Webasto Thermo Top Pro 120 User manual

Operating Instructions
Water Heater
Thermo Top Pro 120 | 150
English

Contents
2 9035350B OI Thermo Top pro 120 _ 150
Contents
1 About this document .......................... 3
1.1 Purpose of the document .......................................... 3
1.2 Using this document.................................................. 3
1.3 Warranty and liability.................................................3
1.4 Use of symbols and highlighting ................................ 3
2 Safety ................................................. 3
2.1 Intended use ............................................................. 3
2.2 General safety information .......................................3
2.3 Regulations and legal requirements ........................... 4
3 Operation ........................................... 4
3.1 Control elements .......................................................4
3.2 Setting up a vehicle heating system ........................... 4
3.3 Switch the heater on and off .....................................4
3.4 Heater operation ....................................................... 5
3.5 Using the heater in hazardous material vehicles (ADR)
................................................................................. 5
3.6 Switching the heater on after automatic switch-off ... 5
3.7 Use of residual heat ..................................................5
4 Fuel..................................................... 5
4.1 Converting from operation with summer diesel to
winter diesel..............................................................5
5 Coolant ............................................... 5
6 Combustion air ...................................5
7 Exhaust............................................... 5
8 Cleaning .............................................5
9 Malfunctions ...................................... 5
10 Service signal...................................... 6
11 Maintenance....................................... 6
12 Disposal end of live.............................6
13 Service and customer services ............6
14 Declarations of conformity ................. 7
15 Type testing and approvals................. 9

About this document | 1
9035350B OI Thermo Top pro 120 _ 150 3 / 10
1 About this document
1.1 Purpose of the document
These operating instructions provide the user with information
on the safe operation of the Thermo Top Pro 120 | 150.
NOTE
The actual availability of these functions depends on
each installed heater.
NOTE
Carefully read through and follow the heater operating
instructions and the safety information contained
therein.
1.2 Using this document
üBefore operating the Thermo Top Pro 120 | 150, carefully
read these operating instructions as well as the operating
instructions for the control element.
üHand these operating instructions on to the following
owner or user of the Thermo Top Pro 120 | 150.
To access further documents use one of the following options:
The Webasto Dealer Portal
(https://dealers.webasto.com)
Webasto Service app (for installation)
To download this app:
uscan the QR code below or
ugo to:
https://apps.apple.com/ (Apple App Store) or
https://play.google.com/ (Google Play Store) as appropri-
ate.
To use the Webasto Service App and access the online Webasto
technical documentation, scan the QR code or the barcode on
your Webasto product box.
Operating instructions are also available from the Webasto
website at www.webasto.com. These instructions are available
in a variety of other national languages on the Webasto web-
site.
1.3 Warranty and liability
Webasto shall not assume liability for defects or damages that
are the result of disregarding the installation and operating in-
structions. This liability exclusion particularly applies to:
lInstallation or maintenance by untrained personnel.
lImproper use.
lRepairs not carried out by a Webasto service workshop.
lUse of non-genuine parts.
lConversion of the unit without permission from Webasto.
lMechanical damage to the equipment.
lFailure to comply with service instructions.
DANGER
Always switch off the heater before refuelling.
1.4 Use of symbols and highlighting
DANGER
This signal word denotes a hazard with a high degree
of risk which, if not avoided, may lead to death or seri-
ous injury.
WARNING
This signal word denotes a hazard with a moderate de-
gree of risk which, if not avoided, may lead to minor or
moderate injury.
CAUTION
This signal word denotes a hazard with a low degree of
risk which, if not avoided, will lead to minor or moder-
ate injury.
NOTE
This signal word denotes a Special Technical Feature or
(if not observed) potential damage to the product.
Refers to separate documents which are enclosed or
can be requested from Webasto.
Requirements for the following necessary action
2 Safety
2.1 Intended use
The heater Thermo Top Pro 120 | 150 is approved for the fol-
lowing applications:
lTrucks, buses in vehicle classes M, N and O.
See also: https://ec.europa.eu/growth/sectors/automot-
ive/vehicle-categories_en.
lConstruction machines
lAgriculture and forestry machines
lEarth-moving machinery
lIndustrial trucks
lCaravans, motor homes, boats, pleasure craft
lVehicles that can be used in residential, commercial, light-
industrial and industrial environments
2.2 General safety information
2.2.1 Safety information on operation
DANGER
Danger of explosion
In environments with combustible vapours, flammable
dust and hazardous goods (e.g., petrol stations, tank fa-
cilities, fuel store, coal bunkers, timber yard or grain
warehouses).
uDo not switch on or operate the heater.
WARNING
Danger of explosion and suffocation
Do not operate the heater:
uat filling stations and tank facilities.
uat locations where highly flammable gases or dust
can form, or at locations where highly flammable li-
quids or solid materials are stored (e.g. near fuel,
coal and wood dust, grain storage areas, dry grass
and leaves, cardboard boxes, paper, etc.).
uin closed rooms such as garages that do not have an
exhaust extraction unit, especially not with pro-
grammed heating start (time preselect or remote
start).

