Webasto Air Top Evo 3900 Series Installation Instructions Manual
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Webasto Air Top Evo 3900 Series Installation Instructions Manual

Webasto Air Top Evo 3900 Series Installation Instructions Manual

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See also: Workshop Manual , Installation Manual
Luftheizgeräte
Air heaters
Luchtverwarmingsapparaten
Einbauanweisung
Installation Instructions
Montagehandleiding
Air Top Evo 3900
Air Top Evo 5500
Handelsbezeichnungen /Trade names / Handelsnamen:
Air Top Evo 3900 B
(Benzin) (petrol) (benzine)
Air Top Evo 3900 D
(Diesel/PME) (diesel/PME)
Air Top Evo 5500 B
(Benzin) (petrol) (benzine)
Air Top Evo 5500 D
(Diesel/PME) (diesel/PME)

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Summary of Contents for Webasto Air Top Evo 3900 Series

  • Page 1 Luftheizgeräte Einbauanweisung Air heaters Installation Instructions Luchtverwarmingsapparaten Montagehandleiding Air Top Evo 3900 Air Top Evo 5500 Handelsbezeichnungen /Trade names / Handelsnamen: Air Top Evo 3900 B (Benzin) (petrol) (benzine) Air Top Evo 3900 D (Diesel/PME) (diesel/PME) Air Top Evo 5500 B (Benzin) (petrol) (benzine) Air Top Evo 5500 D (Diesel/PME) (diesel/PME)
  • Page 3 Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue. 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.

  • Page 4: Table Of Contents

    Air Top Evo 3900 / Air Top Evo 5500 Inhaltsverzeichnis Table of contents Gesetzliche Bestimmungen für den Einbau ... . . 1 Statutory regulations governing installation ...51 Verwendung / Ausführung .

  • Page 5: Air Top Evo 3900 / Air Top Evo

    Failure to follow the installation instructions and the notes contained load; therein will lead to all liability being refused by Webasto. The same applies • The exhaust system as well as the exhaust pipes shall be so directed or if repairs are carried out incorrectly or with the use of parts other than gen- protected to avoid any danger to the load through heating or ignition.

  • Page 6: Statutory Regulations Governing Installation

    Statutory regulations governing installation Air Top Evo 3900 / Air Top Evo 5500 • The combustion heater may only be switched on manually. Program- 2.1.2. / 5.3.1.2. (Part I) Vehicles of category O having liquid fuel ming devices shall be prohibited. The combustion heater may be heaters are deemed to comply with the requirements of this An- switched on again manually after the vehicle engine has been switched nex.
  • Page 7 Air Top Evo 3900 / Air Top Evo 5500 Statutory regulations governing installation 2.3.3. / 5.3.3.3. (Part I) A notice, indicating that the heater must 2.8. / 5.3.8.1. (Part I) The heating system must be switched off au- be shut down before refuelling, must be affixed to the fuelling tomatically and the supply of fuel must be stopped within five sec- point.
  • Page 8 Statutory regulations governing installation Air Top Evo 3900 / Air Top Evo 5500 1.3. Extract from directives 2001/56/EC Annex IX and ECE R122 3.1.2. The combustion heater shall be switched on manually. Pro- Annex 9 gramming devices shall be prohibited. Start of extract.

  • Page 9: Use / Version

    2.1. Use of the air heaters 2.2. Version The Webasto Air Top Evo 3900 and Air Top Evo 5500 air heaters are de- Air Top Evo 3900 B (petrol) signed Air Top Evo 5500 B (petrol) – to heat cabins, boats, trucks, minibuses, vans, ambulances and mo- Air Heater for "Petrol"...

