Webasto Thermo Top Z Shop Manual
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Webasto Thermo Top Z Shop Manual

Supplementary heater, auxiliary heater
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Water Heaters
Repair Shop Manual
Thermo Top Z
Supplementary Heater
Thermo Top E
Thermo Top C
Auxiliary Heater
Type Thermo Top E - B
Type Thermo Top Z/C - B
Fuel
Type Thermo Top E - D
Type Thermo Top Z/C - D
Diesel
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Summary of Contents for Webasto Thermo Top Z

  • Page 1 Thermo Top Z Supplementary Heater Thermo Top E Thermo Top C Auxiliary Heater Type Thermo Top E - B Type Thermo Top Z/C - B Fuel Type Thermo Top E - D Type Thermo Top Z/C - D Diesel www.butlertechnik.com...
  • Page 2 Circulation Pump (Thermo Top E and C only) ..................203 Dosing Pump ............................203 Functional Description Functional Description Thermo Top Z (Supplementary Heater) ............301 3.1.1 Switch On / Starting ........................301 3.1.2 Heating Operation........................301 3.1.3 Switch Off / Deactivation......................301 Functional Description Thermo Top E and C (Auxiliary Heater) ............
  • Page 3 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C List of Contents Troubleshooting General Fault Symptoms ........................501 Error Messages during Functional Test with Diagnosis Tester Thermo Test ........502 Malfunctions............................503 5.3.1 Error Lockout by Malfunction of Heater ..................503 5.3.2 Error Lockout due to Low or High Voltage..................
  • Page 4 Visit www.butlertechnik.com for more technical information and downloads. List of Contents Thermo Top E and Z/C Repair General ..............................901 9.1.1 Work on Components after Disassembly ................... 901 Disassembly and Assembly ........................902 9.2.1 Circulation Pump, Replacement (Thermo Top E and C) ............902 9.2.2 Combustion Air Fan, Replacement.....................
  • Page 5 Automatic Switching Circuit for Thermo Top E and Z/C, 12 V Timer and Telestart T60......702 Automatic Switching Circuit for Thermo Top E and Z/C, 12 V Timer............703 Automatic Switching Circuit for Thermo Top Z, 12 V ................. 704 "Inline Integration" in the Engine Water Cooling Circuit................801 Example for Heater Installation in Passenger Vehicle ................
  • Page 6 Visit www.butlertechnik.com for more technical information and downloads. List of Figures Thermo E and Top Z/C www.butlertechnik.com...
  • Page 7 Motor Traffic exist for the Water Heaters Thermo Top with (vegetable methyl ester). the following official marks of conformity: Thermo Top E and C are variants of Thermo Top Z with a ~ S316 for Heater Thermo Top E-B (fuel type) circulation pump.
  • Page 8 A drain hole may be Non-compliance with the installation instructions will void provided as required. the Webasto warranty. The same applies for unskilled repairs or repairs not using original spare parts. This will The openings of the combustion air inlet and the exhaust...
  • Page 9 The Thermo Top E and C heater The heater Thermo Top Z may be converted into an has an additional circulation pump. auxiliary heater using a retrofit kit.
  • Page 10 Visit www.butlertechnik.com for more technical information and downloads. 2 General Description Thermo Top E and Z/C Combustion Air Fan Assembly The combustion air fan assembly includes the combustion air fan combustion air line inlet fuel supply inlet. The heater Thermo Top E and Z has the circulation pump mounted on the combustion air fan assembly.
  • Page 11 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 2 General Description Control Unit / Heat Exchanger 2.4.4 Heat Exchanger The heat exchanger transfers the heat generated by The control unit / heat exchanger includes the combustion to the coolant circuit.
  • Page 12 Visit www.butlertechnik.com for more technical information and downloads. 2 General Description Thermo Top E and Z/C Page free for notes www.butlertechnik.com...
  • Page 13 3 Functional Description Functional Description 3.1.2 Heating Operation Fuel Functional Description Thermo Top Z When the temperature rises to reach 72° C the heater (Supplementary Heater) switches to the energy saving part load operation. A rise in temperature up to 76.5° C causes the heater to enter a control idle period.
  • Page 14 Visit www.butlertechnik.com for more technical information and downloads. 3 Functional Description Thermo Top E and Z/C Functional Description 3.2.2 Heating Operation Thermo Top E and C (Auxiliary Heater) Fuel When the temperature rises to reach 72° C the heater 3.2.1 Switch On switches to the energy saving part load operation.
  • Page 15 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 3 Functional Description 3.2.4 Auxiliary Heater in Supplementary Heater Function 3.2.4.1 Switch On When starting the engine the heater goes in standby (see 3.1.1). With the temperature of the water circuit below 60° C and the outside temperature below 5°...
  • Page 16 Visit www.butlertechnik.com for more technical information and downloads. 3 Functional Description Thermo Top E and Z/C Page free for notes www.butlertechnik.com...
  • Page 17 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 4 Technical Data Technical Data Propellant for Thermo Top E (Fuel): The proper fuel is the fuel specified by the vehicle manufacturer. Thermo Top E Propellant for Thermo Top E (Diesel): Where no threshold values are specified technical data in The proper Diesel fuel is the one specified by the vehicle the table are understood to include standard tolerances...
  • Page 18 Visit www.butlertechnik.com for more technical information and downloads. 4 Technical Data Thermo Top E and Z/C Thermo Top Z/C Propellant for Thermo Top Z/C (Fuel): The proper fuel is the fuel specified by the vehicle (Heating Flow 5.0 kW) manufacturer...
  • Page 19 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 4 Technical Data Thermo Top Z/C Propellant for Thermo Top Z/C (Fuel): The proper fuel is the fuel specified by the vehicle (Heating Flow 5.2 kW) manufacturer...
  • Page 20 Visit www.butlertechnik.com for more technical information and downloads. 4 Technical Data Thermo Top E and Z/C Page free for notes www.butlertechnik.com...
  • Page 21 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 5 Troubleshooting Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components and provides information on General Fault Symptoms defective wiring and connections. The following possible causes for trouble have not been taken into consideration and must always be excluded as The following table (Fig.
  • Page 22 • High transition resistance in the power supply lines (plus and minus) Flame before combustion • Glow plug / flame sensor defective operation (not applicable for Thermo Top Z) Overheating • Coolant level too low • Heater has not been bled •...
  • Page 23 5.3.1 Error Lockout by Malfunction of Heater Before attempting an error lockout reset check fuse F1 in Webasto flat fuse holder. A 15 A fuse must be replaced In case of a "no flame-up" condition fuel is delivered for a with a 20 A fuse.
  • Page 24 5 Troubleshooting Thermo Top E and Z/C 5.3.3.2 Error Lockout Reset Thermo Top E and C with 5.3.3.3 Error Lockout Reset Thermo Top Z "Telestart" In case of a malfunction the control unit enters an error Eliminate cause of trouble.
  • Page 25 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 6 Functional Checkouts Functional Checkouts NOTE Heating efficiency depends on several factors: for assessment use outside temperature, type of vehicle, General engine temperature or type of heater integration in the vehicle's cooling system, the quantity of the coolant to be heated and the time passed since heater start.

