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This signal word denotes a hazard with a high degree of risk which, if not avoided, may lead to death or serious injury.
This signal word denotes a hazard with a moderate degree of risk which, if not avoided, may lead to minor or moderate injury.
This signal word denotes a hazard with a low degree of risk which, if not avoided, may lead to minor or moderate injury.
NOTE
This symbol denotes a special technical feature, or (if not observed) potential damage to the product.
This symbol refers to separate documents which may be enclosed or can be requested from Webasto.
The heater is used exclusively for comfort purposes. Due to its installation, it must not become a safety-relevant component for proper functioning of the vehicle.
NOTE
The heater is not approved for the purpose of directly heating the cargo area of ADR vehicles (hazardous substance transportation).
The heater works independently of the vehicle engine and is integrated in the electrical system of the vehicle.
The heater is approved for the following applications:
Safety information on operation
Risk of injury from the defective unit
Do not operate a defective Air Top Evo 40 | 55 and put it out of service by removing the fuse:
Risk of burn injuries due to insufficient distance between hot air outlet and persons
Burn injuries
Danger of explosion
In environments with combustible vapours, flammable dust and hazardous goods (e.g., petrol stations, tank facilities, fuel store, coal bunkers, timber yard or grain warehouses).
Risk of explosion from explosive and flammable hazardous goods
For hazardous material vehicles, restriction of the heater operation (ADR) is required to prevent severe burns.
Danger of poisoning and suffocation
Do not operate the heater in closed rooms that do not have an exhaust extraction unit.
Danger of fire
Flammable materials or liquids in the hot air flow.
NOTE
Do not operate heater without control unit cover in place.
Safety information on installation
Danger of lacerations due to sharp edges
Live parts are dangerous
Avoiding damage to property
NOTE
Protect the Air Top Evo 40 | 55 against mechanical stress:
NOTE
The fan of the heater keeps running for approx. 240 seconds after switching off via the control element (40 s for ADR). Switching off incorrectly, without afterrun, can cause damage to the Air Top Evo 40 | 55.
The Air Top Evo 40 | 55 heater has been type-tested and approved in accordance with ECE-R 10 (EMC) and ECE-R 122 (heater).
Application of combustion heaters in hazardous material vehicles (ADR)
The requirements stipulated in Regulation ECE R122, Annex 9 – Combustion Heaters – must additionally be observed when installing the Air Top Evo 40 | 55 in hazardous material vehicles. The relevant measures are specified in this document.
Vehicles used for the purpose of transporting dangerous goods are type approval tested in accordance with ECE-R 105. The following measures are derived for our combustion heaters.
Requirements relating to the basic unit:
When switched off, it is permissible for combustion heaters to continue running for max. 40 seconds. Only combustion heaters are to be used with heat exchangers that are not damaged during their standard operating period by the reduced afterrunning time of 40 seconds.
Danger of overheating
Outcome: Risk of fire. Protect vehicle components in the vicinity of the heater, hot air outlet and exhaust line from overheating by implementing the following measures:
The installation location must satisfy the following requirements:
Danger of poisoning and suffocation due to exhaust fumes
Make sure that:
Except for the year of installation, remove all the year numerals on the type label and type label duplicate.
If the type label (Fig. 5) is not visible after installing the heater:
NOTE
The maximum pressure loss in the hot air system must not exceed 2 hPa (Air Top Evo 40) or 3 hPA (Air Top Evo 55) (see chapter "Technical data"). The heating capacity will be reduced if the limits are exceeded.
Recirculated air mode and fresh air mode
The cold air can be drawn in from the outside (fresh air mode) or inside (recirculated air mode).
Temperature control
There are two options for temperature control. One of the two options is specified automatically.
Options:
Installation location requirements (cold air)
The installation location for the cold air inlet must satisfy following requirements:
Installation location requirements (hot air)
Risk of burn injuries due to insufficient distance between hot air outlet and persons
Burn injuries
Requirements for the cold and hot air ducts
Requirements for the cold and hot air ducts | Value | |
Thermal endurance | > 130°C* | |
Recommended inside diameter of main hot air duct | Air Top Evo 40 | 55 | 90 mm |
* (short-term > 150°C)
Installing cold and hot air ducts
Risk of injury by rotating fan wheel
Lacerations. If no cold air duct is used: Install mesh guard over intake.
Installation without cold air duct (cold air)
Installing heater in casing
Installation location requirements for the external room temperature sensor
The installation location must satisfy the following requirements:
NOTE
Preferably, install the heater and fuel pump components at the same height as the fuel tank. Failing that, pay attention to the figures and the tables.
