Technical data

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Thermo Top Z/C

List of Contents

1. Introduction

1.1 Scope and Purpose ................................................................................................................................101

1.2 Meaning of Warnings, Cautions, and Notes ...........................................................................................101

1.3 Additional Documentation to be used .....................................................................................................101

1.4 Safety Information and Regulations........................................................................................................101

1.4.1 General Safety Notes ...................................................................................................................101

1.5 Legal Provisions for Installation ..............................................................................................................102

1.6 Corrections and Improvements...............................................................................................................102

2. General Description

2.1 Combustion Air Fan Assembly ...............................................................................................................202

2.1.1 Combustion Air Fan......................................................................................................................202

2.2 Burner Housing.......................................................................................................................................202

2.3 Burner Insert ...........................................................................................................................................202

2.4 Control Unit/Heat Exchanger ..................................................................................................................203

2.4.1 Control Unit...................................................................................................................................203

2.4.2 Temperature Sensor.....................................................................................................................203

2.4.3 Overheat Protection......................................................................................................................203

2.4.4 Heat Exchanger............................................................................................................................203

2.5 Circulation Pump (Thermo Top C only) ..................................................................................................203

2.6 Dosing Pump ..........................................................................................................................................203

3. Functional Description

3.1 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

3.2 Functional Description Thermo Top C (Auxiliary Heater) .......................................................................302

3.2.1 Switch On .....................................................................................................................................302

3.2.2 Heating Operation ........................................................................................................................302

3.2.3 Switch Off .....................................................................................................................................302

3.2.4 Auxiliary Heater in Supplementary Heater Function.....................................................................303

4. Technical Data

Summary of content (36 pages)

