.1. Use of the water heaters................................................ 3
2.1.1. Parking heater............................................... 3
2.1.2. Auxiliary heater ............................................. 3
2.2. Version .......................................................................... 3
3 Installation location and installation position................................... 4
4 Type label ....................................................................................... 5
5 Standard bracket............................................................................. 5
6 Example of Installation in a Passenger Car....................................... 5
7 Integration in Coolant System ......................................................... 6
7.1. Connection .................................................................... 6
7.2. Installing coolant connection pieces .............................. 6
7.3. Installing coolant hoses.................................................. 7
7.4. Installing circulation pump ............................................. 7
7.5. Checking........................................................................ 7
8 Fuel integration............................................................................... 8
8.1. Integration in engine supply or return line...................... 8
8.2. Integration via vehicle's own fuel delivery unit ............... 8
8.3. Fuel line ......................................................................... 8
8.3.1. Line installation............................................. 9
8.3.2. Line design.................................................... 9
8.3.3. Connecting two lines with a hose ................. 9
8.3.4. Metering pump ............................................. 9
8.3.5. Installation location....................................... 9
8.3.6. Installation and attachment........................... 9
8.4. Label............................................................................ 10
8.5. Cold-resistant fuels....................................................... 10
9 Combustion air supply.................................................................. 11
9.1. Combustion air pipe..................................................... 11
9.2. Intake silencer .............................................................. 11
9.3. Notes on installation .................................................... 11
10 Exhaust System ............................................................................. 12
10.1. Exhaust pipe ................................................................ 12
10.2. Exhaust silencer............................................................ 12
10.3. Recommendations for installation ................................ 12
11 Electrical Connections ................................................................... 14
11.1. Connecting control unit/heater .................................... 14
11.2. Connecting circulation pump ...................................... 14
11.3. Installation and connection of the timer ...................... 14
11.4. Installation of other heater controls ............................ 14
11.5. Vehicle blower ............................................................. 14
12 Wiring diagrams............................................................................ 15
13 Initial start-up................................................................................ 17
14 Technical Data .............................................................................. 18
14.1. Technical Data for Thermo Top Evo.............................. 18
14.2. Technical data of circulation pump............................... 18
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Thermo Top Evo
1
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 corner of the page in question.
Sections in italics contain an excerpt from the Directive ECE-R 122.
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Technical Information
2
1Regulationsgoverning installation
1.1. Statutory regulations governing installation
Type approvals according to ECE-R 10 (EMC) and ECE-R 122 (Heater) exist for
the Thermo Top Evo heater.
See chapter 14, "Technical Data" for the approval number.
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 heaters.
In addition, the operating instructions must also be used.
The provisions of these Directives are binding within the
territory governed by EU Directive 70/156/EEC and/or EC/2007/
46 (binding 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
contained 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
therefore of its homologation/ECE type approval.
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Technical Information
3
2Use/version
2.1. Use of the water heaters
2.1.1. Parking heater
The Thermo Top Evo water heaters were designed for installation in Class M1
motor vehicles. Installation in Class O, N2 and 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.
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
integrated in the vehicle's cooling system, fuel system and electrical system.
2.1.2. Auxiliary heater
The water heater operates 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 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 12 V operation.
See chapter 14, "Technical Data" for the technical design.
Thermo Top Evo 5+ heater versions must not be used for island
coolant system applications.
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Technical Information
4
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
contamination.
(Requirement from ECE-R 122, Point 5.3.2.1.).
The heater shall not constitute a risk of fire, even in the case of overheating.
This requirement shall be deemed to be met if the installation 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 ECE-R 122, Point 5.3.2.2.).
The heater must not be installed in the vehicle interior. 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. This is particularly important as
the circulation pump is not self-priming.
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 14, "Technical Data".
Legend Fig. 2:
21) Heat exchanger inlet
22) Heat exchanger outlet
23) Combustion air inlet
24) Fuel inlet
25) Exhaust outlet
L) Length
B) Width
H) Height
The openings of the heat exchanger may not face downward in
any installation position.
