Home

Corel Ventura - INHALT.CHP

1. With plus from terminal 15 75 to connection 10 Wire Colours continuous operation in instant heating as long as ignition is on Wire Gauges Without plus to connection 10 bl blue heating time programmable as required 10 min to 120 min lt 75m_ 7 5 15m br brown default setting 120 min gt 0 75 mm2 1 5 mm2 ge yellow 1 0 mm 1 5 mm resh Diagnosis line K 1 5 mm 2 5 mm2 g greg 3 Diagnosis line L SE S oe g 40mm 6 0 mm S ted ge Input pin pin 7 connector X7 wire colour on wiring harness ws rt sw black ventilate fan speed is dependent on control element position A vi violet 5 CO adjustment ws white Item Nomenclature Remark Item Nomenclature Remark Al Heater Air Top 3500 5000 Vi Diode A2 Control unit v2 Diode B2 Temperature sensor x1 Connection 2 pole on item A2 ST B B3 Temperature limiter Overheat protection X2 Connection 2 pole on item A2 ST V E Glow plug flame sensor X3 Connection 2 pole on item A2 ST U F1 Fuse 24V 15A 12V 20A Flat fuse SAE J 1284 X4 Connection 2 pole on item A2 ST Z F3 Fuse max 15A Flat fuse SAE J 1284 X5 Connection 2 pole on item A2 ST Y H3 LED red in item P Instant heat switch illumination X6 Connection 2 pole on item A2 ST X standby indication E X7 Connection 12 pole on item A2 ST 1 Ba Gap KEE Ze indicator ight X8 Connection 2 pole Er SE in display perating indication X10 Connection 2 pole H5 Lights in item P Display and push button switch X1 Connec
2. EN Diagnosis line K Diagnosis line L 000 CO adjustment 0 5mrr bl AT 3500 rt AT 5000 sw A1 Input pin pin 7 connector X7 wire colour on wiring harness ws rt ventilate fan speed is dependent on control element position Air Top 3500 5000 30 15 X1 X2 2 1 X3 X4 X5 X6 Wire Gauges Wire Colours bl blue 19 m 75 15 i br brown 2 SC mm T mm ge yellow LU mm 3mm pm 1 5 mm 2 5 mm a oe 2 5 mm2 4 0 mm 9 grey 4 0 mm 6 0 mm or orange rt red sw black vi violet ws white Item Nomenclature Remark X7 Connection 12 pole on item A2 ST 1 X8 Connection 2 pole x9 Connection 4 pole on item S1 X10 Connection 2 pole X11 Connection 2 pole on item Y1 Y1 Dosing pump Item Nomenclature Remark Al Heater Air Top 3500 5000 A2 Control unit B2 Temperature sensor B3 Temperature limiter Overheat protection E Glow plug flame sensor F1 Fuse 24V 15A 12V 20A Flat fuse SAE J 1284 H1 LED green in item S1 Operating indicator light M1 Motor Combustion and heating air fan S1 Control element Rated value transmitter switch S6 Switch Ventilate X1 Connection 2 pole on item A2 ST B X2 Connection 2 pole on item A2 ST V X3 Connection 2 pole on item A2 ST U X4 Connection 2 pole on item A2 ST Z X5 Connection 2 p
3. 14 5 Secure burner 19 in position using fastening clamp 20 6 Insert glow plug flame sensor 11 in burner with shield 18 cable routed towards opening for cable grommet in shield and fasten with oval head screw 9 7 Feed cable of glow plug flame sensor 11 through opening in shield 8 Torque oval head screw 9 to 0 8 0 08 Nm 9 Hold burner with shield 18 upside down engage burner tube 12 and rotate to assemble with combustion tube 10 Push grommet of fuel supply into housing of heat exchanger 14 11 Fasten shield and combustion tube 12 with EJOT FDS screws SF 10 12 Torque EJOT FDS screws SF 10 to 2 5 0 25 Nm 13 Feed cable of glow plug flame sensor 11 through heat exchanger and plug grommet 14 Install combustion and heating air fan see 9 2 5 2 15 Install control unit sed 9 2 4 2 16 Fit insulation collar 15 17 Refit housing components covers N 905 9 Repair Air Top 3500 5000 k OO oO OO JO Om E OON Control unit Torx screw 2 Temperature limiter Torx screw Temperature sensor Torx screw 8 Combustion and heating air fan Flat gasket Oval head screw EJOT FDS screw SF 3 NOTE ZA the temperature limiter may be additionally fastened with a washer This washer must be replaced with a new washer during installation Glow plug flame sensor Burner tube Seal Heat exchanger Insulation mat Seal Torx screw 4
4. Air Top 3500 5000 2 3 Burner with Combustion Tube Inside the burner insert fuel is distributed across the combustion tube fuel cross section Combustion of the fuel air mixture takes place within the combustion tube to heat the heat exchanger Combustion tube or Combustion tube Burner with shield Air Top 3500 5000 2 4 Control Unit The control unit ensures control and monitoring of combustion operation A temperature sensor plugged on the control unit is used for temperature control On all heaters this temperature sensor may be substituted with an externally mounted temperature sensor In case of a heater malfunction an error code is output to the display of the combination timer When equipped with a control element the operating indicator light will flash The heater may be additionally checked using a personal computer refer to operating instructions for PC heater fault diagnosis 2 5 Glow Plug Flame Sensor The glow plug also functions as flame sensor The glow plug ignites the fuel air mixture during heater start The glow plug represents an electrical resistance and is located on the side of the burner exposed to the flame When operating as a flame sensor the glow plug behaves like a low Ohm PTC resistor changing its resistance dependent on its heat up by the flame The signals are routed to the control unit for processing The flame sensor monitors the flame up condition throughout the he
5. Burner with shield Burner Fastening clamp Fig 902 Disassembly and Assembly 906 Air Top 3500 5000 9 2 7 Burner Replacement 9 2 7 1 Removal Remove housing components covers see 9 2 1 Remove insulation mat 15 Fig 902 Remove control unit see 9 2 4 1 ON NOTE Perform steps 5 through 11 for a burner 19 without shield Steps 12 through 16 refer to an installed burner with shield 18 5 Loosen lever off fastening clamp 20 of burner 19 6 Push grommet of fuel supply line out of housing of heat exchanger 14 7 If required carefully bend up fastening clip for cable of glow plug flame sensor 11 located on burner tube 12 8 Withdraw burner 19 9 Remove oval head screw 9 10 Withdraw glow plug flame sensor 11 from burner 19 11 Remove burner 19 12 Remove EJOT FDS screws SF 10 13 Push grommet of glow plug flame sensor 11 out of housing of heat exchanger 14 and withdraw burner with shield 18 from burner tube 12 14 Remove oval head screw 9 15 Withdraw glow plug flame sensor 11 from burner with shield 18 16 Remove burner with shield 18 17 Perform procedures on components after disassembly refer to 9 1 1 9 2 7 2 Installation NOTE Perform steps 1 through 5 for a burner 19 Fig 902 without shield Steps 6 through 13 refer to an installed burner with shield 18 1 Insert glow plug flame sensor 11 into burner cable in direct
6. it will be shut off immediately upon switch off The heater will be cooled down by a run down of 180 seconds at full speed NOTE Reactivation of the heater during run down is permitted The run down will first be completed with a subsequent restart 3 6 Heater Functions when installed in ADR Vehicles Switch off of the heater with the control element has no influence on the run down A short run down max 20 seconds will be automatically initiated in case the e vehicle engine is stopped e aconveyor device is activated The short run down period depends on the operating condition The short run down period is always 20 seconds Run down speed is the same speed as before switch off After an ADR switch off the control unit is in error lockout position Prior to reactivation the control element must be set to OFF 303 3 Functional Description 3 7 Error Lockout The control unit detects malfunctions of individual heater components and errors in the start sequence and in heater operation The heater is switched off and enters error lockout under the following conditions e control unit error e no start e flame out e premature flame detection e temperature sensor open circuit or temperature sensor short circuit e glow plug flame sensor open circuit or glow plug flame sensor short circuit fan motor open circuit or fan motor short circuit or fan motor wrong speed e dosing pump open circuit or dosing pum
7. 802 803 land 804 This separate fuel tapping avoids an influence on the pressure max 3m i 2 mm bg Fig 801 Fuel Supply Air Top 3500 5000 Hole Pattern gt Fig 802 Webasto Fuel Tap Fuel tap to be used only for metal fuel tanks TO Gasket q Fig 803 Fuel Tapping from Plastic Tank tapping via fuel drain plug 8 Servicing Fuel Tank Tap Gasket Tank Fitting Plate Fig 804 Fuel Tapping from Plastic Tank tapping via fitting plate NOTE Tank fitting plate to be made from sheet metal 8 6 2 2 Fuel Lines Fuel lines may only be steel copper or plastic lines made of unhardened light and temperature stabilised PA 11 or PA 12 e g Mecanyl RWTL according to DIN 73378 A descending line routing from the dosing pump to the heater should be avoided As a permanently rising fuel line routing cannot always be ensured the inner diameter must not exceed a certain value Too large inner diameters cause air or gas bubbles to accumulate resulting in malfunctions should the lines be descending or having sags The diameters specified in Fig 801 Ensure no disturbing formation of bubbles Loose fuel lines must be secured in order to avoid sagging The installation must ensure protection against stone impacts and undue temperatures exhaust line Fuel line connections must be sec
