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Webasto Air Top 3500 Workshop Manual

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Air Heaters
07/2000
Workshop Manual
Air Top 3500
Air Top 5000
Type AT 3500 D (Diesel)
Type AT 5000 D (Diesel)

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Summary of Contents for Webasto Air Top 3500

  • Page 1 Air Heaters Workshop Manual Air Top 3500 Air Top 5000 Type AT 3500 D (Diesel) Type AT 5000 D (Diesel) 07/2000...

  • Page 2: Table Of Contents

    Air Top 3500/5000 List of Contents List of Contents Introduction Scope and Purpose ..........................101 1.1.1 Use of the Air Heaters ......................... 101 Meaning of Warnings, Cautions, and Notes ..................101 Additional Documentation to be used ....................101 Safety Information and Regulations....................... 101 1.4.1 General Safety Notes ........................

  • Page 3: Adjustment Of Co Contents

    List of Contents Air Top 3500/5000 Functional Checkouts General ..............................601 Adjustments ............................601 6.2.1 Adjustment of CO Contents ...................... 601 Components Testing..........................601 6.3.1 Glow Plug / Flame Sensor Resistance Check ................601 Circuit Diagrams General ..............................701 Servicing General ..............................

  • Page 4: List Of Contents

    Air Top 3500/5000 List of Contents Disassembly and Assembly........................903 9.2.1 Housing Components / Covers, Removal ................... 903 9.2.2 Temperature Sensor, Replacement .................... 904 9.2.3 Temperature Limiter, Replacement ..................... 904 9.2.4 Control Unit, Replacement ......................904 9.2.5 Combustion and Heating Air Fan (Drive), Replacement ............. 904 9.2.6 Glow Plug / Flame Sensor, Replacement..................
  • Page 5 Control Unit Pin Assignment, Air Top 3500/5000 ..................701 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Control Element........702 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer ........ 703 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer and Battery Switch .............................

  • Page 6: Safety Information And Regulations

    Warnings, Cautions, and Notes. 1.1.1 Use of the Air Heaters 1.4.1 General Safety Notes The air heaters Air Top 3500 and Air Top 5000 are used to – heat the cabin Within the scope of the StVZO (Road Traffic Licensing –...

  • Page 7: Legal Provisions For Installation

    Air Top 3500/5000 1 Introduction Ignoring installation instructions and its procedures will When installing the Air Top 3500 and Air Top 5000 in vehicles intended for the transportation of dangerous void the warranty by Webasto. The same applies to goods, the TRS 002 and TRS 003 (Technical Guidelines unskilled repairs or repairs not using original spare parts.

  • Page 8: Corrections And Improvements

    In compartments accommodating persons, exhaust lines Installation Instructions for Webasto Fuel Tanks for must not have more than one disconnect and must have Fuel Supply of Heaters in Vehicles a splash-water protected feedthrough in the exterior wall/ floor.
  • Page 9 Air Top 3500/5000 1 Introduction Page free for notes...

  • Page 10: General Description

    The heater may be controlled by means of an external temperature sensor instead of the internal temperature sensor. The air heaters Air Top 3500 and Air Top 5000 working to Fuel supply is provided by an external dosing pump. the evaporator principle of operation basically consist of...

  • Page 11: Burner With Combustion Tube

    Air Top 3500/5000 2 General Description Combustion and Heating Air Fan Burner with Combustion Tube The combustion and heating air fan delivers the air Inside the burner insert fuel is distributed across the necessary for combustion from the combustion air inlet combustion tube fuel cross section.

  • Page 12: Control Unit

    Air Top 3500/5000 2 General Description Control Unit Analogue Temperature Limiter The control unit ensures control and monitoring of The analogue temperature sensor protects the heater combustion operation. A temperature sensor plugged on against undue high operating temperatures. For the control unit is used for temperature control. On all...
  • Page 13 Air Top 3500/5000 2 General Description Page free for notes...

  • Page 14: Switch On

    Air Top 3500/5000 3 Functional Description Functional Description Start The glow plug/flame sensor is activated. After (Fig. 301) approximately 22 seconds the dosing pump is put into operation and combustion commences. After 116 seconds the glow plug is deactivated and the flame Control Element sensor becomes active.
  • Page 15 Air Top 3500/5000 3 Functional Description on on 100% 2,0 (2,8)* Hz 0,5 Hz 116 124 *) AT5000 (180) Seconds Sekunden Start A = Control element Controlled operation B = Temperature sensor Rated (set) value achieved C = Glow plug...