  • Page 26: Out +15

    Visit www.butlertechnik.com for more technical information and downloads. 6 Functional Checkouts Thermo Top E and Z/C 6.2.2 Timer Functional Test 6.2.2.2 Switch On Signal Test (Thermo Top E and C) 1. Operate "ON" button and check voltage between "–" and "OUT". Voltage is approx. 7 V with the timer 6.2.2.1 Voltage Check connected to the control unit or 12 V with the output not connected.

  • Page 27: Heater

    Equipment selection By pressing left key select heater and • Thermo Top language • Thermo Top E • Thermo Top Z/C • Language Acknowledge Thermo Top E or Z/C selection Main menu by pressing "OK" key By pressing left key select desired function •...
  • Page 28 Visit www.butlertechnik.com for more technical information and downloads. 6 Functional Checkouts Thermo Top E and Z/C 6.2.6 CO Setting CAUTION For starting heater diagnostic line must be disconnected. Connection of diagnosis tester with heater on and NOTE operating at full load (approx. 5 min after switch on). The CO setting is performed with the diagnosis tester Change of CO...

  • Page 29: Summer/Winter Switch

    Thermo Top E and Z/C is shown in Fig. 701. The circuit diagrams (Fig. 702 and 703) show the electrical circuit of the heater in combination with Timer and Telestart T60. The circuit diagram (Fig. 704) shows the electrical circuit of Thermo Top Z. GS/FW 12V+ Clock Diagnosis...
  • Page 30 Visit www.butlertechnik.com for more technical information and downloads. 7 Circuit Diagrams Thermo Top E and Z/C ϑ ϑ Item Nomenclature Remark Wire Gauges Heater Thermo Top E or Z/C < 7.5 m 7.5 - 15 m Control unit 0,5 mm 0,75 mm Connector box 0,75 mm...

