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Air Top Evo 3900 Air Top Evo 5500

1. Resistance in Ohm 10 12 14 16 18 20 22 24 26 28 30 Temperature in C Characteristic resistance values of a PT 2000 overheating system in a temperature range of 10 C to 30 C 601 6 Function tests Air Top Evo 3900 5500 Page for notes 602 Air Top Evo 3900 5500 7 Circuit diagrams 7 1 General The Air Top Evo 3900 and Air Top Evo 5500 heater units can be operated with the heater control setpoint generator switch a combination timer or the MC04 05 heater control The circuit diagrams Fig 702 to 707 show the possible circuits for 12 and 24 Volt with e Control element and vehicle blower ADR operation with control element e Combination timer and vehicle blower e Combination timer and electrical battery isolation switch Control Panel MC04 05 and vehicle blower ADR operation with Control Panel MC04 05 7 Circuit diagrams Fig 701 shows the plug assignment on the control unit Fig 708 shows the schematic connection of the combination timer Fig 709 shows the schematic connection of the Control Panel MC04 05 See Paragraph 7 2 for the legend of the wiring diagrams X1 Combustion and hot air blower connection X2 7 Glow plug Flame sensor connection X3 Overheating sensor connection X4 Metering pump connection X5 External temperature sensor or terminating resistor connection X6 D and auxil
2. 0 5mm ge rt X7 0 5mm sw 0 5mm rt 0 5mm bl 0 5mm ws X9b X9a br br 0 5mm Yi E 0 5mm gr I e X1 X2 g 1 X3 X4 X5 X6 x9 1 ooo 704 Fig 707 System circuit diagram diesel 24V ADR operation with Control Panel MC04 05 Air Top Evo 3900 5500 7 Circuit diagrams Combination timer 1531 black Terminal 15 red Terminal 30 brown Terminal 31 Fig 708 Schematic connection of the combination timer Control Panel MC04 05 Observe coloured markings Optional connection for Telestart Thermo Call Webasto Thermo Test Diagnose Fig 709 Schematic connection of the Control Panel MC04 05 705 7 Circuit diagrams 7 2 Legend for circuit diagrams 1 With positive from terminal 15 75 to connection 10 Permanent operation for immediate heat as long as the ignition is switched on Without positive at connection 10 Heating time is variably programmable 10 min to 120 min default setting 120 min 2 Connection for Telestart Thermocall W bus diagnosis only when usin
3. Correct Wrong Fig 805 Pipe Hose connections 8 6 3 Metering pump The metering pump is a combined delivery metering and shutoff system and is subject to specific installation criteria Figs 801 and 806 8 Servicing work 12 V and 24 V diesel DP 30 Horizontal installation only Fig 806 Metering pump installation position 8 6 3 1 Installation location It is advisable to install the metering pump in a cool place The maximum ambient temperature must not exceed 20 C at any time during operation The metering pump and fuel lines must not be installed within range of the radiated heat from hot vehicle parts A heat shield must be used if necessary 8 6 3 2 Installation and attachment The metering pump must be secured with a vibration damping mounting Its installation position is limited as shown in fig 806 in order to ensure effective auto bleeding As a result of the risk of corrosion only genuine Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness 8 6 4 Fuel filter Only a Webasto filter ident no 487 171 is allowed to be used if the fuel is expected to be contaminated Install vertically if possible however at least horizontally check flow direction Fig 807 Fuel filter 805 8 Servicing work 8 6 5 Combustion air supply Under no circumstances may the combustion air be taken from areas occupied by people The
4. 83 The flame has gone out during a heating cycle more than FAZ times EEPROM Check fuel supply tank empty lines blocked Clean burner insert replace flame sensor F 03 Undervoltage or overvoltage 84 The voltage was less than 10 5 V or 21 V for longer than 20 seconds 04 The voltage was more than 16 V or 32 V for longer than 6 seconds F 04 Premature flame recognition 05 The flame sensor recognised a flame before combustion had started Replace flame sensor F 06 External temperature sensor break or External temperature sensor short circuit 14 Temperature sensor circuit short circuit to earth 94 Temperature sensor circuit break or short circuit to Ub Check cables replace temperature sensor Check cables and terminating resistor replace temperature sensor Fig 503 Troubleshooting page 1 of 2 503 5 Troubleshooting Air Top Evo 3900 5500 break or short circuit to Ub Error Error group Additional information during PC Troubleshooting code diagnostic F 07 Metering pump interrupt or 88 Break or short circuit to Ub Check cables replace metering pump teri hort circuit A AA 08 Short circuit to earth Check cables replace metering pump F 08 Fan motor interrupt or fan motor 89 Break or short circuit to Ub Replace drive unit combustion and hot air hort circuit or f t load bl Orfan motorblocked 09 The switched drive unit cab
5. duplicate model plate must be positioned so that it can be easily read when the heater is installed in the vehicle 2 2 5 Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property 2 3 Fuel supply 2 3 1 The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage 2 3 2 In the case of liquid fuel heaters where a supply separate to that of the vehicle is provided the type of fuel and its filler point must be clearly labelled 2 3 3 A notice indicating that the heater must be shut down before refuelling must be affixed to the fuelling point In addition a suitable instruction must be included in the manufacturer s operating manual 2 4 Exhaust system 2 4 1 The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators heated air inlets or opening windows 2 5 Combustion air inlet 2 5 1 The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle 2 5 2 The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely 102 Air Top Evo 3900 5500 2 6 Heating air inlet 2 6 1 The heating air supply may be fresh or recirculated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the
6. 2 seconds Switch on heater unit again with heater control NOTE The following error has occurred several times Fault counter more than 5 times Incorrect start counter more than 9 times Flame failure counter more than 5 times F 14 Overheating sensor incorrect 97 Incorrect position of the overheating Position the overheating sensor correctly position sensor OHS gradient too low F 15 Setpoint generator short circuit 9B Nominal value potentiometer circuit Check cables replace control element 504 Fig 503 Troubleshooting page 2 of 2 Air Top Evo 3900 5500 6 Function tests 6 1 General This section describes the tests conducted on the heater when it is installed and not installed to verify that it is in working order WARNING The heater must not be operated in enclosed areas such as garages and workshops without an emissions extraction system 6 2 Settings 6 2 1 Setting the CO content The CO content in the emissions is set using the adjustment knob on the control element At a constant blower speed the volume of fuel is controlled by changing the metering pump cycle IMPORTANT The CO measuring instruments must be calibrated The heater must be switched off 1 Connect the CO line to minus Turn the adjustment knob on the control element to the centre setting The heater will start and go automatically to low fire rate mode NOTE If the heater can be adjusted the operating indicator will flash as if the co
7. C 85 C Control element Operation 40 C 75 C Warehouse 40 C 85 C Combustion air intake temperature 40 C 20 C Adjustment range for interior Control temperature range 5 C 35 C Delivery rate of hot air against 0 5 at fan speed bar max 132 200 m h at 3900 5500 rpm CO in exhaust gas 1 7 kW 5 0 8 0 96 1 5 kW 5 0 8 0 permitted function range 3 5 5 0 kW 9 0 12 5 3 5 5 0 kW 9 0 12 5 Heater dimensions Length 42342 mm Width 148 1 mm Heights 162 1 mm Weight of heater 5 9 kg 401 4 Technical data Air Top Evo 3900 5500 Page for notes 402 Air Top Evo 3900 5500 5 Troubleshooting 5 1 General This section describes how to identify and deal with errors on the Air Top Evo 3900 and Air Top Evo 5500 heaters If a fault occurs an error code will be output in the display of the combination timer Ifthe heater has a control element the ON control light will flash In addition the heater can be checked using a personal computer see PC heater diagnostic operating manual IMPORTANT Troubleshooting work demands precise knowledge of the structure and theory of operation of the various components and must be carried out by trained personnel only If in doubt refer to sections 2 and 3 for a description of how the functions interact NOTE For ADR mode only After an ADR shut down or an operating voltage has been applied by switching the main v
8. Disconnect the main power cable from the vehicle s battery before carrying out any work on the heater The main battery power must not be disconnected whilst the heater is operating or slowing down as a result of the risk of the heater overheating and the overheating guard thus being tripped If you wish to carry out extensive repair work on the heater it may be a good idea to remove it completely Refer to the relevant installation instructions and the installation proposal for the heater for the specific vehicle for repairs that necessitate the installation position being changed 8 3 Work on the vehicle IMPORTANT A temperature of 85 C must not be exceeded in the vicinity of the heater in any circumstances for example when competing painting work on the vehicle 8 4 Heater trial WARNING The heater must not be operated in enclosed areas such as garages and workshops without an emissions extraction system even if you use the timer IMPORTANT The heater must not be operated without the cover for the control unit as this will cause it to overheat 8 5 Servicing work NOTE To prevent mechanical parts seizing the heater should be operated for approx 10 minutes every four weeks The heater requires no servicing However it should be checked at regular intervals at the latest at start of the heating period the time after which the heater will be used due to adverse weather conditions by Webasto trained personnel 8 Serv
