Thermo Top

5
5.1

5 Troubleshooting
CAUTION Troubleshooting requires profound knowledge about components and their theory of operation and may only be performed by trained personnel. In case of doubt functional interrelations may be derived from Sections 2 and 3 as well as from Fig. 504 in this Section. The control unit Thermo Top includes a failure diagnosis facility to identify and store errors.

Troubleshooting
General

This section describes troubleshooting procedures for the heaters Thermo Top and Thermo Top T in installed and removed condition. Failure symptoms of general nature (heater installed in vehicle) with their troubleshooting procedures are described in Section 5.2. Section 5.3 contains failure symptoms which may be corrected with the heater removed. 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Vehicle battery Flat fuse holder Relay, vehicle fan Grounding point Diagnosis line Timer Vehicle fan switch Combustion air intake line Exhaust pipe Muffler Vehicle fan Heat exchanger of vehicle heating system Coolant hoses Fuel tapping from return line Fuel tank Heater Wiring harness 15

17

8 16 9

14 10

11

12 13

Fig. 501 Representative Installation Arrangement in Vehicle 501

5 Troubleshooting
5.2 Troubleshooting, Heater installed

Thermo Top
The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunctions: loose contacts wrong crimping on connectors corrosion on wiring and fuses

Heater troubleshooting may be performed using the diagnosis tester Thermo Test or by readout of the error memory with the Webasto fault diagnosis. The diagnosis identifies faulty electrical components, failed starts, flame-outs, low voltage and overheating providing important information for troubleshooting. Troubleshooting should always begin with a readout of the diagnosis. Fig. 503 lists possible error messages and their probable cause as encountered during the functional test with the diagnosis tester Thermo Test. Failure to identify the fault requires removal of the heater. Fig 504 contains additional information for probable causes should no diagnosis tester be available or identification of the fault not be possible.

The circuit diagrams (Fig. 702 and 703) are a useful aid. In emergencies our technicians on the service telephone may be contacted. After any fault correction a functional test in the vehicle has to be performed (see 6.2).

Symptom 1. Heater cannot be switched on

Probable Cause Heater is in error lockout No power supply to heater Summer/winter switch in summer position Battery discharged Fuse defective Timer defective

Remedy See 3.6.3 Check for voltage at heater connector X15 Reverse switch Charge battery Replace fuse Check for timer to heater switching by disconnecting connector X14 from heater, activating timer and by checking for 12 V on contact 1 of 6-pole connector X14. Perform functional test of timer (see 6.2.2) and check for 12 V between red and brown on connector of timer. Check 1 A fuse and wiring as required. Allocate transmitter according to installation instructions Replace batteries Place batteries as shown on figure Disconnect connector X14 (6-pole) and apply 12 V to contact 1 (only fan motor is in operation) Remove heater and isolate defective component Operate engine for approx. 30 seconds Start heater with vehicle engine running Charge battery Disconnect battery charger Remove heater and isolate defective component

No power supply to timer

Heater with telestart

Transmitter not allocated Transmitter batteries low Batteries placed wrong Transmitter or receiver defective Heater defective

2. Heater does not ignite; fan motor operating

Intermediary fuel container empty Solenoid valve does not open Voltage too low Voltage too high because battery charger connected Heater defective

Fig. 502 Troubleshooting with Heater installed (Sheet 1 of 2)

502

Thermo Top
Symptom 3. Heater burns for several minutes only Probable Cause Heater not properly placed in support and taking in exhaust fumes Heaters fuel integration not correct; supply and return lines interchanged Return valve possibly installed in fuel line between heater and vehicle tank or in vehicle tank (intermediary fuel container is not vented) Heater defective Heat exchanger hot, engine cold Circulation pump defective Coolant hose kinked or system not completely bled 4. Heating performance insufficient, however heater is burning Vehicle heating system or fan adjustment wrong Coolant circuit not properly bled Integration in cooling system wrong Vehicle fan operation not initiated when reaching switching temperature (coolant >30 C) 5. Blue smoke or exhaust fumes sooty, heater develops smoke Relay for vehicle fan (see Fig. 501) defective 25 A fuse defective Heater defective Intake or exhaust line kinked or clogged Lack of combustion air Wrong installation, heater not properly seated in support or exhaust gasket not fitted Heater defective 6. Heater alternates frequently between full load (VL), part load (TL) and off. 7. Heater "tickers" in combustion operation or in run-down Circulation pump defective Remedy

