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Thermo Top - Troubleshooting Tree
07-15-2002
CAUTION
Troubleshooting requires comprehensive knowledge about the structure and theory of operation of the Thermo
Top heater. Troubleshooting and repairs may only be performed by Webasto trained and certified, professionals.
Functional Description - Thermo Top
Switch On
When operating via the "instant heat" button on the 24 hour digital timer, or when the timer reaches the preset
starting time, the flame indicator on the timer display illuminates. This activates the heater, glow pin, combustion
air fan and the circulation pump. After 30 seconds the fuel pump starts and the combustion air fan operation is
suspended for 3 seconds. Subsequently, the combustion air fan speed is increased in two ramps within 56 seconds to
part load operation. After a stabilization phase (constant speed) of 15 seconds the combustion air fan speed is again
increased in a ramp within 50 seconds to full load. After reaching full load, the glow pin is deactivated and the
combustion air fan operation is increased. During the next 45 seconds and during normal heater operation, the glow
pin functions as a flame sensor to monitor the flame condition. Once the start-up and stabilization periods have been
completed the heater begins the automatically controlled heating operation. In case of a no-flame condition during
start-up or a flameout during normal combustion operation, the heater will go into a “shut-down upon malfunction”
state with a run-down of the combustion air fan.
Heating Operation
When the coolant reaches temperature the heater switches to the energy saving part load operation. A rise in coolant
temperature above the upper threshold causes the heater to enter a control idle period. The circulation pump and the
operation indicator light remain on during control idle. After cool-down of the coolant, the heater resumes full load
operation. Another rise in coolant temperature above the upper threshold causes the heater to enter the control idle
period again. A drop in the coolant temperature during part load operation due to an increased demand in heat will
cause the heater to switch to full load operation.
Switch Off
When turning the heater off by pushing the "instant heat" button on the 24 hour digital timer or after the preset
timer cycle elapses, the indicator on timer panel extinguishes, combustion terminates and the shutdown (after-run)
phase commences. The circulation pump and the combustion air fan continue operation during the shutdown phase
to cool the heater down and will be automatically switched off afterwards. The duration time and the combustion air
fan speed during the shutdown phase depend on the heater operating condition at the time the heater is turned off.
Shut-down time duration is normally 180 seconds (3 minutes) when deactivated in full load operation and 100 seconds
(1.6 minutes) when deactivated in part load operation.
Dependent on the software variant implemented in the control unit there might be time duration deviations from those
shut-down periods as stated.
Webasto Product North America, Inc.
• 3333 John Conley Drive • Lapeer, Michigan 48446
For Technical Assistance In USA Call:
(800) 555-4518 •
In Canada Call:
(800) 667-8900
Visit us on the Web at:
www.webasto.us
Org. 07/2002
Thermo Top - Troubleshooting Tree
(Continued from page 1)
Page 2
ATTENTION!
Troubleshooting is normally limited to the isolation of defective components and provides information on defective
wiring and connections.
The following possible causes for trouble have not been taken into consideration and must always be excluded as
a possible cause for malfunctions:
• power supply to heater is less than 10.5 volts at main power connections (charge batteries and perform load test).
See wiring diagram on page 5 for reference to power connections.
• blown fuses.
• corrosion on battery terminals for heater, electrical wiring, connections and fuses.
• loose contacts or connectors, wrong crimping on connectors.
• ensure heater and components have been correctly installed following all pertaining installation instructions.
Troubleshooting Steps
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. Before troubleshooting the heater,
ensure heater is not in the “Lockout” mode by performing the following reset procedure:
1. Ensure timer or switch is in the off position. Turn timer or switch to the on position. Remove fuse F2 (20 Amp),
refer to wiring diagram on page 5 for identification. Reinsert after 5 seconds.
2. Cycle timer or switch off and then back on once more. Remove fuse F2 once again and reinsert after 5
seconds. Heater should attempt to start in 10 seconds after inserting fuse. Coolant temperature must be below
the lower threshold before heater will attempt to start.
NO
Did heater attempt to start?
(Combustion fan running)
Check for 12V on signal at
heater connector X1, pin 3
with timer/switch on.
Repair or replace harness,
connectors, fuses, or
timer/switch accordingly.
Check for 12V at heater
connector X2, pin 1.
Repair or replace harness,
connectors, connections or
fuses accordingly.
Check for ground at heater
connector X2, pin 2.
Repair or replace harness,
connectors or connections
accordingly.
YES
Continued on page 3
Replace Thermo Top heater.
Webasto Product North America, Inc.