  • Page 16: Heating Operation

    Air Top 3500/5000 3 Functional Description Heating Operation Switch off During operation there is a flow of combustion gasses Switching the heater off extinguishes the operating through the heat exchanger. The heat of combustion is indicator light of the control element.

  • Page 17: Error Lockout

    Air Top 3500/5000 3 Functional Description Error Lockout The control unit detects malfunctions of individual heater components and errors in the start sequence and in heater operation. The heater is switched off and enters error lockout under the following conditions: •...

  • Page 18: Technical Data

    12 Volt or 24 Volt. of fuel. The components timer*, temperature limiter and temperature sensor are independent of voltage. *not for ADR Air Top 3500 D Air Top 3500 D Air Top 5000 D Heater Operation Volume Plus...
  • Page 19 Air Top 3500/5000 4 Technical Data Page free for notes...

  • Page 20: Troubleshooting

    This section describes the troubleshooting for the heater Air Top 3500 and Air Top 5000. • corrosion on connectors •...

  • Page 21: Failure Symptoms During Operational Sequence

    Air Top 3500/5000 5 Troubleshooting Failure Symptoms during Operational Should the symptom not be listed in the table or the fault of a symptom listed, cannot be isolated our technicians Sequence are available in emergencies (service telephone 0 89 / 8 57 94 - 5 12).

  • Page 22: Error Code Output

    Air Top 3500/5000 5 Troubleshooting Error Code Output When equipped with a combination timer a malfunction will output an error code to the timer display. NOTE When equipped with a control element the error code output after a malfunction will be a flashing operating indicator light/error code indication.
  • Page 23 Air Top 3500/5000 5 Troubleshooting Page free for notes...
  • Page 24 Return the heater to control element adjustment (CO pin connected to vehicle Webasto Thermosysteme GmbH for testing and repair. ground). For adjustment a suitable CO detector must be used.
  • Page 25 Air Top 3500/5000 6 Functional Checkouts Page free for notes...

  • Page 26: Glow Plug / Flame Sensor

    7 Circuit Diagrams Circuit Diagrams General The heater Air Top 3500 and Air Top 5000 may be operated with the control element (rated value setting/ switch) or with a combination timer. The circuit diagrams (Fig. 702 to 706) show possible 12 V or 24 V circuits with: •...
  • Page 27 A2 (ST U) Connection 2-pole on item A2 (ST Z) Connection 2-pole on item A2 (ST Y) Connection 2-pole on item A2 (ST X) Fig. 702 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Control Element...
  • Page 28 Combustion and heating air fan Combination timer Timer and rated value transmitter Switch Ventilate Push button switch Instant heat switch remote control Connection 2-pole on item A2 (ST B) Fig. 703 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer...
  • Page 29 Combustion and heating air fan Combination timer (1631) Timer and rated value transmitter Switch Ventilate Push button switch Instant heat switch remote control Battery switch Fig. 704 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer and Battery Switch...
  • Page 30 Switch Boost or Ventilate Connection 2-pole on item A2 (ST B) Connection 2-pole on item A2 (ST V) Connection 2-pole on item A2 (ST U) Fig. 705 Automatic Switching Circuit Air Top 3500/5000, 24 V ADR Operation with Control Element...
  • Page 31 Connection 2-pole on item A2 (ST Z) Connection 2-pole on item A2 (ST Y) Connection 2-pole on item A2 (ST X) Fig. 706 Automatic Switching Circuit Air Top 3500/5000, 24 V ADR Operation with Control Element and no Auxiliary Drive...

  • Page 32: Work On The Heater

    It must also be protected against direct exposure to sun and draught wind. The heater does not require any maintenance. It should however be inspected in regular intervals by Webasto Minimum inner diameter of heating air duct: trained maintenance personnel, the latest date for...

  • Page 33: Fuel Supply

    Maximum pressure drop between suction and pressure 8.6.2.1 Fuel Tapping side of heating air duct: 2.0 mbar (20 mm water column) Air Top 3500 Diesel fuel tapping must be from the fuel tank or a 3.0 mbar (30 mm water column) Air Top 5000 separate fuel reservoir (Fig.

  • Page 34: Dosing Pump

    8 Servicing Hole Pattern Fuel Tank Tap Gasket Tank Fitting Plate Fig. 802 Webasto Fuel Tap* *Fuel tap to be used only for metal fuel tanks Fig. 804 Fuel Tapping from Plastic Tank (tapping via fitting plate) NOTE Tank fitting plate to be made from sheet metal! Plastic tank 8.6.2.2 Fuel Lines...