The fuel can be taken off at the following points:
The fuel line consists of an intake and pressure side:
Requirements for the fuel lines | Value | ||
Inside diameter | 2 mm | ||
L1 | Length (intake side) | max. 5m | |
L2 | Length (pressure side) | max. 10m | |
L1 + L2 | Overall length | max. 12m | |
H1 | Height difference from heater – fuel pump (heater above fuel pump) | max. 3m | |
H2 | Height difference from heater – fuel pump (heater below fuel pump) | max. 1m | |
h1 [m] | pmax [bar] | ||
h1 = 0 | -0.1 to +0.5 | ||
h1 = 0 to 1 | -0.1 to +0.4 | ||
h1 = 1 to 2 | -0.1 to +0.3 | ||
h2 [m] | pmax [bar] | ||
h2 = 0 to 1.3 | -0.1 to +0.5 | ||
Fuel pressure correction at height difference between tank and fuel pump [m] | pmax [bar] | ||
h1 = 0 | -0.1 to +0.5 | ||
h1 = 0 to 1 | -0.1 to +0.4 | ||
h1 = 1 to 2 | -0.1 to +0.3 | ||
h2 = 0 to 1.3 | -0.1 to +0.5 |
Installing fuel extractor
Risk of fire by fuel escaping from leaking fuel tank
Skin burns.
Installing tank extracting device on vehicle fuel delivery unit
Fuel line requirements
NOTE
Use only steel or plastic fuel lines made from light and temperature-resistant P A12/ETFE, PA12/ EFEP, PA9T/ PA12 in accordance with DIN 73378.
Connecting fuel lines
Install fuel line
NOTE
Malfunctions during combustion caused by gas bubbles and high fuel temperatures. Gas bubbles caused by the heat from the engine and high fuel temperatures can cause malfunctions during operation.
NOTE
Use the Webasto Thermo Test to fill the fuel lines before starting the heater.
NOTE
Damage to the fuel pump.
NOTE
Operating the heater with any other than the DP 42.4 fuel pump will invalidate the warranty and type approval.
Installation location requirements:
The installation location must satisfy the following requirements:
Installing fuel pump
NOTE
A heat shield can be installed to protect against shortterm overheating and radiated heat.
NOTE
Installation position of fuel filter
NOTE
Webasto recommends installing the fuel filter in a vertical position. Vertical installation improves bleeding of the fuel filter.
Fuel filter installation
Unconsciousness and risk of suffocation
Possible lack of oxygen. Reduced oxygen levels due to incorrectly positioned combustion air intake opening
NOTE
During installation, make sure that any fuel pump cables in the vicinity are not damaged.
NOTE
Use only combustion air intake lines approved by the manufacturer. Damage caused by confusing the exhaust line with the combustion air intake line:
Requirements of the combustion air intake line | Value |
Recommended min. length with integrated combustion air intake silencer | 0.5 m |
Min. length with external combustion air intake silencer | *1 |
Max. length of exhaust gas line and combustion air intake line without silencer | 5 m |
Min. length with exhaust or/and combustion air intake silencer | 2.5 m |
Inside diameter | 25 mm |
Smallest bend radius | 50 mm |
Max. sum of all bends | 270° |
*1: The external combustion air intake silencer can be connected directly to the heater. The combustion air intake line serves as a connection piece.
Installation of an external combustion air intake silencer is recommended.
Comply with installation position in Fig. 16.
Danger of suffocation
Outcome: Poisoning and asphyxiation
Fire risk due to hot exhaust gasses
Outcome: Injuries or damage to property caused by fire
Requirements of the exhaust line | Value |
Inside diameter | 24 mm |
Material | Non-corroding |
Minimum length | 0.5 m |
Maximum length | 1.0 m |
Smallest bend radius | 50 mm |
Max. sum of all bends | 270° |
Danger of fire and/or overheating caused by live parts.
Danger of fire and/or overheating caused by live parts
Danger of explosion and suffocation
For ADR vehicles: The heater must only be switched on manually via a switch. The heater must not be switched on automatically via a programmable switch.
NOTE
Malfunctions caused by corroded plug connections. Possible malfunction between fuel pump and wiring harness of fuel pump.
Observe additional requirements from the operating and installation instructions for the Air Top Evo 40 | 55 and the control element.
Select appropriate wiring diagram (dependent on application and Webasto control element).
See Fig. 22 to Fig. 28.
NOTE
After it is switched off the heater continues running. The power supply must not be disconnected before approx. 240 seconds have elapsed.
An electrical battery disconnector or relay can be connected in accordance with the wiring diagram.
Danger of explosion and suffocation
For ADR vehicles: The heater must only be switched on manually via a switch. The heater must not be switched on automatically via a programmable switch.