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.
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Technical Information
5
4Typelabel
The label referred to in Annex 7, paragraph 4, or a duplicate, must be
positioned so that it can be easily read when the heater is installed in the
vehicle.
(Requirement from ECE-R 122, Point 5.3.2.4.).
The type label must be located in an area protected against damage.
Inapplicable years must be erased from the type label 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 heaters specific
M5 bolts with 8 Nm.
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 of 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) 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)
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
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Coolant circuit
6
7 Integration in Coolant System
7.1. Connection
The heater is connected to the vehicle coolant system as shown in Fig. 4, 6
and 7. The coolant quantity present must at least be equivalent to the
volume specified in chapter 14, "Technical Data".
It is preferable to integrate the heater in the coolant system at the vehicle
heat exchanger inlet.
Legend Fig. 4:
1) Radiator
4) Combustion engine
7) Circulation pump
10) Water heater
14) Heat exchanger for vehicle heater
28) Expansion tank
29) Thermostat
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
The contact surfaces of the O-rings in the heat exchanger must be clean and
must not be damaged.
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.
Legend Fig. 5:
21) Heat exchanger inlet
22) Heat exchanger outlet
30) Sensor cable
Any coolant running off should be collected using an
appropriate container.
Never mount the retaining plate and the water connection
pieces when the heater has been installed.
See Fig. 8: Installing water connection pieces.
Ensure proper positioning of the sensor cable!
See Fig. 5: Position of sensor cable.
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Coolant circuit
7
7.3. Installing coolant hoses
Ensure the correct direction of flow of the coolant when integrating the
coolant hoses in the coolant circuit. To simplify installation, the coolant
hoses, the water inlet and outlet on the heater and the circulation pump are
marked with white arrow markings.
The clamps on the heat exchanger fittings must be mounted between 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.
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 upward via the
connection piece. Incorrect installation can result in malfunctions of the
circulation pump.
See Fig. 7: U4847 Econ circulation pump.
Also see chapter 11.2, "Connecting 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 pressure
specified by the vehicle manufacturer.
Only spring band clamps approved by Webasto may be used for
the installation of the coolant hoses.
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Fuel
8
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 ECE-R 122, Point 5.3.3.1.).
In the case of liquid fuel heaters, where a supply separate from that of the
vehicle is provided, the type of fuel and its filler point must be clearly
labelled.
(Requirement from ECE-R 122, Point 5.3.3.2.).
The fuel integration is carried out either in the supply or return line, or with
a special fuel standpipe.
8.1. Integration in engine supply or return line
On vehicles with their own fuel feed pump in the fuel tank, the fuel must 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
standpipe.
Legend:
33) from fuel tank
34) to metering pump
35) to engine
8.2. Integration via vehicle's own fuel delivery unit
Also see chapter 6, "Example of Installation in a Passenger Car"
The fuel standpipe is installed in the fuel delivery unit of the fuel tank. See
Fig. 12.
Legend for Fig. 12:
31) Fuel standpipe
32) Vehicle's own fuel delivery 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 delivery unit, ensure
careful routing of the standpipe. This may not impair the operation of the
parts of the fuel delivery unit including the fuel gauge in any operating mode.
The length of the standpipe must be chosen so that a minimum distance of
10 mm over the fuel tank bottom or 20 mm over the bottom of the fuel
delivery unit is ensured.
The specified securing measures of the vehicle manufacturer and the
corresponding torques must be complied with.
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.
Under no circumstances whatsoever may the fuel standpipe be
installed in the fuel tank body, but instead only in the vehicle's
own fuel delivery unit.
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Fuel
9
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.
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 for Fig. 10:
41) Hose clamp
42) Air bubble
Check for leaks!
Only Webasto-approved fastening and connecting parts may be used.
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 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 14, "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
inclination of metering pump, axial installation position of metering pump)
to ensure 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
Do not route fuel lines through the vehicle interior.