  • Page 10: Installation

    A special tools can be pur- NOTE: chased from Webasto to drill the holes and, if necessary, smooth the sup- Check the installation situation of the relevant vehicle type. port area. The seal can compensate for unevenness of max. 1 mm.
  • Page 11 Air Top Evo 3900 / Air Top Evo 5500 Installation Hot air inlet Space requirement for hot air inlet Hot air outlet Space requirement for hot air outlet Combustion air intake Space requirement for removing the heater Exhaust fume outlet Cable outlet (either right or left) Fuel intake Fig.
  • Page 12 Installation Air Top Evo 3900 / Air Top Evo 5500 Diesel heaters Ensure that all moving parts can move easily. Fig. 4 Installation Petrol heaters Fig. 2 Approved installation position Fig. 3 Seal...

  • Page 13: Type Label

    Air Top Evo 3900 / Air Top Evo 5500 Type label Type label 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). Inapplicable years must be erased from the model plate.

  • Page 14: Installation Example

    Installation example Air Top Evo 3900 / Air Top Evo 5500 Installation example Control element Heater Metering pump Fuel filter (accessory) Tank connector Exhaust silencer (accessory) Fuse Maximum water passage height Fig. 5 Installation example for air heater in recirculation mode...
  • Page 15 Air Top Evo 3900 / Air Top Evo 5500 Installation example 5.1. Design as system The variants Air Top Evo 3900 AM and Air Top Evo 5500 AM enable up to IMPORTANT 4 heaters to be operated in one system. The use of an Air Top Evo 3900 AM or Air Top Evo 5500 AM system is not Here Unit 1 is defined as the master heater and others as slave heaters.
  • Page 16 Installation example Air Top Evo 3900 / Air Top Evo 5500 5.2. Heating Capacity of Entire System Heating Capacity Heater Number of Range Units 1.5 - 3.9 kW Air Top Evo 3900 1.5 - 5.5 kW Air Top Evo 5500 1.5 - 7.8 kW Air Top Evo 3900 1.5 - 11.0 kW...

  • Page 17: Hot Air System

    For fresh air mode it must be ensured that the hot air is taken from an area The points table for air guide parts in the Webasto catalogue may be used protected from splashing water and spray and in such a way that no water to design the hot air system.
  • Page 18 Hot air system Air Top Evo 3900 / Air Top Evo 5500 NOTE: 6.1. External temperature sensor The installation must be checked for: For fresh air mode an external temperature sensor must be fitted in the ap- – Air short circuit between the vehicle’s heating system and the heater air propriate zone.

  • Page 19: Fuel Supply

    Air Top Evo 3900 / Air Top Evo 5500 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 20 If the fuel pump is located inside the tank, fuel can only be extracted from The fuel extractor must be fitted in such a way that any air or gas bubbles the return line using the Webasto fuel extractor (see Figure 10), in which are automatically discharged towards the tank (see Figure 10).
  • Page 21 Only use a tank connector if the fuel tank is made from metal Tank fitting Minimum distance 25 mm Fig. 11 Webasto tank connector Plastic tank Fig. 13 Fuel pick-up from the plastic tank (Pick-up via tank fitting) 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).
  • Page 22 Fuel supply Air Top Evo 3900 / Air Top Evo 5500 7.4.1. Connecting two pipes with a hose Air Top Evo 3900 / Air Top Evo 5500 12 Volt - petrol The correct procedure for connecting fuel lines with hosing is shown in Fig- ure 14.
  • Page 23 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 24: Combustion Air Supply

    Combustion air supply Air Top Evo 3900 / Air Top Evo 5500 Combustion air supply Under no circumstances may the combustion air be taken from areas oc- cupied by people. The combustion air intake opening must not point in the direction of travel.

  • Page 25: Exhaust Pipe

    Air Top Evo 3900 / Air Top Evo 5500 Exhaust pipe Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of The exhaust silencer should ideally be installed near the heater. 1.0 mm or flexible piping of alloyed steel only must be used as exhaust line. The heater may also be operated without a silencer.

