Water Heater Operating instructionsInstallation instructions

Thermo TopThermo TopThermo Top TTele Thermo Top

Thermo Top SThermo Top STele Thermo Top S

BW 50 DW 50

Petrol Diesel

8/1995

Table of contents VersionsPage

Operating instructions 2Safety Information 4Operation of the Heater 6Maintenance of Heater 15Troubleshooting 18Functional Description 20Technical Data 22

Installation instructions 23Installation ExampleThermo Top 25Installation ExampleThermo Top S 26Fuel installationThermo Top S 27Fuel installationThermo Top 30Troubleshooting 43Webasto Service Telephone 47

Please mark:

Installed is:

Thermo Top

Thermo Top T

with Telestart T6

with Telestart T60

with Telestart T5

Tele Thermo Top

Thermo Top S

Tele Thermo Top S

Summer/Winter Sw itch

Thermo Top Petroltype BW 50Water heater for fuel “petrol”Thermo Top Dieseltype DW 50Water heater for fuel “Diesel/fueloil EL”

Thermo Top S Petroltype BW 50Water heater for fuel “petrol” withmetering pumpThermo Top S Dieseltype DW 50Water heater for fuel “Diesel/fueloil EL” with metering pump

The water heaters Thermo Top aredesigned to operate on 12 volts.

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Operating instructions

Optional Equipment

Digital Timer Telestart T6 Telestart T60For switching the heater on and offand preprogramming it.

Note:• When the red display lamp is il-

luminated, the maximum oper-ating time is 60 minutes.

• When the green display lampis illuminated, the maximumoperating time is 30 minutes.

For operating the heater by remotecontrol (switching on and off)

Note:• When the operation indicator

light (LED) is red, the maxi-mum operating time is 60minutes.

• When the operation indicatorlight (LED) is green, the maxi-mum operating time is 30minutes.

For operating the heater by remotecontrol (switching on and off)

Note:• When the operation indicator

light (LED) is red, the maxi-mum operating time is 60minutes.

• When the operation indicatorlight (LED) is green, the maxi-mum operating time is 30minutes.

1 1

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Telestart T5For operating the heater byremote control (switching on).

1 Transmitter2 Receiver3 Pushbutton with indicator lamp

1 2

3

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Safety Information1. Within the scope of the StVZO(Road Traffic Licensing Act)“General Design Approvals” laiddown by the Federal Office forMotor Traffic exist for the ThermoTop water heater with the followingofficial marks of conformity: ~ S238 for the Thermo Top

Petrol heater type BW 50 and ~ S239 for the Thermo Top

Diesel heater type DW 50.

2. Installation of the heater mustbe performed in accordance withthe installation instructions andwhen retrofitted it is to be exam-ined by an officially recognized ex-pert or examiner (TÜV) in accord-ance with article 19 para. 2 StVZOupon presentation of the “Opera-ting Instructions” and the “Installa-tion Instructions”. A new operatinglicence for the vehicle has to beapplied for at the Motor VehicleRegistration Office on the basis of

the test report.

Modifications are subject to writ-ten approval by an officially rec-ognized expert or examiner(TÜV).

The year of the initial start-up(commissioning) must be durablymarked on the nameplate.

3. The heaters are approved forheating motor vehicle engines anddriver’s cabs. When using theheater in special vehicles that arenot governed by the StVZO (e.g.ships) any existing local regula-tions are to be observed.Use in “Vehicles for the Transportof Dangerous Goods” (TRS) is notpermissible.

4. Due to the danger of poison-ing and suffocation, the heatermust not be operated in closed

rooms, such as garages or work-shops, without adequate ex-haust extraction. This should beconsidered when presettingheater operating times or usingthe Telestart remote control.

5. Due to the danger of explo-sion the heater must beswitched off at filling stationsand fuel depots.

6. In the vicinity of the heater atemperature of 120°C (storagetemperature) must not be ex-ceeded (e.g. when carrying outpaint work on the vehicle).If the temperature is exceeded per-manent damage to the electronicsmay be caused.

7. Checking the cooling waterlevel is to be performed in accord-ance with vehicle manufacturer’sinstructions. The water contained

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in the heating circuit of the heatermust contain a minimum of 10% ofa quality brand antifreeze.

