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The Webasto TTC is designed for Class 3-7 vehicles. This dynamic system allows you to preheat engines on or offsite. The TTC offers high performance with low power and fuel consumption. Approximately 2-hours of operation eliminates overnight idling for heating and the need for expensive electrical plug-ins. The compact design allows the heater to be frame rail or engine compartment mounted. The TTC is easy to install, maintain and operate. The universal package fits most of today vehicles.
This heading is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel.
This heading is used to highlight that non compliance with instructions or procedures may cause damage to equipment.
NOTE:
This heading is used to highlight and draw specific attention to information.
Before switching on the TTC, set vehicle heating system to the heat position and open any shut off valves. Depending on the type of control installed in the dashboard of the vehicle, the TTC can be operated by the following methods.
Using the Switch:
When the switch is used for turning ON the TTC, the operation indicator (toggle) lights up. Shortly thereafter, the heater begins operation and delivers heated coolant to the engine.
Using the Optional 7-Day Digital Timer:
Pushing the Instant Heat button or when timer setting reaches desired start time, the Heat indicator on the timer will light, signaling that the heater is in operation.
See section Operation with 7-Day Digital Timer for complete instructions.
NOTE:
If heater is being switched on while the engine is warm only the circulating pump will run, coolant temperature must fall below 86°F. (30°C.) before heater starts.
Startup Sequence:
The coolant circulating pump, ceramic igniter and combustion air fan start operation and after approximately 60 seconds combustion starts (audible combustion sound).
After the coolant temperature has reached the set point of 170°F (77°C) the TTC will automatically adjust its heat output to a lower operating range (part-load heat output).
If the temperature of the coolant continues to rise and climb over 174°F (79°C) at the heater outlet, the heater will cycle off.
When the temperature falls below 149°F (65°C) the heater will restart and repeat the heating cycle.
Due to the danger of poisoning and asphyxiation the heater must not be operated in enclosed spaces such as garages or workshops without adequate exhaust extraction or ventilation.
The Thermo Top C (TTC) will cycle on and off until:
Explosion hazard! The heater must be switched OFF while refueling and at fueling stations.
Explosion hazard! Do not operate any Webasto heater in an area where toxic or explosive materials or fumes may be present.
Manually: When heating is no longer required, switch the TTC heater off by means of the toggle switch or by pressing the Instant Heat button on the optional timer.
The indicator light turns off, combustion is extinguished followed by an after run cycle of approximately 90 seconds.
Automatically: When the optional timer has reached the end of the timed cycle (up to 2 hours).
NOTE:
Restarting the heater during the after-run period is permitted.
The timer enables you to preset the start time of the heater up to 7 days in advance.
In addition, the timer enables the heater to be switched on and off instantly thereby eliminating the need for a separate switch.
When the heater is in operation, the display and operation buttons of the timer are illuminated. The timer features a wake up alarm function.
Programmed Heater Operation
Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week of which only one can be activated at any one time.
Preselected Starting Times
The preselected starting time is the time at which the timer switches the heater on automatically. We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours of setting the timer.
Memory location 3 can be used for a starting time within the next 7 days of setting the timer.
Operating Time
The period of time during which the heater is in operation is referred to as operating time. The heater remains in operation for as long as the operating time has been preset.
Heater operation can be preselected for any time from as little as 1 minute to a maximum of 120 minutes (factory preset is 60 minutes).
Remaining Operating Time
The remaining operating time refers to the period of time the heater still continues to remain in operation. It can only be changed while heater is in operation.
Setting the Digital Timer
After the power has been connected, all symbols on the digital display will be flashing.
The time of the day and the day of the week must be set.
The Timer can be programmed in that all flashing symbols can be adjusted by means of the and
buttons.
If the buttons are not pressed within 5 seconds, the currently displayed time or function will be stored.
When the and
buttons are pressed for more than 2 seconds, the quick digit advance mode is activated.
See table 201 below for setting reference or full instructions supplied with timer.