  • Page 26: Combustion Air Inlet And Exhaust Lines

    Combustion air inlet and exhaust lines Air Top Evo 3900 / Air Top Evo 5500 Combustion air inlet and exhaust lines Both lines are to be installed falling away from the heater. If this is not pos- sible, a condensate drain hole with a diameter of 4 mm must be made at its lowest point.
  • Page 27 Air Top Evo 3900 / Air Top Evo 5500 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 28: Electrical Connections

    Electrical connections Air Top Evo 3900 / Air Top Evo 5500 Electrical connections All lines that are not required must be insulated at their free end. IMPORTANT In accordance with the regulations of the act governing the road/rail haul- NOTE: age of hazardous materials, heaters are only allowed to be taken into serv- If the combination or standard timer is used, a touch-sensitive switch may ice with a special manually operated switch fitted in the cab.
  • Page 29 Air Top Evo 3900 / Air Top Evo 5500 Electrical connections The cable passage can be placed at either the left or right side. F = 15 A (24 V) To ensure that the cable passage in the control unit cover seals correctly, F = 20 A (12 V) the cable grommet is to be adjusted appropriately on the wiring harness.
  • Page 30 Electrical connections Air Top Evo 3900 / Air Top Evo 5500 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 31: Connection Diagram/Circuit Diagram

    Air Top Evo 3900 / Air Top Evo 5500 Electrical connections 11.5. Installation Instructions for Control Panel MC04/05 Install control panel: The control panel should be installed in a suitable location (on a flat surface if possible) in the area visible to the driver. –...
  • Page 32 Connection diagram/Circuit diagram Air Top Evo 3900 / Air Top Evo 5500 Connection diagram/Circuit diagram Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig. 31 Air Top Evo 3900 and Air Top Evo 5500 with combination timer connection diagram...
  • Page 33 Control Panel MC04/05 Observe coloured markings Optional connection for: - Telestart/Thermo Call (12 V only) - Webasto Thermo Test Diagnose Heaters wiring harness Fig. 32 Connection Diagram for Air Top Evo 3900 and Air Top Evo 5500 with Control Panel MC04/05...
  • Page 34 Connection diagram/Circuit diagram Air Top Evo 3900 / Air Top Evo 5500 MC04 heater control Connection for Webasto Thermo Test diagnosis Observe coloured markings ... Connection to additional heaters Control line W bus + heaters wiring harness Connection for We-...
  • Page 35 Air Top Evo 3900 / Air Top Evo 5500 Connection diagram/Circuit diagram Fig. 34 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500, 12 V/24 V with control element and vehicle fan, for legend see pages 87 and 88...
  • Page 36 Connection diagram/Circuit diagram Air Top Evo 3900 / Air Top Evo 5500 Fig. 35 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500, 24 V ADR operation with control element, for legend see pages 87 and 88...
  • Page 37 Air Top Evo 3900 / Air Top Evo 5500 Connection diagram/Circuit diagram Fig. 36 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500, 12 V/24 V with combination timer and vehicle fan, for legend see pages 87 and 88...
  • Page 38 Connection diagram/Circuit diagram Air Top Evo 3900 / Air Top Evo 5500 Fig. 37 System wiring diagram for the Air Top Evo 3900 D and Air Top Evo 5500 D, 12 V/24 V with combination timer and electrical battery isolation switch, for legend see pages 87 and 88...
  • Page 39 Air Top Evo 3900 / Air Top Evo 5500 Connection diagram/Circuit diagram Fig. 38 System wiring diagram for the Air Top Evo 3900 D and Air Top Evo 5500 D, 12 V/24 V with Control Panel MC04/05 and vehicle fan, for legend see pages 87 and 88...
  • Page 40 Connection diagram/Circuit diagram Air Top Evo 3900 / Air Top Evo 5500 Fig. 39 System wiring diagram for Air Top Evo 3900 and Air Top Evo 5500 “Slave Heater”, 12 V/24 V diesel, for legend, see Page 87 and 88...
  • Page 41 Air Top Evo 3900 / Air Top Evo 5500 Legend for circuit diagrams Legend for circuit diagrams Cable cross-sections < 7.5 m 7.5 - 15 m 0.75 mm 1.0 mm 1.0 mm 1.5 mm 1.5 mm 2.5 mm 2.5 mm 4.0 mm 4.0 mm 6.0 mm...

