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A

IR

T

OP

5000

5

I

NSTALLATION

5-9

5.7

Wiring Connections

5.7.1

General Information

The Air Top 5000 heater may be operated using the standard rheostat switch or with the optional 7-Day digital “Combi”
Timer model 1531.  The following section shows the possible circuits with the standard rheostat switch installed.

5.7.2

Connector Identification

Fig. 5-12: Connector Identification

Table 5-1:

Connector Identification

Refer to wiring diagram on page 5-10, figure 5-13.

ITEM

DESCRIPTION

X1

Blower Motor

X2

Ceramic Igniter / Flame Detector

X3

Temperature Limiter

X4

Fuel Pump

X5

Temperature Sensor

X6

Not Used

X7

Main Harness Connection to Control Unit

X8

Diagnostic Link Connection (Key Word 2000 - PC Download System)

X9

Control Element (On - Off Switch and Temperature Controller or Combi Timer)

X10 - X11

Fuel Pump

X12

Not Used (Future Timer Connection Provision)

Содержание Air Top 5000 ST

Страница 1: ...witch On 3 2 3 1 3 Heating Operation 3 2 3 1 4 Switch Off 3 2 3 1 5 Switch Off upon Malfunction 3 3 3 2 7 Day Digital Timer Model 1531 with 3 Time Settings and Temperature Selector 3 3 4 Technical Data 4 1 General Information 4 1 4 2 Dimensions 4 2 5 Installation 5 1 General Information 5 1 5 2 Installation Location 5 1 5 3 Mounting the Air Top 5000 Heater 5 2 5 4 Exhaust System 5 4 5 5 Combustion...

Страница 2: ...el Metering Pump Harness 5 12 5 8 2 Remote Temperature Sensor Optional 5 12 5 9 Ducting the System 5 13 5 9 1 General Information 5 13 5 10 Initial Start Up 5 14 6 Maintenance Troubleshooting 6 1 Heater Maintenance 6 1 6 2 Troubleshooting 6 1 6 2 1 Heater Shuts Off Automatically 6 1 6 2 2 Heater Emits Black Smoke from Exhaust 6 2 6 2 3 Self Diagnostic System Reading Flash Codes 6 2 6 2 4 Diagnosti...

Страница 3: ...neral Safety Regulations and Information The general safety regulations for the prevention of accidents and relevant operating safety instructions must be observed at all times The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warning Caution and Attention notations see section 1 2 1 4 1 General Safety Notes The Air Top 5000 heater is approved ...

Страница 4: ...operating conditions The operational state of the heater i e an indication on or off must be clearly visible to the operator The Air Top 5000 Air heater may only be operated within the specified operating voltage range designated by type The fuel specified by the vehicle manufacturer for use in the engine is suitable fuel for use in the Air Top 5000 air heater Air Top 5000D Diesel 1 Diesel 2 Arcti...

Страница 5: ...Cargo Heating The Air Top 5000 can be used an as independent heating system to protect temperature sensitive valuable products from freezing produce beverages etc Webasto cargo kits are supplied with an installation instruction supplement to cover the specific requirements of this application 2 Marine The Air Top 5000 can be used as the primary heating source for watercraft Boat installations may ...

Страница 6: ...2 GENERAL DESCRIPTION AIR TOP 5000 2 2 ...

Страница 7: ...shooting 3 Functional Description WARNING Due to the risk of carbon monoxide poisoning causing death or serious injury the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction WARNING Due to the risk of fire or explosion causing death or serious injury to personnel the heater must be switched off while refueling and at fueling stations WA...

Страница 8: ...elected rated temperature only the motor of the combustion and heating air fan will operate control idle Start operation will be initiated with a heating air temperature below the rated temperature ATTENTION Re activation of the heater during run down is permitted Run down will be completed first with a subsequent restart ATTENTION New settings on the control element are executed by the control un...

Страница 9: ...e below 20 Volt and in excess of 20 seconds for 24 Volt heaters control unit defective In case of overheating there will be no fuel supply A run down like after manual switch off will be performed After run down the control unit is in the error lockout mode Overheating is indicated by the operation indicator flashing For error unlock the air heater has to be switched off momentarily at least 2 sec...

