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heater 12 V(including circulating pump and electronic control unit)standdigital timer 1530, 3 preset timestransmitter T70, heating period 10-60 minwiring harnessmetering pumpfuel hose Øi 1,5 / Øa 5; 5000 lg.air-intake hose PAP Øi 18 / Øa 25; 500 lg.air-intake hoseexhaust silencer Ø 22flexible pipe (inoxyd.) Øa 22; 1000 lg.bag (mounting hardware for Thermo Top C) consisting of:connection pipe, plastic Ø 18 x 20hose clamp (chrome) Ø 20 ... 27pipe clip Ø 25pipe clip Ø 24 ... 26mounting strip 25 x 100cable tie 178 lg.mounting hardwarebag (accessories) consisting of:hose clamp (steel) Ø 10hose clamp (steel) Ø 12fuel hose B8 x 12fuel extractor 8 x 5 x 8fuel hose 4,5 x 10

Item Qty. Description

1

11111111111

2723130

84214

1

234567891011

131415161718

2021222324

Thermo Top E / Thermo Top C

5

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31.08.01 / tt051200 / WTI / ATT-T

Thermo Top Z/CTelestart T 60 retrofit kit

6

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31.08.01 / tt071200 / WTI / ATT-T

Thermo Top Z/C; E

Heat outputControl, variableVoltageFuelDesign certification

Heat outputControl, variableVoltageFuelDesign certification

5 kW2,5-5 kW12 voltsDieselS 289

5 kW2,5-5 kW12 voltsgasoline and DieselS 292 and S 289

Thermo Top Z

Thermo Top Z/C

Heat outputControl, variableVoltageFuelDesign certification

4 kW2,5-4 kW12 voltsgasoline and DieselS 316 and S 317

Thermo Top E

Technical data

214

235

163

163

106

106

7

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Thermo Top Z/C; E

31.08.01 / tt071100 / WTI / ATT-T

Installation positions

0 - 9 0°

0 - 9 0 °

8

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71

2

3

4

5

6

8

1 Timer 2 Exhaust system 3 Central cover 4 Metering pump 5 Burner with glow plug 6 Combustion air fan 7 Control unit with heat exchanger 8 Circulating pump

31.08.01 / tt020500 / WTI / ATT-T

Thermo Top Z/C; EOverview of subassemblies

9

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技术培训 Check

Comment

Function

- Control and regulation of the operation pro- cesses- Dissipation of combustion heat

- PC diagnosis, Thermo test- Check for tightness, damage, deposits in combustion chamber

- Can only be replaced as a unit.

31.08.01 / tt031100 / WTI / ATT-T

Thermo Top Z/C; EControl unit with heat exchanger

10

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技术培训 Check

Comment

Function

Supply of combustion air.

Imax: 2.5 A, Urated = 12 VCheck for damage, easy movement

Use new gaskets for installation.

31.08.01 / tt031300 / WTI / ATT-T

Thermo Top Z/C; ECombustion air fan

11

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Check

Comment

Function

- Fuel distribution and vaporization- Fuel vaporization during the starting phase- Monitoring of combustion process

- Check vaporizer for damage and coking- Pencil-type glow plug / flame detector R25 = 0,30 - 0,33 I < 5 mA

Do not connect pencil-type glow plug / flame detector to external power source.

31.08.01 / tt031200 / WTI / ATT-T

Thermo Top Z/C; EBurner with pencil-type glow plug / flame detector

12

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Comment

Function

Circulation of the heating medium.

Apply 12 V power = > Imax = 1 A

For various installation variantsreplacement of pump cover is possible- the marked version is the standard version

31.08.01 / tt031400 / WTI / ATT-T

Thermo Top Z/C; ECirculating pumps

13

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0-90° 0-90°

max.80°

max.80°

120

120

25 25 45

O6,5

HE IZG ERÄT Typ

Wärm estrom

Spannung/El.Leis tung

Br ennstoff

zu l. Betriebs überdruck

Ident Nr. 66887A

Inbetriebnahmejahr

Prüf zeichen S 316/3172 bar

B enz i n/D ie sel

The rm o To p E- B /D

4 kW

2 1V / 4 0 W

99 00 011 9

e1

EMV P rüfz.: 0 21232

20 20

A us f. 0 1 Fa br.N r.

