Webasto Air Top 3500 ST Workshop Manual
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Webasto Air Top 3500 ST Workshop Manual

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See also: Instruction and Installation Manual
Air heaters
03/2003
Workshop manual
Air Top 3500 ST
Air Top 5000 ST
Air Top 3500/5000 ST B (petrol)
Air Top 3500/5000 ST D (diesel)
Air Top 3500 ST D Volume Plus (diesel)

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Summary of Contents for Webasto Air Top 3500 ST

  • Page 1 Air heaters Workshop manual Air Top 3500 ST Air Top 5000 ST Air Top 3500/5000 ST B (petrol) Air Top 3500/5000 ST D (diesel) Air Top 3500 ST D Volume Plus (diesel) 03/2003...

  • Page 2: Table Of Contents

    Air Top 3500/5000 ST Table of contents Table of contents Introduction Contents and purpose ........................... 101 1.1.1 Using the air heaters ........................101 Meaning of signal words ........................101 Additional documentation to be used..................... 101 Statutory regulations and safety instructions ..................101 1.4.1 Regulations for installation in the vehicle ..................

  • Page 3: 8 Servicing Work

    Table of contents Air Top 3500/5000 ST Troubleshooting General ..............................501 General error symptoms ........................501 Error symptoms during function ......................502 Fault code output ..........................503 Function tests General ..............................601 Settings ..............................601 6.2.1 Setting the CO content......................601 Testing individual components......................
  • Page 4 Air Top 3500/5000 ST Table of contents Repair General ..............................901 9.1.1 Working on components after they have been dismantled............901 9.1.2 Carrying out modifications ......................901 Dismantling and assembling........................902 9.2.1 Remove the casing parts......................902 9.2.2 Fit the casing parts ........................902 9.2.3 Change the control unit .......................
  • Page 5 Schematic connection of the combination timer ..................707 Fuel supply..............................802 Webasto fuel extractor ..........................803 Fuel extraction from the plastic tank (extraction through tank drain screw) ..........803 Fuel extraction from the plastic tank (extraction through tank fittings)............803 Pipe/Hose connections ..........................

  • Page 6: Contents And Purpose

    – to heat cabins, boats, trucks, minibuses, vans, The Air Top 3500 ST / Air Top 5000 ST heaters have been ambulances and motorhomes. type-tested and approved in accordance with EC – to defrost vehicle windows.

  • Page 7: General Safety Information

    1 Introduction Air Top 3500/5000 ST 2.2.2. The internal combustion heater must not pose a fire 2.6. Hot air inlet hazard even when overheated. This requirement is 2.6.1. The supply of heating air must consist of either deemed to have been met if care is taken during fresh air or recirculated air and must be taken from installation to ensure an adequate distance from all a clean area which cannot be contaminated by...
  • Page 8 The fuel lines (Mecanyl hose) must not be immediately next to the exhaust pipe and must be thermally insulated The Air Top 3500 ST and Air Top 5000 ST air heaters are if necessary, otherwise they will pose a fire risk.
  • Page 9 Webasto The same applies if repairs are carried out After an overheating lock-out, check that the air system is incorrectly or with the use of parts other than genuine clear, remove any materials that may block the air current spare parts.

  • Page 10: Drive Unit

    If a fault occurs, an error code will be output in the display The Air Top 3500 ST and Air Top 5000 ST air heaters are of the combination or standard timer. If the heater has a based on the evaporator principle and essentially consist control element, the ON control light will flash.

  • Page 11: General Description

    2 General description Air Top 3500/5000 ST Drive unit Burner insert with combustion pipe The drive unit consists of the drive motor, the combustion The fuel is distributed over the burner cross-section in the air blower, the heat air blower and the intake casing. combustion pipe in the burner insert.
  • Page 12 Air Top 3500/5000 ST 2 General description Control unit Overheating sensor The control unit is the central component for ensuring the The overheating sensor measures the temperatures in function is maintained and for monitoring the heater’s the rib area of the heat exchanger whenever the heater is operation.
  • Page 13 2 General description Air Top 3500/5000 ST Page for notes...

  • Page 14: Function Description

    Air Top 3500/5000 ST 3 Function description Function description 2. Automatic restart If the flame sensor does not find a flame, the starting Control element procedure will be repeated. The glow plug will be switched on again (cycled). The motor for the hot and combustion air blower will be set to approx.
  • Page 15 3 Function description Air Top 3500/5000 ST Control pause If the heater is switched off using the control element the slow down time remains unchanged. After the temperature set on the control element has been A brief slow down time (max. 40 seconds) is started reached the heat output is reduced.
  • Page 16 Air Top 3500/5000 ST 3 Function description The error counter SZ is incremented by 1 each error for which there is no separate counter. The error counter is reset to 0 at the start of control mode. If the error counter reaches its maximum value of 9 the heater will go into the heater lock-out status HGV.
  • Page 17 3 Function description Air Top 3500/5000 ST Page for notes...