Preselected Starting Times
The preselected starting time is the time at which the timer switches the heater on automatically. The Webasto SmarTemp Control fx allows for preset start-up cycles of your Webasto heater up to 7 days in advance with 4 unique programs for each day.
Operating Time
The period of time during which the heater is in operation is referred to as operating time. The heater remains in operation for as long as the operating time has been preset. Heater operation can be preselected for any time from as little as 10 minutes to a maximum of 120 minutes (factory preset is 60 minutes).
Remaining Operating Time
The remaining operating time refers to the period of time the heater still continues to remain in operation.
This can be changed with duration menu feature explain further in menu descriptions.
Setting the SmarTemp Control fx
The Webasto SmarTemp Control fx can be operated using a single rotary dial around the outside of the unit to browse through different menu options. Simply click the selection button () to make your choice. The following sections will define each menu item and its default setting.
Once the power has been connected, the time and date must be set. This can be done by using the rotary knob and the selection button as mentioned above. Within the timer menu, select the day or the specific timer program (T1 - T4) using the rotary knob. Once the day, time, and duration have been entered within the calendar table, press the selection button to set. A checkmark will confirm the program has been saved. Each program can be edited or removed simply by selecting the box again.
* The micro USB Service Port is used for Webasto heater diagnostic purposes only. This adaptor cannot be used to charge cell phones or other electronic devices.
Table 202: SmarTemp Control Setting Instructions
Definitions | Default | |
Time & Date | Time & Date allows user to properly set the current date and time. User also has the ability to switch between AM/PM and 24 hour modes. | AM/PM (12 Hour) |
Mode | Two modes are possible:
| Manual |
Duration | Duration allows for the selection of timed heater run-time. Set range is between 10 – 120 minutes selectable by 10 minute increments. While using Manual Mode, the "Duration" setting will be used for the run-time of the heater when the Webasto button is pressed. | 60 minutes |
Timer | Timer allows the user to set 4 heater start-up cycles per day up to 7 days in advance. Select the day or the specific timer program (T1 – T4) using the rotary knob and the selection button. Once the day, time, and duration have been entered, press the selection button to set. A checkmark will confirm the program has been saved. Each program can be edited or removed simply by selecting the box again. Note: Setting the Duration run-time (in the Duration section) before setting a timer program will default all new programs to the user defined duration time. | No Presets |
Skip | The Skip feature looks similar to timer programming; however when a specific timer program is selected, it will update the checkmark to an "s" for skipped. When a program has been skipped, it will disable that specific timer program for one cycle (7 day period). Preset timer programming will reactivate after this one-time skip cycle. Note: To permanently remove a program, refer to the "Timer" section. | N/A |
LVD | LVD "Low Voltage Disconnect" allows the user to adjust the battery voltage level at which the Webasto SmarTemp Control fx will shut down heater functionality. If battery voltage is equal to or less than the threshold selected +0.1v, the heater will not start. i.e. if an 11.5v threshold is selected the heater cannot be started until B+ has reached 11.7v. | |
12 volt - Range between 11v – 12.5v 24 volt - Range between 21v – 25.5v | 12.1v 24.2v | |
Error Codes | This section will log the last 5 error codes and the date that it was set. Highlight and select an error code for a full description. If the heater produces an error code, the status indicator lights will flash red and the error will display on the main screen. Error codes cannot be reset through the Webasto SmarTemp Control fx. Refer to the heater service manual for resetting an error code. Note: Error code functionality does not apply to Thermo Top C heaters. Errors codes for this product can still be obtained using PC Diagnostics. Refer to the applicable service manual by visiting www.techwebasto.com for detailed PC diagnostics information. | No Errors |
Hour Meter | The hour meter logs the operating hours that the heater is commanded "ON" from the SmarTemp Control fx. Note: For warranty purposes a diagnostic printout is still required where applicable. This hour meter is for reference only! | N/A |
Default | Default allows the user to perform a factory reset of the control settings and saved timer program data. | N/A |
SW Version | This displays the firmware version of the Webasto SmarTemp Control fx. | Installed Version |
Back | Select this to return to the previous screen. | N/A |
The following data is subject to the normal tolerance for heaters, if no tolerance is specified.
