Webasto Thermo Top Z User manual

Wasserheizgeräte
Water heaters
Verwarmingsapparaat
Chauffages à eau
Riscaldori ad acqua
Vattenwärmeaggregat
02/2003
Einbauanweisung
Installation instructions
Inbouw handleiding
Notice de montage
Istruzioni di montaggio
Monteringsanvisning
Thermo Top Z
Aufrüstung zur Standheizung
Upgrade to auxiliary heating system
Montageset voor parkeerverwarming
Kit d'extension pour chauffage auxiliaire
Montaggio integrativo per il riscaldamento
supplementare a vettura ferma
Eftermontering till kupévärmare
Thermo Top C
Thermo Top C - D Diesel/diesel
Thermo Top C - B Benzin/Petrol/Benzine/Essence/Benzina/bensin
Thermo Top C PME(Biodiesel)/PME(biodiesel)/PME(esterebimetile
a base di olio vegetale) (biodiesel)
TTopZC_Titel_.fm Seite I Montag, 3. Februar 2003 11:13 11

Inhaltsverzeichnis
1 Bestimmungen für den Einbau . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Verwendung / Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Einbauort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Typschild (nur Zuheizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Halter (nur Zuheizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Einbaubeispiel in PKW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Anschluss an das Kühlsystem des Fahrzeuges . . . . . . . . . . . 9
8 Brennstoffeinbindung (nur Zuheizer) . . . . . . . . . . . . . . . . . . . 11
9 Brennluftversorgung (nur Zuheizer) . . . . . . . . . . . . . . . . . . . . 15
10 Abgasleitung (nur Zuheizer) . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11 Elektrische Anschlüsse (Zuheizer) . . . . . . . . . . . . . . . . . . . . . 17
12 Schaltpläne (Zuheizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13 Elektrische Anschlüsse (Nachrüstung) . . . . . . . . . . . . . . . . . . 20
14 Schaltpläne (Nachrüstung) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
15 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16 Störungen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
17 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Contents
1 Regulations governing installation . . . . . . . . . . . . . . . . . . . . . .29
2 Use / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4 Model plate (additional heater only) . . . . . . . . . . . . . . . . . . . . .34
5 Bracket (additional heater only) . . . . . . . . . . . . . . . . . . . . . . . .35
6 Installation example in a car . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7 Connection to the vehicle cooling system . . . . . . . . . . . . . . . .37
8 Fuel system integration (additional heater only) . . . . . . . . . . . .39
9 Combustion air supply (additional heater only) . . . . . . . . . . . .43
10 Exhaust pipe (additional heater only) . . . . . . . . . . . . . . . . . . . .44
11 Electrical connections (additional heater) . . . . . . . . . . . . . . . . .45
12 Circuit diagrams (additional heater) . . . . . . . . . . . . . . . . . . . . . 46
13 Electrical connections (retrofit) . . . . . . . . . . . . . . . . . . . . . . . . . 48
14 Circuit diagrams (retrofit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15 Starting the heater for the first time . . . . . . . . . . . . . . . . . . . . .52
16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
III
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Thermo Top Z / Thermo Top C Regulations governing installation
29
1 Regulations governing installation
1.1. Statutory regulations governing installation
The Thermo Top Z and Thermo Top C heaters have been type-tested
and approved in accordance with EC Directives 72/245/EEC (EMC) and
2001/56/EC (heater) with the following EC permit numbers:
e1* 72/245*95/54*1232*--
e1*2001/56*0002*--
Installation is governed above all by the provisions in Annex VII of
Directive 2001/56/EC.
NOTE:
The provisions of these Directives are binding within the territory
governed by EU Directive 70/156/EEC and should similarly be
observed in countries without specific regulations.
(Extract from Directive 2001/56/EC Annex VII)
1.7.1. A clearly visible indicator within the user's field of vision must
show when the heater is switched on or off.
2. Regulations for installation in the vehicle
2.1. Scope
2.1.1. Subject to the provisions of paragraph 2.1.2, internal combustion
heaters must be installed in accordance with the requirements contained
in this Annex.
2.1.2. In the case of class O vehicles of class O ( trailers ) with heaters for
liquid fuel, it is presumed that these vehicles comply with the requirements
in this Annex.
2.2. Position of the heater
2.2.1.
Parts of the vehicle body and other components in the immediate
vicinity of the heater must be protected against excessive heat and the
danger of contamination by fuel or oil.