  • Page 18: Technical Data

    The fuel specified by the manufacturer must be used. Air Top 3500 (5000) ST D Heater Operation Air Top 3500 (5000) ST B Air Top 3500 ST D Volume Plus Type test permit EMC heater e1*72/245*95/54*1221*00 e1*2001/56*0021*00 (3500) e1*2001/56*0020*00 (5000)
  • Page 19 4 Technical data Air Top 3500/5000 ST Page for notes...

  • Page 20: Troubleshooting

    This section describes how to identify and deal with errors fault: on the Air Top 3500 ST and Air Top 5000 ST heaters. • Corroded plugs If a fault occurs, an error code will be output in the display •...
  • Page 21 5 Troubleshooting Air Top 3500/5000 ST Error symptoms during function fault is not found under the specific error symptom heading, in an emergency you can contact our technicians on our service hotline (see last page). The following table (Fig. 502) lists the possible error symptoms in the order in which they may occur during operation.

  • Page 22: Error Code Output

    Air Top 3500/5000 ST 5 Troubleshooting Error code output NOTE The error code is output if the heater is fitted with a control element after an error has occurred by the switch-on If the heater is fitted with a combination timer, an error indicator/error code indicator flashing.
  • Page 23 5 Troubleshooting Air Top 3500/5000 ST Error Error (group) Additional information during PC Remedy code diagnostic F 07 Metering pump interrupt or short 88 Break or short circuit to +Ub Check cables, replace metering pump circuit 08 Short circuit to earth Check cables, replace metering pump F 08 Drive unit (combustion and hot air...
  • Page 24 Air Top 3500/5000 ST 6 Function tests Function tests Testing individual components IMPORTANT General For function tests always break the connection between the control unit and the component you wish to test. This section describes the tests conducted on the heater when it is installed and not installed to verify that it is in 6.3.1 Glow plug resistance test working order.
  • Page 25 6 Function tests Air Top 3500/5000 ST Page for notes...