8. Installation of Air Heater for Air Circulation Mode of Operation 807 Removal of Housing Components Covers cnn rn naar nana nc ran nn nnnn rca 903 Disassembly and ul EE 906 Air Top 3500 5000 1 Introduction 1 1 Scope and Purpose This repair shop manual is intended to support familiarised personnel in the repair of the air heaters Air Top 3500 Air Top 3500 Volume Plus and Air Top 5000 of the Diesel type 1 1 1 Use of the Air Heaters The air heaters Air Top 3500 and Air Top 5000 are used to heat the cabin defrost the windscreens heat the goods in transport They are not cleared to be used for heating a compartment intended for the transportation of dangerous goods The heaters work independently from the vehicle engine and are connected to the vehicle s fuel and electrical system The use in vehicles with water or air cooled engine is possible 1 2 Meaning of Warnings Cautions and Notes WARNINGS CAUTIONS and NOTES in this manual have the following meaning WARNING This heading is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel CAUTION This heading is used to highlight that non compliance with instructions or procedures may cause damage to equipment NOTE This heading is used to highlight and draw specific attention to information 1 3 Additional Documentation to be used This workshop manual contains all information a
9. RON DARAN 908 11 1999
10. achieved by installing an external temperature sensor in the appropriate room area Procedure 1 Select appropriate installation location for the external temperature sensor NOTE e The temperature sensor should not be directly exposed to warm air flow and not be located in the vicinity of heat sources e g vehicle s own heating system e It should be mounted in mid height of the vehicle cabin on possibly vertical surfaces The installation location should not be exposed to direct sunlight e Do not mount temperature sensor behind curtains or similar 2 Remove cover see 9 2 1 1 and pull off internal temperature sensor 3 Mount external temperature sensor and route cable to heater Connect electrical connector and fit cover Perform heater test run and check control behaviour St Cover External temperature sensor 901 9 Repair 9 1 2 2 Installation of Burner with Shield General Retrofit kit 12 V Ident No 679 84A Retrofit kit 24 V Ident No 679 56A The retrofit kit includes 1 Burner with shield 1 Combustion tube 3 EJOT FDS screws SF Procedure 1 Remove burner with burner tube and discard see 9 2 8 1 2 Insert glow plug flame sensor 11 in burner with shield 17 cable routed towards opening for cable grommet in shield and fasten with oval head screw 9 3 Feed cable of glow plug flame sensor 11 through opening in shield 4 Torque oval head screw 9 to 0 8 0 08
11. insulation mat 15 Fig 902 Remove control unit seel 9 2 4 1 i heating air fan see 9 2 5 1 Remove torx screws 17 Withdraw and remove burner tube 12 Remove and discard sealing ring 13 Perform procedures on components after disassembly refer to 9 1 1 Ee IN 9 2 8 2 Installation 1 Place new sealing ring 13 Fig 902 into groove on flange of heat exchanger Locate burner tube 12 for installation and secure with torx screws 17 Torque tighten screws to 4 0 0 4 Nm Install burner see 9 2 7 2 Install combustion and heating air fan see 9 2 5 2 Install control unit see 9 2 4 2 Fit insulation collar 15 Assemble housing components covers N NDA 907 9 Repair Air Top 3500 5000 9 2 9 Heat Exchanger Replacement CAUTION Replacement of heat exchanger requires additional replacement of temperature limiter 9 2 9 1 Removal Remove housing components covers seel9 2 1 Remove insulation mat 15 Fig 902 Remove control unit see 9 2 4 1 Remove combustion and heating air fan see 9 2 5 1 Remove burner see 9 2 7 1 Remove burner tube see 9 2 8 1 Perform procedures on components after disassembly refer to 9 1 1 9 2 9 2 Installation Install burner tube see 9 2 8 2 Install burner see 9 2 7 2 Install combustion and heating air fan see 9 2 5 2 Install control unit see 92 4 2 Fit insulation mat 15 Assemble housing components covers NOOO
12. of a malfunction this table is to be used for isolation and removal of the malfunction It is important to clearly identify the failure symptoms Air Top 3500 5000 Should the symptom not be listed in the table or the fault of a symptom listed cannot be isolated our technicians are available in emergencies service telephone 0 89 8 57 94 5 12 NOTE Overheating and dosing pump failure are always and additionally indicated by a flashing LED of the control element after run down In all cases of malfunction a faulty control unit could be the cause should the remaining components be serviceable Symptom Symptom shows after s Probable Causes No start up and no illumination of LED of control element No start up but LED comes on Very low speed without start Motor starts to run up but then stops Stop without run down Run down after Run down after Run down after and dosing pump does not cycle Run down after Run down after Run down Stop without run down Interruption of dosing pump cycle and max speed for 30 sec with subsequent restart immediately immediately immediately 20 120 40 to 120 230 during combustion operation during combustion operation during combustion operation Wrong wiring defective fuse Fan or control unit defective or fan blocked Control idle operation wrong manual setting selected temperature on control element below air intake t
13. of the heating air taken in is measured by a temperature sensor located at the suction side of the heater or with an external temperature sensor If the measured temperature is below that set with the control element the performance of the heater will increase up to maximum To increase the heater life in continuous operation the dosing pump rate of delivery is reduced for 15 seconds every 10 minutes After reaching the temperature set with the control element heater performance is reduced by lowering the combustion and heating air fan speed and by decreasing the dosing pump rate of delivery 3 4 Control Idle NOTE The combustion and heating air fan of heaters installed in boats or ships will not operate during control idle When exceeding the air intake temperature set with the control element at minimum heating performance the dosing pump is deactivated and combustion terminates During run down lasting 90 seconds and during the total of the control idle period the combustion and heating air fan operates at minimum speed If the temperature sensor senses a temperature below the one set with the control element the heater will restart without break away torque NOTE New control element settings will be executed by the control unit heater with a time delay 3 Functional Description 3 5 Switch off Switching the heater off extinguishes the operating indicator light of the control element Should fuel delivery have commenced
14. on The control element is to be set to the desired temperature When switching the heater on the operating indicator light will illuminate The motor of the combustion and heating air fan runs up at low speed NOTE If the temperature of the combustion air taken in exceeds the set temperature the heater will enter control idle With the combustion air temperature below the set temperature the starting sequence commences The function of the glow plug flame sensor is checked Should the glow plug flame sensor already signal at this stage bright for longer than 60 seconds there will be a 150 second run down and an error lockout of the control unit A malfunction of another component monitored causes an error lockout without run down 3 Functional Description Start The glow plug flame sensor is activated After approximately 22 seconds the dosing pump is put into operation and combustion commences After 116 seconds the glow plug is deactivated and the flame sensor becomes active After 136 seconds a check is performed to verify a proper burning of the flame Detection of a flame will cause the flame to be stabilised for 50 seconds by burning at 1 5 kW No flame detection will initiate a repeat start 2nd Start Repeat Start For this purpose the dosing pump is switched off and the glow plug is activated After 40 seconds the dosing pump is reactivated After another 40 seconds the glow plug is deactivated and 20 seconds late
15. wire colour on wiring harness ws rt 0 75 mm 1 5 mm ge yellow ventilate fan speed is dependent on control element position 1 0 mm2 1 5 mm2 z 5 gn green CO adi m 1 5mm 2 5 mm e re gacjustment 2 5mm 4 0 mm S SEN NOTE 4 0 mm 6 0 mm2 9 s f f rt red Grey and violet wires required for ADR function sw black vi violet ws white Item Nomenclature Remark Item Nomenclature Remark Al Heater Air Top 3500 5000 X7 Connection 12 pole on item A2 ST 1 A2 Control unit X8 Connection 2 pole B2 Temperature sensor x9 Connection 4 pole on item S1 B3 Temperature limiter Overheat protection X10 Connection 2 pole E Glow plug flame sensor X11 Connection 2 pole on item Y1 F1 Fuse 24V 15A 12V 20A Flat fuse SAE J 1284 Yi Dosing pump H1 LED green in item P1 Operating indicator light M1 Motor Combustion and heating air fan S1 Control element Rated value transmitter switch S2 Disconnect switch 1 or 2 pole Emergency off switch X1 Connection 2 pole on item A2 ST B X2 Connection 2 pole on item A2 ST V X3 Connection 2 pole on item A2 ST U X4 Connection 2 pole on item A2 ST Z X5 Connection 2 pole on item A2 ST Y X6 Connection 2 pole on item A2 ST X Fig 706 Automatic Switching Circuit Air Top 3500 5000 24 V ADR Operation with Control Element and no Auxiliary Drive 706 Air Top 3500 5000 8 Servicing 8 1 General This section describes the servicing procedures allowed on the h