PAGE 1
Thermo Top Z/C List of Contents List of Contents 1. Introduction 1.1 1.2 1.3 1.4 Scope and Purpose ................................................................................................................................101 Meaning of Warnings, Cautions, and Notes ...........................................................................................101 Additional Documentation to be used .....................................................................................................
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List of Contents 5. Thermo Top Z/C Troubleshooting 5.1 5.2 General Fault Symptoms ....................................................................................................................... 501 Malfunctions........................................................................................................................................... 502 5.2.1 Error Lockout by Malfunction of Heater ....................................................................................... 502 5.2.
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Thermo Top Z/C 9. List of Contents Repair 9.1 General ...................................................................................................................................................901 9.1.1 Work on Components after Disassembly .....................................................................................901 9.2 Disassembly and Assembly....................................................................................................................902 9.2.1 9.2.2 9.2.3 9.2.
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Thermo Top Z/C List of Figures List of Figures 501 Fault Symptoms .......................................................................................................................................... 501 701 Automatic Switching Circuit for Thermo Top Z/C, 12 V Timer and Telestart T60 ....................................... 702 801 802 803 804 805 806 807 808 “Inline” Integration in the Engine Water Cooling Circuit ..............................................................................
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Thermo Top Z/C 1. Introduction 1.1 Scope and Purpose This repair shop manual is intended to support familiarised personnel in the repair of the water heaters Thermo Top Z and Thermo Top C of the fuel and Diesel types. As their appearance is identical or similar, the heaters are marked by type on their identification plate with "Benzin" (fuel) or "Diesel". The heaters may only be operated with the specified type of Diesel (or with fuel oil EL) and the appropriate type of electrical installation.
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Thermo Top Z/C 1 Introduction The heater must not be installed in the passenger or driver compartments of vehicles. At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosion. For the routing of fuel lines and the installation of additional fuel tanks §§ 45 and 46 of the StVZO are to be adhered to.
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Thermo Top Z/C 2. 2 General Description General Description The water heater Thermo Top Z supplementary heater is intended to compensate for the shortage in heat generated by engines optimised for low fuel consumption. The water heater Thermo Top C auxiliary heater is used to: • heat the vehicle cabin, • defrost the vehicle windscreens, • preheat water-cooled vehicle engines. The supplementary heater Thermo Top Z may be converted into an auxiliary heater using a retrofit kit.
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Thermo Top Z/C 2 General Description 2.1 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 Z has the circulation pump mounted on the combustion air fan assembly. 2.1.1 Combustion Air Fan The combustion air fan delivers the air required for combustion from the combustion air inlet to the burner insert. Coolant outlet Coolant inlet Exhaust outlet Burner Housing 2.
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Thermo Top Z/C 2.4 2 General Description Control Unit/Heat Exchanger The control unit/heat exchanger includes the control unit temperature sensor overheat protection heat exchanger connector terminal. 2.4.4 Heat Exchanger The heat exchanger transfers the heat generated by combustion to the coolant circuit. 2.5 CAUTION The control unit/heat exchanger and the burner housing represent an assembly and must not be disassembled.
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2 General Description Page free for notes 204 Thermo Top Z/C
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Thermo Top Z/C 3. Functional Description 3.1 Functional Description Thermo Top Z (Supplementary Heater) 3.1.1 Switch On/Starting Fuel When starting the vehicle engine the heater goes in standby. With a water circuit temperature below 60 °C and an outside temperature below 5 °C (option with outside temperature sensor) the starting sequence commences. The glow plug and the combustion air fan are activated.
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Thermo Top Z/C 3 Functional Description 3.2 Functional Description Thermo Top C (Auxiliary Heater) 3.2.1 Switch On Fuel When operating the "instant heat" switch button the timer display shows or when operating the switch on the Telestart transmitter the operating indicator light on the transmitter flashes. This puts the heater in standly. The glow plug, the combustion air fan and the circulation pump are activated.
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Thermo Top 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 °C (option with external temperature sensor) the starting procedure is initiated. NOTE When operating in the supplementary heater function there will be no automatic trigger of the circulation pump and the vehicle's heating air fan. 3.2.4.
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3 Functional Description Page free for notes 304 Thermo Top Z/C
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Thermo Top Z/C 4. 4 Technical Data Technical Data Where no threshold values are specified technical data in the table are understood to include standard tolerances for heater units of ± 10 % at an ambient temperature of + 20 °C. All electrical components are selected for a nominal voltage of 12 Volts. Heater Operation Mark of conformity Type Heating flow Permissible operating overpressure (heat carrier) ~ S289 5.0 kW 2.5 kW Fuel Full load Part load Diesel 0.50 kg/h 0.
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4 Technical Data Page free for notes 402 Thermo Top Z/C
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Thermo Top Z/C 5. Troubleshooting 5.1 General Fault Symptoms 5 Troubleshooting The following table (Fig. 501) lists possible fault symptoms of general nature for heaters in installed condition. CAUTION Troubleshooting requires profound knowledge about components and their theory of operation and may only be performed by trained personnel. In case of doubt functional interrelations may be derived from Sections 2 and 3.
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5 Troubleshooting 5.2 Malfunctions 5.2.1 Error Lockout by Malfunction of Heater In case of a "no flame-up" condition fuel is delivered for a maximum of 180 seconds. In the event of overheating (temperature limiter responds) fuel delivery is stopped immediately. In all cases of malfunction (except for a defect on the combustion air fan) there will be an error lockout with a subsequent run-down. Dependent on the software variant implemented there might be deviations from the run-down times specified.