See also chapter "Regulations and legal requirements".
NOTE
Wires or components shown with dashed lines are optional and not included in the scope of delivery or in the wiring harness.
Graphic | <7.5 m | 7.5 – 15 m | |
Cable cross-sections (Wiring diagram based on < 7.5 m) | 0.5 mm2 | 1.0 mm2 | |
1.0 mm2 | 1.5 mm2 | ||
1.5 mm2 | 2.5 mm2 | ||
2.5 mm2 | 4.0 mm2 | ||
4.0 mm2 | 6.0 mm2 | ||
Colour | Abbreviation | Colour | Abbreviation |
blue | bl | orange | or |
brown | br | red | rt |
yellow | ge | black | sw |
green | gn | violet | vi |
grey | gr | white | ws |
No. | Description | Remarks |
A1 | Heater | Air Top Evo 40/55 |
A2 | Control unit | Control unit 1580 |
B2 | Temperature sensor | Inside |
B3 | Blow out temperature sensor | Overheating protection |
B4 | Temperature sensor | External (optional) |
B5 | Exhaust gas temperature sensor | Overheating protection/flame monitor |
E | Glow plug | – |
F1 | Fuse 24 V, 15 A/12 V, 20 A | Blade fuse DIN 72581-3 |
F2 | Fuse 1A | Blade fuse DIN 72581-3 |
F3 | Fuse 1A | Not included in wiring harness |
F4 | Fuse 1A | Not included in wiring harness |
H1 | LED green (in Item S1) | ON indicator, fault code indicator |
H5 | Bulb/LED | ON indicator, pumping device (max. 500 mA) |
H6 | LED (green, blue, white, red) | Operation indicator, Ready indicator, ON indicator, fault list |
H7 | Symbol on display | – |
M1 | Motor | Combustion air and heating air blower |
P | SmartControl/MultiControl/UniControl/Thermo-Connect2 | (WBus) |
S1 | Control element (rotary switch) | ON/OFF switch and temperature setpoint sensor |
S3 | Switch | CO2 setting |
S4 | Pushbutton | External Quick Heating button (optional) |
S5 | Switch | Auxiliary drive/pumping device |
S6 | Switch, 1 or 2-pin | Disconnector |
S7 | Battery disconnector | Electronically controlled disconnector (max. 500 mA) |
V1/V2 | Diode | Min. 500 mA (not included in wiring harness) |
X1 – X8 | Plug connection | To Item A2 |
X9 | 4-pin plug connection | – |
X9 (a) | 4-pin plug connection | To Item S1 |
X9 (b) | 4-pin plug connection | To Item S |
X9 (c) | 4-pin plug connection | WBus, connection for SmartControl/MultiControl, UniControl, Thermo- Connect2 or diagnostics |
X9 (d) | 4-pin plug connection | WBus, SmartControl/MultiControl connection |
X9 (e) | 4-pin plug connection | WBus temperature sensor connection |
X10 | 4-pin plug connection | To Item P |
X11 | 2-pin plug connection | To Item B4 (optional) |
X13 | 2-pin plug connection | To Item Y1 |
X15 | 1-pin plug connection | To Item S3 |
X16 | 2-pin plug connection | Wiring harness connection DP42.4 |
X17 | 2-pin plug connection | Wiring harness connection DP42.4 |
X27 | 10-pin plug connection | To Item P3 |
X28 | 4-pin plug connection | To Item P3 |
Y1 | Fuel pump | DP42.4 |
Y2 | Solenoid valve/pump | Auxiliary drive/pumping device (max. 500 mA) |
![]() | Positive from terminal 15/75 to connection 10: Continuous heating mode is possible in connection with quick heating function provided the ignition is switched on. | |
![]() | All heater versions: connection of W-bus diagnostics, SmartControl/MultiControl/UniControl or Thermo- Connect2. | |
![]() | CO2 setting (see workshop manual) | |
![]() | Connection to terminal 30: Continuous heating mode is possible with ignition switched off. | |
![]() | Grey and violet wires required for ADR function. Non- ADR vehicles: Insulate and tie back ends of wires. | |
![]() | External room temperature sensor (optional) | |
![]() | Pin 7 "Boost". Only "ambulance" heater version (door contact connected to terminal 31). | |
![]() | Wiring harness adapter (optional) | |
![]() | Switching capacity 500 mA | |
![]() | Connection for SmartControl/MultiControl, switch and/or ThermoConnect2, analogue connection |
No. | Description |
1 | Output, battery disconnector afterrunning signal/output, operating indicator |