16. without insulation It must also be protected against direct exposure to sun and draught wind Minimum inner diameter of heating air duct 80 mm Air Top 3500 90 mm Air Top 5000 NOTE For heating air ducting only materials with a temperature resistance of at least 150 C may be used The heating air opening is to be located so that components not temperature resistant are exposed to the heating air flow 801 8 Servicing Maximum pressure drop between suction and pressure side of heating air duct 2 0 mbar 20 mm water column Air Top 3500 3 0 mbar 30 mm water column Air Top 5000 NOTE Exceeding this value will cause the temperature limiter to respond The heating air hose connections must be secured In the air circulation mode the heater may be used without any accessories for heating air ducting A short circuit of the heating air flow should be avoided 8 6 2 Fuel Supply Fuel supply is from the vehicle fuel tank or a separate fuel reservoir Fig 801 lists the pressure permitted at the fuel tapping location Permitted fuel feed height at max permissible H m overpressure bar in fuel line 0 00 0 20 1 00 0 11 2 00 0 03 Permitted suction height at max permissible S m negative pressure bar in fuel tank 0 00 0 10 0 50 0 06 1 00 0 02 802 Air Top 3500 5000 8 6 2 1 Fuel Tapping Diesel fuel tapping must be from the fuel tank or a separate fuel reservoir Fig
17. 02 Control Unit Pin Assignment Air Top 3500 5000 c ocococccconcccnnoncnconcnnnnnnnnnnnoncnnnnnnnnnn cc ran n cnn nnn nacen n nn anar a nnnnnccns 701 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Control Element 702 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Combination Timer ccecsseeeeeeees 703 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Combination Timer and Batty Wii a E 704 Automatic Switching Circuit Air Top 3500 5000 24 V ADR Operation with Control Element 705 Automatic Switching Circuit Air Top 3500 5000 24 V ADR Operation with Control Element and no Auxiliary Drive 706 FS UI lo 802 Webasto Fuel RE DEET 803 Fuel Tapping from Plastic Tank tapping via fuel drain olugo narnia 803 Fuel Tapping from Plastic Tank tapping via fitting Date 803 Pipe Hose Connection 12 Volt and 24 Volt Installation position horizontal only cescceeeeeeeeseeeeeeeees 804 Dosing Pump Installation FOSON cionales 804 A O 804 Exhaust Muffler Direction Of low 805 Installation Arrangement of Exhaust Pipe Outlet oooococonnncccnnccccnnccconncccccnnccnononannnn cono n cnn nnn cnn rca 805 Removal of the Fuse Holder Mounting Plate oooonoocccnnnnnccccnnnnnoccccnnncoccccnnnnnonc coronan cnn rra rr 806 Fuse Holder Installation Positi0N oooooccccnnnncccconnnncccnnnnnncccnnnnnnnccn rn none 806 Control Elemental tia aati 806 Pulling the Gonfiector tilapia illa 806 Sample
18. Air Top 3500 5000 List of Contents List of Contents 1 Introduction 1 1 SCOPE ANA PUTOS EE 101 Tila Use of the Alr HE ate rs onien a ido Eege eege e ee 101 1 2 Meaning of Warnings Cautions and Notes 101 1 3 Additional Documentation to De use 101 1 4 Safety Information and Regulations cccccceceeeeceeseeeceeeeeeeeeeeeaeeeeeaeeeceeeeseaaeeeseaeeseaeeesaaeeseeeeessaaeeneees 101 1 4 1 General Safety Notes 101 1 5 Legal Provisions for installation esineeseen ia oe aen eA E cnn rre 102 1 6 Corrections and Improvements naar nn nn cnn 103 2 General Description 2 1 Combustion and Heating Air Fan 202 2 2 HIG AVEXCMANGEM usa lead ds beca 202 2 33 Burner with Combustion Tube oooonncccnncnnnnnccnnnccccnnccnnnncn nn crac 202 KE Deele RE EE 203 2 5 Glow Plug Flame Sensor 0 ccsccecescceeeeeeeeeeeeeeeeaeseeeneecaaaeseaneeseaaesseaaesgeneeesaaeeseeaeeeseaeeeseaaeeessaeesseneees 203 2 6 Analogue Temperature Limiter aicsean ineen EES ERRE EAEE EA E EERE ERN 203 2 4 DOSING PUND EE 203 3 Functional Description 3 1 Control Element serioses a ar dd data 301 CE e Ne EE 301 330 Heating Operation tada 303 34 Cono A Ee AS 303 ES A NO 303 3 6 Heater Functions when installed in ADR Vebcdes AAA 303 Ss Error Lock batata tanta 304 4 UN EE 401 5 Troubleshooting Bali NN 501 5 2 General Failure SyMptOMS ooonnoccnnccnnnnconnnncccnncnnnn aran crac cnn 501 5 3 Failure Symptoms during Operational Sequence cccece
19. Nm 902 Air Top 3500 5000 Fit new seal 13 in groove of flange of heat exchanger 14 Position burner tube 12 for assembly and fasten with Torx screws 16 Torque screws to 4 0 0 4 Nm Hold burner with shield 17 upside down engage burner tube 12 and rotate to assemble with combustion tube Fasten shield and burner tube 12 with EJOT FDS screws SF 10 Torque EJOT FDS screws SF 10 to 2 5 0 25 Nm Push grommet of fuel supply into housing of heat exchanger 14 Feed cable of glow plug flame sensor 11 through heat exchanger and plug grommet Mount combustion and heating air fan see 9 2 5 2 Install control unit see 9 2 4 2 Fit insulation mat 15 Refit housing components covers N Control unit Torx screw 2 Temperature limiter Torx screw Temperature sensor Torx screw 8 Combustion and heating air fan drive Flat gasket Oval head screw EJOT FDS screw SF 3 Glow plug flame sensor Burner tube Seal Heat exchanger Insulation mat Torx screw 4 Burner with shield Air Top 3500 5000 9 2 Disassembly and Assembly 9 2 1 Housing Components Covers Removal 9 2 1 1 Cover for Electrical Connection The wiring harness leaves the heater either on the left or right side depending on installation conditions The cover 1 Fig 901 may be levered off on both sides with a blunt blade in the areas and can then be pulled off 9 2 1 2 Cove
20. W 9 0 12 5 Dimensions of heater length 425 2mm width 148 1mm height 148 1mm Weight of heater 5 9 kg Booster stage max 30 min 401 Air Top 3500 5000 5 Troubleshooting 5 1 General This section describes the troubleshooting for the heater Air Top 3500 and Air Top 5000 After heater malfunction an error code is output to the display of the combination or standard timer When equipped with a control element the operating indicator light will flash The heater may also be checked with a personal computer refer to Operating Instructions PC Heater Fault Diagnosis 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 NOTE For ADR operation only When applying electrical power with the control element still set to on e g by closing the battery switch as well as after a ADR switch off the control unit will go in error lockout For re activation the control element must be momentarily switched off and on again or the instant heat switch on the combination timer be operated 5 Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause or reason for malfuncti
21. accordance with the German standard DIN 51603 A disadvantageous influence by additives is not known When using fuel of the vehicle tank the information about additives of the vehicle manufacturer must be observed When switching to low temperature combustibles the heater must be operated for approximately 15 minutes to also fill the fuel lines and the fuel pump with the new type of fuel not for ADR 8 Air Top 3500 D Heater Operation Air Top 3500 D Volume Plus Air Top 5000 D Mark of conformity 306 303 Type Air heater with evaporator burner Heating flow controlled 1 5 3 5 kW 1 5 5 0 5 5 0 kW range Fuel Diesel Fuel consumption controlled 0 17 0 60 range 0 17 0 42 I h 0 66 Uu Nominal voltage 12 24 V 12 24 V Operating voltage range 10 5 15 10 5 15 21 30V 21 30V Nominal power consumption controlled 15 36 W 15 90 W range Permissible ambient temperature Heater operation 40 40 C storage 40 85 C Dosing pump operation 40 20 C storage 40 85 C Control element operation 40 75 C storage 40 85 C Permissible combustion air intake An 420 C temperature Interior temperature 10 440 C setting range VO ume Now of neating air max 139 m3 h max 218 m3 h against 0 5 bar CO in exhaust 15kW 5 0 80 15kW 5 0 8 0 perm functional range 3 5 kW 9 0 12 5 5 0 k
22. al flat fuse holder included in the heater delivery must be fitted The fuse holder may only be installed in the vehicle interior a a gt Fig 810 Removal of the Fuse Holder Mounting Plate F 10A 24V 15A 12V 0 300 0 300 Fig 811 Fuse Holder Installation Position 806 Air Top 3500 5000 8 6 8 3 Connection of Control Element The wiring harness is prepared for connection to the control element rated value transmitter For disconnection of the connector simply pull on the connector terminal Fig 813 Pulling on the wiring harness will lock the connector self locking Fig 812 Control Element NOTE Light guide must contact rotary knob Fig 813 Pulling the Connector Air Top 3500 5000 8 Servicing re NS Seed Control element Heater Dosing pump Fuel filter accessory Fuel tap Exhaust muffler accessory Flat fuse holder NOOR WD A Fig 814 Sample Installation of Air Heater for Air Circulation Mode of Operation 807 8 Servicing 8 7 Removal and Installation CAUTION With the heater installed no component removal or disassembly procedures are permitted 8 7 1 Heater Removal and Installation 8 7 1 1 Removal 1 Disconnect vehicle battery Remove cover from upper housing shell according to N 3 Disconnect wiring harness connector from heater 4 Disconnect fuel supply line from heater 5 Disconnect combustion air intake line
