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Webasto Air Top Evo 3900 B, Installation Instructions Manual

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Webasto Air Top Evo 3900 B Installation Instructions Manual Download Page 23

Air Top Evo 3900 / Air Top Evo 5500

Fuel supply

69

7.5.2.

Installation and attachment

The metering pump must be secured with a vibration-damping mounting 
(for example a rubberised clip). Its installation position is limited as shown 
in Figures 15 and 16 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 meter-
ing pump wiring harness.

7.6.

Fuel filter

Only a Webasto filter, order no. 487 171, is allowed to be used if the fuel 
is expected to be contaminated. Install vertically if possible, however at 
least horizontally (check flow direction).  

Fig. 17

Air Top Evo 3900 and Air Top Evo 5500 fuel filter 

0° - 90°

Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl.book  Page 69  Wednesday, November 3, 2010  11:58 AM

Summary of Contents for Air Top Evo 3900 B

Page 1: ...Air Top Evo 5500 Handelsbezeichnungen Trade names Handelsnamen Air Top Evo 3900 B Benzin petrol benzine Air Top Evo 3900 D Diesel PME diesel PME Air Top Evo 5500 B Benzin petrol benzine Air Top Evo 55...

Page 2: ...Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl book Page 2 Wednesday November 3 2010 11 58 AM...

Page 3: ...ine Haftung f r M ngel und Sch den die auf einen Einbau durch ungeschultes Per sonal zur ckzuf hren sind Improper installation or repair of Webasto heating and cooling systems can cause fire or the le...

Page 4: ...schaltung 41 16 Technische Daten 43 17 Bohrschablonen 47 Table of contents 1 Statutory regulations governing installation 51 2 Use version 55 3 Installation 56 4 Type label 59 5 Installation example 6...

Page 5: ...cence NOTE For vehicles with an EU permit no entry in accordance with 19 Sub Sec tion 4 of Annex VIII b to the Road Traffic Act is required 1 1 Application of combustion heaters in vehicles for transp...

Page 6: ...vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination 2 2 2 5 3 2 2 Part I The combustion heater shall not constitute a risk of fire even in the...

Page 7: ...pply may be fresh or re circulated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the propulsion engine the combustion heater or any other veh...

Page 8: ...of the vehicle or the load b fuel tanks containing petrol shall be equipped with an ef fective flame trap at the filler opening or with a closure en abling the opening to be kept hermetically sealed 3...

Page 9: ...are connected direct ly to the fuel tank and the electrical system of the vehicle They may be used for vehicles with either water or air cooled engines They are not approved for heating the space in...

Page 10: ...if the vehicle travels through a water hazard for which that vehicle is licensed The openings for the combustion air inlet port the exhaust outlet port and the fuel pipe must be sealed if the heater...

Page 11: ...mbustion air intake 4 Exhaust fume outlet 5 Fuel intake 6 Space requirement for hot air inlet 7 Space requirement for hot air outlet 8 Space requirement for removing the heater 9 Cable outlet either r...

Page 12: ...8 Fig 2 Approved installation position Fig 3 Seal Diesel heaters Petrol heaters Fig 4 Installation Ensure that all moving parts can move easily Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl...

Page 13: ...d 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 Installati...

Page 14: ...e for air heater in recirculation mode 1 Control element 2 Heater 3 Metering pump 4 Fuel filter accessory 5 Tank connector 6 Exhaust silencer accessory 7 Fuse Maximum water passage height 1 2 3 5 4 7...

Page 15: ...iagram in Figure 34 36 and 38 The slave heat er is connected in accordance with the wiring diagram see Figure 39 The units communicate with each other via a serial bus system This system can therefore...

Page 16: ...heaters of the same output type Heating Capacity Range Heater Number of Units 1 5 3 9 kW Air Top Evo 3900 1 1 5 5 5 kW Air Top Evo 5500 1 1 5 7 8 kW Air Top Evo 3900 2 1 5 11 0 kW Air Top Evo 5500 2 1...