  • Page 42: Legend For Circuit Diagrams

    Legend for circuit diagrams Air Top Evo 3900 / Air Top Evo 5500 Item Description Comment Item Description Comment Heater Air Top Evo 3900/5500 Control Panel MC04/05 On/Off switch, setpoint generator and selector switch for additional Control module Control unit 1580 functions Temperature sensor Internal...

  • Page 43: Initial Start-Up

    Air Top Evo 3900 / Air Top Evo 5500 Initial start-up Initial start-up After you have installed the heater, bleed the fuel supply system carefully. Initial start-up NOTE: 1. Start master heater with controls => Master heater "starts up" As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line.
  • Page 44 Initial start-up Air Top Evo 3900 / Air Top Evo 5500 14.2. Resetting Air Top Evo System If for some reason (communication error, time expired, etc.) teaching has not functioned, it is possible to reset the system to its original state. 1.

  • Page 45: Fault Lock-Out

    Air Top Evo 3900 / Air Top Evo 5500 Fault lock-out Fault lock-out The control unit has identified errors on individual heater components and Rectify the cause of the fault. faults during the operation. To reset the fault switch the heater on and off briefly (at least 2 seconds). If serious faults like overheating or failure to start occur frequently, then the The heater is shut down (fault lock-out) if: –...
  • Page 46 Fault lock-out Air Top Evo 3900 / Air Top Evo 5500 15.1. Error code output NOTE: Air Top Evo System: The error code is output if the heater is fitted with a control element after The displayed error codes (F00 - F15) for an Air Top Evo system match an an error has occurred by the switch-on indicator/error code indicator flash- error on the master heater.

  • Page 47: Technical Data

    Air Top Evo 3900 / Air Top Evo 5500 Technical data Technical data Except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °C and at the rated voltage and in rated conditions.
  • Page 48 Technical data Air Top Evo 3900 / Air Top Evo 5500 Values in brackets apply to the expanded heating capacity "Plus", which can be activated with the MC heater control. Heater Operation Air Top Evo 3900 B Air Top Evo 5500 B Air Top Evo 3900 D Air Top Evo 5500 D Type test permit...
  • Page 49 Air Top Evo 3900 / Air Top Evo 5500 Technical data Heater Operation Air Top Evo 3900 B Air Top Evo 5500 B Air Top Evo 3900 D Air Top Evo 5500 D Adjustment range for interior Control range +5 °C to +35 °C temperature Volume flow of heating air against 0.5...
  • Page 50 Technical data Air Top Evo 3900 / Air Top Evo 5500...

  • Page 51: Drilling Templates

    Air Top Evo 3900 / Air Top Evo 5500 Drilling templates Drilling templates Seal ø7.5 ø28 ø29 ø7.5 ø7.5 NOTE: Max. base unevenness around the seal: 1 mm Fig. 40 Heater drilling template...
  • Page 52 Drilling templates Air Top Evo 3900 / Air Top Evo 5500...
  • Page 53 Air Top Evo 3900 / Air Top Evo 5500 Drilling templates Fig. 41 Drilling Template for Control Panel MC04/05...
  • Page 54 Drilling templates Air Top Evo 3900 / Air Top Evo 5500...
  • Page 55 Im Fall einer mehrsprachigen Version ist Deutsch verbindlich. In multilingual versions the German language is binding. Bij een meertalige versie is de Duitse versie bindend. Webasto AG Postfach 80 D - 82132 Stockdorf Germany National: Hotline: 01805 93 22 78 (€...

This manual is also suitable for:

Air top evo 5500 seriesAir top evo 5500 bAir top evo 3900 bAir top evo 3900 dAir top evo 5500 d

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