23. aling joint is permissible The drain pipe must be routed sealed through the exterior wall or the vehicle floor The heat exchanger the exhaust line connected as well as the possible drain pipe must be sealed so that with an overpressure double the overpressure of the exhaust having the maximum permissible exhaust line length at least however at an overpressure of 0 5 bar a total leak rate of 30 I h is not exceeded The line including feedthrough disconnects material and specific type must be described in the installation instructions The line must require tools for installation and removal and must be protected against damage and must be long time shockproof Metal lines must be used These may not heat to more than 110 C should the possibility of body contact exist within the room interior Protective devices against body contact may be fitted Should exhaust pipes be routed through rooms accommodating persons these pipes shall be renewed after 10 years using genuine spare parts Combustion Air Inlet and Exhaust Outlet In installations these ports for combustion air entry and exhaust fume exit must be of such type that a ball of 16 mm in diameter cannot be inserted Electrical lines switch gear and control gear of the heater must be located in the vehicle so that their proper function cannot be impaired under normal operating conditions 1 Introduction For the routing of fuel lines and the installation of addi
24. and exhaust line from heater 6 Remove four nuts and washers from heater 7 Remove heater and discard gasket 8 7 1 2 Installation 1 Locate heater with new gasket for installation and secure with four nuts and washers use Webasto original nuts only Tighten nuts with 6 1 Nm Connect and secure fuel supply line to heater Connect and secure combustion air intake line and exhaust line to heater Route cable to dosing pump and connect to dosing pump Connect wiring harness connector to control unit Plug on cover and arrest Reconnect vehicle battery Bleed fuel supply system ao Pon COND 808 Air Top 3500 5000 8 8 Initial Operation After heater installation the fuel supply system must be carefully bled NOTE Due to the low fuel consumption itis required to switch the heater several times on and off for priming the fuel line During the heater test run inspect all connections for leakage and security Should the heater during operation enter an error lockout condition perform troubleshooting Air Top 3500 5000 9 Repair 9 1 General This section describes the repairs that may be performed on the heaters Air Top 3500 and Air Top 5000 when removed Any further disassembly will void the warranty For assembly only spares from the original spares kits must be used 9 1 1 Work on Components after Disassembly CAUTION All gaskets located between disassembled components as well as the gasket on the exh
25. ater time of operation 2 General Description 2 6 Analogue Temperature Limiter The analogue temperature sensor protects the heater against undue high operating temperatures For protection against overheating the temperature limiter responds at a heating air temperature higher than 150 C The control unit disconnects the dosing pump circuit and deactivates the heater with a run down After cooling down the circuit is re established The heater may be reactivated by switching the heater off and on again using the control element 2 7 Dosing Pump The dosing pump is a combined delivery dosing and shut off system for the fuel supply of the heater out of the vehicle fuel tank 203 Air Top 3500 5000 3 Functional Description Fig 301 3 1 Control Element The control element is used to switch the heater on and off to set the desired room temperature air intake temperature between 5 C and 35 C to reset the heater after a malfunction with error lockout and to adjust the CO value The integrated green LED indication is used as e operating indicator light LED permanently on error code overheat indicator LED flashes NOTE Only applicable to ADR operation When applying electrical power with the control element still set to on e g by closing the battery switch the control unit will go in error lockout For re activation the control element must be momentarily switched off and on again 3 2 Switch
26. ature limiter 3 from control unit 1 NOTE The temperature limiter may be additionally fastened with a washer This washer must be replaced with a new washer during installation 4 Remove torx screw 4 and washer as required 5 Remove temperature limiter 3 6 Perform procedures on components after disassembly refer to 9 1 1 9 2 3 2 Installation CAUTION The temperature sensor must be installed so that the sensor element faces the heat exchanger 1 Position temperature limiter 3 Fig 902 for installation and secure with torx screw 4 and washer as required 2 Tighten screw 4 with 2 5 0 25 Nm 3 Connect electrical connector of temperature limiter 3 to control unit 1 Fit insulation mat 15 Assemble housing components covers IZ 904 Air Top 3500 5000 9 2 4 Control Unit Replacement 9 2 4 1 Removal Remove housing components covers see 9 2 1 Remove insulation mat 15 Fig 902 Disconnect all connectors from control unit 1 Remove torx screws 2 Slide control unit 1 towards fan and remove Perform procedures on components after disassembly refer to DAMIAN 9 2 4 2 Installation 1 Position control unit 1 Fig 902 for installation on combustion and heating air fan 7 slide towards fan housing and secure with torx screws 2 Tighten screws with 3 0 0 3 Nm Connect all electrical connectors to control unit 1 Fit insulation mat 15 Assemble housing component
27. aust outlet must always be discarded and replaced 9 1 1 1 Cleaning e All components disassembled must be cleaned with cleaning spirit and blown dry with pressurised air e Sealing compound on components must be carefully and completely removed using suitable means 9 1 1 2 Visual Inspection e Inspect all components for damages cracks deformation wear etc and replace as required e Inspect connectors and wiring for corrosion loose contacts wrong crimping etc and repair as required 9 1 2 Modification Procedures NOTE A continuous design improvement of the heaters is intended for their optimization to prevent failures or malfunctions Normally equipment already in operation may be modified by retrofits using the relevant modification kits available The following details modifications which may be easily performed at low expenditure during repairs e installation of an external temperature sensor for best temperature control see 9 1 2 1 e installation of a burner with shield see 9 1 2 2 9 Repair 9 1 2 1 Installation of an External Temperature Sensor General The heater Air Top 3500 and Air Top 5000 control the desired temperature the best when the air temperature of the most frequented area is applied to its temperature sensor This may sometimes not be possible for the temperature sensor integrated in the heater due to unfavourable installation conditions In such case optimum temperature control may be
28. eater when installed 8 2 Work on the Heater For any type of work on the heater the fuses for the heater must be removed As long as the heater is in operation or in run down the battery main power supply must not be disconnected to prevent the heater from overheating by response of the overheat protection Repairs requiring a change of location the relevant installation instructions and the vehicle specific heater installation proposal have to be observed 8 3 Work on the Vehicle CAUTION In the vicinity of the heater a temperature of 85 C must under no circumstances be exceeded e g during paint work on the vehicle 8 4 Heater Test Run WARNING The heater must not be operated in enclosed areas like garages or workshops not provided with exhaust ventilation facilities CAUTION Operation of the heater without control unit cover is not permitted and causes overheating 8 5 Servicing NOTE To prevent seizure of mechanical components the heater should be operated every 4 weeks for at least 10 minutes The heater does not require any maintenance It should however be inspected in regular intervals by Webasto trained maintenance personnel the latest date for inspection being the start of the heating season point of time with increased use of heater 8 Servicing To ensure functional reliability of the heater the following servicing must be performed e inspect heating air inlet and outlet for contamination and fo