Page 17: ...y be used for the hot air line The hot air opening is to be posi tioned in such a way that the air is not blown on to any parts that cannot withstand the heat IMPORTANT In vehicles used to transport p...

Page 18: ...tted in the ap propriate zone 6 1 1 To install the external temperature sensor The external temperature sensor must be installed at medium height in the passenger cabin on vertical surfaces if possibl...

Page 19: ...par route govern ing fuel tanks part 9 para 9 2 4 7 must be adhered to A sign must be affixed to the fuel filler neck warning that the heater must be switched off before refuelling Permissible fuel i...

Page 20: ...he tank ter minates near the bottom of the fuel tank see Figure 11 for details of the minimum distance from the bottom of the tank If this is not the case We basto fuel extractor see Figure 11 12 and...

Page 21: ...ad chippings and high temperatures exhaust line The fuel lines must be secure at the connections using hose clips to prevent their slipping Fig 11 Webasto tank connector Fig 12 Fuel pick up from the p...

Page 22: ...not ex ceed 20 C for petrol heaters at any time during operation 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 u...

Page 23: ...risk of corrosion only genuine Webasto parts may be used for the plug connections between the metering pump and the meter ing pump wiring harness 7 6 Fuel filter Only a Webasto filter order no 487 171...

Page 24: ...0 6 m NOTE The combustion air must be extracted using a combustion air line from a position that is as cool as possible and protected from splashing water Do not use an exhaust line as the combustion...

Page 25: ...using a clamping collar for ex ample See the statutory regulations for other requirements The exhaust silencer should ideally be installed near the heater The heater may also be operated without a si...

Page 26: ...fire risk Length of the combustion air inlet and exhaust lines in total With exhaust silencer max 2 0 m Without exhaust silencer max 5 0 m NOTE If the exhaust line is over 2 m in length the lines mus...

Page 27: ...e govern ing the routing of the exhaust line part 9 para 9 2 4 7 must be adhered to Fig 23 Exhaust pipe opening Installation position An attachment is required no further than 150 mm from the end of t...

Page 28: ...rol unit input X6 1 when the system is switched on The control unit continues to run briefly for a maximum of 40 seconds and then switches to the ADR lock out operating mode when a positive volt age i...

Page 29: ...Supply voltage connection Ideally from the vehicle s central electrical system An additional blade terminal fuse holder is to be fitted to protect the heater supplied with the heater The fuse holder...

Page 30: ...self locking action by simply pulling on the wiring harness NOTE The fibre optic cable must be in contact with the rotary knob NOTE As an option an external temperature sensor may be installed in the...

Page 31: ...ctors on heater unit wiring har ness see chapter 12 Connection diagram Circuit diagram Premount control unit in cut out Lightly press fastening screws into holes and screw in Carefully clip on trim fr...

Page 32: ...m Fig 31 Air Top Evo 3900 and Air Top Evo 5500 with combination timer connection diagram black Terminal 15 Combination timer 1531 Adapter wiring harness red Terminal 30 brown Terminal 31 grey Terminal...

Page 33: ...3900 and Air Top Evo 5500 with Control Panel MC04 05 Observe coloured markings Control Panel MC04 05 Heaters wiring harness Optional connection for Telestart Thermo Call 12 V only Webasto Thermo Test...

Page 34: ...so possible MC04 heater control Connection for We basto Thermo Test di agnosis Observe coloured markings heaters wiring harness Connection to additional heaters Control line W bus Connection for Webas...

Page 35: ...ram 81 Fig 34 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500 12 V 24 V with control element and vehicle fan for legend see pages 87 and 88 Installation_Instructions_Air_Top_Evo_39...

Page 36: ...vo 5500 82 Fig 35 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500 24 V ADR operation with control element for legend see pages 87 and 88 Installation_Instructions_Air_Top_Evo_3900_...

Page 37: ...am 83 Fig 36 System wiring diagram for the Air Top Evo 3900 and Air Top Evo 5500 12 V 24 V with combination timer and vehicle fan for legend see pages 87 and 88 Installation_Instructions_Air_Top_Evo_3...