2 | Power supply, control element/error code output |
3 | Output, battery disconnector afterrunning signal/output, operating indicator |
4 | Power supply + (terminal 30) |
5 | Power supply – (terminal 31) |
6 | Input switch-on signal (ON/OFF) |
7 | Multifunction (ventilation, boost, ECO), only Boost activation for ambulance units |
8 | Setpoint sensor - |
9 | CO2 setting |
10 | Not used |
11 | Setpoint sensor + |
12 | W-bus |
No. | Description |
1 | Terminal 31 (vehicle), battery - |
2 | WBus, data link for heater |
3 | Switch output, analogue switch-on signal for the heater |
4 | Switch input, button, analogue switch-on by a temporary earth |
5 | Terminal 30 (vehicle), battery + |
6 | Setpoint sensor - Temperature set point (only for analogue air heaters) |
7 | Setpoint sensor + Temperature set point (only for analogue air heaters) |
8 | - |
9 | Terminal 58 (vehicle), illumination (dashboard illumination) |
10 | Terminal 15 (vehicle), ignition positive |
Air Top Evo 40 | 55 W-Bus
Air Top Evo 40 | 55 MultiControl
Air Top Evo 40 | 55 Rotary switch
Air Top Evo 40 | 55 Rotary switch ADR
Air Top Evo 40 | 55 SmartControl ADR
Air Top Evo 40 | 55 ThermoConnect2
Air Top Evo 40 | 55 UniControl (with battery disconnector)
Observe additional requirements from the operating and installation instructions for the Air Top Evo 40 | 55 and the control element.
NOTE
The performance values (in brackets) apply for the extended heating capacity (boost function) that is activated temporarily during each start.
NOTE
The technical data apply under the following conditions: ambient temperature: +20°C, geodetic height: 0 m above sea level, rated voltage. The standard tolerances of ±10% for heaters shall apply if no limits are specified.
Heater | Air Top Evo 40 B | Air Top Evo 40 D | Air Top Evo 55 B | Air Top Evo 55 D | |
Type approval: EMC | E1 05 5529 | ||||
Type approval: Heating | E1 00 0385 | E1 00 0386 | |||
Design | Air heater with evaporator burner | ||||
Heat flow over control range [kW] (boost) | 1.7 to 3.5 (4.0) | 1.5 to 3.5 (4.0) | 1.7 to 5.0 (5.5) | 1.5 to 5.0 (5.5) | |
Fuel | Petrol DIN EN 228 | Diesel DIN EN 590 biodiesel DIN EN 14214 HVO DIN EN 15940 | Petrol DIN EN 228 | Diesel DIN EN 590 biodiesel DIN EN 14214 HVO DIN EN 15940 | |
Fuel consumption over control range [kg/h] (l/h) | 0.18 to 0.38 (0.43) (0.25 to 0.51 (0.54)) | 0.15 to 0.36 (0.41) (0.18 to 0.43 (0.49)) | 0.18 to 0.54 (0.59) (0.25 to 0.70 (0.80)) | 0.15 to 0.51 (0.56) (0.18 to 0.61 (0.67)) | |
Rated voltage [V] | 12 | 12/24 | 12 | 12/24 | |
Operating voltage range [V] | 10.5 to 16 | 10.5 to 16/20.5 to 31 | 10.5 to 16 | 10.5 to 16/20.5 to 31 | |
Rated power consumption over control range [W] (boost) | 15 to 40 (55) | 15 to 95 (130) | |||
Permissible ambient temperature Heater (operation/storage) [°C] | –40 to +40/–40 to +85 | ||||
Permissible combustion air intake temperature [°C] | –40 to +20 | ||||
Maximum permissible operating altitude [m above sea level] | 2,200 | 2,200 High altitude: 5,500 | 2,200 | ||
Setpoint temperature range [°C] | +5 to +35 | ||||
Max. permissible pressure loss in hot air system [hPa] | 2.0 | 3.0 | |||
Volumetric flow rate in cold/hot air system 0.5 hPa [m3/h] (boost) | max. 132 (140) | max. 200 (220) | |||
CO2 in exhaust gas: CO2 rated value full load [vol%] | 10.0 ± 0.5 | ||||
Length/Width/Height [mm] | 423 ± 2/162 ± 1/148 ± 1 | ||||
Heater weight [kg] | 5.9 | ||||
IP class: Heater | IP5K4K | ||||
IP Protection class: Fuel pump | IPX6/IPX7/IP6K9K |
Webasto Thermo & Comfort SE
Postfach 1410
82199 Gilching
Germany
Company address: Friedrichshafener Str. 9 82205 Gilching Germany
UK only
Webasto Thermo & Comfort UK Ltd
Webasto House
White Rose Way
Doncaster Carr
South Yorkshire
DN4 5JH
United Kingdom
www.webasto.com
Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.
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