29. eeeeeeeceeeeeeseeeceaeeeeeaaeeeeeeeeesaaeeseeeeeesaeeeneneees 502 SA Ero Code OVPU a O O O 503 List of Contents Air Top 3500 5000 6 Functional Checkouts ECH ener eet ietesie sg E reen deed eggt ege De egen Let E ier gt Leetegegtesn 601 Bi AQUStiMeniS ut taaan 601 6 2 1 Adjustment of CO Contents oocconncconccononononcnnononancnnonannn cnn rncnn rene 601 6 3 Components Testiddr EE 601 6 3 1 Glow Plug Flame Sensor Resistance Check 601 Circuit Diagrams TIN E E111 EE 701 Servicing Sl Generada eg eene ee e ee eeh Ae tbe 801 82 Workonthe Hetero 801 8 39 Workon the Vella ui aid 801 9 4 Heater Test RUN tiran aaa 801 0 OSIVICINO tines lic o ear 801 8 6 Visual Inspections and Installation Hegoulatons cnn nn rnnn nn rn 801 8 6 1 Heating AIS Ste EE 801 86 2 TTT 802 8 6 3 Dosing PUMP iaa ado 804 8 6 5 Combustion Air S P Y cccceeceeeeeeeeeeeeeeeeeeeeceeaeeeeeeeeecaaeeeseeeeseaeeeseaeeseeaeeesaaeseeaaeeseieeeesaeeenaes 805 8 6 6 Exhaust BEE 805 8 6 7 Combustion Air Intake and Exhaust Lines 805 8 6 8 Electrical COMMS CHONG veceicinincansitcescusvstesaiavocdesvinsscacevasasehduotehdanunugabaucsdudassedatava d NENNEN E ee 806 8 7 Removaland Installation taa ara reis 808 8 7 1 Heater Removal and Installaiion 808 8 8 Initial Operati ie enn a a taria 808 Repair Ech General ona als 901 9 1 1 Work on Components after Disassembly 0oococccinnncninncccnnocnnnnncccnnnrnnn nn nnnnnn cn nan ona nnnn cnc
30. emperature or wrong heater integration excessive air intake temperature Glow plug flame sensor open or short circuit or control unit defective Fan motor seized or not moving freely Wrong flame detection Control unit electrical supply underpowered Wiring to dosing pump pump itself or temperature limiter defective Short time interruption of connection to dosing pump or to temperature limiter No flame wrong fuel quantity defective fan or fan too slow coked burner combustion air exhaust ducting obstructed or heat exchanger coked dosing pump seized Overheating or voltage too low or component failure glow plug flame sensor temperature limiter dosing pump burner or no fuel supply or combustion air exhaust ducting obstructed Fan motor failure or seizure Flame out by gas bubbles in fuel supply or strong head wind at exhaust outlet or no flame detection erroneous Fig 502 Failure Symptoms during Operational Sequence 502 Air Top 3500 5000 5 4 Error Code Output When equipped with a combination timer a malfunction will output an error code to the timer display NOTE When equipped with a control element the error code output after a malfunction will be a flashing operating indicator light error code indication The flash pulses correspond to the number of the table below After a rapid pulse train there will always be an error code output Error code output on display of combination timer F 00 contr
31. fax 089 857 94 7 57 103 Air Top 3500 5000 2 General Description The air heaters Air Top 3500 and Air Top 5000 working to the evaporator principle of operation basically consist of the combustion and heating air fan heat exchanger burner combustion tube control unit For control and monitoring the following components are located inside the air heater control unit glow plug flame sensor analogue temperature limiter temperature sensor 2 General Description The heater may be controlled by means of an external temperature sensor instead of the internal temperature sensor Fuel supply is provided by an external dosing pump In case of a heater malfunction an error code is output to the display of the combination timer When equipped with a control element the operating indicator light will flash The heater may be additionally checked using a personal computer refer to operating instructions for PC heater fault diagnosis Air Heater Air Top 3500 5000 201 2 General Description 2 1 Combustion and Heating Air Fan The combustion and heating air fan delivers the air necessary for combustion from the combustion air inlet into the burner The fan also supplies heating air to the heating air outlet 2 2 Heat Exchanger Within the heat exchanger the air delivered by the combustion and heating air fan is charged with the heat generated by combustion 202
32. have more than four disconnects and a splash water protected exterior wall feedthrough The disconnects must be sealed in a way not to exceed a leak rate of 200 l h at an overpressure of 0 5 mbar The line including feedthrough disconnects material and specific type must be described in the installation instructions The line must require tools for installation and removal and must be protected against damage and must be long time shockproof Air Top 3500 5000 Exhaust Line The heaters must be designed for exhaust emission to the exterior Exhaust lines must be routed so that exhaust fumes are unlikely to penetrate into the vehicle s interior The function of any part of the vehicle essential for operation must not be impaired No condensate or water penetrations may accumulate in the exhaust line Drain holes may be provided as required these must drain the liquid to the exterior via drain lines sealed against the vehicle interior The exhaust line outlet is to point upwards with rain protection or in case of exhaust venting below the vehicle floor to be located atthe nearest possible location of the vehicle s or cockpit side or rear end pointing downwards In compartments accommodating persons exhaust lines must not have more than one disconnect and must have a splash water protected feedthrough in the exterior wall floor For water that has penetrated into the exhaust line the connection of a drain line with a metal se
33. horizontal observe direction of flow Fig 807 Fuel Filter Air Top 3500 5000 8 6 5 Combustion Air Supply The combustion air must not be taken in from rooms accommodating persons The intake must not point in the direction of forward motion The combustion air intake must be located so that clogging by contamination is not to be expected The use of an air intake muffler or an equivalent air intake extension is necessary If the heater is contained in an installation box the combustion air must be taken in from and the exhaust vented to the exterior The line feedthroughs must not allow exhaust fumes to enter the vehicle interior In order to avoid damage to the dosing pump cable no exhaust line must be used for extension of the combustion air supply line 8 6 6 Exhaust Line Rigid pipes of unalloyed steel with a minimum wall thickness of 1 0 mm or flexible hoses of alloyed steel only may be used as exhaust ducts The exhaust line is fastened to the heater e g with a hose clamp The exhaust muffler is to be preferably mounted near the heater the direction of flow is optional Operation of the heater is also permitted without exhaust muffler Fig 808 Exhaust Muffler Direction of Flow 8 Servicing 8 6 7 Combustion Air Intake and Exhaust Lines Max total length of the combustion air intake and exhaust line with muffler without muffler max 2 6 m max 5 6 m Both lines are to be routed away f
34. ion of opening for cable grommet and secure with oval head screw 9 2 Tighten oval head screw 9 with 0 8 0 08 Nm 3 Locate burner 19 for installation and press grommet of fuel supply line into housing of heat exchanger 14 4 Secure burner 19 in position using fastening clamp 20 5 Route cable of glow plug flame sensor 11 below fastening clip on burner tube 12 Bend down fastening clip as required 6 Insert glow plug flame sensor 11 in burner with shield 18 cable routed towards opening for cable grommet in shield and fasten with oval head screw 9 7 Feed cable of glow plug flame sensor 11 through opening in shield Remove combustion and heating air fan see 9 2 5 1 9 Repair D Torque oval head screw 9 to 0 8 0 08 Nm 9 Hold burner with shield 18 upside down engage burner tube 12 and rotate to assemble with combustion tube 10 Push grommet of fuel supply into housing of heat exchanger 14 11 Fasten shield and combustion tube 12 with EJOT FDS screws SF 10 12 Torque EJOT FDS screws SF 10 to 2 5 0 25 Nm 13 Feed cable of glow plug flame sensor 11 through heat exchanger and plug grommet 14 Install combustion and heating air fan see 9 2 5 2 15 Install control unit sed 9 2 4 2 16 Fit insulation mat 15 17 Refit housing components covers 9 2 8 Burner Tube Replacement 9 2 8 1 Removal Remove housing components covers see 9 2 1 Remove
35. led tight against the vehicle interior There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 40 C in the installation box Excessive temperatures may cause malfunctions At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosion Where flammable fumes or dust may build up e g in the vicinity of fuel coal wood cereal depots or similar installations the heater must be switched off to prevent explosions Due to the danger of poisoning and suffocation the heater must not be operated not even with timer in enclosed areas such as garages or workshops not equipped with an exhaust venting facility When removing the heater the bottom gasket must be renewed The heat exchanger of the air heater remains serviceable for a maximum of 10 years and must then be replaced with an original spare part by the manufacturer or by one of its authorized workshops The heater must then be provided with a label detailing the sales date of the heat exchanger and the words original spare part When replacing the heat exchanger it is mandatory to also replace the overheat protection element temperature limiter to avoid possible malfunctions when using the old temperature limiter The heater must be inspected by an expert in time before the beginning of the heating season Should the heater develop strong smoke emission
