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Page 1

Luft-Heizgeräte 03/2003

Water heaters Workshop Manual

Thermo Top V

Type Thermo Top V (Petrol)

Type Thermo Top V (Diesel)

Page 2
Thermo Top V

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.

To install and repair Webasto heating and cooling systems you need to have
completed a Webasto training course and have the appropriate technical
documentation, special tools and special equipment.

NEVER try to install or repair Webasto heating or cooling systems if you have not
completed a Webasto training course, you do not have the necessary technical skills
and you do not have the technical documentation, tools and equipment available
to ensure that you can complete the installation and repair work properly.

ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.

Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.

Page 3
Thermo Top V Table of Contents

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Contents and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1.1 Using water heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Meaning of signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Additional documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Statutory regulations and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4.2 Statutory regulations governing installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4.3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.1 Combustion-air fan unit/control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Diesel/petrol burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2.1 Fuel preheating

(diesel burner with FPH only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.2.2 Solenoid valve

(diesel burner with SV only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.3 Temperature sensor and overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.4 Heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.5 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.6 Metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

3 Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

3.1 Switching on/starting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.2 Heating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.3 Restarting after fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.4 Starting after long period of non-use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.5 Switching off/Switch-off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1 General error symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.1.1 Fault analysis on heater and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.2 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
5.2.1 Fault lock-out due to fault on heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
5.2.2 Fault lock-out due to undervoltage or overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

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Table of Contents Thermo Top V

6 Operating tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.2 Operating checks in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.2.1 Testing heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.2.2 Setting CO2 content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.3 Operating test in workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.3.1 Testing individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.3.1.1 Testing fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.3.1.2 Testing fuel preheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.3.1.3 Testing solenoid valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.3.1.4 Electrical test of glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.3.1.5 Testing temperature sensor and overheating sensor . . . . . . . . . . . . . . . . . . . . . . 603

7 Circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
7.2 Legend for wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703

8 Servicing work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.2 Work on the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.3 Work on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.4 Heater trial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.5 Servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.6 Visual inspections and installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.6.1 Connection to vehicle cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.6.2 Connection to vehicle fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6.2.1 Fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6.2.2 Metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.7 Heater, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8.7.1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8.8 Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.2 Dismantling and assembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.2.1 Dismantling heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
9.2.2 Assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.2.3 Installing water connection piece variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
9.2.3.1 Installing water connection-piece variant A with teeth . . . . . . . . . . . . . . . . . . . 902
9.2.3.2 Installing water connection-piece variant B without teeth . . . . . . . . . . . . . . . . 903

9.2.4 Dismantling combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903

9.2.5 Removing burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.2.6 Cable routing for glow plug on burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.2.7 Installing burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.2.8 Removing temperature sensor and overheating sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.2.9 Installing temperature sensor and overheating sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
9.2.10 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905

II

Page 5
Thermo Top V Table of Contents

10 Packing, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

10.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
10.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

III

Page 6
List of illustrations Thermo Top V

List of illustrations

Fig. 201 Cross-sectional functional model of Thermo Top V water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Fig. 202 Combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Fig. 203 Standard connector plate with AMP connector basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 204 Connector plate with FEP connector basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 205 Connector plate for VW single board with FEP connector basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 206 Diesel burner with solenoid valve (SV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 207 Diesel burner with fuel preheating (FPH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 208 Diesel burner without fuel preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 209 Petrol burner with guard plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 210 Petrol burner without guard plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 211 Fuel preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 212 Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 213 Heater with temperature sensor and overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 214 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 215 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 216 DP40/DP41 metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 301 Start-up process for Thermo Top V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Fig. 302 Unlocking heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Fig. 401 Technical data for Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Fig. 402 Technical data for circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Fig. 501 Overview of possible faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Fig. 502 Overview of functional analysis of heater and components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Fig. 601 CO2 setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Fig. 602 CO2 setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Fig. 603 Resistance values for fuel preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Fig. 604 Resistance values of temperature sensor and overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Fig. 701 Connector assignment of heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Fig. 702 Wiring diagram of Thermo Top V additional heater and 12 V digital timer.. . . . . . . . . . . . . . . . . . . . . . . 702
Fig. 801 Circulating pump U4849 and U4847 ECON installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Fig. 802 Pipe/hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 803 Installation position of DP40/DP41 metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 804 Information sign of DP40/DP41 metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Fig. 901 Dismantling heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Fig. 902 Installing air-intake and exhaust connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Fig. 903 Installing water connection-piece variant A with teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Fig. 904 Installing water connection-piece variant B without teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 905 Detail of lock on water connection-piece variant B without teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 906 Removing and installing burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 907 Cable routing of glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 908 Cable routing of glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 909 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 910 Cable routing for temperature sensor and overheating sensor with water connection-piece variant A . . 906
Fig. 911 Cable routing for temperature sensor and overheating sensor with water connection-piece variant B. . . 906
Fig. 1001 Preferred position of TT-V heater for storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