9. air system must be reduced If a filter is used for the hot air it must have the following properties e The current of air must not carry any inflammable andi or harmful fibres or particles into the heater or the interior of the vehicle The filter material must be able to withstand temperatures of at least 60 C The filter must be resistant to all the substances that may be drawn in with the hot air for example moisture salt fuel vapours etc e The resistance of the filter must be taken into consideration when designing the hot air system 802 Air Top Evo 3900 5500 8 6 2 Fuel supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank The values for the maximum pressure at the fuel extraction point are shown in Figure 801 Permissible fuel inflow At max perm pressure height H m bar in fuel line 0 00 0 20 1 00 0 11 2 00 0 03 Maximum fuel intake At max perm negative height S m pressure bar in the fuel tank 0 00 0 10 0 50 0 06 1 00 0 02 Air Top Evo 3900 5500 8 Servicing work 8 6 2 1 Fuel extraction Vehicles with diesel engines The fuel must be taken from the vehicle fuel tank or from a separate tank Fig 802 803 or 804 This separate fuel pickup precludes any effect of pressure max 3 m l 12 lt 10m ER l4 lt 1 2m l2 88m Fig 801 Fuel supply 803 8 Servicing work Ve
10. and hot air blower 1 fig 902 and on the heat exchanger 7 are not damaged 2 Fita new flat seal 6 on the flange of the combustion and hot air blower 1 3 Position the combustion and hot air blower 1 into the assembly position and secure it with screws 2 Tighten the screws to 6 0 0 6 Nm Fit the control unit see 9 2 3 2 Fit the casing parts see 9 2 2 Install the heater see 8 7 1 2 Check the CO setting and adjust it if necessary see 6 2 e UO gre Air Top Evo 3900 5500 9 Repair 1 Combustion and hot air fan drive unit Torx screw 8 Control unit Torx screw 2 Terminating resistor Flat seal Heat exchanger Overheating sensor 0 JO Qn E G K Detail A Fig 902 Change the control unit overheating sensor and the combustion and hot air blower drive unit 905 9 Repair 9 2 6 Change the burner and the glow plug flame sensor 9 2 6 1 Removal Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the combustion and hot air blower see 9 2 5 1 5 Remove 2 screws 1 fig 903 and take off the retaining bar 2 6 Press the grommet on the glow plug flame sensor 8 inwards out of the heat exchanger casing 6 7 Press the grommet on the burner s fuel line 3 or 7 inwards out of the heat exchanger casing 6 8 Carefully pull the burner 3 or 7 out of the combustion pipe 4 and take the fuel supply
11. clear remove any materials that may block the air current and have any damage to the air lines repaired by an authorised Webasto workshop After this the heater lockout can be cancelled by switching it off and then on again If this action does not produce the required success if the heater overheats again take it to an Webasto authorised workshop The air outlet jets or air vents with adjustable flaps must always be opened to some extent so that the air current through the heater is not completely blocked At least one air vent must be non closable If the heater is installed in a storage area you must ensure that no inflammable substances are kept in this area and that other material does not restrict the air supply to the heater Air lines must be securely fixed to the heater using pipe clips for example and all other connection points for example vents IMPORTANT The errors described below are to be avoided at all costs Do not stand on the heater and do not place any heavy items on the heater or throw items at the heater Do not place any items of clothing textiles or similar materials over the heater or in front of the hot air inlet and the hot air outlet The current of hot air in the heater must not be restricted or blocked by highly inflammable substances or materials such as rags cleaning wool etc Inflammable or explosive substances and gases must not be placed near or in contact with the heater t
12. combustion air intake opening must not point in the direction of travel It must be located so that it cannot become clogged with dirt NOTE The combustion air must be extracted using a combustion air line from a position that is as cool as possible and protected from splashing water for petrol heaters If the heater is in a sealed installation box the combustion air must be drawn in from the outside and the emissions fed to the outside Pipe passage holes must be made in such a way as to ensure that the ingress of exhaust fumes into the interior of the vehicle should not occur If dirty combustion air is expected a combustion air filter may be fitted Air Top Evo 3900 5500 D only An intake silencer must be used for an intake hose length of lt 0 6 m 8 6 6 Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1 0 mm or flexible piping of alloyed steel only must be used as exhaust line The exhaust pipe must be secured to the heater and exhaust silencer with a pipe clip Part No 20 965A The exhaust silencer fig 808 should ideally be installed near the heater The flow direction is arbitrary The heater may also be operated without a silencer Fig 808 Exhaust silencer 8 6 7 Combustion air inlet and exhaust lines NOTE To prevent damaging the metering pump cable exhaust line must not be used to extend the combustion air supply line Length of the combustion air intake and exhaust
13. control unit 4 Disconnect the cable to the metering pump at the disconnection point 5 If necessary disconnect the hot air hose or hoses connection 6 Disconnect the connection for the combustion air inlet on the heater 7 Disconnect the connections for the combustion air inlet and exhaust outlet on the heater 8 Remove four nuts and locking washers from the heater 9 Remove the heater and discard the seal on the exhaust outlet 8 7 1 2 Installation 1 Place the heater with a new seal on the exhaust outlet in the installation position and secure it with 4 nuts and locking washers use only genuine Webasto nuts Tighten the nuts to 6 1 Nm Secure the connection for the combustion air inlet on the heater 4 Secure the connections for the combustion air inlet and exhaust outlet on the heater 5 Connect the metering pump cable to the metering pump wiring harness 6 Connect the wiring harness plug to socket X7 on the control unit 7 Fit the cover as described in 9 2 2 5 and secure it 8 If necessary fit the hot air hose or hoses and secure them 9 Connect the battery 10 Bleed the fuel supply system M M 8 Servicing work 8 8 Start up After you have installed the heater bleed the fuel supply system carefully NOTE As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line Conduct a trial of the heater to check all the connections for leaks and
14. extractor with metal fuel tanks Fig 802 Webasto fuel extractor 804 Air Top Evo 3900 5500 O Sealing ring Fig 803 Fuel extractor from the plastic tank extraction through tank drain screw Fuel extractor Sealing ring Tank fittings NOTE The fitting must be made from metal Fig 804 Fuel extractor from the plastic tank Pickup via tank fitting Air Top Evo 3900 5500 8 6 2 2 Fuel lines Only steel copper and plastic lines of plasticised light and temperature stabilised PA11 or PA12 e g Mecanyl RWTL pursuant to DIN 73378 may be used for the fuel lines Since the lines cannot always be routed with a constant rising gradient the internal diameter must not be allowed to exceed a certain size Air or gas bubbles will accumulate in lines with an internal diameter of more than 4 mm and these will cause malfunctions if the lines sag or are routed downwards The diameters specified in Fig 801 will ensure that bubbles do not form The lines should not be routed downwards from the metering pump to the heater Unsupported fuel lines must be secured to prevent them sagging They must be installed in such a way that they cannot be damaged by flying road chippings and high temperatures exhaust line The fuel lines must be secure at the connections using hose clips to prevent their slipping Connecting two pipes with a hose The correct procedure for connecting fuel lines with hosing is shown in Fig 805
15. hot and combustion air intake openings must be positioned in such a way that no water can ingress into them if the vehicle drives through a water hazard for which it has been approved The heater must not be installed in the driver s or passenger cabin of buses vehicle classes M and M3 If the heater is nevertheless installed in such a place the installation box must be tightly sealed against the vehicle interior The installation box must have sufficient external ventilation to ensure that a maximum temperature of 40 C is not exceeded in the box Fault faults may occur if the temperature exceeds this level The heater must be switched off at filling stations and tank farms as a result of the risk of explosion 1 Introduction Wherever inflammable vapours or dust may form for example in the vicinity of fuel carbon wood dust or cereal stores or the like the heater must be switched off as a result of the risk of explosion The heater must not be operated in enclosed areas such as garages and workshops without an emissions extraction system even if you use the timer because of the risk of asphyxiation and poisoning In the event of lengthy heavy smoke development unusual combustion noise or a smell of fuel the heater must be put out of action by removing the fuse and must not be started again until it has been examined by Webasto trained personnel Claims can only be made if it can be verified that the claimant has complied w