36. nd procedures necessary for the repair of air heaters Air Top 3500 and Air Top 5000 The use of additional documentation is normally not necessary Operating instructions installation instructions and the vehicle specific installation proposal may be used as complementary information as necessary 1 Introduction 1 4 Safety Information and Regulations The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times General Safety Regulations beyond the scope of these regulations are detailed in the following The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings Cautions and Notes 1 4 1 General Safety Notes Within the scope of the StVZO Road Traffic Licensing Regulations of the Federal Republic of Germany Design General Approvals laid down by the Federal Office for Motor Traffic exist for the Air Heaters Air Top 3500 and Air Top 5000 with the following official marks of conformity S306 for Air Top 3500 Diesel S303 for Air Top 5000 Diesel Installation of the heater is to be performed in accordance with the installation instructions and must be checked in case of a the vehicle type inspection in accordance with 20 StVZO b the individual inspection in accordance with 21 StVZO or c The examination in accordance with 19 StVZO performed by an officially authorised exper
37. ng clamp 20 of burner 19 6 Push grommet of glow plug flame sensor 11 out of housing of heat exchanger 14 7 If required carefully bend up fastening clip for cable of glow plug flame sensor 11 located on burner tube 12 8 Withdraw burner 19 Remove oval head screw 9 0 Withdraw glow plug flame sensor 11 from burner 19 and remove 11 Remove EJOT FDS screws SF 10 12 Push grommet of glow plug flame sensor 11 out of housing of heat exchanger 14 and withdraw burner with shield 18 from burner tube 12 13 Remove oval head screw 9 14 Withdraw glow plug flame sensor 11 from burner with shield 18 and remove 15 Perform procedures on components after disassembly refer to 9 1 1 O Remove combustion and heating air fan see 9 2 5 1 9 Repair 9 2 6 2 Installation NOTE Steps 1 through 5 to be performed for a burner 19 Fig 902 without shield Steps 6 through 13 refer to an installed burner with shield 18 1 Insert glow plug flame sensor 11 into burner 19 cable in direction of opening for cable grommet and secure with oval head screw 9 Tighten oval head screw with 0 8 0 08 Nm 3 Locate burner for installation and press grommet of glow plug flame sensor 11 into housing of heat exchanger 14 Bend down fastening clip as required 4 Route cable of glow plug flame sensor 11 below fastening clip and through opening in housing of heat exchanger
38. ol unit malfunction wrong parameter set warm start detection F 01 no start after 2 start attempts no flame up F 02 flame out repeated gt 5 F 03 voltage too low or too high F 04 premature flame detection F 06 temperature sensor open circuit or temperature sensor short circuit F 07 dosing pump open circuit or dosing pump short circuit F 08 fan motor open circuit or fan motor short circuit or fan motor wrong speed F 09 glow plug flame sensor open circuit or glow plug flame sensor short circuit F 10 overheating F 11 temperature limiter open circuit or temperature limiter short circuit F 12 control element open circuit short circuit 5 Troubleshooting 503 Air Top 3500 5000 6 Functional Checkouts 6 1 General This section describes the tests on the heater in installed and removed condition to prove its serviceability WARNING The heater must not be operated in enclosed areas like garages or workshops not provided with exhaust ventilation facilities 6 2 Adjustments 6 2 1 Adjustment of CO Contents 6 2 1 1 General The CO contents in the exhaust is adjusted by means of the rotary setscrew of the control element The heater is preset by the manufacturer as applicable for the combustion and heating air fan installed The manufacturer s setting may be corrected by changing the control element adjustment CO gt pin connected to vehicle ground For adjustment a suitable CO detector must be
39. ole on item A2 ST Y X6 Connection 2 pole on item A2 ST X Fig 702 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Control Element Air Top 3500 5000 7 Circuit Diagrams 30 15 58 X1 X2 2 4 1 X3 X4 X5 X6 0 5mm sw E 2 0 5mm ws El El El y AT 3500 rt AT 5000 sw 31 OO With plus from terminal 15 75 to connection 10 Wire Colours continuous operation in instant heating as long as ignition is on Wire Gauges Without plus to connection 10 O 75m bl blue heating time programmable as required 10 min to 120 min SE gt br brown default setting 120 min 0 75 mm 1 5mm ge yellow 1 0mm 1 5mm n Ger 2 Diagnosis line K ism 25mm A A Di is line L 2 5 mm 4 0 mm2 A ie e Diagnosis line A0 mm 6 0 mm rt red 9 Input pin pin 7 connector X7 wire colour on wiring harness ws rt SEENEN i 8 SW black ventilate fan speed is dependent on control element position 5 vi violet CO adjustment ws white NOTE Connection to terminal 30 enables continuous heating operation with ignition off In this case no connection to terminal 15 75 must be made Item Nomenclature Remark Item Nomenclature Remark Al Heater Air Top 3500 5000 X2 Connection 2 pole on item A2 ST V A2 Control unit X3 C
40. onnection 2 pole on item A2 ST U B2 Temperature sensor X4 Connection 2 pole on item A2 ST Z B3 Temperature limiter Overheat protection X5 Connection 2 pole on item A2 ST Y E Glow plug flame sensor X6 Connection 2 pole on item A2 ST X F1 Fuse 24V 15A 12V 20A Flat fuse SAE J 1284 X7 Connection 12 pole on item A2 ST 1 F3 Fuse max 15A Flat fuse SAE J 1284 X8 Connection 2 pole H3 LED red in item P Instant heat switch illumination X10 Connection 2 pole standby indication X11 Connection 2 pole on item Y1 operating indicator light X12 Connection 12 pole on item P H4 Heating symbol in display Operating indication vi Dosing pump in item P H5 Lights in item P Display and push button switch illumination M1 Motor Combustion and heating air fan P Combination timer Timer and rated value transmitter S6 Switch Ventilate S7 Push button switch Instant heat switch remote control X1 Connection 2 pole on item A2 ST B Fig 703 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Combination Timer 703 7 Circuit Diagrams Air Top 3500 5000 58 15 30 X1 X2 o H S x8 2 q a y 1 vif V2 E X3 X4 X5 X6 oja mic S el 9 1 0 5mm sw L Janssen 0 5mm bl 0 5mm ws AT 3500 rt AT 5000 sw A1 e E O e S7 O Ll 31
41. ons corrosion on connectors e loose contacts on connectors e wrong crimping on connectors e corrosion on wiring and fuses e corrosion on battery terminals For checking individual components the electrical connectors on the control unit must be disconnected After any fault correction a functional checkout in the vehicle has to be performed 5 2 General Failure Symptoms The following table Fig 501 lists possible failure symptoms of general nature Symptom Probable Cause Remedy Heater does not switch off automatically restart No combustion after start and Flame out during operation Heater overheats Operating indicator light flashes Vehicle electrical system power supply underpowered Switch off heater momentarily and switch on once again Switch off heater momentarily and switch on once again Check heating air ducting for obstructions allow heater to cool down switch off heater momentarily and switch on once again Charge vehicle battery Switch off heater momentarily and switch on once again Heater develops black smoke Combustion air and or exhaust ducting obstructed Check combustion air and exhaust ducting for obstructions Fig 501 General Failure Symptoms 501 5 Troubleshooting 5 3 Failure Symptoms during Operational Sequence The following table Fig 502 lists possible failure symptoms in the time pattern of the functional sequence In case
42. p short circuit e temperature limiter open circuit or temperature sensor short circuit e overheating e voltage too low less than 10 Volt or e voltage too high more than 15 Volt for longer than 20 seconds 12 Volt heaters e voltage too low less than 20 Volt or voltage too high more than 30 Volt for longer than 20 seconds 24 Volt heaters e control element open circuit Switch off is identical as described in Switch off In case of overheating there will be no fuel delivery After run down the control unit will be in error lockout The control element will display a flash code For error lockout reset switch off heater at least for 2 seconds and switch on again 304 Air Top 3500 5000 Air Top 3500 5000 4 Technical Data Where no threshold values are specified technical data in the table are understood to include standard tolerances of 10 for heater units at an ambient temperature of 20 C and at nominal voltage and nominal conditions Electrical Components Control unit combustion air fan dosing pump indicator light in timer and glow plug flame sensor are either for 12 Volt or 24 Volt The components timer temperature limiter and temperature sensor are independent of voltage 4 Technical Data Combustible Diesel Fuel Oil EL The appropriate combustible is the Diesel fuel specified by the vehicle manufacturer Also class EL fuel oils not fuel oil L may be used if their quality is in