  • Page 35: Volt (Green)

    The installation location is limited according to bubble Fig. 806 to ensure sufficient self-venting capability. Due to bubble the danger of corrosion only Webasto original parts may be used for the plug connection between dosing pump and dosing pump wiring harness. 8.6.4 Fuel Filter Fig.

  • Page 36: Combustion Air Supply

    Air Top 3500/5000 8 Servicing 8.6.5 Combustion Air Supply 8.6.7 Combustion Air Intake and Exhaust Lines The combustion air must not be taken in from rooms Max. total length of the combustion air intake and exhaust accommodating persons. The intake must not point in the line: direction of forward motion.

  • Page 37: Electrical Connections

    Air Top 3500/5000 8 Servicing 8.6.8.3 Connection of Control Element 8.6.8 Electrical Connections The wiring harness is prepared for connection to the 8.6.8.1 Connection of Heater, Control Element control element (rated value transmitter). For disconnection of the connector simply pull on the The electrical connection is according to the circuit connector terminal (Fig.
  • Page 38 Air Top 3500/5000 8 Servicing 1 Control element 2 Heater 3 Dosing pump 4 Fuel filter (accessory) 5 Fuel tap 6 Exhaust muffler (accessory) 7 Flat fuse holder Fig. 814 Sample Installation of Air Heater for Air Circulation Mode of Operation...

  • Page 39: Removal And Installation

    7. Remove heater and discard gasket. 8.7.1.2 Installation 1. Locate heater with new gasket for installation and secure with four nuts and washers (use Webasto original nuts only). 2. Tighten nuts with 6 + 1 Nm. 3. Connect and secure fuel supply line to heater.

  • Page 40: General

    9.1.2.1 Installation of an External Temperature Sensor General General The heater Air Top 3500 and Air Top 5000 control the desired temperature the best when the air temperature of the most frequented area is applied to its temperature This section describes the repairs that may be performed sensor.

  • Page 41: 9 Repair

    Air Top 3500/5000 9 Repair 9.1.2.2 Installation of Burner with Shield 5. Fit new seal (13) in groove of flange of heat exchanger (14). General 6. Position burner tube (12) for assembly and fasten with Retrofit kit, 12 V (Ident. No. 679 84A) Torx screws (16).

  • Page 42: Disassembly And Assembly

    Air Top 3500/5000 9 Repair Disassembly and Assembly 9.2.1.3 Upper Housing Shell The upper housing shell (2, Fig. 901) may be lifted after 9.2.1 Housing Components / Covers, Removal removal of the covers for the heating air inlet and outlet.

  • Page 43: Temperature Sensor, Replacement

    Air Top 3500/5000 9 Repair 9.2.2 Temperature Sensor, Replacement 9.2.4 Control Unit, Replacement NOTE 9.2.4.1 Removal • The temperature sensor may be replaced without removal of the heater. 1. Remove housing components/covers (see 9.2.1). • The internal temperature sensor may be substituted 2.

  • Page 44: Glow Plug / Flame Sensor, Replacement

    Air Top 3500/5000 9 Repair 9.2.6.2 Installation 9.2.6 Glow Plug / Flame Sensor, Replacement NOTE 9.2.6.1 Removal Steps 1 through 5 to be performed for a burner (19, Fig. 902) without shield. Steps 6 through 13 refer to 1. Remove housing components / covers (see 9.2.1).

  • Page 45: 9 Repair

    Air Top 3500/5000 9 Repair NOTE The temperature limiter may be additionally fastened with a washer. This washer must be replaced with a new washer during installation. 1 Control unit 11 Glow plug / flame sensor 2 Torx screw (2)

  • Page 46: Burner, Replacement

    Air Top 3500/5000 9 Repair 8. Torque oval head screw (9) to 0.8 ± 0.08 Nm. 9.2.7 Burner, Replacement 9. Hold burner with shield (18) upside down, engage burner tube (12) and rotate to assemble with 9.2.7.1 Removal combustion tube.

  • Page 47: Heat Exchanger, Replacement

    Air Top 3500/5000 9 Repair 9.2.9 Heat Exchanger, Replacement CAUTION Replacement of heat exchanger requires additional replacement of temperature limiter. 9.2.9.1 Removal 1. Remove housing components / covers (see 9.2.1). 2. Remove insulation mat (15, Fig. 902). 3. Remove control unit (see 9.2.4.1).

  • Page 48: General

    10 Packaging, Storage and Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Webasto Thermosysteme GmbH for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage. When in storage an ambient temperature of +85°...
  • Page 49 Air Top 3500/5000 10 Packaging, Storage and Shipping Page free for notes 1002...

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Air top 5000

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