16. lines with silencer max 2 0 m without silencer max 5 0 m 806 Air Top Evo 3900 5500 Both lines are to be installed falling away from the heater If this is not possible a condensate drain hole with a diameter of 4 mm must be made at its lowest point or a connection element with a condensate drain used Internal diameter of the lines Combustion air line Exhaust line 25 mm 24 mm NOTE If the exhaust line is 2 m or more insulated exhaust lines must be used to prevent the temperature falling below the dew point Minimum bending radius 50 mm Total bends Combustion air line max 270 Exhaust line max 270 An attachment is required no further than 150 mm from the end of the exhaust pipe to ensure that the angle of 90 10 is achieved Discharge direction e almost vertical 90 10 Fig 809 Exhaust pipe mouth installation position WARNING If the exhaust pipe ends is other than as shown in the fig 809 it will pose a fire risk Air Top Evo 3900 5500 8 6 8 Electrical connections 8 6 8 1 Heater connection control element The electrical connection is to be made as shown in the appropriate circuit diagram see section 7 To connect the wiring harness remove the cover see 9 2 1 1 on the heater and connect the wiring harness plug to the control unit Before using the heater for the first time fit the cover to prevent the illegal escape of hot air heater overheating The wiring harn
17. not correctly followed may result in damage to the equipment or its components NOTE This heading is used to direct your attention to a special feature deemed essential to highlight 1 3 Additional documentation to be used This workshop manual contains all the information and instructions required for repairing the Air Top Evo 3900 and Air Top Evo 5500 air heaters Normally there is no need to use additional documentation If necessary the operating installation instructions and the installation suggestion for the specific vehicle may also be used 1 Introduction 1 4 Statutory regulations and safety instructions In principle the general accident prevention regulations and current works safety instructions are applicable The General safety regulations that go beyond the scope of the above regulations are stated below Any special safety regulations relevant to this instruction manual will be highlighted in the relevant sections or text passages of the procedures 1 4 4 Statutory regulations governing installation The Air Top Evo 3900 and Air Top Evo 5500 heaters have been type tested and approved in accordance with EC Directives 72 245 EEC EMC and 2001 56 EC heater with the following EC permit numbers e1 72 245 2006 28 5079 __ e1 2001 56 2006 119 0219 __ e1 2001 56 2006 119 0220 __ Installation is governed above all by the provisions in Annex VII of Directive 2001 56 EC NOTE The provisions of these Di
18. out of the heat exchanger casing 6 by turning the burner 9 Remove the retaining clip 9 and pull the glow plug flame sensor 8 out of the burner 3 or 7 10 Complete the work on stripped down components see 9 1 1 Pons 9 2 6 2 Installation 1 Insert the glow plug flame sensor 8 fig 903 into the burner 3 or 7 cable towards the opening for the cable grommet and secure it with the retaining clip 9 2 Insert the burner 3 or 7 into the heat exchanger 6 in the opposite direction and insert it into the combustion pipe 4 3 Place the retaining bar 2 in its assembly position and secure it with 2 screws 1 4 Tighten the screws to 4 0 4 Nm 5 Press the grommet on the fuel line into the heat exchanger 6 6 Thread the cable for the glow plug flame sensor 9 through the opening in the heat exchanger casing 6 7 Press the grommet into the heat exchanger Ensure that the glow plug cables do not form a loop in the heat exchanger 8 Fit the combustion and hot air blower see 9 2 5 2 9 Fit the control unit see 9 2 3 2 10 Fit the casing parts see 9 2 2 11 Install the heater see 8 7 1 2 906 Air Top Evo 3900 5500 9 2 7 Change the combustion pipe and the heat exchanger 9 2 7 1 Removal Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the overheating sensor see 9 2 4 1 Remove the combustion and hot air b
19. petrol and combustion pipe 202 Air Top Evo 3900 5500 2 4 Control unit The control unit is the central component for ensuring the function is maintained and for monitoring the heater s operation A temperature sensor in the control unit is designed to control the room temperature An external temperature may also be connected to all the heaters If a fault occurs an error code will be output in the display of the combination timer If the heater has a control element the ON control light will flash In addition the heater can be checked using a personal computer see PC heater diagnostic operating manual Control module 2 5 Glow plug Flame monitor The glow plug also acts as a flame monitor The mixture of fuel and air is ignited by the glow plug when the heater is started The glow plug takes the form of an electrical resistor and is positioned in the burner on the side facing the flame As a flame sensor the glow plug reacts in the same way as alow ohm PTC resistor which changes its resistance depending on the heat emitted by the flame The signals are fed to the control unit where they are processed The flame status is monitored by the flame sensor whenever the heater is operating Glow plug Flame monitor 2 General description 2 6 Overheating sensor The overheating sensor measures the temperatures in the rib area of the heat exchanger whenever the heater is operating The control unit evaluates
20. propulsion engine the combustion heater or any other vehicle source 2 6 2 The inlet duct must be protected by mesh or other suitable means 2 7 Heating air outlet 2 7 1 Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched 2 7 2 The air outlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely 2 8 Automatic control of the heating system The heating system must be switched off automatically and the supply of fuel must be stopped within five seconds when the vehicle s engine stops running If a manual device is already activated the heating System can stay in operation 1 4 2 General safety information The mouth of the exhaust pipe should be installed upwards to the side or if the exhaust pipe passes under the floor of the vehicle to the side or rear limit of the driver s cab or the vehicle The function of important parts of the vehicle must not be adversely affected It must not be possible for condensate or water to collect in the exhaust pipe Drain holes may be used The electric cables and controls for the air conditioning system must be arranged in the vehicle so that their proper functioning cannot be adversely affected in normal operating conditions Air Top Evo 3900 5500 Compliance with 88 45 and 46 of the Road Vehicle Licensing Act must be ensured for the installati
21. the signal and protects the heater from hot air outlet temperatures above 150 C and surface temperatures above 80 C by shutting down the combustion process and blowing cold air over the heater The heater then suffers a fault lock out and can by restarted by being switched off and on again see 3 2 Overheating sensor 2 7 Metering pump The metering pump is a combined transport metering and shut off system for supplying fuel from the vehicle s tank to the heater Metering pump DP 30 2 3 203 2 General description Air Top Evo 3900 5500 Page for notes 204 Air Top Evo 3900 5500 3 Function description 3 1 Control element The control element is designed to switch the heater on and off adjust the required room temperature intake temperature between 5 C and 35 C and to reset the heater after a fault In addition other comfort functions Eco Normal Plus Ventilation Altitude Compensation can also be activated with the MC04 05 heater control The integral green LED is designed to act e as an ON signal asa fault signal e as service display LED flashes NOTE ADR operation After an operating voltage has been applied by switching the battery isolation switch and control element to ON the control unit will be set to the Fault lock out position Before it can be restarted the control element must be set to OFF 3 2 Switch on Set the control element to the required temperatur
22. to ensure that they are secure If the heater suffers a fault during operation the fault must be located and remedied 809 8 Servicing work Air Top Evo 3900 5500 Page for notes 810 Air Top Evo 3900 5500 9 Repair 9 1 General This section describes the repair work that may be carried out on the Air Top 3900 5500 heater after it has been removed from the vehicle Any further dismantling will invalidate the warranty Only use the spare parts from the appropriate spare parts kits for assembling the heater 9 1 1 Work on stripped down components IMPORTANT All sealing elements between the stripped down components and the seal on the exhaust outlet must always be discarded and replaced 9 1 1 1 Cleaning Clean all stripped down components with benzene and then dry them with compressed air Remove all seal residue on the components in full carefully using a suitable tool 9 1 1 2 Visual inspection e Check all components for damage cracks deformation wear etc and fit new ones if necessary e Inspect the plugs and cables for corrosion loose contacts crimping faults etc and repair them if necessary Check plug strips for signs of corrosion and contacts to ensure they are secure Repair them if necessary 9 1 2 Carrying out modifications NOTE The constant development of our heaters is aimed at optimising them so as to prevent failures and malfunctions Generally it is possible to modify heaters that
23. 9 Repair QA General nia RE OR MO N 901 9 1 1 Work on stripped down components ss eee 901 9 1 2 Carrying out modificatiONS ccoocococccononinnnnnnnoncnnononononcnnonnnnccnnnnnnnnnnnnn nr r rro ee ee ee aia 901 9 2 Dismantling and asseMbling ccccccccnnnnnnnnononononnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnn nono n nne nn nennen nenne EEEE nennen 902 9 2 1 Remove the casing parts ee ee ee RR RA RA AA AA ee ee ee ee ee ER RR Re ee ee ee ee ee ee EEEE 902 9 2 2 Fit the Casing parts hiere Be ED Rd eke EE ede ES cate ee ette Ee ete reo ele ER UR GEGEE GEE E ee 902 9 2 3 Change the control unit sss ee ee ER AR RA AA ee dee ee n ee ee ee RR nennen ee ee ee ee EEE 904 9 2 4 Change the overheating sensor eee eee 904 9 2 5 Change the combustion and hot air blower drive unit 904 9 2 6 Change the burner and the glow plug flame sensor ssssse en 906 9 2 7 Change the combustion pipe and the heat exchanger sese 906 10 Packaging storage and shipping 10 1 General BE Eee teo e pee fate ate OR ane fece 1001 501 502 503 701 702 703 704 705 706 707 708 709 801 802 803 804 805 806 807 808 809 810 811 812 813 814 901 902 903 List of illustrations Air Top Evo 3900 5500 List of illustrations General error SYMptOMS c eee eee eee 501 Error symptoms during fun CON iis ii tdo 502 TUE oa PS E E 503 Plug ASSIGNMENE 55 a ditte t e OE OR N 701 System circuit diag