2.2.2. The internal combustion heater must not pose a fire hazard even
when overheated. This requirement is deemed to have been met if care
is taken during installation to ensure an adequate distance from all parts,
as well as adequate ventilation and if fire-resistant materials or heat
shields are used.
2.2.3. In class M2 and M3 vehicles the heater must not be installed in
the passenger cabin. A device in a sealed cover, which also meets the
requirements set out in paragraph 2.2.2, may be used, however.
2.2.4. The plate mentioned in paragraph 1.4 ( model plate ) or a duplicate
thereof (
duplicate model plate ) must be fitted in such a way that it is still
clearly legible when the heater has been installed in the vehicle.
2.2.5. When positioning the heater, all reasonable precautions must be
taken to minimise the risk of personal injury or damage to items in the
vehicle.
2.3. Fuel supply
2.3.1.
The fuel filler neck must not be located in the passenger compart-
ment and must have a tightly fitting cap to prevent any fuel leaks.
2.3.2. The type of fuel and the fuel filler neck must be clearly identified
on heaters for liquid fuel, for which the fuel supply is separate from the
fuel supply for the vehicle.
2.3.3. A sign must be affixed to the fuel filler neck warning that theheater
must be switched off before refuelling. An identical warning must also be
included in the manufacturer's operating instructions.
2.4. Exhaust system
2.4.1.
The exhaust outlet must be positioned in such a way that exhaust
fumes cannot get into the interior of the vehicle through ventilation
devices, hot-air inlets or open windows.
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Regulations governing installation Thermo Top Z / Thermo Top C
30
2.5. Combustion air inlet
2.5.1.
The air for the combustion chamber of the heater must not be
extracted from the passenger cabin of the vehicle.
2.5.2. The air inlet must be positioned in such a way that it cannot be
obstructed by other objects.
2.6. Hot air inlet
2.6.1.
The supply of heating air must consist of either fresh air or
recirculated air and must be taken from a clean area which cannot be
contaminated by exhaust fumes from the engine, the internal
combustion heater or any other source in the vehicle.
2.6.2. The inlet line must be protected by a grating or other suitable
means.
2.7. Hot air outlet
2.7.1.
Hot air lines within the vehicle must be positioned or protected in
such a way as to exclude all risk of injury or damage caused by direct
contact.
2.7.2. The air outlet must be positioned or protected so that it cannot be
obstructed by other objects.
2.8. Automatic control of the heating system
When the engine stops, the heating system must cut out automatically
and the fuel supply must be stopped within 5 seconds.
The heating system may remain in operation if a manual unit has
already been activated.
IMPORTANT
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 withthe 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.
NOTE:
Contrary to point 2.2.3 the heater must also not be installed in the
passenger cabin of class M1 and N vehicles. A device in asealed cover,
which also meets the requirements set out in paragraph 2.2.2, may be
used, however.
1.2. General regulations
1.2.1. Exhaust
Exhaust pipes must be positioned at an adequate distance (at least
20 mm) from heat-sensitive vehicle parts (underseal, plastics parts, etc.).
1.2.2. Fuel lines
The fuel line must be installed in cool areas to prevent the formation of
bubbles due to heating.
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Thermo Top Z / Thermo Top C Use / version
31
2 Use / version
2.1. Use of the water heaters
The
Thermo Top C water heater is designed for use as an auxiliary
heating system in conjunction with the vehicle’s own heating system
– to heat the passenger cabin
– to defrost the vehicle windows
– to preheat water-cooled engines and
– to compensate for the heat deficit in engines with optimised fuel
consumption.
The
Thermo Top Z water heater is designed for use as an additional
heating system in conjunction with the vehicle’s own heating system
– to compensate for the heat deficit in engines with optimised fuel
consumption.
If the vehicle’s engine is not running the water heater auxiliary heating
system operates independently of the vehicle’s engine.
If the vehicle’s engine is running the water heater auxiliary heating
system and the additional heater supply heat to specific areas.
The water heater is connected to the vehicle’s cooling system, fuel
system and electrical system.
2.2. Version
Type
Thermo Top Z
Water heater for “diesel” or “PME”
Type
Thermo Top Z
Water heater for “petrol”
Type
Thermo Top C
Water heater for “diesel” or “PME”
Type
Thermo Top C
Water heater for “petrol”
The Thermo Top Z / Thermo Top Z water heater is designed for 12V
operation.
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Installation location Thermo Top Z / Thermo Top C
32
3 Installation location
The water heater must be installed outside the passenger cabin.
The heaters should ideally be installed in the engine compartment in a
splash-proof area of the front wing or on the bulkhead.