Th ermosysteme GmbH

Made in Germany

direction of travel any installation

Thermo Top Z/C; E

31.08.01 / tt070402 / WTI / ATT-T

Installation positions and type plate

14

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31.08.01 / tt071500 / WTI / ATT-T

Thermo Top

The pencil-type glow plug is a silicon-nitride sintered ceramic pin with integrated tungsten filament.

+12V nominal resistance R25 = 360 m % 010-+24V nominal resistance R25 = 1400 m % 0

10-

200 400 600 800 1000 1200 1400 18001600 2000 2200 2400 28002600 3000t(ms)

I(A)

00

5

10

15

20

25

30

35

40

Glow plug current

15

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+-3

= 3,4 = 2,6

= 3,0

R R

R

2

400-75°C ca. 500°C25°C

600 800 1400200

1

3

4

5

6

7

8

9

15

10

25 25

25

31.08.01 / tt071600 / WTI / ATT-T

Thermo Top

Resistance FD

Interruption resulting in shutdown due to fault

Short circuitresulting in shutdowndue to fault

Temperature“flame”T=(°C)

Flame

Flame 'light' 7

'dark' 5,6

Flame detector characteristics

R

!

!

= ( )FW

0,4 at: 25°C

16

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31.08.01 / tt040100 / WTI / ATT-T

Thermo Top

Thermo Top

1 2

1 Engine2 Vehicle heat exchanger

Integration into engine/water circuit In-series integration

17

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31.08.01 / tt040200 / WTI / ATT-T

Thermo Top

Thermo Top

1 2 3

1 Engine2 Non-return valve3 Vehicle heat exchanger

Integration into engine-water circuit, integration in secondary circuit (non-return valve)

18

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Thermo Top C

2 5 3 1 4

31.08.01 / tt040400 / WTI / ATT-T

Thermo Top C

1 Engine2 Vehicle heat exchanger3 El. pump (off)4 Combination valve5 Thermostat

Integrtion into engine-water circuit, example MB E class

19

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Thermo Top Z

12 34 5

31.08.01 / tt040300 / WTI / ATT-T

Thermo Top Z

1 Engine2 Vehicle heat exchanger3 Heater heat exchanger4 Compensator tank5 Thermostat

Integration in engine-water circuit, example MB E class

20

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31.08.01 / tt040500 / WTI / ATT-T

Thermo Top

Water-integration, small Thermostatcircuit TT1 2 76 8 453

1 Engine2 El. pump3 Vehicle heat exchanger4 Heater heat exchanger5 Compensator tank6 Thermostat7 Non-return valve8 Thermostat (Webasto)

21

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31.08.01 / tt050601 / WTI / ATT-T

Thermo Top Z

1 Digital timer 2 Connection f. supplementary heating device 3 'Equipment on' indicator 4 Circulating pump 5 Fan connection 6 Negative conductor 7 Relay base 8 Relay base 9 Fan relay10 Negative conductor11 Fuse block12 Negative conductor13 Mounting plate14 Fuse cover15 Voltage supply terminal 3016 Werle relay

Wiring harness, upgrade kit

5

1

234

8

6

12

13

16

14

15

107

11

9

22

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31.08.01 / tt050501 / WTI / ATT-T

Thermo Top Z

HeaterMetering pumpDiagnostic connectorThermostat

ABDC

Wiring harness, supplementary heating device

A

A

B

D

C

23

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31.08.01 / tt050602 / WTI / ATT-T

Thermo Top Z

Automatic circuit diagram for auxiliary/supplementary heating device (retrofit)

(7 5 ) 1 5

6 13 0

3 1

-

+

O UT+15

87a

E1

85

E2

86

A

87

87

30

31

30

I m a x . = 0 ,5 A

1mm

21

mm

2

4

32

1

2

1

5

6

21 21 12

1 2

6

4123 5

12

1

2

1

1

12

2

2

X 1 4

X 1 5

X 1 6

X 1 8X 1 9

X 1 7

Y 1

P

X 9

X 9

B 2

A 1

X 1 4

F 1

F 2

F 3

K 3

M 1

X 1 7 X 1 8

M 2

X 1 9

A 2

X 1 5

A 3

X 1 3

X 1 6

EM 3

S 2

S 1

H 1

24

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31.08.01 / tt050503 / WTI / ATT-T