  • Page 31: Table Of Contents

    Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 7 Circuit Diagrams (75) 15 ϑ I max. = 0,5 A gn/ws ϑ Item Nomenclature Remark Wire Gauges Heater Thermo Top E or Z/C < 7.5 m 7.5 - 15 m Control unit 0,5 mm...

  • Page 32: Wire Gauges

    Connection 2-pole water repellant yellow Connection 2-pole water repellant green grey Dosing pump orange black violet white Legend for circuit diagrams 1 Diagnosis 2 Outside air temperature Fig. 704 Automatic Switching Circuit for Thermo Top Z, 12 V www.butlertechnik.com...
  • Page 33 Heizwasserkreislauf Motor Heater Test Run Heating water circuit when operating Heizwasserkreislauf bei Betrieb with Webasto auxiliary heater der Webasto Standheizung The heater must not be operated, not even with the timer, 1 Engine with water pump 5 Heater 1 Motor mit Wasserpumpe 5 Heizgerät...
  • Page 34 Visit www.butlertechnik.com for more technical information and downloads. 8 Servicing Thermo Top E and Z/C The coolant hoses supplied by Webasto must be installed, Prior to the heater's first operation or after renewal of the other hoses must meet at least the DIN 73411 coolant the cooling system must be carefully bled.
  • Page 35 PA 12 (e.g. Mecanyl RWTL) according to DIN 73378. Fuel tappings from the supply or return line may only use the special Webasto fuel tap. As in most cases a permanently rising fuel line routing cannot be ensured, the inner diameter must not exceed a certain value.
  • Page 36 Should the temperature within the installation box exceed the permitted ambient temperature of the heater, the vent hole must be enlarged after consulting Webasto. The combustion air intake must be located so that clogging by contamination is not to be expected. The intake must not point in the direction of forward motion.
  • Page 37 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 8 Servicing combustion air must be taken in from and the exhaust 8.6.4 Exhaust Line vented to the exterior. The line feedthroughs must be sealed against splash water. The exhaust line (inner diameter 22 mm) may be routed in several bends (total of 270°, smallest bending radius 50 mm).
  • Page 38 Only the timer shown in Fig. 809 may be used in combination with the heater. 1. Disconnect heater power supply by removing 20 A flat fuse (yellow) from Webasto fuse holder. 2. Disconnect electrical connections from heater. Disconnect antenna cable to Telestart receiver T60 at screw type locking connector.
  • Page 39 Repair General This section describes the repairs that may be performed on the heaters Thermo Top Z and Thermo Top E and C when removed. Any further disassembly will void the warranty. After repairs a functional test must be performed.
  • Page 40 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair Thermo Top E and Z/C Disassembly and Assembly 9.2.1.2 Installation 1. Slide spring band steel clamp (5, Fig. 901) onto hose 9.2.1 Circulation Pump, Replacement end. (Thermo Top E and C) 2.
  • Page 41 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 9 Repair 9.2.2 Combustion Air Fan, Replacement 4. Plug on electrical connections of combustion air fan. 5. Install circulation pump as required (see 9.2.1.2). CAUTION In case of Thermo Top E and C the circulation pump must 6.
  • Page 42 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair Thermo Top E and Z/C Torque 4 Nm Paper gasket Rubber gasket 1 Combustion air fan 7 Control unit / heat exchanger 2 Gasket 8 Glow plug / flame sensor 3 Burner insert 9 Fuel pipe 4 Gasket...
  • Page 43 Visit www.butlertechnik.com for more technical information and downloads. Thermo Top E and Z/C 9 Repair 9.2.3 Burner Insert with Glow Plug / 9.2.4 Control Unit / Heat Exchanger with Burner Flame Sensor, Replacement Housing, Replacement CAUTION CAUTION In case of Thermo Top E and C the circulation pump must In case of Thermo Top E and C the circulation pump must be removed first (see 9.2.1.1).
  • Page 44 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair Thermo Top E and Z/C Page free for notes www.butlertechnik.com...
  • Page 45 10 Packaging, Storage and Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Webasto for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage.
  • Page 46 Visit www.butlertechnik.com for more technical information and downloads. 10 Packaging, Storage and Shipping Thermo Top E and Z/C Page free for notes 1002 www.butlertechnik.com...
  • Page 47 Visit www.butlertechnik.com for more technical information and downloads. www.butlertechnik.com...
  • Page 48 Visitors’ address: Friedrichshafener Str. 9 82205 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com The telephone number of the respective country is shown on the Webasto service center leaflet or can be found on the website of your Webasto subsidiary. www.butlertechnik.com...

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Thermo top eThermo top c

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