43. peat setting procedure once If the second attempt of CO adjustment is unsatisfactory a heater component is defective Return the heater to Webasto Thermosysteme GmbH for testing and repair 6 3 Components Testing CAUTION For individual components checks the electrical connections on the control unit and the component under test must be disconnected 6 3 1 Glow Plug Flame Sensor Resistance Check When checking the glow plug flame sensor with a digital multimeter the following values should be obtained Glow plug flame sen Resistance at 25 C Test current 12 Volt red 0 3 0 6 Q lt 5mA 24 Volt green 1 18 1 32 Q lt 5mA 601 Air Top 3500 5000 7 Circuit Diagrams 7 Circuit Diagrams 7 1 General The heater Air Top 3500 and Air Top 5000 may be operated with the control element rated value setting switch or with a combination timer The circuit diagrams Fig 702 to 706 show possible 12 V or 24 V circuits with control element combination timer combination timer and battery switch control element for ADR ADR operation for vehicles without secondary drive Fig 701 shows the control unit pin assignment Wiring harness Temperature sensor Dosing pump Wiring harness Control unit Glow plug flame sensor Combustion and heating air fan Temperature limiter Fig 701 Control Unit Pin Assignment Air Top 3500 5000 701 7 Circuit Diagrams 30 15
44. r the flame is checked Detection of a flame will cause the flame to be stabilised for approximately 50 seconds by burning at 1 5 kW Should flame detection at that time be still negative there will be a run down of the combustion and heating air fan at full speed approx 5000 rpm with an error lockout after 180 seconds NOTE After the first repeat start the heater enters an error lockout condition For error lockout reset the heater must be switched off at least for 2 seconds and switched on again 301 3 Functional Description D 100 90 60 30 0 2 0 2 8 Hz 0 5 Hz lon AT5000 116 124 10 302 Start Controlled operation Rated set value achieved Rated set value exceeded e g due to reduced heat consumption Run down Control idle Start Controlled operation increased heat consumption Switch off Run down Air Top 3500 5000 Seconds A Control element B Temperature sensor C Glow plug D Combustion and heating air fan E Dosing pump F Flame sensor Fig 301 Functional Diagram Air Top 3500 5000 3 3 Heating Operation During operation there is a flow of combustion gasses through the heat exchanger The heat of combustion is thereby dissipated onto the heat exchanger walls and is absorbed by the heating air delivered from the heating air fan to be routed to the vehicle passenger cabin The temperature
45. rca 901 Gil 2 Modification Procedure Si inn EA Ae e EA 901 Air Top 3500 5000 List of Contents 9 2 Disassembly and Assembly viciado iaa iio dd 903 9 2 1 Housing Components Covers Removal oomcccinccccinoccccnocccononcnnnnccnnnnnnn nano coran nn nnnnn cn cercanas 903 9 2 2 Temperature Sensor Replacement occccncinnncinincccnncccnnnncccnonnnnnnn cc nn rca 904 9 2 3 Temperature Limiter Replacement eos nano ENKE AE EKRAAN narrar nn 904 9 2 4 Control Unit Replacement rn nn cnn ENEA A ENER RA N Ana a 904 9 2 5 Combustion and Heating Air Fan Drive Replacement ooooccnncccnonccnnnccnccnnccnnnonnncnnccnnnananannccnnns 904 9 2 6 Glow Plug Flame Sensor PHeplacement cnn rnnr nn 905 9 27 Burner Replace Medici ERR eege R dd EL ee 907 9 2 8 Burner Tube Replacement cccccececncceceeeeeeeeeeeeeneaeeaeceeeeeeeeeeeeecaaaaeaaeceeeeeseseeeeencacaeeeeeeaeeees 907 9 2 9 Heat Exchanger ReplaceMent oooonmoccccnnnncccccnnnnncncccnnnnencnnnnnnnencn EAEE E EREE 908 10 Packaging Storage and Shipping 10 1 EL EC 1001 List of Figures Air Top 3500 5000 301 501 502 701 702 703 704 705 706 801 802 803 804 805 806 807 808 809 810 811 812 813 814 901 902 List of Figures Functional DIAG Ten EE 302 General Failure SyMptOMS oooccccnnnccconicconnccnnnnnnccnn crio cnn cnn 501 Failure Symptoms during Operational Sequence occoconocccnnccccconcncnononnnonncnnnnnnnn noc n non rca nn rra rn nnn cnc 5
46. reign matter Contaminations or obstructions in heating air lines may cause overheating and thus response of the temperature limiter e clean heater exterior prevent the ingress of water e examine electrical connections for corrosion of contacts and for security e inspect combustion air and exhaust ducting for damage and obstructions e inspect fuel lines and fuel filter for leakage e replace fuel filter if installed 8 6 Visual Inspections and Installation Regulations 8 6 1 Heating Air System CAUTION Integration of the heater in the vehicles own air ducting is not allowed due to the high pressure in the vehicle system Both the circulation and ventilation mode of operation are permitted In fresh air ventilation mode ensure to use heating air only from areas protected against splash and spray water On the air intake side of the heater a temperature sensor is located which in combination with the control element makes the heater operate with adequate heating performance dependent on air intake temperature and control element setting Heating performance is set so that after fast heat up to the preselected indoor temperature this temperature will be maintained NOTE In the fresh air ventilation mode of operation or when installing the heater in an installation box an external temperature sensor must be mounted in the room area to be under heat control The temperature sensor must not be mounted on exterior walls
47. rom the heater in a descent If this is not possible a condensate drain hole with a diameter of 4 mm must be provided at the lowest point Inner diameter of the lines combustion air intake line exhaust line metal 25 mm 24 mm NOTE Exhaust line lengths exceeding 2 m require the use of insulated exhaust lines dew point below minimum Smallest bending radius 50 mm Sum of bends combustion air intake line max 270 exhaust line max 270 Direction of exhaust 7 J 1 0 flow nearly vertical e 90 10 D H hid el Fig 809 Installation Arrangement of Exhaust Pipe Outlet In order to ensure an angle of 90 10 an attachment is required away not more than 150 mm from the exhaust pipe end WARNING Any other installation of the exhaust pipe outlet as shown in Fig 809 will provoke the danger of fires 805 8 Servicing 8 6 8 Electrical Connections 8 6 8 1 Connection of Heater Control Element The electrical connection is according to the circuit diagram see Section 7 For connection to the wiring harness the cover on the heater must be removed and the wiring harness connector be plugged onto the heater Prior to first operation of the heater the cover must be fitted to avoid undue escape of heating air heater overheating The cable passage may be on the left or right 8 6 8 2 Connection of Power Supply Preferably from the vehicle central electrics For heater protection an addition
48. rs for Heating Air Inlet and Outlet Both covers 3 and 5 Fig 901 may be unlocked from arrested position and removed by pressing in the locking tabs top and bottom k Cover for electrical connection Upper housing shell Cover for heating air outlet Lower housing shell Cover for heating air inlet 2 3 4 5 Fig 901 9 Repair 9 2 1 3 Upper Housing Shell The upper housing shell 2 Fig 901 may be lifted after removal of the covers for the heating air inlet and outlet 9 2 1 4 Lower Housing Shell An easy pull on both sides of the lower shell 4 Fig 901 in the areas Y unlocks the shell from arrested position to be separated from the fan housing Removal of Housing Components Covers 903 9 Repair 9 2 2 Temperature Sensor Replacement NOTE The temperature sensor may be replaced without removal of the heater The internal temperature sensor may be substituted against an external temperature sensor see 9 1 2 1 9 2 2 1 Removal a4 Remove cover 1 Fig 901 2 Pull temperature sensor 5 Fig 902 from control unit 1 and remove 3 Perform procedures on components after disassembly refer to 9 1 1 9 2 2 2 Installation 1 Plug temperature sensor 5 Fig into control unit 2 Refit cover 9 2 3 Temperature Limiter Replacement 9 2 3 1 Removal 1 Remove housing components covers see 9 2 1 2 Remove insulation mat 15 Fig 902 3 Disconnect connector of temper
49. s covers Mib 9 2 5 Combustion and Heating Air Fan Drive Replacement NOTE The drive combustion and heating air fan may only be replaced as complete assembly Repair is not possible CAUTION The drive must only be replaced by a drive with the same nameplate rating and the same ident no 9 2 5 1 Removal Remove housing components covers see Remove insulation mat 15 Fig 902 Remove gasket 16 Remove control unit see 9 2 4 1 Remove torx screws 6 Withdraw and remove combustion and heating air fan 7 Remove flat gasket 8 and discard Perform procedures on components after disassembly refer to 9 1 1 9 OTR GaN co N 9 2 5 2 Installation 1 Place new flat gasket 8 Fig 902 onto flange of heat exchanger 14 Position combustion and heating air fan 7 for installation and secure with torx screws 6 Tighten screws with 4 0 0 4 Nm Install control unit see 9 2 4 2 Fit insulation mat 15 Refit housing components covers Fit seal 16 N NOP amp HINWEIS Adjust CO contents according to 6 2 1 Air Top 3500 5000 9 2 6 Glow Plug Flame Sensor Replacement 9 2 6 1 Removal Remove housing components covers see 9 2 1 Remove insulation mat 15 Fig 902 Remove control unit seg 9 2 4 1 ON NOTE Perform steps 5 through 10 for a burner 19 without shield Steps 11 through 14 refer to an installed burner with shield 18 5 Loosen lever off fasteni
