Webasto Thermo Top Z Installation Instructions Manual

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Installation instructions manual (30 pages)

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Page 1 Chauffages à eau Notice de montage Riscaldori ad acqua Istruzioni di montaggio Vattenwärmeaggregat 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...
Page 2: Table Of Contents
TZea_e.IVZ.fm Seite 1 Montag, 3. Februar 2003 2:08 14 Inhaltsverzeichnis Contents 1 Bestimmungen für den Einbau ......1 1 Regulations governing installation .
Page 3: Regulations Governing Installation
2.2.2. The internal combustion heater must not pose a fire hazard even 1.1. Statutory regulations governing installation The Thermo Top Z and Thermo Top C heaters have been type-tested when overheated. This requirement is deemed to have been met if care and approved in accordance with EC Directives 72/245/EEC (EMC) and...
Page 4 Failure to follow the installation instructions and the notes contained 2.5.1. The air for the combustion chamber of the heater must not be therein will lead to all liability being refused by Webasto The same extracted from the passenger cabin of the vehicle.
Page 5: Use / Version
If the vehicle’s engine is not running the water heater auxiliary heating system operates independently of the vehicle’s engine. The Thermo Top Z / Thermo Top Z water heater is designed for 12V operation. If the vehicle’s engine is running the water heater auxiliary heating system and the additional heater supply heat to specific areas.
Page 6: Installation Location
TZea_02_gb_e.fm Seite 32 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Installation location 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.
Page 7 Thermo Top Z / Thermo Top C Installation location Circulating pump (optional with the Thermo Top Z) Fuel filler neck Water outlet port Exhaust outlet port Combustion air inlet Water inlet port Fig. 2: Thermo Top Z / Thermo Top C installation drawing...
Page 8: Model Plate (Additional Heater Only)
TZea_02_gb_e.fm Seite 34 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Model plate (additional heater only) 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).
Page 9: Bracket (Additional Heater Only)
TZea_02_gb_e.fm Seite 35 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Bracket (additional heater only) Bracket (additional heater only) The bracket must be secured to the car body or an intermediate bracket with at least four M6 screws.
Page 10: Installation Example In A Car
19 Circulating pump (additional heater only) * Fuse holder 14 Fuse strip in the car 20 Fuel metering pump * Supplied in the upgrade kit Installation example for a Thermo Top Z / Thermo Top C heater in a car Fig. 4:...
Page 11: Connection To The Vehicle Cooling System
Figures 4, 5 and 6. The system must contain at least 4 litres of coolant. 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 ϑ...
Page 12 TZea_02_gb_e.fm Seite 38 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Connection to the vehicle cooling system 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.
Page 13: Fuel System Integration (Additional Heater Only)
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 ≤...
Page 14 TZea_02_gb_e.fm Seite 40 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Fuel system integration (additional heater only) 8.2. Fuel lines NOTE: The hose clips must be tightened with a torque of 1.0 + 0.4 Nm.
Page 15 TZea_02_gb_e.fm Seite 41 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Fuel system integration (additional heater only) 8.3. Connecting two pipes with a hose 8.4. Metering pump The correct procedure for connecting fuel lines with hosing is shown in The metering pump is a combined delivery, metering and shut-off Figure 9.
Page 16 TZea_02_gb_e.fm Seite 42 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Fuel system integration (additional heater only) 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.
Page 17: Combustion Air Supply (Additional Heater Only)
TZea_02_gb_e.fm Seite 43 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Combustion air supply (additional heater only) Combustion air supply (additional heater only) The intake opening for combustion air must be located so that it cannot become clogged with dirt.
Page 18: Exhaust Pipe (Additional Heater Only)
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. Discharge direction almost vertical 90° ± 10°...
Page 19: Electrical Connections (Additional Heater)
Thermo Top Z / Thermo Top C Electrical connections (additional heater) 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...
Page 20: Circuit Diagrams (Additional Heater)
TZea_02_gb_e.fm Seite 46 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Circuit diagrams (additional heater) Circuit diagrams (additional heater) 12.1. Legend for circuit diagrams Item Designation Comment Heater Thermo Top Z/C ➀ Diagnostic Control module ➁...
Page 21 TZea_02_gb_e.fm Seite 47 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Circuit diagrams (additional heater) (75) 15 ➁ ϑ ➀ ϑ Fig. 16: Automatic circuit for Thermo Top Z additional heater, 12 V (see page 46 for legend)
Page 22: Electrical Connections (Retrofit)
TZea_02_gb_e.fm Seite 48 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Electrical connections (retrofit) Electrical connections (retrofit) 13.1. Control module / heater connection 13.3. Vehicle fan (auxiliary heater only) Make the electrical connections to the heater as shown in Figure 19.
Page 23 TZea_02_gb_e.fm Seite 49 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Electrical connections (retrofit) sw 0,5 sw 0,5 gn/ws 0,5 sw 0,5 Fig. 18: To retrofit the Thermo Top Z to an auxiliary heater...
Page 24: Circuit Diagrams (Retrofit)
TZea_02_gb_e.fm Seite 50 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Circuit diagrams (retrofit) Circuit diagrams (retrofit) 14.1. Legend for circuit diagrams Item Designation Comment Heater Thermo Top Z/C ➀ Diagnostic Control module ➁ Connection box...
Page 25 TZea_02_gb_e.fm Seite 51 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Circuit diagrams (retrofit) (75) 15 ➁ ϑ ➀ ➃ gn/ws I max. = 0,5 A ϑ Fig. 19: Automatic circuit for Thermo Top C auxiliary heater, 12 V timer (see page 50 for legend)
Page 26: Starting The Heater For The First Time
TZea_02_gb_e.fm Seite 52 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Starting the heater for the first time Starting the heater for the first time NOTE: Refer to the safety instructions in the operating and maintenance instructions.
Page 27: Troubleshooting
TZea_02_gb_e.fm Seite 53 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Troubleshooting Troubleshooting 16.1. Fault lock-out due to faults in the heater Fuel is supplied for max. 180 seconds if the flame does not start to burn.
Page 28: Technical Data
TZea_02_gb_e.fm Seite 54 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Technical data Technical data 17.1. Technical data Except where limit values are specified, these technical data refer to the usual heater tolerances of ± 10% at an ambient temperature of +20 °C and at the rated voltage.
Page 29 TZea_02_gb_e.fm Seite 55 Montag, 3. Februar 2003 2:09 14 Thermo Top Z / Thermo Top C Technical data Thermo Top Z - B Thermo Top Z - D Heater Operation Thermo Top C - B Thermo Top C - D...

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