3 | Operation
4 / 10 9035350B OI Thermo Top pro 120 _ 150
NOTE
Use suitable Webasto control elements approved for
use with the heater.
2.2.2 Avoiding damage to property
NOTE
Incorrect handling
uProtect the heater against mechanical stress (e.g.
dropping, impacts or knocks).
uDo not stand on the heater.
uDo not place any objects on top of the heater.
uAvoid shutting down the heater incorrectly during
the after-running period. After switching off via the
control element, the fan of the heater continues to
run.
uAlways switch off the heater via the control ele-
ment.
uDo not disconnect from the power supply until the
after-running period has elapsed.
DANGER
Risk of injury from the defective unit
Do not operate a defective Thermo Top Pro 120 | 150
and put it out of service by removing the fuse:
- prolonged heavy smoke development.
- unusual burner noise.
- smell of fuel.
- permanent fault switch-offs with error messages (flash
code).
- damaged heater.
uContact a Webasto service workshop.
DANGER
Risk of explosion from explosive and flammable
hazardous goods
For hazardous material vehicles, restriction of the
heater operation (ADR) is required to prevent severe
burns.
uDo not operate the heater at hazardous material
loading points.
uDo not operate the heater when loading and un-
loading hazardous materials.
NOTE
After switching off via the control element, the heater
switches to a short controlled run-on phase. Switching
off incorrectly, without after-run, can cause damage to
the Thermo Top Pro 120 | 150.
uAlways switch off the Thermo Top Pro 120 | 150 via
the control element.
NOTE
After switching off via the control element, the fan of
the heater continues to run (shortened to 40 s for ADR).
Switching off incorrectly, without after-run, can cause
damage to the Thermo Top Pro 120 | 150.
uAlways switch off the heater via the control ele-
ment.
uThe use of programmable control elements in ADR
vehicles is not permitted.
NOTE
The heater is not approved for the purpose of directly
heating the cargo area of ADR vehicles (hazardous sub-
stance transportation).
2.3 Regulations and legal requirements
üRegulations in the Installation Instructions must be ob-
served.
3 Operation
NOTE
Hazardous material vehicles (ADR) must not be
switched on or off using a timer control or remote con-
trol.
Observe additional requirements from the operating
and installation instructions for the Thermo Top Pro 120
| 150 and the control element.
3.1 Control elements
The Thermo Top Pro 120 | 150 can be fitted with various con-
trol elements:
2
3
Fig.1
1 Rocker switch
2 MultiControl or SmartControl
3 ThermoCall TC4
A combination of control elements is also possible.
üObserve the Operating instructions for the control element.
3.2 Setting up a vehicle heating system
NOTE
Depending on the type of vehicle, the air-conditioning
system can perform these settings automatically or
partly autonomously. Ask your specialist dealer to ex-
plain the optimum settings.
1. Before switching on the heater (with the ignition on), set
the vehicle heating system to “warm”.
2. Set the vehicle fan to the lowest setting (lower power con-
sumption).
3.3 Switch the heater on and off
The heater is switched on and off by different switch signals.
Depending on the system equipment, the switch signals are
produced by a switch, control element or a climate control sys-
tem.
DANGER
Danger of explosion and suffocation
For ADR vehicles: The heater must only be switched on
manually via a switch. The heater must not be switched
on automatically via a programmable switch.