8. The heater’s “General DesignApproval” and thus the GeneralOperating Licence of the vehicleare void if the installation of aheater is not approved. The sameapplies to improperly performed re-pairs or those where others thangenuine spare parts have beenused.

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Operation of the HeaterNOTE:Prior to switching on the heater,the vehicle’s heating system is tobe turned to “warm”.In the case of 3-speed blowerfans, the vehicle’s blower fan is tobe set to the 1st position, in thecase of 4-speed blowers to the2nd position. In the case infinitelyvariable fans adjust to at least 1/3of the fan capacity.

Depending on the features fitted,the water heater can be activatedby means of the following controlelements:

Switching on by means ofDigital timer:

manually: by pressing the “instantheat” buttonautomatically: by presetting thestart of the heating operationOn the display the symbolappears and the display light isilluminated.

Switching off by means ofDigital timer:manually: by pressing the “instantheat” buttonautomatically: by presetting theend of operating timeThe digital readout disappears.

Switching on by means ofTelestart T6

by actuating the slide switch onthe transmitterThe operation indicator light (LED)on the transmitter flashes

Switching off by means ofTelestart T6:manually: by actuating the slideswitch on the transmitterautomatically: by presetting theend of operating timeSwitching on by means of Tele-start , Switching off by means ofDigital timer:Press instant heat button twice

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Switching on by means ofTelestart T60

by pressing the left side of the but-ton on the transmitterThe operation indicator light (LED)on the transmitter flashes

Switching off by means ofTelestart T60:manually: by pressing the right sideof the button on the transmitterautomatically: by presetting theend of operating timeSwitching on by means of Tele-start , Switching off by means ofDigital timer:Press instant heat button twice

Switching on by means of Tele-start T5/pushbutton switch

by pressing the button on the Tele-start device or by pressing thecorresponding Telestart pushbut-ton switch provided in the vehicleThe green indicator light in the ve-hicle is illuminated.

Switching off by means of Tele-start T5:manually: by pressing the pushbot-ton switch in the vehicleautomatically: by presetting theend of operating timeThe green indicator light in the ve-hicle goes off.

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Digital TimerPresetting the starting time ofthe heater:Start of heating operation can beprecisely preselected within arange between »1 minute« and»24 hours«. Three starts may be programmedonly one of which, however, canbe activated.If the red lamp on the display is il-luminated, the operating time is 60minutes, if the green lamp is illumi-nated it is 30 minutes

Heater operation indicator

Symbol for setting/checkingthe time

Program number display

Clock button

Illumination of display

Instant heat Reverse Program selection Forward

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Setting the Digital T imerSetting the Time

- Press “Clock” and then“Forward” or “Reverse” buttons

* During the adjustment, thesymbols “.” and flash onthe display and the display isilluminated.

* After 10 seconds the readoutdisappears and the display il-lumination goes off

NOTE:The longer the buttons arepressed the more rapidly the digitson the display will change.

Recalling time of the day

- Press “Clock” button.* Time is displayed.

Switching heater on immediately

- Press “Instant heating” button

* The heating operation indica-tor and the display illumina-tion light up

Switching heater off

- Press “Instant heating” button

* The operation indicator andthe display illumination go off

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Presetting heater start-up

- Press button

* On the display the following ap-pears for 10 seconds:• a program number• –:– – or a previously set start-up time• in addition, the display is lit up

- Within 10 seconds press “For-ward” or “Reverse” but-ton until the desired time forstart-up of the heater appearson the display

- Each time a different programnumber is desired, the but-ton must be pressed within 10seconds

NOTE:Heater start-up is programmedwhen the program number is dis-played and the display is illumi-nated.

Cancelling preset time

- Momentarily press button- Program number and display

illumination disappear

Selecting a preset time

- Press button within 10 sec-onds until program numberwith the desired preset time as-signed to it is displayed.

* After 10 sec. the time displaygoes off.

