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Air Heater
Air Top Evo 3900/5500 B (Gasoline)
Air Top Evo 3900/5500 D (Diesel)
Installation Manual
WARNING!
– 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.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– 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.
– Improper installation or installation by untrained personnel voids all warranties on
this product.
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Table of Contents
Related Manuals for Webasto Air Top Evo 3900/5500 B
Summary of Contents for Webasto Air Top Evo 3900/5500 B
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Page 1: Installation Manual
– Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. -
Page 3: Table Of Contents
11.1 Legend for Circuit Diagrams ..............24 www.webasto.us Webasto Product N.A., Inc. - Page 4 14.2 Fuel for Air Top EVO 3900/5500 B (Gasoline)....... . .
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Page 5: Safety And General Information
General Information Webasto Product North America, Inc. is pleased to provide this installation manual with the AT 3900/5500 air heater. When installed according to the guidelines stated in this manual, you can expect your customer to enjoy many years of trouble-free heater operation. -
Page 6: Regulations For Installation In The Vehicle
Failure to comply with all installation instructions is a misuse of Webasto products. The same applies for repairs without using genuine Webasto service parts. This will void the heaters “official Marks of Conformity.”... -
Page 7: Exhaust System
When the engine stops, the heating system must cut out automatically and the fuel supply must be stopped within 5 seconds. The heating system may remain in operation if a manual unit has already been activated. www.webasto.us Webasto Product N.A., Inc. -
Page 8: Purpose Of The Air Heater
Purpose of the Air Heater Air Top Evo 3900/5500 Purpose of the Air Heater The Webasto Air Top EVO 3900/5500 air heaters are designed – to heat cabins, boats (Diesel Only), trucks, minibuses, vans and motor homes – to defrost vehicle windows –... -
Page 9: Installation
7. Space required for hot air outlet 3. Combustion air inlet 8. Space required for removing the heater (service) 4. Exhaust gas outlet 9. Cable outlet/Control unit cover (either right or 5. Fuel intake left) Figure 1. Dimensions of the Heater www.webasto.us Webasto Product N.A., Inc. -
Page 10: To Install The Heater
A seal (Figure 4) must be fitted between the heater and the vehicle body. 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. -
Page 11: Optional Mounting Plate
The model/serial number plate of the heater 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. www.webasto.us Webasto Product N.A., Inc. -
Page 12: Installation Example
Installation Air Top Evo 3900/5500 Installation Example Figure 7. Installation example with heater in stalled under-bunk. (Recirculation mode) Webasto Product N.A., Inc. www.techwebasto.com... -
Page 13: Hot Air System
If the heater is used in recirculation mode, for example, in the under bunk compartment of a truck’s sleeper, without a hot air directional outlet grille, do not short circuit the hot air flow. Figure 8. Hot air inlet and hot air outlet (recirculation mode) www.webasto.us Webasto Product N.A., Inc. -
Page 14: External Temperature Sensor
– by close to heat sources (for example the vehicle’s own heating system). – be placed in direct sunlight (for example on the dashboard). – be installed behind curtains or the like. External temperature sensor Cover Figure 10. External temperature sensor - optional Webasto Product N.A., Inc. www.techwebasto.com... -
Page 15: Fuel Supply
Vehicles with a Carburetor Equipped Engine The fuel may only be extracted using the special Webasto fuel extractor (see Figure 12) as close to the tank as possible. The connection 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 (see Figure 13). -
Page 16: Vehicles With Fuel Injection Engines
(see Figure 12), in which case it must be ensured that the return line continues almost to the bottom of the tank (see Figure 13 for details of the minimum distance from the bottom of the tank). If this is not the case Webasto fuel extractors or standpipes (see Figures 13, 14 and 15) may be used. -
Page 17: Connecting Two Fuel Lines With A Coupler Hose
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 Figure 18. Fuel metering pump DP 30.2 / 30.3 www.webasto.us Webasto Product N.A., Inc. -
Page 18: Installation And Attachment
The metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in Figure 18 in order to ensure effective automatic 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. -
Page 19: Combustion Air Supply
