Webasto Air Top Evo 3900 Workshop Manual
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Webasto Air Top Evo 3900 Workshop Manual

Air heaters (petrol) & (diesel/pme)
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See also: Workshop Manual , Instruction and Installation Manual
Air heaters
Air heaters
04/2008
1313560A
03/2003
Workshop Manual
Air Top Evo 3900
Air Top Evo 5500
Type Air Top Evo 3900/5500 ST B
(petrol)
Type Air Top Evo 3900/5500 ST D
(Diesel/PME)

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Summary of Contents for Webasto Air Top Evo 3900

  • Page 1 Air heaters 03/2003 Air heaters Workshop Manual Air Top Evo 3900 Air Top Evo 5500 Type Air Top Evo 3900/5500 ST B (petrol) Type Air Top Evo 3900/5500 ST D (Diesel/PME) 04/2008 1313560A...
  • Page 2 Air Top Evo 3900/5500 Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and have the appropriate technical documentation, special tools and special equipment.

  • Page 3: Table Of Contents

    Air Top Evo 3900/5500 Table of Contents Table of Contents Introduction Contents and purpose ........................... 101 1.1.1 Use of the air heaters ........................101 Meaning of signal words ........................101 Additional documentation to be used..................... 101 Statutory regulations and safety instructions ..................101 1.4.1 Statutory regulations governing installation.................
  • Page 4 Table of Contents Air Top Evo 3900/5500 Troubleshooting General ..............................501 General error symptoms ........................501 Error symptoms during function ......................502 Error code output ..........................503 Function tests General ..............................601 Settings ..............................601 6.2.1 Setting the CO content......................601 Testing individual components......................
  • Page 5 Air Top Evo 3900/5500 Table of Contents Repair General ..............................901 9.1.1 Work on stripped down components ................... 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 6 List of illustrations Air Top Evo 3900/5500 List of illustrations General error symptoms ..........................501 Error symptoms during function ......................... 502 Troubleshooting ............................503 Plug assignment ............................701 System circuit diagram 12V/24V with control element and vehicle blower ..........702 System circuit diagram 24V ADR operation with control element..............

  • Page 7: Statutory Regulations And Safety Instructions

    1.1.1 Use of the air heaters 1.4.1 Statutory regulations governing The Webasto Air Top Evo 3900 and Air Top Evo 5500 air installation heaters are designed –...

  • Page 8: General Safety Information

    1 Introduction Air Top Evo 3900/5500 2.2.2. The combustion heater shall not constitute a risk of 2.6. Heating air inlet fire, even in the case of overheating. This 2.6.1. The heating air supply may be fresh or recirculated requirement shall be deemed to be fulfilled if the...
  • Page 9 Fuel tanks for normal and super grades of petrol must not be immediately behind the front trim of the The Air Top Evo 3900 and Air Top Evo 5500 air heaters vehicle.They must be separated from the engine in are prepared for interior installation and sealing direct on such a way that in the event of an accident the fuel will the cabin floor or a cabin wall.
  • Page 10 1 Introduction Air Top Evo 3900/5500 Overheating NOTE Keep the hot air inlet and hot air outlet free of dirt and Failure to follow the installation instructions and the notes foreign bodies. Dirty, blocked air lines can cause the contained therein will lead to all liability being refused by heater to shut down due to overheating.

  • Page 11: General Description

    If a fault occurs, an error code will be output in the display The Air Top Evo 3900 and Air Top Evo 5500 air heaters of the combination or standard timer. If the heater has a are based on the evaporator principle and essentially control element, the ON control light will flash.In addition...

  • Page 12: General Description 2.1 Drive Unit

    2 General description Air Top Evo 3900/5500 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.

  • Page 13: Control Unit

    Air Top Evo 3900/5500 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 14 2 General description Air Top Evo 3900/5500 Page for notes...

  • Page 15: Function Description 3.1 Control Element

    Air Top Evo 3900/5500 3 Function description off and the existence of the flame established. Function description Automatic restart Control element If the flame sensor does not find a flame, the starting pro- cedure will be repeated.The glow plug will be switched on again (cycled).The motor for the hot and combustion air...

  • Page 16: Switch Off

    NOTE 24V ing and combustion air blower and the delivery rate of the Only for Air Top Evo 3900/5500 D heaters that are metering pump are reduced. installed in vehicles for transporting hazardous If, at minimum heat output, the intake temperature set on substances (ADR).

  • Page 17: Error Monitor

    Air Top Evo 3900/5500 3 Function description The fuel supply is stopped if the heater overheats. 3.3. FL vehicles The heater continues to run in the same way as if it is 3.3.1. The combustion heaters shall be put out of switched off manually.

  • Page 18: Reset A Fault Lock-Out

    3 Function description Air Top Evo 3900/5500 3.8.2 Reset a fault lock-out The various fault statuses can be reset as follows. Fault lock-out: Switch heater off using the control element and then on again after more than 2 seconds Heater fault lock-out: Heater unit is switched on, Fault code F12 is shown.