Страница 10: ...t times Programming duration of operating time Setting the remaining operating time Press the button for more than 2 seconds time of the day is flashing and set the clock using the or buttons Wait 5 seconds Time of day is now stored Day of week is flashing adjust the day of week using the or buttons Wait 5 seconds Day of week is now stored Briefly press button Display of current time and weekday a...

Страница 11: ...e Volts Operating Voltage Volts Power Consumption Watts Start Boost Controlled Range From To Permissible Ambient Temp F C During Operation Heater Fuel Pump Maximum Permissible Heating Air Inlet Temp During Operation F C Hot Air Flow Unrestricted cfm m h Boost Controlled Range From To Permissible Storage Temp F C Heater Fuel Pump CO2 in Exhaust at Max Output Permissible Operating Range by Volume No...

Страница 12: ...n space required for heating air inlet 1 77 in 7 Min space required for heating air outlet 3 14 in 8 Min space required for removal of heater 7 89 in 9 Electrical cable outlet optionally on right or left Dimensions expressed in millimeters Fig 4 1 Dimensions Air Top 5000 Fig 4 2 Fuel Pump Air Top 5000 ATTENTION Webasto recommends installing gasoline operated heaters so that the exhaust gas outlet ...

Страница 13: ...AIR TOP 5000 4 TECHNICAL DATA 4 3 56 mm 2 13 64 in 38 mm 1 1 2 in 30 mm 1 3 16 in Fig 4 3 Control Element Rheostat Air Top 2000 3500 5000 Fig 4 4 Control Element Rheostat Exploded View ...

Страница 14: ...4 TECHNICAL DATA AIR TOP 5000 4 4 ...

Страница 15: ...nlet exhaust gas outlet and fuel line must be splash water protected For this purpose the special gasket supplied with the heater must be used The gasket must be renewed prior to each re installation The heater should be located in or as close as possible to the area being heated This is acceptable provided the following criteria is observed and adhered to 1 Exhaust combustion air intake and fuel ...

Страница 16: ...protected from the environment and if necessary mounted in an enclosure The heater is to be installed on a flat surface utilizing either mounting arrangement as shown in figure 5 2 Basic Kit or figure 5 3 Optional Mounting Plate Access to the heater must not be obstructed The space requirements in figure 4 1 for heater maintenance must be adhered to For mounting hole locations of all other kits wh...

Страница 17: ...an motor failure Tighten mounting fasteners sufficiently to make an air tight seal between the heater base and floor Ensure that the heater base with gasket cover the entire hole Optional Mounting Plate After selecting the heater location use the template provided with kit and cut the center hole 100 mm 4 in dia with a hole saw or jig saw Using the template drill 8 holes 7 mm 1 4 in dia for securi...

Страница 18: ...tion 5 INSTALLATION AIR TOP 5000 5 4 5 4 Exhaust System One meter 39 in of flexible metal exhaust tubing is provided in the installation kit for routing exhaust gases away from the underside of the vehicle or cargo containment area 1 Secure the exhaust tube to the heater with the clamp provided 2 Route the exhaust tube in such a way as to prevent it from touching or being directed toward any part ...

Страница 19: ...er to allow moisture to drain If dips or bends cannot be avoided drill a 5 mm 3 16 in hole at the lowest point of each bend or dip to allow drainage of moisture see figure 5 5 3 Bend inlet end of tube in a downward direction see figure 5 5 Do not point into the direction of travel 4 Secure combustion air intake tube to the vehicle with nylon wire ties where possible NEVER ROUTE COMBUSTION TUBE IN ...

Страница 20: ...he cut to prevent clogging Remove burrs from cut end Apply thread sealant to threaded fittings to prevent fuel leaks 2 Install fuel standpipe using one of the following methods use 1 4 or 1 2 spare port on top of fuel tank if available and install standpipe OR drill or punch a 25 mm 1 in hole in a clear area on top of the fuel tank or spare fuel level sending unit plate assemble tank boss and fuel...