Do not use an exhaust line as the combustion air line since otherwise the metering pump cable from the combustion air inlet port may be damaged. The combustion air opening must not be under the minimum water drive-through level permitted for the vehicle. See the regulations for the installation for further regulations. www.webasto.us Webasto Product N.A., Inc. -
Page 20: Exhaust Pipe
The heater may also be operated without a muffler. Ø 0-90° 0-90° Figure 20. Exhaust muffler - exhaust flow is non-directional (arbitrary) Figure 21. Exhaust silencer for boat applications - Flow direction and installation position is non-directional (arbitrary) Webasto Product N.A., Inc. www.techwebasto.com... -
Page 21: Combustion Air Inlet And Exhaust Lines
Discharge direction almost vertical 90° ± 10° Exhaust line: max. 270°. Figure 25. Exhaust pipe opening IMPORTANT! If the exhaust pipe ends other than as shown in Figure 25, it will pose a fire risk. www.webasto.us Webasto Product N.A., Inc. -
Page 22: Electrical Connections
The main power connection has to be made at a circuit designed to sustain this load without voltage drop. Cigar lighter sockets and auxiliary power outputs for C.B. radio’s and other electronic accessories are not considered adequate power supplies for the Air Top EVO 3900/5500. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 23: Control Element (Rheostat) Connection
As an option an external temperature sensor may be installed in the passenger cabin (see page12). See installation instructions included with the sensor or see the service instructions in the Workshop manual for further information. Cover Figure 31. External temperature sensor - optional www.webasto.us Webasto Product N.A., Inc. -
Page 24: Installation Instructions For Control Panel Mc04/05
Control Panel is only intended for installation in passenger compartment • Ensure good readability when selecting installation location • Observe information on adhesive labels and colored markings when connecting Control Panel to vehicle wiring harness Figure 32. Installing Control Panel MC04/05 Webasto Product N.A., Inc. www.techwebasto.com... -
Page 25: Mc04/05 Control Panel Connections
10.4.1 MC04/05 Control Panel Connections Control Panel MC04/05 Observe coloured markings Optional connection for: - Telestart/Thermo Call - Webasto Thermo Test Diagnose Heater units wiring harness Figure 33. Connection Diagram for Air Top EVO 3900/5500 with Control Panel MC04/05 10.4.2 Combination Timer 1531 Connections... -
Page 26: Combination Timer 1531 Connections
To item A2 (1) Plug connector, 2-pin Plug connector, 4-pin To item S1 Plug connector, 2-pin Plug connector, 2-pin To item Y1 12-pin plug connection To item P Metering pump Solenoid valve for pumping device Webasto Product N.A., Inc. www.techwebasto.com... - Page 27 Air Top Evo 3900/5500 Circuit Diagrams Figure 35. Standard system wiring diagram for the Air Top EVO 3900/5500, 12 / 24 Volt with control element. www.webasto.us Webasto Product N.A., Inc.
- Page 28 Circuit Diagrams Air Top Evo 3900/5500 Figure 36. Standard system wiring diagram for the Air Top EVO 3900/5500, 12 / 24 Volt with combination timer. Webasto Product N.A., Inc. www.techwebasto.com...
- Page 29 Air Top Evo 3900/5500 Circuit Diagrams Figure 37. Standard system wiring diagram for the Air Top EVO 3900/5500, 12 / 24 Volt with control panel MC04/05. www.webasto.us Webasto Product N.A., Inc.
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Page 30: Starting The Heater For The First Time
Refer to Figure 35, item S6 for connection detail. In ventilation mode (switch S6 ‘On’) the fan speed is regulated by the control element knob. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 31: Fault Lock-Out
Overheating: Resulting in permanent heater fault lock-out F 11 Overheating sensor interrupt or short circuit F 12 Heater lock-out F 13 Heater lock-out permanent F 14 Overheating sensor incorrect position F 15 Set point generator interrupt www.webasto.us Webasto Product N.A., Inc. -
Page 32: Technical Data
Control unit, motor, metering pump, lamp in the timer and ceramic glow pin / flame monitor are designed for either 12 or 24 Volt. 14.2 Fuel for Air Top EVO 3900/5500 B (Gasoline): The fuel specified by the vehicle manufacturer must be used. -
Page 33: Version
Air Top Evo 3900/5500 Version 15. Version Air Top EVO 3900/5500 B (Gasoline) Air heater for gasoline (12 V) Air Top EVO 3900/5500 D (Diesel) Air heater for Diesel/heating oil (12 or 24 V) www.webasto.us Webasto Product N.A., Inc. -
Page 34: Drilling Template
Drilling Template Air Top Evo 3900/5500 16. Drilling Template Figure 39. Drilling Template for Heater Installation (Dimensions in millimeters) Ø Ø Ø Ø Ø Figure 40. Drilling Template for MC04/05 Control Panel Webasto Product N.A., Inc. www.techwebasto.com... -
Page 35: Notes
Air Top Evo 3900/5500 Notes: 17. Notes: www.webasto.us Webasto Product N.A., Inc. - Page 36 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org. 05/2009 Rev. N/A P/N LIT909385A Copyright 2009...
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