Webasto Air Top 3500 ST Installation Instructions Manual
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Webasto Air Top 3500 ST Installation Instructions Manual

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Luftheizgeräte
Air heaters
Luchtverwarmingssystemen
04/2004
Einbauanweisung
Installation instructions
Montagehandleiding
Air Top 3500 ST
Air Top 5000 ST
Handelsbezeichnungen / Trade names / Handelsnamen:
Air Top 3500 ST B (Benzin) (petrol) (benzine)
Air Top 3500 ST D (Diesel/PME) (diesel/PME)
Air Top 5000 ST B (Benzin) (petrol) (benzine)
Air Top 5000 ST D (Diesel/PME) (diesel/PME)

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Summary of Contents for Webasto Air Top 3500 ST

  • Page 1 Air Top 3500 ST Air Top 5000 ST Handelsbezeichnungen / Trade names / Handelsnamen: Air Top 3500 ST B (Benzin) (petrol) (benzine) Air Top 3500 ST D (Diesel/PME) (diesel/PME) Air Top 5000 ST B (Benzin) (petrol) (benzine) Air Top 5000 ST D (Diesel/PME) (diesel/PME)

  • Page 2: Table Of Contents

    Air Top 3500 ST / Air Top 5000 ST Inhaltsverzeichnis Table of contents Gesetzliche Bestimmungen für den Einbau ... . 1 Statutory regulations governing installation ... 37 Verwendung der Luftheizgeräte .
  • Page 3 Air Top 3500 ST / Air Top 5000 ST Inhoudsopgave Wettelijke voorschriften voor de inbouw ....73 Gebruik van de luchtverwarmingssystemen ..75 Inbouw .

  • Page 5: Statutory Regulations Governing Installation

    Statutory regulations governing installation Statutory regulations governing installation The Air Top 3500 ST / Air Top 5000 ST heaters have been type-tested 2.2.2. The internal combustion heater must not pose a fire hazard even and approved in accordance with EC Directives 72/245/EEC (EMC) and when overheated.
  • Page 6 Failure to follow the installation instructions and the notes contained 2.4.1. The exhaust outlet must be positioned in such a way that exhaust therein will lead to all liability being refused by Webasto The same fumes cannot get into the interior of the vehicle through ventilation applies if repairs are carried out incorrectly or with the use of parts other devices, hot-air inlets or open windows.

  • Page 7: Use Of The Air Heaters

    Air Top 3500 ST / Air Top 5000 ST Use of the air heaters Use of the air heaters The Webasto Air Top 3500 ST and Air Top 5000 ST air heaters are designed – to heat cabins, boats, trucks, minibuses, vans, ambulances and motorhomes –...

  • Page 8: Installation

    Air Top 3500 ST / Air Top 5000 ST Installation IMPORTANT 3.1. Air Top 3500 ST / Air Top 5000 ST installation situation The statutory regulations governing installation on pages 1 and 2 must NOTE: be adhered to. The requirements of the latest version of the ADR must Check the installation situation of the relevant vehicle type.
  • Page 9 The M6 nuts must be tightened with a torque of 6 Nm +1 Nm for installing licensed. the Air Top 3500 ST or Air Top 5000 ST heater. The openings for the combustion air inlet port, the exhaust outlet port The installation dimensions and space requirement for service access and the fuel pipe must be sealed if the heater is installed in the interior.
  • Page 10 This seal must be replaced each time the heater is installed. The support area for the heater foot must be flat. A special tools can be purchased from Webasto to drill the holes and, if necessary, smooth the support area. The seal can compensate for unevenness of max. 1 mm.

  • Page 11: Factory Plate

    Air Top 3500 ST / Air Top 5000 ST Factory plate Factory plate The model plate must be positioned so that it cannot be damaged and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used).

  • Page 12: Installation Example

    Installation example Air Top 3500 ST / Air Top 5000 ST Installation example Control element Heater Metering pump Fuel filter (accessory) Tank connector Exhaust silencer (accessory) Fuse Maximum water passage height Fig. 6: Installation example for air heater in recirculation mode...

  • Page 13: Hot Air System

    The heat output is controlled such that after The points table for air guide parts in the Webasto catalogue may be the selected interior temperature has been reached quickly, it is then used to design the hot air system.
  • Page 14 Hot air system Air Top 3500 ST / Air Top 5000 ST 6.1. External temperature sensor The installation of an external temperature sensor is recommended if the heater is operated in fresh air mode. 6.1.1. To install the external temperature sensor...

  • Page 15: Fuel Supply

    Air Top 3500 ST / Air Top 5000 ST Fuel supply 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 9.
  • Page 16 (see Figure 11 for details of the minimum distance from the bottom of the tank). If this is not the case Webasto fuel extractor (see Figure 11, 12 and 13) may be used.
  • Page 17 Air Top 3500 ST / Air Top 5000 ST Fuel supply NOTE: The tank fitting must be made from metal! Plastic tank 7.4. Fuel lines Only steel, copper and plastic lines of plasticised, light and temperature- stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines.
  • Page 18 Air Top 3500 ST / Air Top 5000 ST 7.4.1. Connecting two pipes with a hose Air Top 3500 ST / Air Top 5000 ST 12 Volt - petrol The correct procedure for connecting fuel lines with hosing is shown in Figure 14.
  • Page 19 7.6. Fuel filter Only a Webasto filter, order 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). 0° - 90°...