24. EL heating oil not L heating oil may also be used as long as it complies to the normal quality available on the German market pursuant to DIN 51603 We know of no negative influences due to additives If fuel is extracted from the vehicle s tank follow the additive instructions issued by the vehicle manufacturer If you change to low temperature fuel the heater must be operated for approx 15 minutes so that the fuel system is filled with the new fuel The Air Top 3900 5500 ST D heater is also licensed for use with PME bio diesel which complies with DIN EN 14214 The table shows the values for the Air Top Evo 5500 in brackets Heater Operation Air Top Evo 3900 5500 B Air Top Evo 3900 5500 D Type test permit EMC heater e1 72 245 2006 28 5079 e1 2001 56 2006 119 0219 __ e1 2001 56 2006 119 0220 Model Air heater with evaporation burner Heat output Control range 1 7 3 9 5 5 kW 1 5 3 9 5 5 kW Fuel Petrol Diesel PME Fuel consumption Control 0 17 0 39 0 57 kg h 0 15 0 39 0 55 kg h range 0 19 0 51 0 73 Vh 0 18 0 47 0 66 I h Rated voltage 12V 12V 24V Operating voltage range 10 5 16V 10 5 16V 21 31V Rated power consumption Control range 15 45 116 W Ambient temperatures Heater Operation 40 C 40 C Warehouse 40 C 85 C Metering pump Operation 40 C 20 C Warehouse 40
25. Fig 703 System circuit diagram 24V ADR operation with control element 702 15 D 2 X1 X2 lt gt 1 X3 X4 X5 X6 Air Top Evo 3900 5500 7 Circuit diagrams 0 5mmege rt 30 30 15 15 58 58 ge X1 X2 In In 6 AA A F4 F1 3 94 lac o 99 11 xa F2 1 S x tle El g VIE 1 E 15 Elg X3 X4 X5 X6 X7 Y 25 oL 8 9 i 0 5mn sw i 0 5mm bl 0 5mm ws br Fig 704 System circuit diagram 12V 24V with combination timer and vehicle blower 58 58 15 15 ma GE EE EE m X1 X2 00 7 88a rt 5 Gi S8 e E S 86 F4 FI 8 4 hee o 5 L1 x8 3 L Y te E ot 1 Me ES 6 El X3 X4 X5 X6 X7 E se gt 3 9 0 5mm sw 0 5mm ge rt 0 5mmebl 0 5mm sw rt 0 5m
26. air blower will be set to approx 50 of its maximum speed After approx 40 seconds the fuel metering pump will start and the flame formation will begin After a further 50 seconds the glow plus will be switched off and the existence of the flame established If the heater has again failed to ignite properly the it will be shut down using a fault slow down procedure at maxi mum speed after 180 seconds and will suffer a fault lock out NOTE After a restart the heater will suffer a fault lock out To reset the fault switch the heater off briefly at least 2 seconds and then on again 3 3 Heating mode Whilst the heater is operating the combustion gases pass through the heat exchanger During this process the com bustion heat is given off to the walls of the heat exchang er absorbed by the hot air transported by the hot air blower and fed into the interior of the vehicle The temperature of the hot air intake is measured by a temperature sensor in the control unit or an external tem perature sensor If the measured temperature is lower than the value set on the control element the output of the heater is increased to maximum heat output To increase the burner service life when it is used continuously the transport capacity of the metering pump is reduced for 10 seconds every 10 minutes In addition heating mode is interrupted every 8 hours in the same way as for a control pause 3 4 Control mode In control mode the blow
27. anual The drive unit with a combustion and hot air blower The heat exchanger Ha The heater may be controlled using an external The burner insert with combustion pipe temperature sensor instead of the internal temperature The control unit sensor To control and monitor it the heater has Aa control unit with temperature sensor aglow plug flame monitor an overheating sensor inside it Air Top Evo 3900 5500 air heater without casing Air Top Evo 3900 5500 air heater 201 2 General description Air Top Evo 3900 5500 2 1 Drive unit The drive unit consists of the drive motor the combustion air blower the heat air blower and the intake casing The combustion air blower supplies the air required for the combustion process from the combustion air inlet to the burner insert The hot air blower transports the hot air from the hot air inlet via the heat exchanger to the hot air outlet Drive unit 2 2 Heat exchanger The heat generated by the combustion process is transferred to the air transported by the combustion and hot air blowers in the heat exchanger Heat exchanger 2 3 Burner insert with combustion pipe The fuel is distributed over the burner cross section in the combustion pipe in the burner insert The mixture of fuel and air burns in the combustion pipe thus causing the heat exchanger to become hot j Burner insert diesel and combustion pipe j Burner insert
28. are already in use We can supply the appropriate modification kits for this purpose The following describes modifications that can be carried out without any great effort during standard repair work Installation of an external temperature sensor for better temperature control see 9 1 2 1 9 Repair 9 1 2 1 Installation of an external temperature sensor General The Air Top Evo 3900 or Air Top Evo 5500 heater can control the required temperature perfectly if its temperature sensor is exposed to the air temperature of the main area of the vehicle In certain circumstances this is not always possible using the temperature sensor integrated in the control unit due to the installation circumstances In this case perfect temperature control can be ensured using an external temperature sensor fitted in the appropriate area Method 1 Select a suitable position for an external temperature sensor NOTE The temperature sensor should not be in the direct line of hot air and not close to heat sources for example the vehicle s own heating system The sensor is to be installed at medium height in the vehicle cabin on surfaces that are as vertical as possible The installation site should not be exposed to direct sunlight Do not install the temperature sensor behind curtains or the like 2 Remove the cover and disconnect the terminating resistor 5 fig 902 from the control unit plug X5 3 Install the external t
29. circulation system eee eee 808 Remove fit the CaSing parts cia p ede E bet rit e tas 903 Change the control unit overheating sensor and the combustion and hot air blower drive unit 905 Change the burner glow plug flame sensor the combustion tube and the heat exchanger 907 Air Top Evo 3900 5500 1 Introduction 1 1 Contents and purpose This workshop manual is designed to assist trained personnel with repairing both the petrol and the diesel versions ofthe Air Top Evo 3900 5500 air heaters 1 1 1 Use of the air heaters The Webasto Air Top Evo 3900 and Air Top Evo 5500 air heaters are designed to heat cabins boats trucks minibuses vans ambulances and motorhomes to defrost vehicle windows to heat cargo They are not designed for heating cargo areas used to carry hazardous substances The heaters operate independently of the engine and are connected to the fuel tank and the electrical system of the vehicle They may be used for vehicles with either water or air cooled engines 1 2 Meaning of signal words Throughout this manual the signal words WARNING IMPORTANT and NOTE have the following meanings WARNING This heading is used to highlight operating instructions or procedures which if not or not correctly followed may result in personal injury or fatal accidents IMPORTANT This heading is used to highlight operating instructions or procedures which if not or
30. e If the hot air temperature is lower than the nominal tem perature the heater will start NOTE If the temperature of the hot air intake is above the set nominal temperature only the motor for the hot and combustion air blower will start control pause Special feature The control pause speed is 0 rpm if boat heaters are used The function of the flame sensor is checked If the flame sensor now reports light the system will attempt to cool the flame sensor for 60 seconds If the flame sensor still reports light the control unit will suffer a fault lock out If another monitored component has suffered a fault the fault lock out will take effect without any slow down time Start When the heater is switched on the ON signal light will be lit and the glow plug will be switched on cycled The motor for the hot and combustion air blower will be set to approx 50 of its maximum speed After approx 40 seconds the fuel metering pump will start and the flame formation will begin To improve the starting quality the metering pump and combustion air blower are started with different frequencies and speeds After a further 90 seconds the glow plus will be switched 3 Function description off and the existence of the flame established Automatic restart If the flame sensor does not find a flame the starting pro cedure will be repeated The glow plug will be switched on again cycled The motor for the hot and combustion
31. eeling diode for vehicle fan Motor Combustion and hot air fan Motor Vehicle fan Combination timer 1531 Timer and setpoint generator Resistor 620 Q With internal temperature sensor only Control Panel MC04 05 Setpoint generator and selector switch for additional functions Control element Setpoint generator switch 1 or 2 pin disconnecting switch Emergency Stop switch Switch On and for pumping device Switch CO setting Switch Boost only with boost heaters Momentary contact switch Immediate heat button remote control Battery isolation switch Diode Diode Plug connector 2 pin To item A2 ST B Plug connector 2 pin To item A2 ST V Plug connector 2 pin To item A2 ST U Plug connector 2 pin Plug connector 2 pin To item A2 ST Y Plug connector 2 pin To item A2 ST X 12 pin plug connection To item A2 ST Z To item A2 ST 1 Plug connector 1 pin Plug connector 4 pin to item S1 Plug connector 2 pin Plug connector 2 pin to item Y 1 12 pin plug connection to item P Metering pump Solenoid valve for pumping device Air Top Evo 3900 5500 8 Servicing work 8 1 General This section describes the servicing work that can be carried out on the heater when it is installed 8 2 Work on the heater