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Thermo Top Z/C 6 Functional Checkouts 6. Functional Checkouts 5. Allow heater to continue operation. Check heating efficiency at air exit of vehicle heating air fan. 6.1 General NOTE Heating efficiency depends on several factors: for assessment use outside temperature, type of vehicle, 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.
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Thermo Top Z/C 6 Functional Checkouts 6.2.2 Timer Functional Test (Thermo Top C) 6.2.2.2 Switch On Signal Test 6.2.2.1 Voltage Check 1. Remove cover using a small screw driver. 1. Operate "ON" button and check voltage between "-" and "OUT". Voltage is approx. 7 V with the timer connected to the control unit or 12 V with the output not connected. 2. Operate "ON" button again and check voltage between "-" and "OUT". Voltage is 0 V. 2. Loosen screw. 3. Disconnect plug from clock. 4.
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Thermo Top Z/C 7. Circuit Diagrams 7.1 General 7 Circuit Diagrams The circuit diagram (Fig. 701) shows the electrical circuit of the heater Thermo Top Z/C in combination with Timer and Telestart T60.
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Thermo Top Z/C 7 Circuit Diagrams ϑ ϑ Item A1 A2 A3 A4 B2 E F1 F2 F3 H1 K3 M1 M2 M3 P S1 S2 S5 X1 X2 X3 X4 X5 X6 X8 X9 Y1 Nomenclature Heater Control Connector box Telestart receiver Temperature Sensor Glow Plug/Flame sensor Fuse 20A Fuse 1A Fuse 25A LED (in item P) Relay (in item A3) Motor Motor Motor Timer, digital Switch for vehicle air fan Switch for vehicle air fan Switch Connection, 6-pole Connection, 2-pole Connection, 2-pole Connection, 2-pole Connection, 2-pole Connection, 2-pole Connection, 2
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Thermo Top Z/C 8. Servicing 8.1 General This section describes the servicing procedures allowed on the heater when installed. 8 Servicing • inspect fuel lines and fuel filter for leakage. • inspect coolant circuit and circulation pump (Thermo Top C only) for leakage. • inspect hoses for cracks. • replace fuel filter, if installed. WARNING There is a potential danger of skin burns as the heater and its components may be very hot. 8.6 8.2 8.6.
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Thermo Top Z/C 8 Servicing Prior to the heater's first operation or after renewal of the coolant the cooling system must be carefully bled. The heater and the lines must be installed to ensure static venting. Insufficient venting may cause overheating during heater operation.
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Thermo Top Z/C 8 Servicing 8.6.2 Connection to Vehicle Fuel System In vehicles with carburettor or fuel injection including a return line the heater fuel system integration must be according to Fig. 802. Carburettor engines without return line must have the heater integrated in the fuel system's fuel supply line between fuel tank and vehicle fuel pump. NOTE A fuel supply line can normally be identified by the installation of a fuel filter.
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Thermo Top Z/C 8 Servicing 8.6.2.3 Combustion Air Supply correct A combustion air intake line is required. hose clamp The combustion air intake location must be protected against splash water. wrong bubble bubble Fig. 805 Pipe/Hose Connection 8.6.2.2 Dosing Pump The dosing pump is a combined delivery, dosing and shutoff system and is subject to certain installation criteria (Fig. 803 and 806).
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Thermo Top Z/C 8 Servicing NOTE Collect coolant escaping in a vessel or prevent coolant from escaping by using squeezing tongs. 4. Loosen hose clamps and disconnect coolant hoses from heater. 5. Loosen heater from its mount. Exhaust flow direction nearly vertical 90 °C ± 10 °C 6. Loosen hose clamps, disconnect fuel line and close with suitable plug or any other means. 8.7.1.2 Installation 10° 10° 1. Locate heater for installation. 2. Connect fuel line to heater and secure with clamp. 3.
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Thermo Top Z/C 8 Servicing 8.7.2 Timer, Removal and Installation 8.8 Timer removal and installation is to be performed in accordance with Fig. 808. For initial installation use drilling stencil. The electrical connection is shown in Section 7. After heater installation the coolant circuit as well as the fuel supply system must be carefully bled observing the relevant manufacturer's instructions. CAUTION During installation do not exert pressure on display.
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Thermo Top Z/C 9. Repair 9.1 General 9 Repair This section describes the repairs that may be performed on the heaters Thermo Top Z and Thermo Top C when removed. Any further disassembly will void the warranty. After repairs a functional test must be performed. 9.1.1 Work on Components after Disassembly CAUTION All gaskets located between disassembled components must always be discarded and replaced. 9.1.1.1 Cleaning • All components disassembled must be cleaned.
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Thermo Top Z/C 9 Repair 9.2 Disassembly and Assembly 9.2.1.2 Installation 9.2.1 Circulation Pump, Replacement (Thermo Top C) 1. Slide spring band steel clamp (5, Fig. 901) onto hose end. 9.2.1.1 Removal 2. Position collar (1) on circulation pump (6) as required. 1. Remove cover (4, Fig. 901) and disconnect electrical connector of circulation pump. 3. Locate circulation pump (6) for installation and secure with clamp (2) and screw (7) on combustion air fan (3). 4.
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Thermo Top Z/C 9 Repair 9.2.2 Combustion Air Fan, Replacement 9.2.2.2 Installation CAUTION In case of Thermo Top C the circulation pump must be removed first (see 9.2.1.1). 1. Replace gasket (12, Fig. 902) of combustion air fan (1) as required. 9.2.2.1 Removal 1. Carefully lever off cover (6, Fig. 902). 2. Disconnect electrical connector of combustion air fan. 3. Remove screws (11). 4. Withdraw combustion air fan (1) from burner housing (5) and fuel pipe (9). 5. Remove gasket (2) and discard. 2.
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Thermo Top Z/C 9 Repair 3 2 1 10 12 1 2 3 4 5 6 11 1 1 Combustion air fan Gasket Burner insert Gasket Burner housing Cover 1 7 8 9 10 11 12 Control unit/heat exchanger Glow plug/flame sensor Fuel pipe Screw (4) Screw (4) Gasket Fig. 902 Heater Disassembly 904 Torque 3.
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Thermo Top Z/C 9 Repair 9.2.3 Burner Insert with Glow Plug/Flame Sensor, Replacement 9.2.4 Control Unit/Heat Exchanger with Burner Housing, Replacement CAUTION In case of Thermo Top C the circulation pump must be removed first (see 9.2.1.1). CAUTION In case of Thermo Top C the circulation pump must be removed first (see 9.2.1.1). 9.2.3.1 Removal 9.2.4.1 Removal 1. Remove combustion air fan (see 9.2.2.1). 1. Remove combustion air fan (see 9.2.2.1). 2.
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9 Repair Page free for notes 906 Thermo Top Z/C
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Thermo Top Z/C 10. 10 Packaging, Storage and Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Webasto Thermosysteme GmbH for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage. CAUTION When shipping a complete heater assembly it must be drained completely. No fuel is allowed to escape from a packaging or during shipping.
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10 Packaging, Storage and Shipping Thermo Top Z/C Page free for notes 1002 02/2002