The heaters must be installed in as low a position as possible to allow
the heater and circulating pump to be bled automatically. This is
particularly important as the circulating pump is not self-priming.
IMPORTANT
The openings in the water ports must not point downwards in any
installation location.
IMPORTANT
The heaters must not be installed:
– in the immediate vicinity of or above hot parts,
– in areas directly exposed to splashing water from the wheels,
– below the water clearance level line of the vehicle.
Fig. 1: Installation positions
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Thermo Top Z / Thermo Top C Installation location
33
Fig. 2: Thermo Top Z / Thermo Top C installation drawing
1 Circulating pump (optional with the Thermo Top Z)
2 Fuel filler neck
3 Water outlet port
4 Exhaust outlet port
5 Combustion air inlet
6 Water inlet port
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Model plate (additional heater only) Thermo Top Z / Thermo Top C
34
4 Model plate (additional heater only)
The model plate must be positioned so that it cannot be damaged
and must be clearly legible when the heater is installed (otherwise
a duplicate model plate must be used).
Inapplicable years must be erased from the model plate.
Fig. 3: Model plate
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Thermo Top Z / Thermo Top C Bracket (additional heater only)
35
5 Bracket (additional heater only)
The bracket must be secured to the car body or an intermediate bracket
with at least four M6 screws.
Washers and spring rings must be used.
Washers with a minimum diameter of 22 mm must be used if the body
surfaces are flat.
The bracket must not be secured to the car body with self-tapping
screws.
The holder must be correctly machined in compliance with the minimum
bending radii and in accordance with general technical regulations.
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Installation example in a car Thermo Top Z / Thermo Top C
36
6 Installation example in a car
Fig. 4: Installation example for a Thermo Top Z / Thermo Top C heater in a car
1 Radiator
2 Cooling water thermostat
3 Water pump (for the car engine)
4 Car engine with standard equipment
5 Water heater
6Battery
7 Fuse holder
* Supplied in the upgrade kit
8 Control module (in the heater)
9 Relay (for the car’s fan) *
10 Regulating valve for car’s heating system
11 Heat exchanger, car’s heating system
12 Fan for car’s heating system
13 Switch for car’s heating system fan
14 Fuse strip in the car
15 Timer
16 Fuel extractor
17 Intake silencer,
combustion air intake line
18 Exhaust silencer
19 Circulating pump (additional heater only) *
20 Fuel metering pump
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Thermo Top Z / Thermo Top C Connection to the vehicle cooling system
37
7 Connection to the vehicle cooling system
The heaters are connected to the vehicle cooling system as shown in
Figures 4, 5 and 6. The system must contain at least 4 litres of coolant.
The heater must be integrated into the cooling system in the feed line to
the vehicle’s heat exchanger.
NOTE:
Leaking cooling water must be collected in a suitable container.
The water hoses supplied by Webasto must always be used. If you do
not use these hoses, the hoses that you do use must comply with
DIN 73411. The hoses must be installed without kinks and (to ensure
perfectbleeding)risingif possible.Hose connections must be supported
by hose clips to prevent them slipping.
NOTE:
The hose clips on the heater must be fitted between the flared neck and
the heater.
The hose clips must be tightened with a torque of 2.0 + 0.5 Nm.
The cooling system must be bled carefully before using the heater for
the first time or after replacing the coolant. The heater and lines should
be installed in such a way as to ensure static bleeding.
Poor bleeding may cause malfunctions due to overheating whilst the
heater is operating.
Fig. 5: Installation in engine’s water system “inline integration”
ϑ
1 Expansion tank
2 Thermostat
3 Engine
4 Circulating pump
5Heater
6 Heating system
heat exchanger
7Radiator
723
1
6
45
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Connection to the vehicle cooling system Thermo Top Z / Thermo Top C
38
7.1. To retrofit the circulating pump (retrofitting only)
Make the electrical connection as shown on the circuit diagram. The
circulating pump may be installed either on the space available for it on
the heater or in the water system away from the heater.
Ensure that that water passes through the heater correctly (water outlet
at the top / water inlet at the bottom) (otherwise it will malfunction).
Fig. 6: Circulating pump U4847
Installation positions
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Thermo Top Z / Thermo Top C Fuel system integration (additional heater only)
39
8 Fuel system integration (additional heater only)
8.1. Fuel supply
The values for the maximum pressure at the fuel extraction point are
shown in the table below.
NOTE
A fuel feed line can normally be identified by the fact that a fuel filter is
installed in it.
Fuel may only be taken from the return line using the special Webasto
fuel extractor (see Figure 8).