  • Page 20: Combustion Air Supply

    Combustion air supply Air Top 3500 ST / Air Top 5000 ST Combustion air supply Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt.

  • Page 21: Exhaust Pipe

    Air Top 3500 ST / Air Top 5000 ST Exhaust pipe Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness The exhaust silencer should ideally be installed near the heater. The of 1.0 mm or flexible piping of alloyed steel only must be used as heater may also be operated without a silencer.

  • Page 22: Combustion Air Inlet And Exhaust Lines

    Combustion air inlet and exhaust lines Air Top 3500 ST / Air Top 5000 ST Combustion air inlet and exhaust lines 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.
  • Page 23 Air Top 3500 ST / Air Top 5000 ST Combustion air inlet and exhaust lines 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 almost vertical 90°...

  • Page 24: Electrical Connections

    (ADR) To install the Air Top 3500 ST D and Air Top 5000 ST D heaters in hazchem vehicles, the requirements of ADR/RID part 9 para. 9.2.4.7 – Combustion heating systems, must also be satisfied. The electrical connection is made as shown in the circuit diagram in Figure 34.
  • Page 25 Air Top 3500 ST / Air Top 5000 ST Electrical connections The cable passage can be placed at either the left or right side. To F = 15A (24V) ensure that the cable passage in the control unit cover seals perfectly, F = 20A (12V) the cable grommet is to be adjusted appropriately on the wiring harness.
  • Page 26 Electrical connections Air Top 3500 ST / Air Top 5000 ST 11.4. Control element connection The wiring harness is prepared for connection to the control element. Simply pull on connector housing to unplug the connector. The connector housing can be locked (self-locking action) by simply pulling on the wiring harness.

  • Page 27: Connection Diagram / Circuit Diagrams

    Connection diagram / Circuit diagrams Connection diagram / Circuit diagrams Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig. 30: Air Top 3500 ST and Air Top 5000 ST with combination timer connection diagram...
  • Page 28 Connection diagram / Circuit diagrams Air Top 3500 ST / Air Top 5000 ST Fig. 31: System wiring diagram for the Air Top 3500 ST and Air Top 5000 ST, 12V/24V with control element and vehicle fan, for legend see pages 64 and 65...
  • Page 29 Air Top 3500 ST / Air Top 5000 ST Connection diagram / Circuit diagrams Fig. 32: System wiring diagram for the Air Top 3500 ST and Air Top 5000 ST, 12V/24V with combination timer and vehicle fan, for legend see pages 64 and 65...
  • Page 30 Air Top 3500 ST / Air Top 5000 ST Fig. 33: System wiring diagram for the Air Top 3500 ST and Air Top 5000 ST, 12V/24V with combination timer and electrical battery isolation switch, for legend see pages 64 and 65...
  • Page 31 Air Top 3500 ST / Air Top 5000 ST Connection diagram / Circuit diagrams Fig. 34: System wiring diagram for the Air Top 3500 ST D and Air Top 5000 ST D, 24V ADR mode with control element, for legend see pages 64 and 65...

  • Page 32: Legend For Circuit Diagrams

    Legend for circuit diagrams Air Top 3500 ST / Air Top 5000 ST Legend for circuit diagrams 1. With positive from terminal (15/75) to connection 10: Cable cross-sections Permanent operation for immediate heat as long as the ignition is switched on <...
  • Page 33 Air Top 3500 ST / Air Top 5000 ST Legend for circuit diagrams Item Description Comment Item Description Comment Heater Air Top 3500 ST/5000 ST Switch Ventilation or boost Control module Momentary-contact switch Immediate heat button remote control Temperature sensor...

  • Page 34: Starting The Heater For The First Time

    Starting the heater for the first time Air Top 3500 ST / Air Top 5000 ST Starting the heater for the first time 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.

  • Page 35: Fault Lock-Out

    Air Top 3500 ST / Air Top 5000 ST Fault lock-out Fault lock-out The control unit has identified errors on individual heater components 15.1. Error code output and faults during the operation. NOTE: The heater is shut down (fault lock-out) if: The error code is output if the heater is fitted with a control element after –...

  • Page 36: Technical Data

    15 minutes so that the fuel system is filled with the new fuel. The Air Top 3500 ST and Air Top 5000 ST D heaters are also licensed for use with PME (bio-diesel), which complies with DIN EN 14214.
  • Page 37 Air Top 3500 ST / Air Top 5000 ST Technical data Heater Operation Air Top 3500 (5000) ST B Air Top 3500 (5000) ST D Air Top 3500 ST D Volume Plus Type test permit e1*72/245*95/54*1221*00 e1*2001/56*0021*00 e1*2001/56*0020*00 Model Air heater with evaporator burner...

  • Page 38: Version

    Version Air Top 3500 ST / Air Top 5000 ST Version Air Top 3500 ST B (petrol) Air Top 5000 ST B (petrol) Air heater for petrol (12 V) Air Top 3500 ST D (diesel) Air Top 5000 ST D (diesel)

  • Page 39: Drilling Template

    Air Top 3500 ST / Air Top 5000 ST Drilling template Drilling template Seal NOTE: Max. base unevenness around the seal: 1 mm Fig. 35: Drilling template...

This manual is also suitable for:

Air top 5000 st

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