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Operation of Telestart T6The wireless Webasto TELE-START T6 unit enables WebastoThermo Top heating units to beswitched on and off from a dis-tance of up to 300 m. The TELE-START remote control makes useof UHF radio signals. The receiverlimits the operating time after theheater has been switched on bythe transmitter. Owing to the opera-ting time presetting the heater isswitched off automatically. Maxi-mum range of remote control is ob-tained in open country. In built-upareas the reach is likely to be re-duced. Transmitter and receiver ofthe Telestart T6 unit have not beentuned by the manufacturer.

Tuning of transmitter and receiveris carried out after installation.

The installer can allocate 2 trans-mitters to one receiver.

Note:Tuning of Telestart T6 handheldtransmitter and receiver isdescribed on page 33.

Switching onPull out antenna of transmitter ap-prox. 2 cm and then extend it asfar as it will to.Slide the switch on the transmitterto the “Start” position.Operation indicator light on trans-mitter flashes.Retract antenna.

Switching offPull out antenna of transmitter ap-prox. 2 cm and then extend it com-pletely.Slide the switch on the transmitterto the “Off” position.Operation indicator light on trans-mitter no longer flashes.Retract antenna.

Switching on by means of Tele-start and switching off bymeans of Digital TimerPush button on digital timer.The symbol appears on thedisplay of the timer.To switch off, push the buttononce more.The symbol of the timer disap-pears.The operation indicator light incor-porated in the transmitter con-tinues to flash until the heater isswitched off at the preset time orthe switch on the Telestart transmit-ter is moved to the “Off” position.

Start

Off

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Operation of Telestart T60The wireless Webasto TELE-START T60 unit enables WebastoThermo Top heating units to beswitched on and off from a dis-tance of up to 600 m. The TELE-START remote control makes useof UHF radio signals. The receiverlimits the operating time after theheater has been switched on bythe transmitter. Owing to the opera-ting time presetting the heater isswitched off automatically. Maxi-mum range of remote control is ob-tained in open country. In built-upareas the reach is likely to be re-duced. Transmitter and receiver ofthe Telestart T60 unit have notbeen tuned by the manufacturer.

Tuning of transmitter and receiveris carried out after installation.

The installer can allocate 2 trans-mitters to one receiver.

Note:Tuning of Telestart T60 handheldtransmitter and receiver isdescribed on page 34.

Switching onPull out transmitter’s antenna allthe way.Push switch on transmitter to“Start”.Operation indicator light on trans-mitter flashes.Retract antenna.

Switching offPull out transmitter’s antenna allthe way.Push switch on transmitter to “Off”.Operation indicator light on trans-mitter no longer flashes.Retract antenna.

Switching on by means of Tele-start and switching off bymeans of Digital TimerPush button on digital timer.The symbol appears on thedisplay of the timer.To switch off, push the buttononce more.The symbol of the timer disap-pears.The operation indicator light incor-porated in the transmitter con-tinues to flash until the heater isswitched off at the preset time orthe switch on the Telestart transmit-ter is moved to the “Off” position.

Start

Off

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Operation of Telestart T5Switching on the Receiver

Actuate the slide switch at thebase of the receiver. The operation indicator is illumi-nated.The receiver is ready for operation.

Start-up of the Heater Using Tele-start

Press the button on the Telestartdevice for at least 2 seconds.When so doing, hold the transmit-ter with the antenna in upright posi-tion. While the button is pressed atone sequence will be audible.The green indicator light in thepushbutton switch inside the ve-hicle is illuminated.

Switching the Heater Off

The heater switches itself automat-ically off after 30 minutes .If heating operation is to be termi-nated prematurely: actuate thepushbutton switch inside the ve-hicle.The green indicator light in thepushbutton switch goes off.

CAUTION:If the system is equipped withTELESTART only , no visual indi-cation will occur in the event of ashutdown due to overheating.

Operation in Summer

If the heater is not used for an ex-tended period of time, e.g. duringthe summer months, power supplycan be interrupted by means ofthe slide switch at the base of thereceiver. The 9V alkaline batteryshould be removed when the hand-held transmitter is not in use.

slide switch

operationindicator

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Summer/Winter Switch(Option, applicable to ThermoTop S only)

The summer/winter switch enablesnormal heating operation duringthe cold months and provides ven-tilation during the warm periodmaking use of the heater fan of thevehicle.With the heater fan switched on(switch position identical to that re-quired for heating), the ventilationswitch positioned to fresh air set-ting and the summer/winter switchset to summer, only the heatingfan of the vehicle is put into oper-ation.