Страница 21: ...nge of hot vehicle parts If necessary a heat shield should be installed The metering pump is to be attached by a vibration damping suspension device rubber isolated clamp The installation position is restricted as shown in figures 5 8 and 5 9 in order to ensure proper operation and self bleeding of the system To minimize the occurrence of corrosion only genuine Webasto parts are to be used for the...

Страница 22: ...d CAUTION Fuel lines must be secured to the vehicle every 305 mm 12 in and routed away from hot exhaust components and moving parts drive shaft wheels etc Fig 5 10 Fuel Line Connection Connect fuel line from fuel standpipe to fuel metering pump inlet and from fuel metering pump outlet to the inlet port of the heater using supplied rubber connectors and clamps Tie fuel line in place every 305 mm 12...

Страница 23: ...ctor Identification Fig 5 12 Connector Identification Table 5 1 Connector Identification Refer to wiring diagram on page 5 10 figure 5 13 ITEM DESCRIPTION X1 Blower Motor X2 Ceramic Igniter Flame Detector X3 Temperature Limiter X4 Fuel Pump X5 Temperature Sensor X6 Not Used X7 Main Harness Connection to Control Unit X8 Diagnostic Link Connection Key Word 2000 PC Download System X9 Control Element ...

Страница 24: ...5 INSTALLATION AIR TOP 5000 5 10 5 7 3 Wiring Diagram Air Top 5000 12 and 24 Volt Fig 5 13 Wiring Diagram Air Top 5000 ...

Страница 25: ...Connector Main Harness Connection X8 2 pin Connector Diagnostic Link X9 4 pin Connector Control Element X10 2 pin Connector Fuel Pump Harness X11 2 pin Connector Fuel Pump Harness Y1 Fuel Dosing Pump 5 7 4 Electrical Component Identification Table Table below refers to wiring diagram on page 5 10 figure 5 13 Table 5 2 Electrical Component Identification Fiber Optic Shaft Nuts Panel Shaft set at pr...

Страница 26: ...555 5 8 2 Remote Temperature Sensor Optional A remote external temperature sensor kit includes updated control unit is available from Webasto under part number 90821A The remote sensor allows temperature monitoring from a remote location other than the heaters inlet This is beneficial where the heater is located in an area where cold air influx does not allow consistent temperature measurement at ...

Страница 27: ...dly due to the high heat output of the AT 5000 heater damage to the vehicle or compartment ducting system is likely to occur Air inlet temperature to the heater must not exceed 104 F 40 C or the temperature limiter is likely to respond Restrictions at the heaters inlet and outlet i e paper clutter etc will also contribute to overheating KEEP THE AIR INLET AND OUTLETS CLEAR OF OBSTRUCTIONS CAUTION ...

Страница 28: ... through 2 start up attempts Watch the clear fuel line for indications of air bubbles and fuel Depending on length of fuel line it may take a few start attempts before the fuel reaches the heater If the fuel line does not prime right away switch heater off and back on to reinitiate the start up cycle Once the heater starts allow it to run until all trapped air bubbles have escaped and heater opera...

Страница 29: ...ory of operation of the heater components and should only be performed by authorized Webasto trained specialists For the purpose of this manual only those items as they pertain to installation will be covered under troubleshooting For malfunctional problems beyond the scope of this manual please call Webasto Product North America Inc directly at 1 800 555 4518 USA or 1 800 667 8900 Canada In the e...

Страница 30: ...ycle after which the code will be stored in the control unit memory Storing a Fault Code in Memory Once the Air Top 5000 heater completes the after run cool down period initiated by a failure event the current flash code will be downloaded stored in memory The Air Top 5000 heater can store up to four fault codes Once the memory is full any additional fault code will replace the earliest code store...

Страница 31: ... your Webasto specialist Fuel level No fuel Fuel system not primed Type of fuel being used Plugged fuel filter replace Fuel line connections and clamps air bubbles in fuel lines Air intake or exhaust restricted or plugged Clean or replace burner unit Restriction in fuel system Plugged fuel filter replace Fuel line connections and clamps air bubbles in fuel lines Type of fuel being used Clean or re...

Страница 32: ...6 MAINTENANCE TROUBLESHOOTING AIR TOP 5000 6 4 Please use this section for your notes and observations ...

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