32. ehicle switch and control element to ON the control unit will be set to the Fault lock out position Before it can be restarted the control element must be set to OFF or the Immediate heat button pressed on the combination timer 5 Troubleshooting IMPORTANT The troubleshooting guide is restricted to the localisation of defective components The following potential sources of malfunctions are not taken into account and should always be checked so that they can then be excluded as the cause of the particular fault e Corroded plugs Loose plug contacts e Poor crimp contacts on plugs e Corroded cables and fuses e Corroded battery terminals If you wish to check individual components the electrical plug connectors on the control unit must be disconnected Conduct a function test in the vehicle after rectifying each fault 5 2 General error symptoms The following table Fig 501 lists the possible error symptoms Error symptom Possible cause Remedy Heater unit cuts out automatically operation No combustion after start and restart ON indicator flashes Flame extinguishes during ON indicator flashes Heater unit overheats ON indicator flashes Vehicle voltage too low ON indicator flashes Switch heater off and then on again Switch heater off and then on again Check that the hot air system is clear allow the heater to cool switch heat off briefly and then on again Charge batter
33. el tanks for supplying the appliance shall meet the following requirements a in the event of any leakage the fuel shall drain to the ground without coming into contact with hot parts of the vehicle or the load b fuel tanks containing petrol shall be equipped with an effective flame trap at the filler opening or with a closure enabling the opening to be kept hermetically sealed 3 1 1 2 The exhaust system as well as the exhaust pipes shall be so directed or protected to avoid any danger to the load through heating or ignition Parts of the exhaust system situated directly below the fuel tank diesel shall have a clearance of at least 100 mm or be protected by a thermal shield 3 1 2 The combustion heater shall be switched on manually Programming devices shall be prohibited 3 2 EX Il and EXIIII vehicles Combustion heaters using gaseous fuels are not permitted Air Top Evo 3900 5500 3 3 FL vehicles 3 3 1 The combustion heaters shall be put out of operation by at least the following methods a intentional manual switching off from the driver s cab b stopping of the vehicle engine in this case the heating device may be restarted manually by the driver c start up of a feed pump on the motor vehicle for the dangerous goods carried 3 3 2 After running is permitted after the combustion heaters have been put out of operation For the methods set out in points b and c of paragraph 3 3 1 the supply of co
34. emperature sensor and route the cable to the heater 4 Connect the plug on the external temperature to Socket X5 on the control unit and fit the cover 5 Conduct a trial and check the control properties Cover External temperature sensor 901 9 Repair 9 2 Dismantling and assembling 9 2 1 Remove the casing parts 9 2 1 1 Cover for electrical connection The cover 1 Fig 901 can be levered off using a blunt blade in the areas marked X 9 2 1 2 Grate for hot air inlet and outlet The grate 6 fig 901 can be released from its mounting by twisting it and then pulled off forwards 9 2 1 3 Covers for hot air inlet and outlet Both covers 3 and 5 fig 901 can be released from their mountings and removed by pressing the four detents at the top and bottom using a suitable tool 9 2 1 4 Top shell NOTE The covers for the hot air inlet and outlet must have been removed The top shell 2 fig 901 can be raised after the covers for the hot air inlet and outlet have been removed 9 2 1 5 Bottom shell Remove the seal from the exhaust outlet NOTE The insulating mat 7 fig 901 is only fixed on the heater by the casing parts By pulling the bottom shell 4 on both sides gently around areas Y you can release the fixing and the shell can be taken off the motor casing Take the insulating mat off 7 at the same time 9 2 2 Fit the casing parts 9 2 2 1 Bottom shell IMPORTANT To ensure that t
35. er speed and the metering pump delivery rate are dependent on the heat output The glow plus is switched off 301 3 Function description 3 5 Control pause After the temperature set on the control element has been reached the heat output is reduced The speed of the heat ing and combustion air blower and the delivery rate of the metering pump are reduced If at minimum heat output the intake temperature set on the control element is exceeded the metering pump is shut down and the combustion process ended To burn off the flame properly the blower speed falls after 20 seconds to low fire rate speed and then returns to the initial soeed after 15 seconds after which it falls to the control pause speed in 3 minutes where it remains for the entire control pause The control pause speed is 0 if an external temperature sensor is used If the temperature set on the control element is exceeded at the temperature sensor the heater will restart NOTE Changes to the setting on the control element are implemented by the control unit and heater after a delay 3 6 Switch off When the heater is switched off the ON control LED on the control element goes out If no fuel has been transported or if the heater is in the control pause the heater is switched off immediately without a slow down time If the fuel transport has been started it is ended when the heater is switched off The heater is switched off using the same method as the tran
36. er the selected interior temperature has been reached quickly it is then kept at this selected value Alternatively the Air Top Evo 3900 5500 heaters can be operated with an external temperature sensor see 9 1 2 NOTE Only materials that can permanently withstand temperatures of at least 130 C may be used for the hot air line Maximum pressure drop between the inlet and outlet side of the hot air line Air Top Evo 3900 Air Top Evo 5500 2 0 hPa 3 0 hPa 1 hPa corresponds to 1 mbar corresponds to 10 mm H20 water column 801 8 Servicing work If this value is exceeded the heat output may be reduced as a result of the hot air outlet temperature control The heater can be used with grates on the air inlet and outlet side if it is used in an air circulation system Do not short circuit the current of hot air Minimum internal diameter of the main section of hot air line 80 mm for the Air Top Evo 3900 90 mm for the Air Top Evo 5500 The hot air hose must be secured at its connection points IMPORTANT In vehicles used to transport people the air outlet opening is to be directed in such a way that itis at least 20 cm away from all body parts The heaters check the internal temperature rise automatically each time they are switched on If this is above the specified limits the start is cancelled and error messages F10 is displayed To ensure that the heater functions stably the flow resistance of the connected hot
37. ess can be fed out of the left or right side of the heater 8 6 8 2 Supply voltage connection Ideally from the vehicle s central electrical system An additional blade terminal fuse holder is to be fitted to protect the heater supplied with the heater The fuse holder may only be installed in the interior of the vehicle F 10A 24V 15A 12V 0 309 0 309 Fig 811 Fuse holder installation position 8 Servicing work 8 6 8 3 Control element connection The wiring harness is prepared for connection to the control element Simply pull on connector housing to disconnect the connector fig 813 Fig 812 Control element NOTE The fibre optic cable must be in contact with the rotary knob NOTE The connector housing can be locked self locking action by simply pulling on the wiring harness Fig 813 Disconnect the plug 807 8 Servicing work Air Top Evo 3900 5500 cs qaad Control element Heater Metering pump Fuel filter accessory Tank connector Exhaust silencer Fuse 1 2 3 4 5 6 7 Fig 814 Specimen installation for heater in an air circulation system 808 Air Top Evo 3900 5500 8 7 Removal and installation IMPORTANT When the heater is installed it must not be dismantled 8 7 1 Heater removal and installation 8 7 1 1 Removal 1 Disconnect the battery 2 Pull the cover off the top shell as described in 9 2 1 1 3 Disconnect the wiring harness plug from the
38. g Control Panel MC04 05 3 CO adjustment see workshop manual NOTE If the connection is made to terminal 30 permanent heating is possible when the ignition is switched off In this case no connection must be made to terminal 15 75 5 NOTE Grey and violet cables required for ADR function External temperature sensor Fuse installed in vehicle PIN 7 BOOST only with boost heaters Cable cross sections lt 7 5m 7 5 15m 0 75 mm 1 0 mm A AA 1 0 mm 1 5 mm 1 5 mm 2 5 mm 2 5 mm 4 0 mm 4 0 mm 6 0 mm Cable colours bl blue br brown ge yellow gn green gr grey or orange rt red Sw black vi violet WS white 706 Air Top Evo 3900 5500 Description Comment Heater Air Top Evo 3900 5500 Control module Temperature sensor In control unit Overheating sensor Overheating guard Temperature sensor External Glow plug Flame monitor Fuse 24 V 15A 12V 20A Flat fuse SAE J 1284 Fuse 20 A Flat fuse SAE J 1284 Fuse 1A Flat fuse SAE J 1284 Fuse max 15A Flat fuse SAE J 1284 Green LED Indicator LED red in item P Light in immediate heat button ready indicator Switch on indicator Heating symbol in the display in item P Indicator Lights Display or button illumination Light at least 1 2 W Switch on indicator pumping device Relay with free wh
39. he hot air line the current of hot air or the exhaust pipe The heater must not be cleaned with a high pressure cleaner Do not switch the heater off at the main battery switch or battery isolation switch since otherwise it is possible that it may suffer long term damage if it is Switched off frequently using the battery isolation Switch and this can cause damage and negative influences on the function of the heater 104 Air Top Evo 3900 5500 NOTE Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts This will result in the invalidation of the type approval for the heater and therefore of its homologation EC type licence You must read the operating manual before starting the heater for the first time Air Top Evo 3900 5500 2 General description 2 General description The fuel supply is provided from an external source using a metering pump If a fault occurs an error code will be output in the display The Air Top Evo 3900 and Air Top Evo 5500 air heaters of the combination or standard timer If the heater has a are based on the evaporator principle and essentially control element the ON control light will flash In addition consist of the following the heater can be checked using a personal computer see PC heater diagnostic operating m