This is approximately +/-10% in an ambient of 20°C at nominal voltage.
Webasto will take you step by step through the installation process to ensure successful operation for years to come. The installation must be performed in accordance with the installation instructions provided in this manual.
Asphyxiation risk! The heater must not be installed in either the driver's compartment or in the passenger area of the vehicle.
NOTE:
This manual does not cover all possible installations. For special applications use this manual as a general guideline only. Contact an authorized Webasto dealer or Webasto Thermo & Comfort N.A., directly at USA: 1-800-555-4518 Canada: 1-800-667-8900
Do not mount the heater directly to the engine! Heavy, constant vibration produced by the engine may interfere with the proper operation of the heater and lead to heater component damage.
Asphyxiation risk! DO NOT mount heater inside passenger, sleeper or storage areas.
The openings of the water connecting pipes must never point in a downward direction in any installation position. Damage to heater will result due to trapped air in heat exchanger.
The heater must not be installed in the immediate vicinity of or above hot vehicle parts.
The heater must not be installed in the direct splash water area of the wheels.
The heater should be mounted as low as possible in the vehicle to assure automatic purging of air from circulating pump and coolant lines. The coolant pump is not self-priming.
Preferably, the heater should be mounted in the engine compartment.
NOTE:
Heavy Duty frame rail bracket is available. Order under part number 901088.
Asphyxiation risk! Exhaust pipes must be so routed that the possibility of exhaust fumes entering the vehicle is unlikely.
Route the exhaust pipe in such a way as to prevent touching or being directed toward any part of the vehicle that may be damaged by heat (i.e., brake lines, electrical wiring, hoses).
NOTE:
Additional flexible exhaust tubing is available from your Webasto Distributor or Dealer under part number 900126.
One meter (39 inches) of flexible exhaust tubing has been supplied with the heater. Attach tube to the heater with exhaust clamp supplied.
The exhaust tube should be routed in a gradual downward slope away from heater allowing condensation to drain.
Secure exhaust tube to vehicle with P-clip supplied. Keep exhaust tube at least 2 in. (50 mm) away from heat sensitive materials.
The outlet opening of the exhaust tube must not point in the direction of travel to avoid any possible clogging caused by snow, mud or foreign materials.
Never draw combustion air from inside the vehicle, or from areas where fumes or gases can accumulate. Drawing of combustion air from areas where people are present is strictly prohibited!
A combustion air tube has been supplied with the heater. Looking at the tube, you will see one end has a staple holding the inner liner and outer casing together.
The stapled end is the inlet end of the tube, the other end is to be attached to the heater.
To attach tube to the heater, stretch the outer casing about an inch further than the inner liner.
This will then slip over the inlet pipe of the heater and clamped in place.
Do not make any bends immediately after the attachment point to the heater. Doing so may cause a restriction where the inner liner of the tube begins. Make all bends at least 3 inches away or further from heater connection point.
The combustion air tube should be routed in a gradual downward slope away from heater allowing moisture to drain.
The intake opening of the combustion air tube must not point in the direction of travel to avoid any possible clogging caused by snow, mud or foreign materials.
Combustion air should always be taken from a clean area protected from road splash.
The TTC with coolant circulating pump must be mounted at least 6" (15 cm) below the lowest permissible coolant level of the vehicles cooling system.
Minimum amount of coolant in the cooling system should be at least 1.0 US gal. (4.0 I). Independent heating systems require a minimum of 3.0 US gal. (12.0 I). A minimum of 10% of a good quality antifreeze should be maintained in the cooling system at all times.
Heater and water pump fit 3/4" (19 mm) I.D. heater hose meeting SAE 20 R3 specifications. Silicone hose requires special hose clamps.
