Webasto AIR TOP 5000 Manual
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Webasto AIR TOP 5000 Manual

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See also: Workshop Manual , Instruction and Installation Manual
A
T
5000
IR
OP
1.
1.1
Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Meaning of Warning, Caution and Notation Headings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Additional Documentation to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
General Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
2.1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.
3.1
Operating the Air Top 5000 with Self Diagnostic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
Heater Control Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 2
Switch-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3
Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.4
Switch-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.5
Switch-Off upon Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
4.
4.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.
5.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Mounting the Air Top 5000 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2
Fuel System Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3
Fuel Standpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.4
Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.5
Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

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3-3
3-3
4-1
4-2
5-1
5-1
5-2
5-4
5-5
5-5
5-5
5-5
5-6
5-7
5-7
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Summary of Contents for Webasto AIR TOP 5000

  • Page 1: Table Of Contents

    Functional Description Operating the Air Top 5000 with Self Diagnostic Control Unit ......
  • Page 2 Wiring Diagram - Air Top 5000, 12 and 24 Volt .......

  • Page 3: Introduction

    Used Scope and Purpose This manual contains all of the information and procedures necessary for the installation of the Air Top 5000 heater in This manual is intended to support authorized Webasto on and off highway vehicles. trained distributors, dealers and personnel in the installation and servicing of the Air Top 5000 air heater.
  • Page 4 The fuel specified by the vehicle manufacturer for use in of 185 °F (85 °C) must not be exceeded under any the engine is suitable fuel for use in the Air Top 5000 air circumstances (e.g. during body paint work). A violation of heater.

  • Page 5: General Description

    2. Marine: The Air Top 5000 can be used as the primary heating source for watercraft. Boat installations may only be performed by a Webasto authorized marine dealer. It is the authorized marine dealer’s responsibility that the installation complies with all applicable Coast Guard regulations.
  • Page 6 5000 ENERAL ESCRIPTION...

  • Page 7: Functional Description

    Due to the risk of explosion causing death or serious injury to personnel, the heater must never be operated in areas where explosive materials, fumes or dusts may be present. Operating the Air Top 5000 with Self Diagnostic Control Unit 1. Operation Indicator / Overheating Indicator 2.

  • Page 8: Switch-On

    5000 UNCTIONAL ESCRIPTION 3.1.2 Switch-On The heater control element (fig.3-1) is used to switch the heater on and off, as well as setting the desired temperature. The control element acts as a thermostat, similar to a dimmer switch. The built in light indicates heater operation status by illuminating while the heater is on.

  • Page 9: Switch-Off Upon Malfunction

    5000 UNCTIONAL ESCRIPTION 3.1.5 Switch-Off upon Malfunction The control unit recognizes malfunctions of individual air heater components and malfunctions in the start sequence and in normal operation. The air heater is deactivated and enters the error lockout mode under the following conditions: •...
  • Page 10 5000 UNCTIONAL ESCRIPTION General The 7-day digital “Combination” timer enables you to preset the start of the heater operation up to 7 days in advance. It is possible to program 3 different starting times, only one of which can be activated. The combination timer has a temperature controller.

  • Page 11: Technical Data

    – 40... +185 (– 40... +85) CO2 in Exhaust at Max. Output Permissible Operating Range % by Volume 9.5... 12 9.5... 10.5 Noise Controlled Range: From Weight of Heater lb (kg) 13.2 (6.0) Table 4-1: Technical Data - Air Top 5000...

  • Page 12: Dimensions

    ø 40 mm (1-9/16 in.) 0° 137 mm (5-25/64 in.) Fig. 4-2: Fuel Pump - Air Top 5000 ATTENTION! Webasto recommends installing gasoline-operated heaters so that the exhaust gas outlet points vertically down. Other installation positions may cause increased wear to the burner.
  • Page 13 5000 ECHNICAL 56 mm (2-13/64 in.) 38 mm (1-1/2 in.) 30 mm (1-3/16 in.) Fig. 4-3: Control Element (Rheostat) - Air Top 2000 / 3500 / 5000 Fig. 4-4: Control Element (Rheostat) - Exploded View...
  • Page 14 5000 ECHNICAL...

  • Page 15: Installation

    Due to the confined spaces within marine vehicles, an increased risk of carbon monoxide poisoning causing death or serious injury to personnel is possible. Therefore, installations in marine vessels are to be performed by Webasto authorized marine equipment specialists only. It is the marine dealer’s responsibility that the installation complies with all applicable Coast Guard regulations.

  • Page 16: Mounting The Air Top 5000 Heater

    5000 NSTALLATION Mounting the Air Top 5000 Heater A mounting template has been included with the heater kit. The template details all required hole locations and clearances for ducting. Also, check for clearance around subfloor cross-members, structures and heat sensitive components before proceeding with installation.
  • Page 17 5000 NSTALLATION Basic Kit Installation After selecting the heater location, temporarily tape the provided template in place and center punch hole locations for drilling or use the rubber base gasket of the heater as a template to map out hole locations.. With a hole saw, cut the 29 mm (1.14 in.) and 28 mm (1.1 in.) holes as shown.