40. he heater and the overheating sensor work perfectly please note the following when fitting the casing Position the insulating mar 7 fig 901 so that half of the width of the mat is under the shells 4 and 2 or under the cover for the hot air outlet 3 When you fit the top shell 2 ensure that the insulating mat is secure e If the insulating mats are heavily pressed or old replace them 902 Air Top Evo 3900 5500 1 Ensure that the insulating mat 7 is properly positioned on the heat exchanger IMPORTANT When you fit the bottom shell 4 spread it slightly so that the spacers on the overheating sensor 9 fig 902 are not damaged 2 Expand the bottom shell 4 Fig 901 slightly at the side and fit it to the heater from underneath until the securing pins on the heater engage in the holes in the shell 3 Fita new seal on the exhaust outlet 9 2 2 2 Top shell Place the top shell 2 fig 901 on the heater and secure itin the grooves in the bottom shell 9 2 2 3 Cover for hot air inlet and outlet NOTE The covers for the hot air inlet and outlet are different Fit the cover with the larger opening at the front on the hot air blower Push on the covers 3 and 5 fig 901 until the four securing holes engage properly in the detents on the bottom and top covers 9 2 2 4 Grate for hot air inlet and outlet Fit the grates 6 fig 901 on the covers for the hot air inlet and outlet and twist them to secu
41. hicles with carburettor engines The fuel may only be extracted on cars using the special Webasto fuel extractor for example Part No 470 910 as close to the tank as possible The connect may be made in either the supply or return line in which case the return line must lead almost to the base of the tank If this is not the case the return line may be extended The fuel extractor must be fitted in such a way that any air or gas bubbles are automatically discharged towards the tank The fuel extractor should not be located near the engine as gas bubbles may form in the lines on account of heat radiated from the engine This may cause problems during combustion Vehicles with injection engines When installing the heater in a vehicle with fuel injection system it is important to establish whether the fuel pump is located inside or outside the tank If the fuel pump is located inside the tank fuel can only be extracted from the return line using the Webasto fuel extractor for example Part No 470 910 in which case it must be ensured that the return line continues almost to the bottom of the tank If this is not the case Webasto fuel extractor see fig 802 803 or 804 may be used If the fuel pump is installed outside the tank the fuel connection may also be made between the tank and the fuel pump again using only the Webasto fuel extractor for example Part No 470 910 Hole pattern gt 25 mm NOTE Only use a tank
42. iary drive unit connection XT Heater wiring harness connection Fig 701 Plug assignment 701 7 Circuit diagrams Air Top Evo 3900 5500 30 30 15 15 X1 X2 FA A F4 Ft oes 7 xs al JO gt E i E Do Y X3 X4 X5 X6 X7 E 5 0 5mm rt 0 5mm sw 2 0 5mm sw rt Z 0 5mm bl N 2 868 378 Hae 0 5mm ws ct 7 a Y 858 1 30 6 Le z e Z LS A D 3 E Sa T i i x9 m Sa 4 1 FE 4H ES J M3 37 7x B4 Y a CO l s 5 fi Oo a 1 E E S 1 31 Fig 702 System circuit diagram 12V 24V with control element and vehicle blower s2 ge EE EE SEE EE EE o E ssa 0 5mm gr D A T i F4 F1 29 55 1 xe SE 7 t HE 5 di 55 o ae 9 0 5mm rt 0 5mm sw 0 5mm bl 0 5mm ws br 0 6mm sw rd o N
43. icing work After 3 000 operating hours a flash code flashing pulses at one second intervals are output with the operation indicator This code indicates the need for maintenance servicing of the heater to the user The service signal is output for 10 seconds during each heater unit start up and can be reset with the Webasto diagnosis by pulling the fuse or with Delete fault The following servicing work is to be carried out to maintain the functional reliability of the heater e Check the hot air inlet and outlet for dirt and foreign bodies Dirty or blocked hot air lines may cause overheating Clean the exterior of the heater avoid the ingress of water e Check the electrical connections for contact corrosion and to ensure that they are secure e Check the exhaust and combustion air lines for signs of damage and to ensure that they are clear e Replace the fuel filter if there is one e Check the fuel line and filter for leaks 8 6 Visual inspections and installation instructions 8 6 1 Hotair system IMPORTANT The integration of the heater into the vehicle s own air system is not permitted as a result of the high pressure in the vehicle s system Inside the control unit there is a temperature sensor which operates the heater in the appropriate heat output range in conjunction with the control element depending on the intake temperatures and the position of the setpoint generator The heat output is set so that aft
44. ith the servicing and safety instructions Installation regulations for Webasto fuel tanks for supplying fuel to heaters in vehicles The tank must not be installed in the passenger or driver s cabin of buses The fuel filler neck must not be inside the passenger or driver s cabin in any vehicle Fuel tanks for normal and super grades of petrol must not be immediately behind the front trim of the vehicle They must be separated from the engine in such a way that in the event of an accident the fuel will not be expected to ignite This does not apply to tractor units with an open driver s seat The fuel lines Mecanyl hose must not be immediately next to the exhaust pipe and must be thermally insulated if necessary otherwise they will pose a fire risk All pipes that come into contact with fuel must have sealed connections they must not be damaged in any way and the must be checked at regular intervals at least the same intervals as an inspection of the vehicle as a whole NOTE If any damage or leaks are found on the fuel line the heater must not be used until the damage has been rectified by an authorised Webasto workshop Put the heater out of action by removing the fuse 103 1 Introduction Overheating Keep the hot air inlet and hot air outlet free of dirt and foreign bodies Dirty blocked air lines can cause the heater to shut down due to overheating After an overheating lock out check that the air system is
45. l Jebasto Feel the drive Air heaters Workshop Manual Air Top Evo 3900 Air Top Evo 5500 Type Air Top Evo 3900 5500 ST B petrol Type Air Top Evo 3900 5500 ST D Diesel PME 04 2008 1313560A Air Top Evo 3900 5500 Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and have the appropriate technical documentation special tools and special equipment NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course you do not have the necessary technical skills and you do not have the technical documentation tools and equipment available to ensure that you can complete the installation and repair work properly ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel Air Top Evo 3900 5500 Table of Contents Table of Contents 1 Introduction 1 1 Contents nd purpose mii a 101 1 1 1 Use of the air heaters eee 101 1 2 Meaning Of signal Words uicem etenim 101 1 3 Additional documentation to be Used sss sss sse 101 1 4 Statutory regulations and safety inStructiONS ccccccnnnnnnnnon
46. le ower combustion and hot air blower has a Eliminate the cause of the blockage short circuit to earth or the drive unit is difficulty in movement overloaded Replace drive unit combustion and hot air bl 15 Burner motor block guard has tripped owen 95 Burner motor not turning easily sensor has tripped F 09 Glow plug interrupt or glow plug 8A Glow plug Flame monitor Break or Replace glow plug flame monitor short circuit short circuit to Ub 19 Glow circuit The switched cable of the element has a short circuit to earth Replace glow plug flame monitor F 10 Overheating 06 The overheating fault lock out has Find and remove the cause of the tripped heater overheated overheating E NOTE 17 Incorrect application or illegal insulation If no other cause can be found for the OHS gradient too high A overheating the pressure losses caused by the hot air distribution too many resistance points are too high or a hot air filter is soiled F11 Overheating sensor interrupt or AB Overheating sensor circuit Replace overheating sensor overheating sensor short circuit break or short circuit to Ub 1B Overheating sensor circuit the switched cable of the element has a Replace overheating sensor short circuit to earth F 12 Heater unit lock out 07 The permanent heater fault lock out Heater unit is switched on has been activated Fault code F12 is shown Remove fuse Switch off heater unit with heater control Insert fuse again after more than
47. lower see 9 2 5 1 Remove the burner see 9 2 6 1 Remove 2 screws 1 Fig 903 and pull the combustion pipe 4 out of the heat exchanger 6 8 Remove and discard the round sealing ring 5 from the heat exchanger 6 9 Complete the work on stripped down components see 9 1 1 AO IN AR 9 2 7 2 Installation 1 Fita new round sealing ring 5 fig 903 into the heat exchanger 6 Secure the combustion pipe 4 with 2 screws on opposite sides 1 Tighten the screws to 4 0 4 Nm Fit the burner see 9 2 6 2 Fit the combustion and hot air blower see 9 2 5 2 Fit the control unit see 9 2 3 2 Fit the overheating sensor see 9 2 4 2 Fit the casing parts see 9 2 2 Install the heater see 8 7 1 2 m DOON BE Air Top Evo 3900 5500 9 Repair Torx screw 4 Retaining bar Diesel burner Combustion pipe Round sealing ring Heat exchanger Petrol burner Glow plug Flame monitor Retaining clip 00 JO GQ E GKM Fig 903 Change the burner glow plug flame sensor the combustion tube and the heat exchanger 907 9 Repair Air Top Evo 3900 5500 Page for notes 908 Air Top Evo 3900 5500 10 Packaging storage and shipping 10 1 General If the heater or its components are sent to Webasto AG for testing or repair it must be cleaned and packed in sucha way that it is protected against damage during handling transport and storage An ambient temperature of 85 C or 40 C mus