Burn risk! When working on the coolant system, allow the engine to cool down and open the radiator cap
NOTE:
Heater hose must meet SAE 20 R3 specifications.
NOTE:
Hose clamps must be tightened to 45 in/LB. (5 Nm) torque. Silicone hose requires special hose clamps.
Engine Block Preheating:
The pump, fuel line and fuel standpipe are integral to the systems reliability and must be installed according to these instructions to ensure proper heater operation.
If the fuel tank is higher than the fuel pump, the top of the tank may not be more than 20" above the pump.
Maximum suction height (A) = 3' 3"(1m)
Maximum suction length (A + B) = 6' 6"(2m)
Maximum delivery length (C + D) = 19' 6"(6m)
Maximum delivery height (D) = 9' 9"(3m)
The fuel pump MUST be mounted in a horizontal position in order to function correctly and deliver the proper quantity of fuel.
Mount the fuel pump as close to the fuel source as practicable.
Do not mount fuel pump near heat sources (exhaust pipes, hot coolant lines, etc.)
Pay particular attention to the fuel line and pump limitations as covered in sections "Fuel System Limitations" and "Fuel Pump".
The fuel is drawn from the vehicles fuel tank through a fuel standpipe. This standpipe can be utilized on vehicles with a spare threaded port, or if no threaded port is available, a 1" hole can be drilled into the tank and the universal tank boss installed as shown in figure 407. Keep the fuel standpipe 2" from the bottom of fuel tank.
Fuel standpipe installation:
NOTE:
Fuel standpipe with universal tank boss can be installed from outside of tank. First assemble fuel standpipe and tank-boss and then insert at an angle through the 1 hole previously drilled into tank. Tighten down with nut provided. Do not over-tighten.
Fuel line, couplers and clamps are provided in the installation kit and are required for proper operation.
Fuel line must be secured every 12f (30 cm) and kept away from hot exhaust and moving parts (drive shaft, wheels, etc.)
NOTE:
Use supplied hose clamps to secure all fuel line connections.
The TTC has been equipped with fuel line meeting the required specifications for proper operation.
The inside diameter of this fuel line is 0.08" (2.0 mm) and must not be substituted for fuel line of a larger diameter. Doing so will result in improper fuel delivery and the formation of air pockets in the fuel system which will interfere with heater operation.
Fuel line connections must be made as shown in figure 407, fuel line connection.
The TTC heater may be equipped with a fuel filter.
Fuel filters require changing at least annually and in cases of dirty fuel more often.
NOTE:
If heater is equipped with a fuel filter, change filter at least annually.
The control unit is equipped with low voltage protection, therefore it is imperative to keep the vehicle's battery connections and battery in good condition.
NOTE:
The Webasto heating system will not perform to your satisfaction with a weak battery.
Power harness connection instructions:
All power connections must be fused within 14" of the battery.
If welding is to be performed on the vehicle, the main battery cables must be disconnected from the battery to protect the electronic control unit.
When drilling holes on the vehicle, do not drill into existing wiring or other mechanical components.
Switch Installation:
Timer installation Instructions:
Relay Connection: (If applicable)
Heaters requiring a higher amperage signal will require a relay to accommodate different heater specifications. If the connected heater requires more than a 1A signal to start use the pin-out of a standard relay below.
Relay | Output |
Relay Pin 30 | Battery (B+) power source |
Relay Pin 85 | Ground |
Relay Pin 86 | Switched 1A signal wire from pin 3 of SmarTemp Control fx harness. |
Relay Pin 87 | Output source to heater (on/off signal) |
The connector pin assignment of control unit for Thermo Top C is shown in fig. 411.
The circuit diagrams (fig. 411 and 412) show the electrical circuit of the heater in the combination with a timer.