The fuel extractor must be fitted in such a way that any air or gas
bubbles are automatically discharged towards the tank (see Figure 8).
Air or gas bubbles may be produced in the vehicle’s fuel line if there
are leaks in the carburettor or vehicle fuel pump or if the ambient
temperature is higher than the evaporation temperature of the fuel.
Maximum fuel feed height H
(m) At max. pressure (bar) in fuel line l1
0,00 0,2
1,00 0,11
Maximum fuel intake height S
(m) At max. negative pressure (bar) in the fuel tank
0,00 -0,10
0,50 -0,06
1,00 -0,02
Fig. 7: Fuel supply
l1+ l2≤7 m
l1≤1.2 m
l2≤5.8 m
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Fuel system integration (additional heater only) Thermo Top Z / Thermo Top C
40
The fuel extractor should not be located near the engine, as gas bubbles
may form in the lines on account of heat radiated from the engine. This
may cause problems during combustion.
When installing the heater in a vehicle with fuel injection system, it is
therefore important to establish whether the fuel pump is located inside
or outside the tank.
If thefuel pump is located inside thetank, fuel canonly be extracted from
the return line. In this case it must be ensured that the return line
continues almost to the bottom of the tank. If this is not the case the
return line may be extended.
8.2. Fuel lines
NOTE:
The hose clips must be tightened with a torque of 1.0 + 0.4 Nm.
Leaked fuel must be removed before the engine or heater is started.
Only steel, copper and plastic lines of plasticised, light and temperature-
stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378
may be used for the fuel lines.
Sincethelinesnormallycannotbe routed withaconstantrising gradient,
the internal diameter must not be allowed to exceed a certain size. Air
or gas bubbles will accumulate in lines with an internal diameter of more
than 4 mm and these will cause malfunctions if the lines sag or are
routed downwards. The diameters specified in Figure 7 will ensure that
bubbles do not form.
The lines should not be routed downwards from the metering pump to
the heater.
Unsupported fuel lines must be secured to prevent them sagging. They
must be installed in such a way that they cannot be damaged by flying
road chippings and high temperatures (exhaust line).
Fig. 8: Webasto fuel extractor
to metering pump
to engine
from tank
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Thermo Top Z / Thermo Top C Fuel system integration (additional heater only)
41
8.3. Connecting two pipes with a hose
The correct procedure for connecting fuel lines with hosing is shown in
Figure 9.
Ensure that there are no leaks.
8.4. Metering pump
The metering pump is a combined delivery, metering and shut-off
system and is subject to certain installation criteria (see Figures 7, 10
and 11).
Fig. 9: Pipe / hose connection
Clip
Bubble
Correct
Wrong
Bubble
Fig. 10: Metering pump DP 2
Installation position and attachment
Fig. 11: Metering pump DP 30
Installation position
Preferably
15° - 90°
Part No. 876 84 . = Diesel
Part No. 893 72 . = For all fuels
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Fuel system integration (additional heater only) Thermo Top Z / Thermo Top C
42
8.4.1. Installation location
Before installing the metering pump ensure that the maximum pressure
at the extraction point is less than the maximum value shown in the table
on page 39.
It is advisable to install the metering pump in a cool place. The maximum
ambient temperature must not exceed +20 °C at any time during
operation.
The metering pump and fuel lines must not be installed within range of
the radiated heat from hot vehicle parts. A heat shield must be used if
necessary.
The pump should ideally be installed near the tank.
8.4.2. Installation and attachment
The metering pump must be secured with a vibration-damping
mounting. Its installation position is limited as shown in Figures 10
and 11 in order to ensure effective automatic bleeding.
8.5. Sticker
The sticker "Switch off heater before refuelling" must be affixed at a
suitable point.
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Thermo Top Z / Thermo Top C Combustion air supply (additional heater only)
43
9 Combustion air supply (additional heater only)
The intake opening for combustion air must be located so that it cannot
become clogged with dirt. It must not point towards the front of the car.
A combustion air intake line is required.
The extraction point for the combustion air must be located in a cool
(temperature ≤20 °C) place where it is protected from splashing water
and above the vehicle’s water clearance level.
Under no circumstances may the combustion air be taken from areas
occupied by people. A ventilation opening measuring at least 3 cm2is
required if the heater is installed in an enclosed box.
If the heater is installed in a general installation space near the vehicle’s
fuel tank, the combustion air must be taken in from the outside and the
exhaust fumes discharged into the atmosphere. The openings must be
splash-proof.
9.1. Air intake silencer
The air intake silencer must beinstalled in a position between 0° and 90°
pointing downwards.