48. m ws br Fig 705 System circuit diagram diesel 12V 24V with combination timer and electrical battery isolation switch 703 7 Circuit diagrams 30 15 58 rt F4 rt 0 5mm ws rt Fi EE X9b 0 5mm ge rt X7 3 0 5mm X8 2 D 0 5mm sw 0 5mm rt 0 5mm bl 0 5mm ws X9b X9a br br Air Top Evo 3900 5500 A c s X1 X2 go 1 X3 X4 X5 X6 31 Fig 706 System circuit diagram diesel 12V 24V with Control Panel MC04 05 and vehicle blower s2 30 lt AR RA ooo S lt lt lt Q_ S 15 DEE p 2 rt 0 5mm ws rt X9b
49. mbustion air shall be interrupted by suitable measures after an after running cycle of not more than 40 seconds Only heaters for which proof has been furnished that the heat exchanger is resistant to the reduced after running cycle of 40 seconds for the time of their normal use shall be used End of extract 3 8 Fault lock out Errors on the various heater components and faults in the starting process and in heating mode are identified in the control unit The heater is switched off and goes into fault lock out if the following conditions occur Noor incorrect start Temperature sensor defective Overheating sensor interrupt or short circuit e Overheating sensor installed incorrectly Glow plug Flame monitor interrupt or short circuit Fan motor overload or blocked or short circuit or interrupt Error in metering pump circuit Undervoltage below 10 5 V 21 V for longer than 20 seconds e Overvoltage above 16 V 32 V for longer than 6 seconds Control unit defective e Overheating 3 Function description The fuel supply is stopped if the heater overheats The heater continues to run in the same way as if it is Switched off manually After it stops the control unit will be set to fault lock out The overheating is indicated by the indicator flashing 10 times Rectify the cause of the fault To reset the fault switch the heater on and off briefly at least 2 seconds 3 8 1 Error monitor The overheat inc
50. ntrol unit has suffered an error 3 Setthe CO value by turning the adjustment knob Turning it anticlockwise will reduce the CO value whilst turning it clockwise will increase it The measured CO content at low fire rate 1 5 kW must be between 5 0 96 and 8 0 96 4 Ifthe CO value is within this range disconnect the CO line from minus This saves the setting NOTE The heater will now run in normal mode again and can be Switched off as normal using the control element The heater is set at the factory to match the fitted combustion air blower 6 Function tests 6 3 Testing individual components IMPORTANT For function tests always break the connection between the control unit and the component you wish to test 6 3 1 Glow plug resistance text NOTE The resistance test must be carried out with an ohmmeter suitable for small resistance values A resistance test with a simple digital multimeter is too inaccurate to find the precise values A new glow plug can be measured to act as a reference The glow plug should have the following values in the test Glow plug 12 V red 24 V green Resistance at 25 C 0 190 0 250 Q 0 740 0 940 Q Test current 5mA 5mA 6 3 2 Overheating sensor resistance test If you conduct this test with a digital multimeter the overheating sensor must have the values shown in the following diagram 2260 2240 2220 2200 2180 2160 2140 2120 2100 2080 2060
51. on of fuel lines and the installation of additional fuel tanks The main points from this law Fuel pipes must be designed in such a way that torsion in the vehicle movements by the engine and the like do not have a negative effect on their durability They must be protected from mechanical damage Parts that carry fuel must be protected from heat that will adversely affect their function and positioned so that dripping or evaporating fuel cannot collect or ignite on hot parts or on electrical equipment The air heater s heat exchanger can be used for a maximum of 10 years and must then be replaced by the manufacturer or one of its authorised workshops using a genuine spare part A label must then be affixed to the heater showing the date of sale and the wording Genuine spare part When you change the heat exchanger it is essential that you also replace the overheating protection element temperature sensor to prevent possible function faults caused by using the old temperature sensor The Air Top Evo 3900 and Air Top Evo 5500 air heaters are prepared for interior installation and sealing direct on the cabin floor or a cabin wall Non release connections must be used in the interior for combustion air and exhaust pipes with the accessories available from Webasto The seal between the heater mounting and the vehicle floor must always be installed otherwise harmful emissions may get into the interior of the vehicle The
52. ononononcnnncnnnnnnnncnnnnnnnnnnnnn nono RARR ee ee ee ee ee ee 101 1 4 1 Statutory regulations governing installation ee eee 101 1 4 2 General safety information sese 102 2 General description 24 jDrivewunil coco tenete EL as Laut ca M ct Lie 202 2 2 Heatexch nger ER IRI RA ER E Eye tege cede E da N 202 2 3 Burner insert with combustion Dipe sese eee eee 202 24 Controluniltg EE 203 2 5 ee plug Flame MONO aiii ier eerte pr E AE N 203 2 6 Overheating T eT 203 2 0 vMeterindBUmMP ESE a i GI nube e 203 3 Function description 3 1 Gontolelement entree e 301 WAN ol es EE RE ON HE EE EE EE ect eee 301 3 39 Heating ee eR 301 Rr oe niie nee N EE EE EE ER EE i 301 A pause Ee EE EE E 302 3 6 Switch off AE EE shes eee eid N EE leg ee HEEL e e EE NE RE 302 3 7 Heater functions when installed in ADR vehicles sss 302 3 7 1 Extract from Directive 2001 56 EC Annex IX 302 3 9 E 0A lee o h AR AE eno ei EG 303 O ee cee 303 3 8 2 Reset a fault lock out RE RR RR N EE OR OE RE EE NN 304 d Technical data T 401 Table of Contents Air Top Evo 3900 5500 5 Troubleshooting A Et 501 5 2 General error symptoms sk RA AA AA ee ER R HARSHA TRR TE TAS 501 5 3 Error symptoms during function seesi eia rai aa Reede ee ee ee ee ee ee ee 502 5 4 Eror code output OR AE ER ER OR EE SR IS RENS 503 Function tests 6 1 General EE EE EE GE EE GE Ee N ue Ei di MM ir 601 62 A EE OE N RE EE N Eea 601 6 21 Setting the CO5 c
53. ontent ote IRE Ro ade ad a dc s 601 6 3 Testing individual components sss eee ER RR AA RA AA ee ee ee ee ee RR RR Re ede dee ee ee ee ee ee ee ee Ee 601 6 3 1 Glow plug resistance ext 601 6 3 2 Overheating sensor resistance Lest 601 Circuit diagrams FAW General ii RE EE OE EE ea ega EEOAE eak EEEE 701 7 2 Legend for circuit diagramS sss sees 706 Servicing work 8 1 ei EE 801 8 2 Workon the fieatef cioe is pe bead ene DE dia 801 8 3 Work on the vehicle sintirina ee ERA AA AA ee ee ee ee Re ee ee ee ee ee ee ee 801 64 Heater trial eate eer ERR ERR RD RED ORBI EE 801 8 5 Servicirig e RE EE EE Du d Rc RU E EE e RU De EE EN dede EP 801 8 6 Visual inspections and installation Instructions eee eee eee 801 8 61 Hotalif system ied ep Re Ge RE An See ee ee Se bi tius 801 8 6 2 Ee AE EE EE EE ieee EE EE a a ed 802 8 63 Metering pump EE ee EE a ER Ee Re 805 8 6 4 Fuel ER EE EE EN ER EEN ER EE Ee 805 8 6 5 Combustion air supply a RR RR RARR AA ee ee ee 1672 Raa ERE ee ee EAA EE aE 806 8 6 6 Exhaust pipe EE ieee ee Ai ad gue OE N 806 8 6 7 Combustion air inlet and exhaust lines eee eee eee ER ER RR RR AA Re ee ee ee ee ee ee ee ee EE ee 806 8 6 8 Electrical connections sieisen ER RR RA AA TR ZR de ER RR AR Re de a ee ee ee ee ee 807 8 7 Removal and installation rc EE e tad 809 8 7 1 Heater removal and installation 809 8 8 Startups HA OE EE EE ER OR e RE N ER ien 809 Air Top Evo 3900 5500 Table of Contents
54. orrect start and flame failure errors are counted and cause the heater to suffer a fault lock out after an error has occurred the maximum number of times The incorrect start counter FSZ is incremented by 1 each time the heater fails to start If the incorrect start counter reaches its maximum value of 9 the heater will go into the heater lock out status HGV The error counter SZ is incremented by 1 each error for which there is no separate counter If the error counter reaches its maximum value of 5 the heater will go into the heater lock out status HGV The overheating counter HZ is incremented by 1 each time the heater overheats If the overheating counter reaches its maximum value of 5 the heater will go into the heater lock out status HGV After a flame abort FAZ a restart is automatically carried out The condition for a restart is that the heater unit was in the control mode directly beforehand During the restart the cycle repetition counter ZWZ is increased by one This process is repeated until the heater unit either burns properly again or the maximum value of 3 for the cycle repetition counter has been reached The flame abort counter FAZ is increased by 1 when the cycle repetition counter ZWZ has reached the maximum value If the flame abort counter reaches its maximum value of 3 the heater will go into the heater lock out status Automatic reset Following each heater unit start up the cycle repetition counter ZWZ is
55. oval 1 Remove the heater see 8 7 1 1 2 Remove the casing parts see 9 2 1 3 Disconnect plug connection X3 on the control unit 3 fig 902 4 Lever the overheating sensor 9 out of the heat exchanger s ribs using a suitable tool see Detail A IMPORTANT Do not pull the cables 5 Remove the overheating sensor 9 9 2 4 2 Installation 1 Measure the resistance of the overheating sensor 9 fig 902 see 6 3 2 2 Position the overheating sensor 9 and press it into place by hand 3 Ensure that the overheating sensor is correctly positioned in the heat exchanger 7 Connect plug connection X3 to the control unit 3 Fit the casing parts see 9 2 2 Install the heater see 8 7 1 2 ome 904 Air Top Evo 3900 5500 9 2 5 Change the combustion and hot air blower drive unit IMPORTANT Replace the drive unit 1 fig 902 only with a drive unit with the same rating data and the same Part No NOTE The drive unit combustion and hot air blower can only be replaced in full It cannot be repaired 9 2 5 1 Removal Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the screws 2 Remove the combustion and hot air blower 1 forwards Remove and discard the flat seal 6 Complete the work on stripped down components see 9 1 1 GAD m c nb 9 2 5 2 Installation 1 Ensure that the sealing surfaces on the combustion
