Webasto Thermo Top C - PME Operations Instructions download pdf

Thermo Top C / Thermo Top E Statutory regulations governing installation

1 Statutory regulations governing installation

1.1. Statutory regulations governing installation

The Thermo Top C and Thermo Top E 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*02

e1*2001/56*0002*00

e1*2001/56*0003*00

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 ob-

served 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 para. 2.1.2, internal combustion

heaters must be installed in accordance with the requirements

contained in the present Annex.

2.1.2. In the case of vehicles of class O (trailers) with heaters for liquid

fuel, it is presumed that these vehicles comply with the requirements in

the present 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 vehicles of classes M2 and M3, the heater must not be installed

in the passenger compartment. However, it is permissible to use a unit

in a tightly sealed enclosure which also meets with the conditions in

para. 2.2.2.

2.2.4. The plate in accordance with para. 1.4 (rating plate) or a duplicate

thereof (duplicate rating 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 due precautions must be taken

to minimize all risk of bodily injury, as well as damage to items in the

vehicle.

2.3. Fuel supply

2.3.1. The fuel filler neck must not be located in the passenger

compartment and must have a tightly fitting cap to prevent any fuel

leakages.

2.3.2. The type of fuel and the fuel filler neck must be clearly identified

on heaters for liquid fuel, in 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 the

heater must be switched off before refuelling. A corresponding warning

must also be included in the manufacturer's operating instructions.

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Summary of Contents

Page 1

Thermo Top C / Thermo Top E Statutory regulations governing installation291 Statutory regulations governing installation1.1. Statutory regulations gov

Page 2

Connection to the vehicle cooling system Thermo Top C / Thermo Top E387.1. Relocating the circulation pumpThe circulation pump can be installed either

Page 3 - 2 Use / version

Thermo Top C / Thermo Top E Fuel connection398 Fuel connection8.1. Fuel connection without non-return valve in tankThe fuel supply for the heater is c

Page 4 - 3 Installation position

Fuel connection Thermo Top C / Thermo Top E408.3. Fuel supply . The values for the permissible pressure at the fuel delivery point are listed in the f

Page 5

Thermo Top C / Thermo Top E Fuel connection41When installing the heater in a vehicle with fuel injection system, it is therefore important to establis

Page 6 - 4 Rating plate

Fuel connection Thermo Top C / Thermo Top E428.5. Connecting two pipes and a hoseThe correct procedure for connecting fuel lines with hosing is illust

Page 7 - 5 Holder

Thermo Top C / Thermo Top E Fuel connection438.6.2. Installation and attachmentThe metering pump must be secured with a vibration-damping suspension.

Page 8

Combustion air supply Thermo Top C / Thermo Top E449 Combustion air supplyThe intake opening for combustion air must be located so that it cannot beco

Page 9

Thermo Top C / Thermo Top E Exhaust line4510 Exhaust lineThe exhaust line (inside diameter 22 mm) can be routed with several bends (270° altogether, m

Page 10

Electrical connections Thermo Top C / Thermo Top E4611 Electrical connections11.1. Connection of control unit / heaterThe electrical connections on th

Page 11 - 8 Fuel connection

Thermo Top C / Thermo Top E Electrical connections4711.4. Vehicle fanThe vehicle fan is controlled via the vehicle fan relay, see circuit diagram in F

Page 12

Statutory regulations governing installation Thermo Top C / Thermo Top E302.4. Exhaust system2.4.1. The exhaust outlet must be positioned in such a

Page 13

Circuit diagrams Thermo Top C / Thermo Top E4812 Circuit diagrams12.1. Legend for circuit diagrams:TroubleshootingOutside temperatureVehicle fan fuse

Page 14

Thermo Top C / Thermo Top E Circuit diagrams49Fig. 17: Automatic circuit for Thermo Top C and E, 12 V timer (legend see page 48)MM M(75) 156130rtswbrb

Page 15

Initial start-up Thermo Top C / Thermo Top E5013 Initial start-upNOTE:The safety instructions in the operating and maintenance instructions must be ob

Page 16 - 9 Combustion air supply

Thermo Top C / Thermo Top E Faults5114 Faults14.1. Fault lock-out due to faults in the heaterFuel is supplied for max. 180 seconds if the flame does n

Page 17 - 10 Exhaust line

Technical data Thermo Top C / Thermo Top E5215 Technical data15.1.Technical data, Thermo Top CExcept where limit values are specified, the technical d

Page 18 - 11 Electrical connections

Thermo Top C / Thermo Top E Technical data53* May only be operated with diesel / PME mixture containing < 50% PME.Heater Operation Thermo Top C -

Page 19

Technical data Thermo Top C / Thermo Top E5415.2.Technical data, Thermo Top EExcept where limit values are specified, the technical data on the right

Page 20 - 12 Circuit diagrams

Thermo Top C / Thermo Top E Technical data55* May only be operated with diesel / PME mixture containing < 50% PME.Heater Operation Thermo Top E -

Page 21 - Ventilation

Technical data Thermo Top C / Thermo Top E56

Page 22 - 13 Initial start-up

Thermo Top C / Thermo Top E Use / version312 Use / version2.1. Use of the water heatersThe Webasto Thermo Top C and E water heaters are used in combin

Page 23 - 14 Faults

Installation position Thermo Top C / Thermo Top E323 Installation positionThe water heater must be installed outside the passenger compartment.The hea

Page 24 - 15 Technical data

Thermo Top C / Thermo Top E Installation position33Fig. 2: Installation drawing for Thermo Top E and Z/C1 Circulation pump2 Fuel filler neck3 Water ou

Page 25

Rating plate Thermo Top C / Thermo Top E344 Rating plateThe rating plate must be positioned so that it cannot be damaged and must still be clearly leg

Page 26

Thermo Top C / Thermo Top E Holder355 HolderThe holder must be secured to the car body or an intermediate holder with at least four M6 screws.Washers

Page 27

Example for installation in a passenger car Thermo Top C / Thermo Top E366 Example for installation in a passenger car Fig. 3: Example for installati

Page 28

Thermo Top C / Thermo Top E Connection to the vehicle cooling system377 Connection to the vehicle cooling systemThe heaters are connected to the vehic