IV

Page 7
Thermo Top V 1 Introduction

1 Introduction

1.1 Contents and purpose NOTE

This heading is used to direct your attention to a special fea-
ture deemed essential to highlight.
This workshop manual supports personnel trained by
Webasto, who are responsible for repairing the
Thermo Top V auxiliary and additional water heaters in the
petrol and diesel versions. 1.3 Additional documentation to be used
This manual applies exclusively for the repair of heaters,
which are only installed with a vehicle-specific vehicle kit or This workshop manual contains all necessary information
directly at the vehicle manufacturer's plant as original equip- and instructions for the repair of Thermo Top V water heat-
ment. ers.
Normally, there is no need to use additional documentation.
If necessary, the operating instructions and/or the installa-
1.1.1 Using water heaters tion suggestion for the specific vehicle may also be
used.When working on OEM heaters and performing diag-
The Thermo Top V water heater was designed for installa- nostic work on them, the instructions of the respective vehi-
tion in Class M1 motor vehicles. Installation in Class O, N2, cle manufacturer must be followed.
N3 motor vehicles and hazard substances transports in
accordance with the EC Directive 70/156/EEC and/or EC/ 1.4 Statutory regulations and safety
2007/46 (for new vehicle models from 29/04/2009) is not
instructions
permissible. The applicable regulations must be taken into
account when installing in special vehicles. No other uses
are permissible. 1.4.1 General safety instructions

The Thermo Top V auxiliary water heater is used to compen- In principle, the general accident prevention regulations and
sate the heat deficit on consumption-optimised vehicle current works safety instructions are applicable.
engines and can be upgraded to an additional/auxiliary
heater with an upgrade kit. Any special safety regulations relevant to this instruction
manual will be highlighted in the relevant sections or text
The Thermo Top V additional water heater is used: passages of the procedures.
– to heat the vehicle interior,
– to defrost the vehicle windows, The repair and commissioning of the unit may only be car-
– to preheat water-cooled vehicle engines. ried out by personnel trained by Webasto. The unit may only
be installed professionally in accordance with the installa-
The heaters are marked on the type label with the text "Pet- tion instructions.
rol" or "Diesel". The heaters may only be operated with the
fuel specified on the type label (for information on diesel The heater must not be operated:
and petrol fuel, see Chapter 4) and only with the respec- • In filling stations and tank farms.
tively specified type of electrical connection. • At locations at which highly flammable gases or dusts
can form, and at locations at which highly flammable
liquids or solid materials are stored (e.g. near fuel, coal
1.2 Meaning of signal words and wood dust, grain warehouses, dry grass and leaves,
cardboard , paper, etc.).
Throughout this manual, the signal words WARNING, • In closed rooms (e.g. garages), not even via the timer or
IMPORTANT and NOTE have the following meanings: Telestart.

WARNING The heater:

This heading is used to highlight operating instructions or • may not be subjected to temperatures of more than
procedures which, if not or not correctly followed, may 120 °C (storage temperature).
result in personal injury or fatal accidents. • must be operated with at least a 20 % mix of a brand-
name antifreeze in the water of the heating circuit.
IMPORTANT • may only be operated with the fuel and the nominal
This heading is used to highlight operating instructions or voltage specified on the type label.
procedures which, if not or not correctly followed, may • must be shut down by immediately switching off the
result in damage to the equipment or its components. heater and removing the fuse in case of heavy smoke,
unusual combustion noises or fuel odours. Restarting
may only be carried out by personnel trained by Webas-
to after the unit has been checked.

101

Page 8
1 Introduction Thermo Top V

• Must be put into operation at least once a year for 10 1.4.3 General information
minutes with the engine cold and the lowest fan speed
selected. Some vehicle manufacturers have provided components like
• Must be checked by a professional every 2 years, at the the auxiliary/additional heater with component protection.
commencement of the heating period. On these vehicles the new unit must be activated after
replacing the unit at a specialist workshop of the respective
Warranty and liability claims: manufacturer.
• A failure to observe the vehicle-specific installation in- Please note that this is generally linked to low additional
structions/operating instructions and the information costs for the customer.
contained in them will result in the warranty being void-
ed by Webasto. The same applies if repairs are carried
out incorrectly or with the use of parts other than gen-
uine spare parts. This will result in the invalidation of the
type approval for the heater and therefore of its ho-
mologation / EC type licence. In addition, we shall also
exclude our liability for slightly negligent violations of
duties, provided damages from injury to life, body or
health or guarantees are not affected or claims in ac-
cordance with the applicable product liability laws are
not concerned. Also unaffected by this is the liability for
the violation of duties which, when fulfilled, enable the
proper execution of the contract in the first place and in
the regular fulfilment of which the customer may place
its trust. The same applies to violations of duties by our
vicarious agents.