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Fuel
10
8.4. Label
A notice, indicating that the heater must be shut down before refuelling,
must be affixed to the fuelling point.
(Requirement from ECE-R 122, Point 5.3.3.3.).
The sticker "Switch off heater when refuelling“ must be applied near the filler
neck.
Use the stickers provided (see Fig. 17 for an example).
8.5. Cold-resistant fuels
If you change to low-temperature fuel, the heater must be operated for
approx. 15 minutes so that fuel line and metering pump are also filled with
the new fuel.
We know of no negative influences due to additives.
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Combustion air
11
9 Combustion air supply
The air for the combustion chamber of the heater must not be drawn from
the passenger compartment of the vehicle.
(Requirement from ECE-R 122, point 5.3.5.1.).
The air inlet must be so positioned or guarded that blocking by rubbish or
luggage is unlikely.
(Requirement from ECE-R 122, point 5.3.5.2.).
See Fig. 13.
9.1. Combustion air pipe
The combustion air intake line can only be used in combination with an
intake silencer.
9.2. Intake silencer
The fuel intake opening must be arranged in such a way that it cannot
become clogged with dirt.
The take-off point for the combustion air must be situated at a location
above the wading depth of the vehicle that is cool and protected against
spray; the installation space must not cause overpressure or underpressure
(e.g. owing to the airstream).
A ventilation opening measuring at least 3 cm2 is required if the intake
opening is installed in an enclosed installation space.
Legend for Fig. 13:
36) Combustion air intake line
37) Combustion-air intake silencer
38) Mounting clip
9.3. Notes on 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
combustion-air intake pipe.
Depending on the installation, the combustion air intake silencer can be
located in a suitable location and secured with the included mounting clip or
other installation materials which utilise the latest technology.
Leaks can result in a higher noise level. Ensure an adequate
distance from the exhaust system to prevent the intake of
exhaust gas!
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Exhaust gas
12
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 1,000 mm.
10.2. Exhaust silencer
It is not permissible to operate the Thermo Top Evo heater without exhaust
silencer.
The exhaust silencer must be installed near the heater and 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.
Fig. 15 shows the exhaust silencer.
10.3. Recommendations for installation
The exhaust silencer and the exhaust pipe may not be fastened to
temperature-sensitive vehicle parts (e.g. brake line, electr. lines, vehicle
control units, headlights, engine undertray, plastic parts, etc.) and there must
be a sufficient distance of at least 20 mm from them.
Only the exhaust pipe approved by Webasto may be used. These must be
sufficiently fixed in place to ensure the minimum distances even during
driving. The approved spacer brackets (see Fig. 14, Pos. 43) must be used for
this purpose. The spacer must be mounted on the exhaust pipe before the
exhaust pipe is installed. It is recommended that the exhaust application be
installed splash-water protected.
To fasten the exhaust line (exhaust outlet), the exhaust-pipe end mounting
device (EFIX, Fig. 14, Pos. 40) must be used in the engine undertray (Fig. 14,
Pos. 39). See the installation instructions of the EFIX exhaust-pipe end
mounting device.
Condensed-water drain holes may not blow onto temperature-sensitive
vehicle parts.
The exhaust outlet must be located so as to prevent emissions from entering
the vehicle through ventilators, heated air inlets or opening windows.
(Requirement from ECE-R 122, 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.
Drill a 2 mm dia. condensed-water drain hole at the lowest
point of the exhaust silencer.
Use approved spacer (see Fig. 14, Pos. 43) and EFIX exhaust-
pipe end mounting device.
The spacer must not be used as an exhaust-pipe end
mounting device in the engine undertray.
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.
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Exhaust gas
13
Point the direction of outflow vertically downward or a maximum of 20°
opposite the direction of travel.
Fig. 14: Exhaust outlet
Legend:
39) Engine undertray
40) Exhaust-pipe end mounting device
43) Spacer
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