50. s over extended periods of time unusual combustion operating noise or smell of fuel the heater must be made inoperative by removing the fuse and returned into service only after inspection by Webasto trained personnel Claims for warranty may only be made providing evidence by the claimant that maintenance and safety regulations have been met 102 Air Top 3500 5000 Ignoring installation instructions and its procedures will void the warranty by Webasto The same applies to unskilled repairs or repairs not using original spare parts This will cause loss of the heater s marks of conformity and thus the vehicle s permit of operation 1 5 Legal Provisions for Installation For testing the heater in accordance with 8 19 20 or 21 of the StVZO the following regulations are to be observed in particular 22 a StVZO Testing is performed upon presentation of the operating and installation instructions of the manufacturer The year of the initial operation must be durably marked on the heater identification plate by the installing person Heating Air System Heating air intake openings must be arranged so that under normal operating conditions exhaust fumes of the vehicle engine or air heater are not likely to be sucked in Extractin m ion air from the vehicle interior i Combustion Air Line The required air for combustion must be taken in from the exterior Within rooms accommodating persons the combustion air lines must not
51. t or examiner for road traffic a vehicle inspector or a public servant as per section 7 4 a of Annex VIII to the StVZO In the event of c the installation must be certified on the acceptance certificate included in the copy of the General Operating License giving details about manufacturer type of vehicle and vehicle identification number This validates the Design General Approval The acceptance certificate must be kept with the vehicle The year of initial operation must be durably marked on the identification plate The heaters are cleared for heating the passenger and driver cabin but not for heating a compartment intended for the transportation of dangerous goods When using the heater in special vehicles e g vehicles for the transportation of dangerous goods ADR or in vehicles not subject to the Road Licensing Regulations StVZO e g ships the applicable partially regional regulations must be observed 101 1 Introduction When installing the Air Top 3500 and Air Top 5000 in vehicles intended for the transportation of dangerous goods the TRS 002 and TRS 003 Technical Guidelines for Regulations concerning the transportation of dangerous goods on roads must be met in addition to the StVZO Road Traffic Licensing Regulations The heater must not be installed in the passenger or driver cabin of busses Should the heater nevertheless be installed in such a compartment the installation box must be sea
52. tion 2 pole on Nem M illumination X12 Connection 12 pole on item P M1 Motor Combustion and heating air fan vi Dosing pump P Combination timer 1631 Timer and rated value transmitter S6 Switch Ventilate S7 Push button switch Instant heat switch remote control S8 Battery switch Fig 704 Automatic Switching Circuit Air Top 3500 5000 12 V 24 V with Combination Timer and Battery Switch 704 Air Top 3500 5000 7 Circuit Diagrams S2 30 Q 15 e D D X1 X2 El 3 S3 A y 5 0 X3 X4 X5 X6 o X9 2o E omen L SS Soe 3 Oe Set 1 0 5mm bi UI gt a 0 a O 0 5mm AT 3500 rt 5 AT 5000 A1 5 o O S6 D Q a S2 I 31 Q 3 2 Diagnosis line K Wire Gauges Wire Colours 3 Diagnosis line L bl blue lt 7 5m 7 5 15m br brown Input pin pin 7 connector X7 wire colour on wiring harness ws rt 0 75 mm 1 5 mm ge yellow ventilate fan speed is dependent on control element position 1 0 mm 1 5 mm2 7 z gn green 1 5mm 2 5 mm COs adjustment man 40mm gr grey p 7 or orange 40mm 6 0 mm NOTE rt red Grey and violet wires required for ADR function sw black vi violet ws white Item Nomenclature Remark Item Nomenclature Remark Al Heater Air Top 3500 5000 X4 Connection 2 pole on item A2 ST Z A2 Control unit X5 Connec
53. tion 2 pole on item A2 ST Y B2 Temperature sensor X6 Connection 2 pole on item A2 ST X B3 Temperature limiter Overheat protection X7 Connection 12 pole on item A2 ST 1 E Glow plug flame sensor X8 Connection 2 pole F1 Fuse 24V 15A 12V 20A Flat fuse SAE J 1284 X9 Connection 4 pole on item S1 H1 LED green in item S1 Operating indicator light X10 Connection 2 pole H6 Light min 1 2W Operating indicator light X11 Connection 2 pole on item Y1 conveyor installation Y1 Dosing pump M1 Motor Combustion and heating air fan Y2 Solenoid valve S1 Control element Rated value transmitter switch S2 Disconnect switch 1 or 2 pole Emergency off switch 3 Switch On or for conveyor installation S6 Switch Boost or Ventilate X1 Connection 2 pole on item A2 ST B X2 Connection 2 pole on item A2 ST V X3 Connection 2 pole on item A2 ST U Fig 705 Automatic Switching Circuit Air Top 3500 5000 24 V ADR Operation with Control Element 705 7 Circuit Diagrams Air Top 3500 5000 2 n Q 15 1 D D X1 X2 i Fl X8 e roy A A 1 El EZ 5 X3 X4 X5 X6 o 3 X9 4 3 0 5mm rt 4 0 5mm sw o var 1 ia o AT 3500 rt AT 5000 sw Al s2 1 31 Q 2 Diagnosis line K Wire Gauges Wire Colours 3 Diagnosis line L bl blue o lt 7 5m 7 5 15m br brown ey Input pin pin 7 connector X7
54. tional fuel tanks 88 45 and 46 of the StVZO are to be adhered to The most important regulations are fuel lines are to be designed in such a way that they remain unaffected by torsional stresses in the vehicle engine movement and the like They must be protected against mechanical damage Fuel carrying parts are to be protected against heat disturbing operation and are to be arranged so that any dripping or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment In busses fuel lines and fuel tanks may be located neither in the passenger area nor in the driver s compartment In these type of vehicles the fuel tanks must be located such that they do not pose a direct hazard to the exits in the event of a fire Fuel supply must not be by means of gravity or pressurization of the fuel tank Installation Instructions for Webasto Fuel Tanks for Fuel Supply of Heaters in Vehicles In busses the installation is not permitted in the passengers or driver s compartment The fuel filler neck must not be located in the passengers or driver s compartment of any type of vehicle The heater operating condition at least on or off must be clearly visible 1 6 Corrections and Improvements Deficiencies improvements or proposals for correction of this workshop manual are to be mailed to Webasto Thermosysteme GmbH Abt Technische Dokumentation D 82131 Stockdorf Telephone 0 89 857 94 5 42 Tele
55. ured against slippage using hose clamps 803 8 Servicing Connection of 2 Pipes with Hose The correct connection of fuel lines with hoses is shown in Fig 805 correct hose clamp wrong bubble Fig 805 Pipe Hose Connection 8 6 3 Dosing Pump The dosing pump is a combined delivery dosing and shut off system and is subject to certain installation criteria Fig 801 land 806 0 90 12 Volt and 24 Volt Installation position horizontal only Fig 806 Dosing Pump Installation Position 804 Air Top 3500 5000 8 6 3 1 Installation Position It is advantageous to mount the dosing pump in a cool location The ambient temperature must never exceed 20 C during operation Dosing pump and fuel lines must not be installed in locations exposed to heat radiated by hot vehicle components e g exhaust line A heat shield is to be provided as necessary 8 6 3 2 Installation and Attachment The dosing pump is to be attached with an anti vibration mount The installation location is limited according to Fig 806 to ensure sufficient self venting capability Due to the danger of corrosion only Webasto original parts may be used for the plug connection between dosing pump and dosing pump wiring harness 8 6 4 Fuel Filter If fuel contaminations are expected only Webasto filter order no 487 171 may be used The filter installation should be vertical and never exceed
56. used 6 2 1 2 Procedure 1 Connect CO pin brown cable in two pin connector of secondary line at wiring harness end of heater to vehicle ground using suitable adapter cable 2 Switch heater on 3 Adjust rotary setscrew on control element to centre position NOTE Perform CO setting only 2 minutes after flashing of the operating indicator light stabilization time of CO value 4 Wait until operating indicator light LED flashes 5 Rotating the setscrew clockwise increases the fan speed and decreases the CO contents Rotating the setscrew counterclockwise decreases the fan speed and increases the CO contents 6 Functional Checkouts NOTE Set CO contents to 10 5 0 3 and measure combustion and heating air fan speed afterwards Air Top 3500 3900 min max Air Top 5000 5200 min max When exceeding the max motor speed with CO value correctly set check fuel and exhaust lines for restrictions in cross section or cloggings If o k replace combustion and heating air fan according to 9 2 5 6 After CO contents adjustment allow heater to operate for another five minutes and readjust CO setting as required Disconnect CO pin from vehicle ground 8 Wait until flashing operating indictor light LED changes to a steady indication 9 Wait for completion of run down and switch heater off N NOTE If setting range is not sufficient e g after replacement of the combustion and heating air fan re

Corel Ventura - INHALT.CHP

Contents

Download Pdf Manuals

Related Search

Related Contents