56. ram 12V 24V with control element and vehicle blower sese ee ee ee ee Re 702 System circuit diagram 24V ADR operation with control element eee eee eee 702 System circuit diagram 12V 24V with combination timer and vehicle blower sees ee ee 703 System circuit diagram diesel 12V 24V with combination timer and electrical battery isolation switch 703 System circuit diagram diesel 12V 24V with Control Panel MC04 05 and vehicle blower 704 System circuit diagram diesel 24V ADR operation with Control Panel MCOA 0B sese 704 Schematic connection of the combination timer sees eee eee ee eee 705 Schematic connection of the Control Panel MCO4 05 see eee 705 Fuel supply t e A o ree oe UE DE EU EC PEU Eee d e EN 803 Webasto fuel extractor 52 dis 804 Fuel extractor from the plastic tank extraction through tank drain screw eee e 804 Fuel extractor from the plastic tank pickup via tank fitting ss eee eee 804 Pipe Hose conne CtoS RA EE ne Late A die ea 805 Metering pump installation position eee eee 805 AE EE EE ed en RR ON ME LE ON RE te N 805 ExhaustsilOncer EE AA EA BE RE RE ER IS BEE 806 Exhaust pipe mouth installation pOSitON ee ee ee ee ee ee ee ee de ee ee de ee ee ek ee ee 806 Remove the fastening plate on the fuse holder 807 Fuse holder installation position eee e 807 Goritrolelement ss ca 807 Disconnect the plug a ER ER ER RE 807 Specimen installation for heater in an air
57. re them 9 2 2 5 Cover for electrical connection NOTE The wiring harness is to be taken out of the left or right of the heater to suit the installation situation Fit the cover 1 fig 901 until it audibly engages in the top cover Air Top Evo 3900 5500 9 Repair l O Q E GKM Cover electrical connection Top shell Cover hot air outlet Bottom shell Cover hot air inlet Grate Insulators 4 Insulator positioning d A Insulator Widening of corner rib Fig 901 Remove fit the casing parts 903 9 Repair 9 2 3 Change the control unit 9 2 3 1 Removal 1 Remove the heater see 8 7 1 1 2 Remove the casing parts see 9 2 1 3 Disconnectthe plug connections on the control unit 3 Fig 902 4 Remove the screws 4 5 Slide the control unit 3 towards the hot air blower and remove it upwards 6 Complete the work on stripped down components see 9 1 1 NOTE Do not carry out any repair work to the control unit 9 2 3 2 Installation 1 Insert the control unit 3 fig 902 on the combustion and hot air blower 1 push it towards the blower casing and secure it with screws 4 2 Tighten the screws 4 to 3 0 0 3 Nm 3 Connect the plug connections on the control unit as shown in fig 701 Fit the casing parts see 9 2 2 Install the heater see 8 7 1 2 Check the CO setting and adjust it if necessary see 6 2 Oak 9 2 4 Change the overheating sensor 9 2 4 1 Rem
58. rectives are binding within the territory governed by EU Directive 70 156 EEC and should similarly be observed in countries without specific regulations Extract from Directive 2001 56 EC Annex VII 1 7 1 A clearly visible tell tale in the operator s field of view shall inform when the combustion heater is switched on or off 2 Vehicle installation requirements 2 1 Scope 2 1 1 Subject to paragraph 2 1 2 combustion heaters shall be installed according to the requirements of this Annex Vehicles of category O trailers having liquid fuel heaters are deemed to comply with the requirements of this Annex 2 2 Positioning of heater 2 2 1 Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination 101 1 Introduction 2 2 2 The combustion heater shall not constitute a risk of fire even in the case of overheating This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation by the use of fire resistant materials or by the use of heat shields 2 2 3 In the case of M2 and M3 vehicles the heater must not be positioned in the passenger compartment However an installation in an effectively sealed envelope which also complies with the conditions in paragraph 2 2 2 may be used 2 2 4 The label referred to in paragraph 1 4 model plate or a duplicate
59. set to 0 The fault counter is set to 0 after a fault free transition to the control mode and the flame abort counter FAZ overheating counter UHZ and false starting counter FSZ are set to 0 after fault free combustion operation 6 min 303 3 Function description 3 8 2 Reset a fault lock out The various fault statuses can be reset as follows Fault lock out Heater fault lock out 304 Switch heater off using the control element and then on again after more than 2 seconds Heater unit is switched on Fault code F12 is shown Remove fuse Switch off heater unit with heater control Insert fuse again after more than 2 seconds Switch on heater unit again with heater control Air Top Evo 3900 5500 Air Top Evo 3900 5500 4 Technical data Except where limit values are specified the technical data listed in the table refer to the usual heater tolerances of 110 at an ambient temperature of 20 C and at the rated voltage and in rated conditions Electrical components The control unit combustion air blower metering pump timer glow plug flame monitor and control element are designed for 12 V or 24 V The voltage is immaterial for the temperature sensor not for ADR Fuel for Air Top Evo 3900 5500 B petrol The fuel specified by the manufacturer must be used Fuel for Air Top Evo 3900 5500 D diesel PME 4 Technical data The diesel fuel specified by the manufacturer must be used Class
60. sition from control mode to control pause The heater is then switched off automatically NOTE The heater may be switched on again during the slow down time In this case the slow down time is completed and the heater is then restarted 302 Air Top Evo 3900 5500 3 7 Heater functions when installed in ADR vehicles NOTE 24V Only for Air Top Evo 3900 5500 D heaters that are installed in vehicles for transporting hazardous substances ADR If the heater is switched off using the control element the slow down time remains unchanged A brief slow down time max 40 seconds is started automatically if e the vehicle s engine is switched off atransport device is started After an ADR shut down process the control unit is in the Fault lock out position Before it can be restarted the con trol element must be set to OFF 3 7 1 Extract from Directive 2001 56 EC Annex IX Start of extract ANNEX IX 3 TECHNICAL PROVISIONS 3 1 General EX II EX III AT FL and OX vehicles 3 1 1 The combustion heaters and their exhaust gas routing shall be designed located protected or covered so as to prevent any unacceptable risk of heating or ignition of the load This requirement shall be considered as fulfilled if the fuel tank and the exhaust system of the appliance conform to the provisions set out in the points 3 1 1 1 and 3 1 1 2 Compliance with those provisions shall be verified on the completed vehicle 3 1 1 1 Any fu
61. t not be exceeded for storage Shipment address Webasto AG Werk Neubrandenburg Garantieabteilung Speicherstrake 3 4 D 17033 Neubrandenburg 10 Packaging storage and shipping 1001 Webasto AG Kraillinger Strasse 5 82131 Stockdorf GERMANY http dealers webasto com http Awww webasto com Subject to modification 2008 All Rights Reserved IDENT NR 1313560A
62. utput If the heater is fitted with a combination timer an error code output will appear on the display of the timer after a fault occurs 5 Troubleshooting NOTE The error code is output if the heater is fitted with a control element after an error has occurred by the switch on indicator error code indicator flashing After 5 seconds of fast flashing the error code will be output by a sequence of long flash pulses the number of flashes is shown in the table below for example F04 4 long flash pulses Error code Error group Additional information during PC diagnostic Troubleshooting F 00 Control unit error incorrect parameter set warm start detection 01 Control unit error 81 EOL checksum error 11 Incorrectly coded control unit or incorrect heater fuel type installed the heater will not work if this error occurs 91 Neutrally coded or disabled control unit the heater will not work if this error occurs 92 Maintain command failed the heater will not work if this error occurs 18 Customer bus defective Replace control unit F 01 No start after 2 starting attempts no flame formation 02 Even after the restart no flame has formed 82 No start in test Check fuel supply tank empty lines blocked Clean burner insert replace flame sensor F 02 Flame abort repeated gt 3 03 The flame has gone out during operation and has not reformed after a restart attempt
63. y Switch heater off and then on again Heater unit emits black smoke blocked Combustion air and or exhaust system Check that the combustion air and exhaust systems are clear Fig 501 General error symptoms 501 5 Troubleshooting 5 3 Error symptoms during function The following table Fig 502 lists the possible error symptoms in the order in which they may occur during operation In the event of a fault the error is to be located using this table and rectified It is important that the error symptom is correctly identified If the error symptom is not included in this table or if the Air Top Evo 3900 5500 fault is not found under the specific error symptom heading in an emergency you can contact our technicians on our service hotline see www webasto com NOTE Every fault is indicated by the flashing LED on the control element after the slow down time has finished If the other components are OK a defective control unit may be the cause of all the faults Error symptom Occurrence possible causes No start and no illumination of the immediate Incorrect cabling defective fuse LED on the control element No start but LED is lit immediate The unit immediately goes into a control pause when switched on the control pause speed is 0 rpm when an external temperature sensor is used Fig 502 Error symptoms during function 502 Air Top Evo 3900 5500 5 4 Error code o

Air Top Evo 3900 Air Top Evo 5500

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