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Maintenance of HeaterThe heater should be checked at aWebasto service center at regularintervals, at the latest, however, atthe beginning of the cold season(when the heater is used fre-quently due to weather conditions).

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Maintenance of Telestart T6Inserting the BatteriesOpen battery compartment in thetransmitter with a quick anti-clock-wise rotation using a suitable ob-ject (e.g. a coin).Place 2 batteries (CR 2430 buttoncells) - positive poles facing up -into the battery compartment. Close battery compartment bytwisting it briefly clockwise.

Checking the BatteriesPush switch on transmitter to“Start”.Batteries okay:Operation indicator is flashing.Subsequently, switch to “Off” again.

Maintenance of Telestart T60Inserting the BatteriesOpen the battery compartment inthe transmitter.Insert two batteries (1.5 V LR1 al-kaline) into the battery compart-ment as shown on this page.Close the battery compartment.

Checking the BatteriesPush the switch on the transmitterto the “Off” position.Batteries are okay:Operation indicator is flashingthree times.

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Maintenance of Telestart T5Loading battery in Telestarttransmitter

Slide 9-volt battery (2) (Webastoordering no. 436704) - only al-kaline batteries to be used - intothe battery compartment at thebase of the hand-held transmitter(1) ensuring that polarities arealigned correctly.Close lid (3). The hand-held trans-mitter (1) is ready for operation.

Checking the battery

Press green button on transmitter.A “tone sequence” becomesaudible.

If no tone sequence can be heard- the battery is either too cold

and must be warmedor the battery is too weak andmust be replaced.

1

3

2

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TroubleshootingIn the event of a malfunction thefuses and plug connections are tobe checked for proper conditionand security of attachment.

Malfunction (Telestart) Cause RemedyTelestart T6/60: After the start-up,the operation indicator does notflashTelestart T60: The operation indi-cator does not flash three times afterthe heater has been switched offTelestart T5: There is no signalemitted when the button on theTelestart transmitter is pressed.

Telestart receiver fails to switch onheater

Transmitter battery colder than-20°C

No contact at batteryOxidized contacts

Battery discharged

Defective vehicle fuse

Weather-related problemsRadio interferenceInsufficient range

Telestart T5 only:No voltage present at receiver

Allow battery to warm up (holdingit in your hand)

Check contact springsCarefully clean contacts

Replace battery

Replace fuse

Actuate switch on transmitter repeatedlyExtend antenna completely

Telestart T5 only:Check slide switch and leads

If the malfunction cannot be reme-died by these measures, pleaseconsult a Webasto service center.

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Malfunction (Heater) Cause RemedyHeater turns itself off automatically(= shut-down on fault)

No combustion took place afterstart-up and repeated start-up.

Flame goes out during operation.

Heater is overheating due to lackor loss of coolant

subsequently it is automatically shutdown by temperature limit switches

CAUTION:On Thermo Top S and TeleThermo Top heaters no messageoccurs when a shutdown due tooverheating occurs.

CAUTION:With the heater Thermo Top S noindication is given In the event of ashutdown due to overheating.

Switch off heater and switch onagain.

If heater fails to operate again,consult a Webasto service center.

Top up coolant as directed by ve-hicle manufacturer

Thermo Top S only:Prior to switching the heater onagain, pull heater fuse (15A) out offuse holder and put it back inagain (power-ON Reset). The fuseis not destroyed by overheating.

Unique to Thermo Top andThermo Top T equipped withDigital Timer: Press the presettingbutton “Set” prior to switching on.

Telestart T5:Prior to switching on, switch offsummer/winter switch on Telestartreceiver and switch on again.

Error message Overheating

Display flash alternately

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Functional DescriptionThe interior of the vehicle is sup-plied with fresh air.

The Webasto water heaterThermo Top is designed for thefollowing uses:- heating of the interior of the cab,- de-icing the vehicle’s windows

as well as- preheating water-cooled engines.