1.4.2 Statutory regulations governing installa-

tion

For the Thermo Top V heater there are homologation

approvals in accordance with the EC Directives 72/245/EEC
(EMC) and 2001/56/EC (heating) with the EC approval num-
bers:

e1*72/245*2006/96*1232*__
e1*2001/56*2006/119*0018*__

Installation is governed above all by the provisions in Annex

VII of Directive 2001/56/EC and the regulations in accord-
ance with the installation instructions.

NOTE:
The specifications of this Directive are binding in the scope
of the Basic Directive EEC/70/156 and/or EC/2007/46 (for
new vehicle models from 29/04/2009) and should also be
observed in countries in which no special regulations exist.

102

Page 9
Thermo Top V General description

2 General description

The heaters operate in accordance with the venturi principle The heater consists of the combustion-air fan unit with the
and use the physical effects of film evaporation and droplet control unit, the heat exchanger with the water connection
evaporation for the processing of the fuel-air mixture. piece and the venturi burner.

After reaching a coolant temperature of approx. 80 °C, the

heater switches from full load to partial load. In this operat-
ing mode the heater runs especially quietly and more effi-
ciently with regards to electrical and fuel consumption.

Coolant outlet Coolant inlet

Sensors
Venturi burner

Combustion air fan

Burner

Control unit

Heat exchanger
Electrical connection
Glow plug

Combustion air inlet

Fuel inlet Exhaust outlet

Fig. 201 Cross-sectional functional model of Thermo Top V water heater

2.1 Combustion-air fan unit/control unit

The combustion air fan supplies the air required for the
combustion process from the combustion air inlet to the
combustion chamber.The combustion-air fan unit contains:
• the heater type label
• the opening for the combustion-air connection piece
and the combustion air pipe
• the control unit with the plug-in contacts for the electri-
cal contact
• the engine and the impeller

For information on checking the fan unit, see section

6.3.1.1.

Fig. 202 Combustion-air fan unit

201

Page 10
General description Thermo Top V

Connector plate variants 2.2 Diesel/petrol burner

The processing of the fuel-air mixture and the actual com-

bustion take place in the burner. The fuel flows into the pre-
heating chamber with the shut-off valve opened, where it is
at first heated up. After exiting from the fuel needle, it is
atomised in a venturi nozzle through which primary air
flows. Additionally directed secondary air is routed into the
AMP connec- combustion chamber via the heat shield. The pilot flame is
tor basket ignited on the hot spot of the glow plug and then, after
slowly running up, leads to the ignition of the flame in the
full load operating mode. In the process, the heater is
dependent on the most bubble-free fuel delivery possible.
The start process differs in different ambient temperatures
ensuring that the heater starts with the minimum of smoke
emission.
Fig. 203 Standard connector plate with AMP connector
basket

FEP connector
basket

Fig. 204 Connector plate with FEP connector basket

Fig. 206 Diesel burner with solenoid valve (SV)

Fig. 205 Connector plate for VW single board with FEP

connector basket
Fig. 207 Diesel burner with fuel preheating (FPH)

For connector assignment on control unit, see section 7.1.

202

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Thermo Top V General description

For information on removing and installing the burner, see

section 9.2.5 and 9.2.7.

IMPORTANT
Ensure that the correct burner is always used, as otherwise
malfunctions and/or damage will occur on the heater and its
service life will be reduced!

2.2.1 Fuel preheating

(diesel burner with FPH only)

The fuel flows in a spiral in the preheater between a

threaded sleeve and a smooth outer sleeve and is heated by
an electrically operated heating cartridge during starting.
Preheating is briefly activated in the burn-out with a low
output to be able to burn the remaining fuel after the unit
Fig. 208 Diesel burner without fuel preheating is switched off.

For information on checking fuel preheating, see section

6.3.1.2.

Fuel preheating

Guard plate
Fuel preheating 1 Fuel preheating 2
(fuel pipe without SV) (fuel pipe with SV)

Fig. 211 Fuel preheating

Fig. 209 Petrol burner with guard plate 2.2.2 Solenoid valve
(diesel burner with SV only)

The solenoid valve is only used with a certain diesel heater

variant. It ensures that fuel is routed into the combustion
chamber at the correct time in the start-up phase. When the
heater is switched off, the solenoid valve is intended to pre-
vent any fuel from flowing into the combustion chamber.

For information on checking the solenoid valve, see section

6.3.1.3.

NOTE
The solenoid valve cannot be removed

Fig. 210 Petrol burner without guard plate

203

Page 12
General description Thermo Top V

2.4 Heat exchanger