Page 38: ...ystem wiring diagram for the Air Top Evo 3900 D and Air Top Evo 5500 D 12 V 24 V with combination timer and electrical battery isolation switch for legend see pages 87 and 88 Installation_Instructions...

Page 39: ...5 Fig 38 System wiring diagram for the Air Top Evo 3900 D and Air Top Evo 5500 D 12 V 24 V with Control Panel MC04 05 and vehicle fan for legend see pages 87 and 88 Installation_Instructions_Air_Top_E...

Page 40: ...r Top Evo 5500 86 Fig 39 System wiring diagram for Air Top Evo 3900 and Air Top Evo 5500 Slave Heater 12 V 24 V diesel for legend see Page 87 and 88 Installation_Instructions_Air_Top_Evo_3900_5500_de_...

Page 41: ...ctions 7 5 m 7 5 15 m 0 75 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 Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet...

Page 42: ...n adapter wiring harness R1 Resistor 620 With internal temperature sensor only S Control Panel MC04 05 On Off switch setpoint generator and selector switch for additional functions S1 Basic heater con...

Page 43: ...trical connections are in accordance with the sys tem wiring diagram Fig 34 Fig 36 Fig 38 4 Installation of the heater control and external temperature sensor NOTE The master heater is only configured...

Page 44: ...possible to reset the system to its original state 1 Switch master heater into Ventilation mode 2 De energise pull fuse NOTE All connected heaters must be disconnected from Terminal 30 3 Connect volta...

Page 45: ...seconds for 24 V heater Control unit defective Overheating The fuel supply is stopped if the heater overheats The heater continues to run in the same way as if it is switched off manu ally After it s...

Page 46: ...tage or overvoltage F 04 Premature flame recognition F 06 Temperature sensor interrupt or temperature sensor short circuit F 07 Metering pump interrupt or metering pump short circuit F 08 Fan motor in...

Page 47: ...ecified by the manufacturer in accordance with DIN EN 228 must be used 16 3 Fuel for Air Top Evo 3900 D diesel Fuel for Air Top Evo 5500 D diesel The diesel fuel specified by the manufacturer in accor...

Page 48: ...W 1 5 to 5 0 5 5 kW Fuel Petrol EN 228 Diesel PME EN 590 DIN EN 14214 Fuel consumption Control range 0 18 to 0 37 0 41 kg h 0 23 to 0 48 0 54 l h 0 18 to 0 52 0 57 kg h 0 23 to 0 69 0 75 l h 0 16 to 0...

Page 49: ...0 220 m3 h CO2 in exhaust gas permitted function range 1 7 kW 5 0 to 8 0 3 5 5 0 kW 9 0 to 12 5 1 5 kW 6 5 to 8 0 3 5 5 0 kW 9 0 to 12 5 Heater dimensions Length 423 2 mm Width 148 1 mm Height 162 1 m...

Page 50: ...Technical data Air Top Evo 3900 Air Top Evo 5500 96 Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl book Page 96 Wednesday November 3 2010 11 58 AM...

Page 51: ...ates 97 17 Drilling templates Fig 40 Heater drilling template 28 44 29 12 55 18 7 5 7 5 7 5 NOTE Max base unevenness around the seal 1 mm Seal Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl...

Page 52: ...Drilling templates Air Top Evo 3900 Air Top Evo 5500 98 Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl book Page 98 Wednesday November 3 2010 11 58 AM...

Page 53: ...p Evo 3900 Air Top Evo 5500 Drilling templates 99 Fig 41 Drilling Template for Control Panel MC04 05 Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl book Page 99 Wednesday November 3 2010 11...

Page 54: ...Drilling templates Air Top Evo 3900 Air Top Evo 5500 100 Installation_Instructions_Air_Top_Evo_3900_5500_de_en_nl book Page 100 Wednesday November 3 2010 11 58 AM...

Page 55: ...com http dealers webasto com Im Fall einer mehrsprachigen Version ist Deutsch verbindlich In multilingual versions the German language is binding Bij een meertalige versie is de Duitse versie bindend...

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