Wiring Diagram - Thermo Top C TTC (12 Volt) with ON/OFF Switch
Wiring Diagram - Thermo Top C TTC (12 Volt) with Timer
HEATER MUST BE SWITCHED "OFF" WHEN REFUELING AT FILLING STATIONS AND/OR WHILE LOADING OR UNLOADING FLAMMABLE MATERIALS FOR TRANSPORT, TO PREVENT THE RISK OF EXPLOSION. PLEASE REVIEW OWNER'S MANUAL FOR SAFETY AND USE INSTRUCTIONS.
Before starting the heater for the first time, complete the following checklist.
If you have any questions, contact our technical support team at (800) 860-7866 or via email at: info-us@webasto.com.
The TTC heater requires a minimum of maintenance to keep in good operating condition.
The following maintenance procedures should be performed annually before each heating season:
NOTE
For major repair and spare parts, return to your authorized Webasto Specialist.
Enclosure Box and Heater
Electrical System
NOTE
The heater will not function properly with weak batteries.
Combustion Air System
Exhaust System
Fuel System
Coolant System
Operational Test
NOTE
Operate your Webasto at least once a month for 20 minutes.
This section describes troubleshooting procedures for the TTC coolant heater.
Troubleshooting is normally limited to the isolation of defective components.
Troubleshooting requires profound knowledge about structure and theory of operation of the heater components and may only be performed by skilled personnel.
Before troubleshooting, check for and eliminate these defects:
NOTE
After any correction of a defect a functional test has to be performed in the vehicle.
The following table lists possible failure symptoms.
Table 601: General Failure Symptoms
Failure Symptom | Probable Cause | Remedy |
Coolant heater switches off automatically (Fault lockout) | No combustion after start or automatic repeat start | Switch off heater momentarily and switch on once again |
Flame extinguishes during operation | Switch off heater momentarily and switch on once again | |
Heater overheats | Check coolant lines for obstructions, closed valves and kinks. Check coolant level. Allow heater to cool down, reset over heat limiter, switch off heater momentarily and switch on once again | |
Vehicle electrical system voltage too low | Charge battery Switch off heater momentarily and switch on once again | |
Heater expels black fumes from exhaust | Combustion air and/or exhaust ducting blocked | Check combustion and exhaust ducting for obstructions |
The TTC is designed with a lockout safety feature built in to the control unit. After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition.
The following procedure will clear the lockout mode and reset the heater for normal operation:
Rectify the cause of the fault.
Heater fault codes can be read using PC Diagnostics, however, the heater lockout reset must be manually performed using the procedure stated above.
Diagnostics equipment is intended for use by Webasto trained personnel at authorized Webasto Distributor, Dealer and End User service facilities.
It is possible to read and remove (reset) stored fault codes from the TTC memory.
This is achieved through the use of a diagnostic interface kit connected to the TTC and an IBM compatible computer having the necessary software installed.
The PC Diagnostic Interface Kit comes complete with connecting hardware, software and instructions. Also available are several interface connectors for use with Webasto heaters equipped with internal diagnostics capabilities such as the TTC.
Order PC Diagnostics Kit under part number 1320920A.
Kit does not include required adapter, please order adapter under part number 92566B.
In addition to working with stored fault codes, the PC Diagnostics Kit allows you to do several other functions such as reading values while the heater is in operation or testing individual components. Printing out of fault codes is also available (User supplied printer required).
For further capabilities and instructions for use with the TTC heater, see instruction manual supplied with the PC Diagnostics Kit.
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.
NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed Webasto factory training and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. Only genuine Webasto parts may be used.
Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.
Webasto products produce temperatures high enough to ignite surrounding combustible materials such as inflammable liquids, gases, vapor, and other combustible matter. The heater must be switched off when loading or unloading inflammable materials to prevent the risk of explosion.
ALWAYS and carefully follow Webasto installation and repair instructions and heed all WARNINGS.
Webasto Thermo & Comfort N.A., Inc.
15083 North Road
Fenton, MI 48430
Technical Assistance Hotline
USA: (800) 860-7866
Canada: (800) 667-8900
www.webasto.us
www.techwebasto.com
Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.
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