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Webasto Air Top Evo 3900/5500 B, Installation Manual, Page: 34 / 36

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Webasto Air Top Evo 3900/5500 B Installation Manual Download Page 34

Webasto Product N.A., Inc.

32

www.techwebasto.com

Drilling Template

Air Top Evo 3900/5500

16. Drilling Template 

Figure 39. Drilling Template for Heater Installation (Dimensions in millimeters)

Figure 40. Drilling Template for MC04/05 Control Panel

Ø

7.5

Ø

7.5

Ø

7.5

Ø

26

Ø

26

18

12

44

55

98

R2

63

Summary of Contents for Air Top Evo 3900/5500 B

Page 1: ...ols 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 techni...

Page 2: ......

Page 3: ...Installation Example 10 5 Hot Air System 11 5 1 External Temperature Sensor 12 5 1 1 To Install the External Temperature Sensor 12 6 Fuel Supply 13 6 1 Vehicles with a Carburetor Equipped Engine 13 6...

Page 4: ...ntrol Element Description 28 12 2 Ventilation Mode Optional Connection 28 13 Fault Lock out 29 13 1 Error Code Output 29 14 Technical Data 30 14 1 Electrical Components 30 14 2 Fuel for Air Top EVO 39...

Page 5: ...s These symbols are used to alert the installer to important or useful information about proper installation of the equipment 1 2 General Information Webasto Product North America Inc is pleased to pr...

Page 6: ...r must not pose a fire hazard even when overheated This requirement is deemed to have been met if care is taken during installation to ensure an adequate distance from all parts as well as adequate ve...

Page 7: ...imilar foam insulation styene sheet installation wood and paper products carpet glycol reservoirs coolant lines brake lines electrical wiring etc 2 5 Combustion Air Inlet 2 5 1 The air for the combust...

Page 8: ...esigned to heat cabins boats Diesel Only trucks minibuses vans and motor homes to defrost vehicle windows to heat cargo The air heaters operate independently of the engine and are connected to the fue...

Page 9: ...on the exterior ensure that the heater is fitted in a position where it is protected from splashing water and spray The heater must be installed in such a way that no water can ingress into it if the...

Page 10: ...nstallation Positions for AT 3900 5500 Heaters 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...

Page 11: ...el 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 I...

Page 12: ...00 4 7 Installation Example Figure 7 Installation example with heater in stalled under bunk Recirculation mode 1 2 3 4 5 6 7 1 Control Element Rheostat 2 AT 3900 5500 EVO Heater 3 Fuel Metering Pump 4...

Page 13: ...4 in minimum for the Air Top EVO 5500 80 mm 3 14 in minimum for the Air Top EVO 3900 NOTE Only materials that can permanently withstand temperatures of at least 130 C 266 F may be used for the hot air...

Page 14: ...get into the installation box 5 1 External Temperature Sensor The installation of an external temperature sensor is recommended if the heater is operated in fresh air mode 5 1 1 To Install the Externa...

Page 15: ...Figure 13 The fuel extractor must be fitted in such a way that any air or gas bubbles are automatically discharged towards the tank see Figure 12 Figure 12 Webasto fuel extractor The fuel extractor s...

Page 16: ...This separate fuel pickup precludes any effect of pressure Figure 13 Webasto fuel standpipe NOTE The tank fitting must be made from metal 6 4 Fuel Lines Only steel copper and plastic lines of plastici...

Page 17: ...advisable to install the metering pump in a cool place The maximum ambient temperature must not exceed 20 C 68 F for gasoline heaters at any time during operation The metering pump and fuel lines must...

Page 18: ...t 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 6 6 Fuel Filter Only a Webasto filter is allow...

Page 19: ...An intake silencer must be fitted if the intake hose length is greater than 0 6 m 24 in NOTE The combustion air must be extracted using a combustion air line from a position that is as cool as possibl...

Page 20: ...e The exhaust pipe is secured to the heater using a clamping collar for example See the regulations for installation for other requirements The exhaust muffler should ideally be installed near the hea...

Page 21: ...e exhaust line is over 2 m in length the lines must be insulated to prevent falling below the dewpoint Internal diameter of the lines Combustion air line 24 mm exhaust line metal 24 mm Minimum bending...

Page 22: ...escape of hot air heater overheating The cable passage of the cover can be placed at either the left or right side To ensure that the cable passage in the control unit cover seals perfectly the cable...

Page 23: ...l external temperature sensor see Figure 31 NOTE The fibre optic lens must be in contact with the rotary knob NOTE The rotary knob must sit flush with the bezel Figure 29 not above it as illustrated i...

Page 24: ...rilling templates Connect Control Panel to existing connectors on heater unit wiring harness see Connection diagram Circuit diagram Pre mount control unit in cut out Lightly press fastening screws int...

Page 25: ...ections Figure 34 Air Top EVO 3900 5500 with combination timer 1531 connection diagram Observe coloured markings Control Panel MC04 05 Heater units wiring harness Optional connection for Telestart The...

Page 26: ...n indicator pumping device K Relay with free wheeling diode for vehicle fan M1 Motor Combustion and hot air fan M3 Motor Vehicle fan P Combination Timer 1531 Timer and setpoint generator R1 Resistor 6...

Page 27: ...www webasto us 25 Webasto Product N A Inc 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...

Page 28: ...Webasto Product N A Inc 26 www techwebasto com 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...

Page 29: ...www webasto us 27 Webasto Product N A Inc 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...

Page 30: ...t during operation the fault must be located and remedied 12 1 Control Element Description Figure 38 Control element 12 2 Ventilation Mode Optional Connection Where desired a separate switch installed...

Page 31: ...iefly at least 2 seconds If serious faults such as overheating or no start occur frequently the heater will be set to fault lock out F 12 and can be restarted by disconnecting the supply voltage e g r...

Page 32: ...heater is also licensed for use with PME bio diesel which complies with DIN EN 14214 Heater Operation Air Top EVO 3900 5500 B Air Top EVO 3900 5500 D Type test permit EMC Heater e1 72 245 95 54 1221 0...

Page 33: ...o us 31 Webasto Product N A Inc 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...

Page 34: ...to com Drilling Template Air Top Evo 3900 5500 16 Drilling Template Figure 39 Drilling Template for Heater Installation Dimensions in millimeters Figure 40 Drilling Template for MC04 05 Control Panel...

Page 35: ...www webasto us 33 Webasto Product N A Inc Air Top Evo 3900 5500 Notes 17 Notes...

Page 36: ...sto 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 2...

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