Fuel | 4
9035350B OI Thermo Top pro 120 _ 150 5 / 10
DANGER
Overheating possible
An emergency off switch may only be actuated in the
event of danger since the heater will be switched off
without after-running period.
NOTE
Always switch off the heater via the control ele-
ment
After switching off via the control element, the heater
switches to a short controlled run-on phase. Switching
off incorrectly, without after-run, can cause damage to
the heater.
3.4 Heater operation
The coolant temperature is controlled automatically throughout
operation. The heater can also be switched on while travelling.
The vehicle blower is only switched on when the coolant tem-
perature is at around 30°C, avoiding unnecessary energy con-
sumption. The vehicle blower can thus be started with a time
delay, depending on the temperature. When switching off the
heater, a cooling afterrunning period is initiated; this can last up
to 60 seconds.
3.5 Using the heater in hazardous
material vehicles (ADR)
It is not possible to set a preselection time in hazardous material
vehicles (ADR). The SmartControl (if present) shows how much
heater operation time is left (remaining operation time).
NOTE
An ADR after-running period is applied in the fol-
lowing cases:
- the generator signal (D+, light machine) is discontin-
ued.
- the pumping device (auxiliary drive) belonging to the
vehicle is put into operation.
After the end of the ADR after-running period, the
heater is in ADR locking mode.
NOTE
Release ADR lock:
uPut the pumping device belonging to the vehicle out
of operation.
uRestart the heater by switching it off and on again
using the control element.
3.6 Switching the heater on after
automatic switch-off
NOTE
Possible loss of heating function
Following an automatic switch-off, the heater may
need to be manually switched back on. The heater can
be restarted by switching it off and on again using the
control element.
3.7 Use of residual heat
Activation
Use of residual heat is only activated when the heater is
switched on. This is a fully automatic function that is activated
when the engine is warm; it is used to conserve energy. Every
time it is switched on, the heater checks the coolant temperat-
ure before starting the heating process. If the coolant temperat-
ure is above a limit value, residual heat utilisation is activated
automatically. When use of residual heat is activated, the
coolant pump for the heater and the vehicle blower are auto-
matically actuated.
Deactivation
Deactivation of the use of residual heat is carried out automatic-
ally by the heater control unit.
4 Fuel
The heater is connected to the fuel tank of the vehicle or to a
separate fuel tank.
Suitable fuels:
lThermo Top Pro 120 | 150 D: Diesel DIN EN 590; biodiesel
DIN EN 14214 and HVO DIN EN 15940
lThermo Top Pro 120 | 150 B: Petrol DIN EN 228
4.1 Converting from operation with
summer diesel to winter diesel
üThe tank is filled up with winter diesel (cold-resistant fuel).
However, the fuel system for the heater may still contain
residues of summer diesel.
uSwitch on the heater for approx. 15 minutes (the fuel sys-
tem is completely filled with cold-resistant fuel).
5 Coolant
Overheating caused by insufficient coolant or de-
fective coolant flow
uCheck coolant system (heater and vehicle).
uContact a Webasto service workshop.
6 Combustion air
DANGER
Danger of fire
Flammable materials or liquids in the hot air flow.
uKeep the hot air flow free
7 Exhaust
WARNING
Blockages
Check combustion air and exhaust system for block-
ages.
A blocked exhaust system or combustion air system can
cause unsafe status of the heater!
8 Cleaning
Carefully clean the heater using water and a cleaning agent suit-
able for cleaning vehicles.
NOTE
Do not clean the Thermo Top Pro 120 | 150 with a
high-pressure cleaner.
9 Malfunctions
A malfunction is indicated by means of a flash code or on the
control element display:
lOn control elements with display, the fault codes F01 to
F15 are output via the display. The fault codes F16 to F19
are shown with “- -”.
lOn control elements without a display (analogue), the fault
code is indicated in the form of a flash pulse. The pulses are
short or long. The number of long pulses corresponds to
the number of the fault code. F00 is just rapid flashing.