5 Troubleshooting

Loosen 2 screws M6 and locate properly

Connect fuel lines properly (see 8.6.2)

Only installation of Thermo Top C is possible

Remove heater and isolate defective component Replace pump Check line routing, bleed cooling system (engine start) Prior to heater operation set vehicle heating system to warm and fan switch to stage 1 or higher (see 3.3) Bleed circuit according to manufacturers instructions, run engine to warm up Integrate heater upstream of vehicle's own heat exchanger Check relay function by triggering relay with components tester, fan must operate Replace fuse Replace heater and isolate defective component Check for proper routing and no obstructions

Adjust CO2 to proper value Check installation

Remove heater and isolate defective component Replace circulation pump

Operating noise of fuel pump

If heater functions properly there is no malfunction

Fig. 502 Troubleshooting with Heater installed (Sheet 2 of 2)

503

5 Troubleshooting

Thermo Top

Error Message Control unit defective Flame-out 1

Probable Cause Faulty electronics EOL programming error

Flame-out during operation and no flame-up after a new attempt to start Intermediary fuel container empty Vehicles own fuel pump or solenoid valve defective

Flame-out 2

More than three flame-outs during operation Intermediary fuel container empty Vehicles own fuel pump or solenoid valve defective Wrong integration in fuel system Check valve in fuel system Burner defective Vehicle battery charger probably defective Battery discharged or defective High transition resistance in the power supply lines (plus and minus) Coolant level too low Heater has not been bled No circulation Ground short in power supply line to dosing pump Open line to solenoid valve Short circuit to plus of power supply Switched line short circuit to plus of power supply Overload or short circuit of burner motor Open line to burner motor Switched line short circuit to plus of power supply Overload or short circuit of glow plug Open line to glow plug Switched line short circuit to plus of power supply Overload or short circuit of circulation pump Open line to circulation pump Line to fan relay shorted against ground Overload of output to fan trigger ( I > 500 mA) Flame sensor short circuit to plus of power supply Open line to flame sensor or shorted against ground

Voltage too high Voltage too low Overheating

Dosing pump short circuit Dosing pump open circuit Burner motor short circuit Burner motor open circuit Glow plug short circuit Glow plug open circuit Water pump short circuit Water pump open circuit Fan short circuit Flame sensor short circuit Flame sensor open circuit

Fig. 503 Error Messages during Functional Test with Diagnosis Tester

504

Thermo Top
5.3 Troubleshooting, Heater removed

5 Troubleshooting
3. Measure resistance of glow plug and flame sensor (see 6.3.4). 4. Perform functional test of heater on test rig according to 6.3. Make conclusions on further possible causes evaluating CO2, CO and smoke spot number. The following table (Fig. 504) lists possible failure symptoms during heater test rig testing:

Perform troubleshooting in the following sequence: 1. Read error memory with Webasto diagnosis. 2. Check power consumption of combustion air fan, solenoid valve and circulation pump as required using components tester.