• 3333 John Conley Drive • Lapeer, Michigan 48446
For Technical Assistance In USA Call:
(800) 555-4518 •
In Canada Call:
(800) 667-8900
Visit us on the Web at:
www.webasto.us
Org. 07/2002
Thermo Top - Troubleshooting Tree
(Continued from page 2)
Page 3
NO
Is combustion air intake free
from damage and
obstructions?
Repair/replace air intake
tube or remove obstruction
accordingly.
Is combustion exhaust pipe
free from damage and
obstructions?
Repair/replace exhaust pipe
or remove obstruction
accordingly.
Does fuel pump operate
(clicking) during start-up
cycle approx. 30 sec. after
switching on?
Connect test light
to fuel pump leads
(leads connected
normally).
Does the light blink
slowly after 30 sec.
of switching the
heater on?
Is fuel pump
harness free of
damage?
Repair or
replace harness
accordingly.
YES
Replace heater.
Reconnect fuel pump and
turn heater on. After 30
sec. lightly tap fuel pump.
Does fuel pump begin to
operate (Click).
Replace fuel pump.
System should resume
normal operation. Pump
may have been stuck due to
dirt in fuel or long periods
of no operation.
Disconnect fuel line from
heater fuel inlet. Turn
heater on and observe fuel
expelled from fuel line.
Does the pump expel fuel
approximately 12 inches?
(1-2 inches if pump is
equipped with a damper)?
Are fuel lines and fuel filter
free of obstructions? Is
there air in the lines? Are
fuel lines free of damage,
pinched sections, or leaks?
Are the fuel line clamps
tight? Is there sufficient
fuel in the fuel tank?
Replace fuel filter.
Repair/replace damaged
and obstructed fuel lines.
Tighten loose fuel line
clamps. Purge air from
lines. Fill fuel tank with
sufficient fuel to reach fuel
standpipe inlet.
Continued on page 4
Replace fuel pump.
Webasto Product North America, Inc.
• 3333 John Conley Drive • Lapeer, Michigan 48446
For Technical Assistance In USA Call:
(800) 555-4518 •
In Canada Call:
(800) 667-8900
Visit us on the Web at:
www.webasto.us
Org. 07/2002
Thermo Top - Troubleshooting Tree
(Continued from page 3)
Page 4
CAUTION
Allow heater to cool down before disassembly of coolant circulating pump. Allow heater to cool down before
attempting to restart.
NO
Does coolant pump operate
when heater is running (can
feel or hear pump running)?
Remove center
plastic cover from
heater. Disconnect
coolant pump
connector X5.
Apply 12V directly
to the pump (+ to
black and – to
brown). Does
pump operate?
Remove
coolant pump
and 4 cover
screws. Clean
pump
accordingly.
Assemble and
reconnect
pump. Does
pump now
operate?
Replace coolant
circulating
pump.
YES
Replace heater.
Problem
resolved. Test
run heater.
Does heater start and
operate normally?
Check coolant hoses for
obstructions, kinked hoses,
low coolant level and
proper hose routing, etc.
Heater is operating
normally. Possible
intermittent problem.
Should problem reoccur,
rerun through this
troubleshooting tree.
Webasto Product North America, Inc.
• 3333 John Conley Drive • Lapeer, Michigan 48446
For Technical Assistance In USA Call:
(800) 555-4518 •
In Canada Call:
(800) 667-8900
Visit us on the Web at:
www.webasto.us
Org. 07/2002
Thermo Top - Wiring Diagram
Page 5
RED
X1
F2
RED (Power supply to heater)
F1
RED
1
X5
X4
BLACK (ON Signal to heater)
X3
+
6
X2
Battery
RED
1
–
MAIN
POWER
X1
BROWN
2
X2
X4
X5
Fuel
Pump
Fan
Motor
Coolant
Pump
RED
BROWN
BROWN
Additional wiring diagrams are available. Refer to the Thermo Top Operation/Installation manual.
PC Diagnostics
A PC Diagnostics kit is available that allows for more thorough testing and troubleshooting of the heater and its
components beyond the scope discussed in this document. Other functions such as reading values while the heater
is in operation and printing out of fault codes is also available (user supplied computer and printer required).
Order PC Diagnostics Kit under P/N 92542F and the required adapter under P/N 92566A.
Webasto Product North America, Inc.
• 3333 John Conley Drive • Lapeer, Michigan 48446
For Technical Assistance In USA Call:
(800) 555-4518 •
In Canada Call:
(800) 667-8900
Visit us on the Web at:
www.webasto.us
Org. 07/2002
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