Installation instructions
Connect the slotted side (approx. 18 mm) of the combustion air intake
line, max. 400 mm long, to the air intake port on the heater and secure
it with the hose clip supplied.
Turn the air intake silencer as far as possible into the unslotted end of
the air intake line (it does not need any additional fastening with a hose
clip).
IMPORTANT
Ensure that it is an adequate distance from the exhaust system.
Depending on the installation situation, the air intake silencer must be
secured at a suitable point with the enclosed mounting clip or cable ties.
9.1.1. To secure the air intake silencer with the mounting clip
– Drill a hole with a diameter of 6.5 mm at a suitable point.
– Press the mounting clip into the hole.
– Fit the air intake silencer in the mounting clip.
Fig. 12: Air intake silencer
Installation position
0-90°0-90°
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Exhaust pipe (additional heater only) Thermo Top Z / Thermo Top C
44
10 Exhaust pipe (additional heater only)
The exhaust pipe (internal diameter 22 mm) can be installed with
several bends (270° altogether, minimum bending radius 50 mm).
The total length of the exhaust pipe must be not less than 500 mm.
The maximum length is 1000 mm.
The exhaust silencer should ideally be installed near the heater, but at
least 200 mm away from it.
The exhaust silencer must not be installed near the combustion air
intake opening.
The exhaust silencer and exhaust pipe must not be secured to heat-
sensitive parts of the vehicle and must be kept at an adequate distance
of at least 20 mm from it.
The opening of the exhaust pipe must move freely and must not be
directed towards any part of the vehicle. The exhaust pipe opening must
remain at an adequate distance (≥0.2 m) from the ground.
The Thermo Top Z/C heater must not be operated without the silencer.
The opening of the exhaust pipe must not point towards the front of the
vehicle (see Figure 14).
Only rigid pipes made of unalloyed steel with a minimum wall thickness
of 1.0 mm or flexible piping made of alloyed steel may be used for the
exhaust pipe.
NOTE:
Condensate accumulations in the exhaust pipe must be discharged
immediately. A condensate drain hole may be drilled if necessary.
Fig. 13: Exhaust silencer
Arbitrary flow direction
Fig. 14: Exhaust pipe opening
Installation position
Discharge direction almost vertical 90° ±10°
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Thermo Top Z / Thermo Top C Electrical connections (additional heater)
45
11 Electrical connections (additional heater)
11.1. Control module / heater connection
Make the electrical connections to the heater as shown in Figure 16.
Fig. 15: Electrical connections for the Thermo Top Z additional heater
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Circuit diagrams (additional heater) Thermo Top Z / Thermo Top C
46
12 Circuit diagrams (additional heater)
12.1. Legend for circuit diagrams
➀Diagnostic
➁External temperature
➂Cooling water
➃Vehicle fan fuse fitted in the vehicle
Cable colours
bl
br
ge
gn
gr
or
rt
sw
vi
ws
blue
brown
yellow
green
grey
orange
red
black
violet
white
Cable cross-sections
< 7.5 m 7.5 - 15 m
0.5 mm20.75 mm2
0.75 mm21.5 mm2
1.0 mm21.5 mm2
1.5 mm22.5 mm2
2.5 mm24.0 mm2
4.0 mm26.0 mm2
Item Designation Comment
A1 Heater Thermo Top Z/C
A2 Control module
A3 Connection box
B2 Temperature sensor
E Glow plug / Flame monitor
F1 20 A fuse Blade-type fuse DIN 72581 Part 3
F2 5 A fuse Blade-type fuse DIN 72581 Part 3
F3 25 A fuse Blade-type fuse DIN 72581 Part 3
H1 LED (in item P) Switch-on indicator
K3 Relay (in item A3) Vehicle fan
M1 Motor Combustion air fan
M2 Motor Circulating pump
M3 Motor Vehicle fan
P Timer, digital For programmed operation
S1 Switch for vehicle fan S1 or S2 depending on vehicle
S2 Switch for vehicle fan S1 or S2 depending on vehicle
S6 Switch ON/OFF
X9 Plug connector, 4-pin
X11 Plug connector, 2-pin
X13 Plug connector, 2-pin
X14 Plug connector, 6-pin Water-repellent
X15 Plug connector, 2-pin Water-repellent
X16 Plug connector, 2-pin Water-repellent
X17 Plug connector, 2-pin Water-repellent
X18 Plug connector, 2-pin Water-repellent
X19 Plug connector, 2-pin Water-repellent
Y1 Metering pump
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