Symptom 1. Heater cannot be activated 2. Heater does not ignite, fan motor operates for 130 s

Probable Cause Heater is in overheat error lockout Intermediary fuel container empty Solenoid valve does not open (no clicking sound audible during components test) No fuel supply within heater

Remedy With heater in operation remove 15 A fuse for a short time and identify cause of trouble Replenish intermediary fuel container

Free valve by short time (1 s) application of overvoltage (max. 20 V), otherwise replace intermediary fuel tank Remove burner insert (see 8.7.3.1), trigger fan motor and solenoid valve with components tester. Fuel must pulsate from black rubber gasket into combustion chamber, otherwise replace intermediary fuel container Assess condition of burner insert, replace as required and install properly according to 8.7.3.2 Identify defective component using components tester and replace component

Burner insert not mounted properly or fabric worn Control unit identifies an error in the electrical circuit of fan motor, circulation pump, solenoid valve, flame sensor or glow plug and goes in error lockout run-down Glow plug resistance too high Control unit defective 3. Heater ignites and burns; extinguishes after repeat start Flame sensor defective, it is possible that flame sensor readings during resistance measurements are correct and sensor fails only as soon as heater is in combustion operation. Lack of combustion air, wrong mounting, gasket is missing Burner insert not properly mounted or fabric worn Fuel rate of delivery in supply unit not correct

Replace glow plug (see 8.7.2) Replace control unit/heat exchanger (see 9.2.6) Replace flame sensor (see 8.7.2)

4. CO2 or CO out of tolerance; heater develops smoke

Using components tester operate fan with 12 V and listen for loss of air. Repair heater Assess condition of burner insert, replace as required and install properly according to 8.7.3.2 Replace supply unit (see 9.2.4)

Fig. 504 Troubleshooting with Heater removed

505

5 Troubleshooting
No. Function Duration (s) Circulation pump UP X18 5...12 V* 5...12 V* 5...12 V* 5...12 V* 5...12 V* Combustion air fan BL X17 6V 6V 6V 6V continuous increase in speed 12 V continuous decrease in speed 6V 35 s 6 V, 85 s 12 V 27 s, 60 s 0V 0V 35 s 6 V, 95 s 12 V 0V 0V Solevoid valve MV X20 0V 12 V 0V 12 V 12 V

Thermo Top
Glow plug GS X16 cycled cycled 0V 0V 0V Vehicle fan FG X14 Pin4 11.5 V** 11.5 V** 11.5 V** 11.5 V** 11.5 V**

1 2 3 4 5

Pre-glowing Safety period Run-down, repeat start Stabilisation time Switch over part load to full load Burning at full load switch over full load to part load Burning at part load Run-down from part load Run-down after switch-off Control idle Off Error lockout rundown Error Error overheating

32 85 60 20 60

6 7

60

5...12 V* 5...12 V*

12 V cycled

0V 0V

11.5 V** 11.5 V

8 9 10 11 12 13 14 15

120 87 130

5...12 V* 5...12 V* 5...12 V* 5...12 V* 0V 5...12 V* 0V 0V

12 V 0V 0V 0V 0V 0V 0V 0V

0V 0V 25 s cycled 0V 0V 0V 0V 0V

11.5 V 11.5 V 0V 11.5 V 11.5 V 0V 0V 0V

All voltages are approximate values *) For Thermo Top T dependent on coolant temperature due to circulation pump control **) in operation with coolant temperature >20 C (Thermo Top T) >30 C (Thermo Top)

FG FW 2 1 UP 2 1 2 1 2 1 1 BL GS 12V+ 1 2 4 5

MV

6 3

X19

X18

X17

X16

X15 Timer Uhr Diagnosis Diagnose 1 T60 T60

1 not used

Fig. 505 Output/Input Voltages on Control Unit Connector Terminal 506

Thermo Top
FW UP BL GS FG MV Flame sensor Circulation pump Combustion air fan Glow plug Vehicle air fan Solenoid valve

5 Troubleshooting

1 not used

2 summer/winter switch (optional)

FG FW 2 1 UP 2 1 2 1 2 1 1 BL GS 12V+ 1 2 4 5

MV

6 3

X19

X18

X17

X16

X14 X15 Timer Uhr Diagnosis Diagnose 1 T60 T60

X20 MV

Fig. 506 Control Unit Connector Assignment 507