  • Page 26: Circuit Diagrams

    General Fig. 707 shows the schematic connection of the combination timer. The Air Top 3500 ST and Air Top 5000 ST heaters can be controlled with the control element (nominal value adjuster/switch) or a combination timer. The circuit diagrams (Fig. 702 to 706) show the possible circuits for 12 and 24 V with •...
  • Page 27 White is replaced by the temperature sensor (B4). Item Designation Comment Item Designation Comment Heater Air Top 3500 ST/5000 ST Plug connector, 2-pin to item A2 Control module Plug connector, 2-pin to item A2 Temperature sensor Internal Plug connector, 2-pin...
  • Page 28 If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4). Item Designation Comment Item Nomenclature Remark Heater Air Top 3500 ST/5000 ST Combination timer (1531) Timer and setpoint generator Resistor 620 Ω Control module With internal temperature sensor only Temperature sensor Internal Switch...
  • Page 29 If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4). Item Designation Comment Item Designation Comment Heater Air Top 3500 ST/5000 ST Switch Ventilation or boost Control module Momentary-contact switch Immediate heat button remote control Temperature sensor Internal...
  • Page 30 The holding input (if there is one) for the isolation switch (S2) must be connected to the control unit in PIN 3/plug X7. Item Designation Comment Item Designation Comment Heater Air Top 3500 ST/5000 ST Plug connector, 2-pin to item A2 Control module Plug connector, 2-pin to item A2 Temperature sensor Internal Plug connector, 2-pin...
  • Page 31 The holding input (if there is one) for the isolation switch (S2) must be connected to the control unit in PIN 3/plug X7. Item Designation Comment Item Designation Comment Heater Air Top 3500 ST/5000 ST Plug connector, 2-pin to item A2 Control module Plug connector, 2-pin to item A2 Temperature sensor Internal Plug connector, 2-pin...
  • Page 32 Air Top 3500/5000 ST 7 Circuit diagrams Terminal 15: black Terminal 30: red Terminal 58: grey Terminal 31: brown Fig. 707 Schematic connection of the combination timer...
  • Page 33 7 Circuit diagrams Air Top 3500/5000 ST Page for notes...
  • Page 34 Air Top 3500 ST 2.0 hPa Servicing work Air Top 3500 ST Volume Plus 2.5 hPa Air Top 5000 ST 2.5 hPa NOTE 1 hPa corresponds to 1 mbar corresponds to 10 mm WC...
  • Page 35 8.6.2.1 Fuel extractor line: Vehicles with diesel engines 80 mm for the Air Top 3500 ST 90 mm for the Air Top 5000 ST The fuel must be taken from the vehicle fuel tank or from a separate tank (Fig. 802, 803 or 804). This separate fuel The hot air hose must be secured at its connection points.
  • Page 36 (for example Part No. 470 910), in which case it must be ensured that the return line continues almost to the bottom of the tank. If this is not the case Webasto fuel extractor (see Fig. 802, 803 or 804) may be used.
  • Page 37 Wrong 8.6.4 Fuel filter Bubble Bubble Only a Webasto filter, Part No. 487 171, may be used if the fuel is expected to be contaminated. Install vertically if possible, however at most horizontally (check flow direction). Fig. 805 Pipe/Hose connections 8.6.3 Metering pump...
  • Page 38 Air Top 3500/5000 ST 8 Servicing work 8.6.5 Combustion air supply 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 or a Under no circumstances may the combustion air be taken connection element with a condensate drain used.
  • Page 39 8 Servicing work Air Top 3500/5000 ST 8.6.8 Electrical connections 8.6.8.3 Control element connection The wiring harness is prepared for connection to the 8.6.8.1 Heater connection, control element control element (adjuster). Simply pull on connector housing to disconnect the The electrical connection is to be made as shown in the connector (Fig.
  • Page 40 Air Top 3500/5000 ST 8 Servicing work 1 Control element 2 Heater 3 Metering pump 4 Fuel filter (accessory) 5 Tank connector 6 Exhaust silencer 7 Fuse Fig. 814 Specimen installation for heater in an air circulation system...
  • Page 41 1. Place the heater with a new seal on the exhaust outlet in the installation position and secure it with 4 nuts and locking washers (use only genuine Webasto nuts). 2. Tighten the nuts to 6 +1 Nm. 3. Secure the connection for the combustion air inlet on the heater.
  • Page 42 9.1.2.1 Installation of an external temperature sensor General General The Air Top 3500 ST or Air Top 5000 ST heater can control the required temperature perfectly if its temperature sensor is exposed to the air temperature of This section describes the repair work that may be carried the main area of the vehicle.
  • Page 43 9 Repair work Air Top 3500/5000 ST Dismantling and assembling 1. Ensure that the insulating mat (7) is properly positioned on the heat exchanger. 9.2.1 Remove the casing parts IMPORTANT When you fit the bottom shell (4), spread it slightly so that 9.2.1.1 Cover for electrical connection the spacers on the overheating sensor (9, Fig.
  • Page 44 Air Top 3500/5000 ST 9 Repair work 1 Cover, electrical connection 2 Top shell 3 Cover, hot air outlet 4 Bottom shell 5 Cover, hot air inlet 6 Grate 7 Insulating mat Fig. 901 Remove / Fit the casing parts...
  • Page 45 9 Repair work Air Top 3500/5000 ST 9.2.3 Change the control unit 9.2.4.2 Installation 1. Measure the resistance of the overheating sensor (9, 9.2.3.1 Removal Fig. 902) (see 6.3.2). 1. Remove the heater (see 8.7.1.1). 2. Position the overheating sensor (9) and press it into 2.
  • Page 46 Air Top 3500/5000 ST 9 Repair work 1 Combustion and hot air fan (drive unit) 2 Torx screw (8) 3 Control unit 4 Torx screw (2) 5 Terminating resistor 6 Flat seal 7 Heat exchanger 8 Insulating mat 9 Overheating sensor Detail A Fig.

  • Page 47: Glow Plug/Flame Sensor

    9 Repair work Air Top 3500/5000 ST 9.2.6 Change the burner and the glow plug/ 9.2.7 Change the combustion pipe and the heat flame sensor exchanger 9.2.6.1 Removal 9.2.7.1 Removal 1. Remove the heater (see 8.7.1.1). 1. Remove the heater (see 8.7.1.1). 2.
  • Page 48 Air Top 3500/5000 ST 9 Repair work 1 Torx screw (4) 2 Retaining bar 3 Diesel burner 4 Combustion pipe 5 Round sealing ring 6 Heat exchanger 7 Petrol burner 8 Glow plug / Flame monitor 9 Retaining clip Fig. 903 Change the burner, glow plug/flame sensor, the combustion tube and the heat exchanger...
  • Page 49 9 Repair work Air Top 3500/5000 ST Page for notes...

  • Page 50: General

    10 Packing / Storage / Shipment Packaging, storage and shipping 10.1 General If the heater or its components are sent to Webasto Thermosysteme GmbH for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, transport and storage.
  • Page 51 10 Packing / Storage / Shipment Air Top 3500/5000 ST Page for notes 1002...

This manual is also suitable for:

Air top 5000 stAir top 3500 st seriesAir top 3500 st bAir top 3500 st dAir top 3500 st d volume plus

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