  • Page 18: Exhaust System

    5000 NSTALLATION Exhaust System WARNING Due to the risk of carbon monoxide poisoning causing death or serious injury to personnel, the exhaust tube must be so routed that the possibility of exhaust gases entering the vehicle / cargo area is avoided. CAUTION The exhaust tube becomes hot during operation.

  • Page 19: Combustion Air Supply

    5000 NSTALLATION Combustion Air Supply WARNING Due to the risk of carbon monoxide poisoning causing death or serious injury to personnel, never draw combustion air from inside of the cab, passenger area or cargo area of any vehicle where personnel are likely to be present. Drawing combustion air from inside of the cab, passenger area or cargo area of any vehicle can create a negative interior pressure which may allow exhaust gases in the immediate area outside the vehicle to seep in, gradually displacing oxygen with poisonous carbon monoxide.

  • Page 20: Fuel Standpipe

    5000 NSTALLATION 5.6.3 Fuel Standpipe WARNING Due to the risk of fire or explosion causing death or serious injury to personnel, extreme care must be exercised when working with gasoline fueled vehicles. Gasoline tanks must never be drilled until first emptied and properly purged of all remaining gasoline and fumes.

  • Page 21: Fuel Metering Pump

    The Air Top 5000 heater uses fuel line that meets specific criteria for proper function and reliable operation. The inside diameter of this fuel line is 2.0 mm (0.08 in.) and must never be substituted with fuel line of a larger inside diameter.

  • Page 22: Fuel Filter

    If the heater kit being installed does not include a fuel filter and dirt in the fuel cannot be avoided or is expected, an optional filter is available from Webasto. Order genuine Webasto fuel filter P/N 487171. The filter should preferably be installed in a vertical position, where this is not possible, it may also be installed horizontally (see figure 5-11).

  • Page 23: Wiring Connections

    5.7.1 General Information The Air Top 5000 heater may be operated using the standard rheostat switch or with the optional 7-Day digital “Combi” Timer model 1531. The following section shows the possible circuits with the standard rheostat switch installed. 5.7.2 Connector Identification Fig.

  • Page 24: Wiring Diagram - Air Top 5000, 12 And 24 Volt

    5000 NSTALLATION 5.7.3 Wiring Diagram - Air Top 5000, 12 and 24 Volt Fig. 5-13: Wiring Diagram - Air Top 5000 5-10...

  • Page 25: Electrical Component Identification Table

    NSTALLATION 5.7.4 Electrical Component Identification Table Table below refers to wiring diagram on page 5-10, figure 5-13. ITEM DESCRIPTION Heater - Air Top 5000 Control Unit Temperature Sensor Temperature Limiter Ceramic Igniter / Flame Detector Flat Fuse - 15 Amp...

  • Page 26: Fuel Metering Pump Harness

    5.8.2 Remote Temperature Sensor (Optional) A remote external temperature sensor kit (includes updated control unit) is available from Webasto under part number 90821A. The remote sensor allows temperature monitoring from a remote location other than the heaters inlet. This is beneficial where the heater is located in an area where cold air influx does not allow consistent temperature measurement at the heater inlet.

  • Page 27: Ducting The System

    CAUTION Due to the high heat output of the Air Top 5000, it is not permissible to integrate the heater into the vehicle’s air ducting system. Doing so will result in melting damage to the vehicle’s air ducting system.

  • Page 28: Initial Start-Up

    After the heater is in operation, all fuel connections must be checked for leakage and all lines/wiring for secure fastening. Fig. 5-19: Control Element Knob Range Using the information from the heater identification plate, complete the warranty card and send to Webasto Thermosystems for warranty registration. 5-14...

  • Page 29: Maintenance/Troubleshooting

    Always use genuine Webasto service and replacement parts to ensure trouble-free operation of the heater. Heater Maintenance The Webasto Air Top 5000 heater is designed for minimal maintenance. Under normal circumstances it should be inspected for proper function at least once annually, perferrably, just prior to the heating season.

  • Page 30: Heater Emits Black Smoke From Exhaust

    Storing a Fault Code in Memory Once the Air Top 5000 heater completes the after run (cool down) period initiated by a failure event, the current flash code will be downloaded (stored) in memory. The Air Top 5000 heater can store up to four fault codes. Once the memory is “full”, any additional fault code will replace the earliest code stored thereby continually updating the fault...

  • Page 31: Diagnostic Code Table

    Damaged or corroded wiring, open or short circuit Defective limiter Replace temperature limiter 12X Flashes (F 12) Wiring Interruption or short circuit Control Element (Temperature Controller) Defective controller Replace control element Table 6-1: Diagnostic Codes - Air Top 5000 Diagnostic...
  • Page 32 5000 AINTENANCE ROUBLESHOOTING Please use this section for your notes and observations.

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