10 | Service signal
6 / 10 9035350B OI Thermo Top pro 120 _ 150
lIn event of an error occurring, check the fuse and plug con-
nectors.
lIf the fault cannot be rectified by the measure described,
contact your Webasto service workshop.
NOTE
Independent maintenance work, particularly using flam-
mable gases or liquids such as accelerators, is forbid-
den.
Code Hex code Possible cause Action
F01 H02 /
H4E / H82
No start Switching the
heater off and on
F02 H03 Flame goes out during
operation
F03 H04 / H84 On-board power sup-
ply too low / under-
voltage or overvoltage
lCharge the
vehicle battery.
lSwitching the
heater off and
on.
F10 H06 Heater overheats lCheck coolant
level.
lSwitch off
heater.
lAllow the
heater to cool
down.
lSwitch on the
heater.
- - On vehicles for trans-
porting hazardous
goods: Vehicle engine
switched off / pump-
ing device in opera-
tion
lMake sure that
the pumping
device is out of
operation.
lWait until the
heater switches
to fault lock-
out.
lSwitch off the
heater via the
control ele-
ment.
lSwitch the
heater on via
the control ele-
ment.
- - Heater produces black smoke
- - Combustion air and
exhaust gas guiding
blocked
Check combustion
air and exhaust gas
routing for free pas-
sage.
In case of any other error messages not listed, contact
the Webasto service workshop.
10 Service signal
In the event of service information, the service signal is shown
via the control element when the heater is switched on.
lIn the case of the MultiControl / SmartControl control ele-
ment, a service symbol is displayed.
lOn control elements without display: indicator lamp flashes
for 60s: on for 1 s, off for 1 s.
uHave the heater checked by a professional.
The heater can continue to be used with limited operation.
11 Maintenance
lPut the heater into operation every 4 weeks in order to pre-
vent mechanical parts from seizing.
lAt the beginning of the heating period, have the heater
checked by a professional.
12 Disposal end of live
The Thermo Top Pro 120 | 150 must not be disposed of in do-
mestic waste.
lObserve the regional regulations for disposal of electronic
products.
13 Service and customer
services
Do you have any technical questions or problem with the
device?
National phone numbers of our representatives are provided
on:
https://www.webasto-group.com/en/the-company/loca-
tions-worldwide/

Declarations of conformity | 14
9035350B OI Thermo Top pro 120 _ 150 7 / 10
14 Declarations of conformity

14 | Declarations of conformity
8 / 10 9035350B OI Thermo Top pro 120 _ 150

Type testing and approvals | 15
9035350B OI Thermo Top pro 120 _ 150 9 / 10
15 Type testing and approvals
Typgenehmigung Thermo Pro 120
Typgenehmigung Thermo Pro 150

Ident No. 9035350B • 09/2022 • Errors and omissions excepted • © Webasto Thermo & Comfort SE
To request this documentation in another language, please locate and contact your local Webasto dealer. You can find
your nearest dealer at: https://dealerlocator.webasto.com/en-int.
To provide feedback (in English or German), please email: [email protected]
www.webasto.com
9035350B
Europe, Asia Pacific:
Webasto Thermo & Comfort SE
Postfach 1410
82199 Gilching
Germany
Company address:
Friedrichshafener Str. 9
82205 Gilching
Germany
UK only:
Webasto Thermo & Comfort UK Ltd
Webasto House
White Rose Way
Doncaster Carr
South Yorkshire
DN4 5JH
United Kingdom
Technical website: https://dealers.webasto.com
Only within Germany
Tel: [phone]
Mail: [email protected]