Upon actuation of the “Instantheat” button the symbol ap-pears on the display of the timer,or the operation indicator on thetransmitter flashes when the slideswitch on the Telestart transmitteris actuated. The recirculatingpump, pencil-type glow plug, com-bustion air fan and vehicle heaterfan (does not apply to Thermo TopS heaters) are put into operation.After 32 seconds the solenoidvalve opens (Thermo Top S : thefuel metering pump is connected

to the system) and combustionstarts under starting load condi-tion. After flames have formed, thepencil-type glow plug is deacti-vated, and at the same time thefuel pump and the combustion airfan are switched to partial load for20 seconds to reach the requiredstabilisation. Thereafter, the sys-tem is brought up to full load by con-tinuous control.The automatically controlled heat-ing operation now starts.After the temperature has in-creased to 30°C, the vehicleheater fan (applies to Thermo TopS heaters only) and the recirculat-ing pump control are switched onin order to obtain a higher wateroutlet temperature during the heat-ing-up phase.When the temperature has in-creased to 78°C, the heater swit-ches to energy-saving partial-loadoperation. If the temperature of the

coolant continues to rise to 85°C,the heater switches to the controlidle mode. The circulating pump,the vehicle heating fan and theoperation indicator continue tooperate during the control idleperiod. When the coolant hascooled to 75°C, the heater re-sumes operation.

Switching off: The vehicle fan isswitched off (On the Thermo Top,Thermo Top T and Tele ThermoTop heaters, the vehicle’s fan isswitched off after the after-run)either by pressing the “Instantheat” button ( on the displaydisappears), or by actuating theslide switch on the Telestartremote control (flashing signal onhand-held transmitter goes off).The combustion process is termi-nated and the after-run periodstarts. However, the circulatingpump and the combustion air fan

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continue to operate in order tocool the heater (after-running) andare switched of automatically.After-run time is 120 seconds.Restarting the heater during theafter-run period is permissible.

Applicable to Thermo Top ,Thermo Top T and Tele ThermoTop onlyAfter a combustion period of 30minutes the fuel supply in theheater is consumed. Allowing thevehicle engine to run for 2 minuteswill replenish the fuel supply.

Applicable to Thermo Top T onlyAn additional thermostat control isprovided in order to reach a higheroutlet temperature during the heat-ing-up phase.Application: on vehicles with acubic capacity of more than1800cc.

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Technical DataUnless limit values are indicated,the technical data shown in theTable on the right apply with theusual ± 10% tolerances for heatersat an ambient temperature of+20°C and at rated voltage.

Fuel for Thermo Top (Petrol) type BW 50:The type of fuel prescribed by themanufacturer of the vehicle maybe used.Both leaded and unleaded fuelcan be used.

Fuel for Thermo Top (Diesel/fuel oil EL) type DW 50:The Diesel fuel recommended foruse by the vehicle manufacturer issuitable as fuel for the heater.When changing to cold-resistantfuels, the heater must be operatedfor approx. 5 minutes (Thermo TopS approx. 15 minutes) to ensurethat the fuel line and the fuel pump

are also filled with the new type offuel.

Any negative effect caused by ad-ditives is not known.

Heater Operation Petroltype BW 50

Dieseltype DW 50

Mark of confirmity ~S238 ~S239

Type Water heater with vaporizing-type burner

Heat output full loadpart load

5,0 kW2,5 kW

Fuel Petrol Diesel/EL fuel oil

Fuel consumption full loadpart load

0,50 kg/h0,25 kg /h

Rated voltage 12 Volt 12 Volt

Operating voltage range 10 ... 14 Volt

Rated power consumption with circulation pump(without vehicle fan)

full loadpart load

44 W27 W

44 W27 W

Max. ambient temperature:Heater: - operation

- storageMetering pump: - operation

-40°... +60°C-40°... +120°C-40°... +20°C

-40°... +80°C-40°... +120°C-40°... +20°C

Max. allow. working pressure(heat transfer medium)

0,4 ... 2,0 bar

Heat exchanger capacity 0,15 l

Min. cooling system capacity 4,00 l

Flow rate of circulating pump at roughly 0,1 bar 500 l/h

CO2 content in exhaust gas (perm. operating range) 9,5 ... 12,0 Vol .-%

Dimensions of heater Length 240 mmWidth 103 mmHeight 168 mm

Weight 4.3 kg

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