Thermo Top Z

Connector block, top view

unused1

unused2

22

2

21 1

1

1 3

4 5 6

X19 X18 X17 X16 X15 X14

CA GP/FD 12V+

diagnosticconnector

MPtimer T60

1

2

Input/output voltages at connector block of control unit

25

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31.08.01 / tt050900 / WTI / ATT-T

Thermo Top

1 Vehicle fuse holder2 Fan motor

3 Recirculating air valve

Example of fan control, Audi A4 air conditioning system

26

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Tele Thermo Top

31.08.01 / tt051602 / WTI / ATT-T

Delivery Volume T70 / T80T70

T80

27

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Thermo Top

31.08.01 / tt051603 / WTI / ATT-T

Delivery Volume of T70 Retrofit Kit

28

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Tele Thermo Top

31.08.01 / tt051606 / WTI / ATT-T

Installation Diagram of T70

29

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Thermo Top

31.08.01 / tt051608 / WTI / ATT-T

Installation Diagram of T70 Retrofit Kit

30

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Tele Thermo Top

31.08.01 / tt051609 / WTI / ATT-T

Installation Diagram of D Network Kit

31

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Thermo Top1

2

3

4

31.08.01 / tt060101 / WTI / ATT-T

Thermo Top

1 Injection system2 Engine3 Return line4 Flow line

Integration into fuel system of injection enginesIn-series integration into return line

32

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Thermo Top / Thermo Top T

31.08.01 / tt060104 / WTI / ATT-T

Venting of supply unitT-piece with non-return valve64545A

Joint, fuel return line

Tank vent pipe

Activated carbon filter

Fuel system

33

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31.08.01 / tt060102 / WTI / ATT-T

Thermo Top Z/C; E / Thermo Top S

1 Webasto fuel pick-up2 Webasto fuel tank3 Tank extractor 259 08B / 641 67B /67930A / 838 13A / 97186A / 9001450A4 Non-return valve 114 6465 Tank extractor Ø 18 mm 863 79A Ø 15 mm 862 77A

CautionThe "Legal Provisions for Installation" and the "ImportantNotes" contained in the installation instructions of the applicable heater must, on principle, be observed!

to metering pump

fromengine

non-return valve

remove non-return valve

34 1

1

5

2

Possibilities of fuel extraction in passenger cars

34

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0,150,00

0,00

0,50

1,00

1,00

0,30

0,07

– 0,04 – 0,35

– 0,00 – 0,31

– – 0,27

0,21

l + l

1 2

7ml 1,2 ml 5,8 m 1

2

l + l

1 2

4,5ml 0,5 ml 4 m 1

2

Fuel Supply

Diesel Gasoline

Permissible fuel feed height H (m)

Diesel

Diesel

gasoline

with max. perm. vacuum (bar)in fuel tank

perm. fuelsuction height S (m)

gasoline

with max. perm. overpressure(bar) in fuel line

31.08.01 / tt060213 / WTI / ATT-T

Thermo Top Z/C; E / Thermo Top S

Connection to the vehicle fuel system

max.3m

H

S

I

I

I

I

1

1

2

2

iO2mm

iO2m

m

iO2mm

iO2mm

35

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Thermo Top Z/C; E

31.08.01 / tt060212 / WTI / ATT-T

0-90° 0-90°

horizontal only

0-180° 0-180°0-180°0-180° 0-180°0-180°

DP 2

DP 2 DP 30DP 2 R 2

Metering pump

36

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31.08.01 / tt060215 / WTI / ATT-T

Thermo Top E / Thermo Top Z/C

Installation example VW Bora TT-E/TT-Z/C

1 Seal, Formwasher2 Stopnut3 Hose4 Wireclip

5 Clip6 Clip7 Clamptube, black

1 Heating unit Thermo Top Z/C or E 2 Flat fuse holder and fan relay3 Digital timer4 Exhaust silencer5 Combustion air intake line6 Metering pump

5 1 4 2 3 6

1

2

4

3

5

6

7

3

37

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