  • Page 19: Technical Data

    DIN EN 14214. * not for ADR The table shows the values for the Air Top Evo 5500 in Fuel for Air Top Evo 3900/5500 B (petrol): brackets. The fuel specified by the manufacturer must be used. Fuel for Air Top Evo 3900/5500 D...
  • Page 20 4 Technical data Air Top Evo 3900/5500 Page for notes...

  • Page 21: General

    This section describes how to identify and deal with errors fault: on the Air Top Evo 3900 and Air Top Evo 5500 heaters. • Corroded plugs If a fault occurs, an error code will be output in the display •...

  • Page 22: Error Symptoms During Function

    5 Troubleshooting Air Top Evo 3900/5500 fault is not found under the specific Error symptoms during function error symptom heading, in an emergency you can contact our technicians on our service hotline (see The following table (Fig. 502) lists the possible error www.webasto.com).

  • Page 23: Error Code Output

    Air Top Evo 3900/5500 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 24: Troubleshooting

    5 Troubleshooting Air Top Evo 3900/5500 Error Error (group) Additional information during PC Troubleshooting code diagnostic F 07 Metering pump interrupt or 88 Break or short circuit to +Ub Check cables, replace metering pump metering pump short-circuit 08 Short circuit to earth...

  • Page 25: Function Tests 6.1 General

    Air Top Evo 3900/5500 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 text...
  • Page 26 6 Function tests Air Top Evo 3900/5500 Page for notes...

  • Page 27: Circuit Diagrams 7.1 General

    Fig. 701 shows the plug assignment on the control unit. General Fig. 708 shows the schematic connection of the The Air Top Evo 3900 and Air Top Evo 5500 heater units combination timer. can be operated with the heater control (setpoint generator/switch), a combination timer or the MC04/05 Fig.
  • Page 28 7 Circuit diagrams Air Top Evo 3900/5500 Fig. 702 System circuit diagram 12V/24V with control element and vehicle blower Fig. 703 System circuit diagram 24V ADR operation with control element...
  • Page 29 Air Top Evo 3900/5500 7 Circuit diagrams Fig. 704 System circuit diagram 12V/24V with combination timer and vehicle blower Fig. 705 System circuit diagram (diesel) 12V/24V with combination timer and electrical battery isolation switch...
  • Page 30 7 Circuit diagrams Air Top Evo 3900/5500 Fig. 706 System circuit diagram (diesel) 12V/24V with Control Panel MC04/05 and vehicle blower Fig. 707 System circuit diagram (diesel) 24V ADR-operation with Control Panel MC04/05...

  • Page 31: Circuit Diagrams

    Air Top Evo 3900/5500 7 Circuit diagrams Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig. 708 Schematic connection of the combination timer Control Panel MC04/05 Observe coloured markings Optional connection for:...

  • Page 32: Legend For Circuit Diagrams

    7 Circuit diagrams Air Top Evo 3900/5500 Legend for circuit diagrams Item Description Comment Heater Air Top Evo 3900/5500 Control module 1. With positive from terminal (15/75) to connection 10: Temperature sensor In control unit Permanent operation for immediate heat as long as...

  • Page 33: Servicing Work 8.1 General

    The heater must not be operated without the cover for the control unit as this will cause it to overheat. Alternatively the Air Top Evo 3900/5500 heaters can be operated with an external temperature sensor (see 9.1.2). Servicing work...

  • Page 34: Fuel Supply

    H (m) (bar) in fuel line line: 0.00 0,20 1.00 0.11 80 mm for the Air Top Evo 3900 2.00 0.03 90 mm for the Air Top Evo 5500 Maximum fuel intake At max. perm. negative height S (m) pressure (bar) in the fuel The hot air hose must be secured at its connection points.
  • Page 35 Air Top Evo 3900/5500 8 Servicing work 8.6.2.1 Fuel extraction. Vehicles with diesel engines The fuel must be taken from the vehicle fuel tank or from a separate tank (Fig. 802, 803 or 804). This separate fuel pickup precludes any effect of pressure.
  • Page 36 8 Servicing work Air Top Evo 3900/5500 Vehicles with carburettor engines Plastic tank The fuel may only be extracted on cars using the special Webasto fuel extractor (for example Part No. 470 910) as close to the tank as possible.The connect may be made in either the supply or return line, in which case the return line must lead almost to the base of the tank.

  • Page 37: Metering Pump

    Air Top Evo 3900/5500 8 Servicing work 8.6.2.2 Fuel lines Only steel, copper and plastic lines of plasticised, light and temperature-stabilised PA11 or PA12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines. Since the lines cannot always be routed with a constant rising gradient, the internal diameter must not be allowed to exceed a certain size.

  • Page 38: Combustion Air Supply

    Exhaust line: max. 270° (Air Top Evo 3900/5500 D only). An intake silencer must be used for an intake hose length of < 0.6 m. An attachment is required no further than 150 mm from the end of the exhaust pipe to ensure that the angle of 90°...

  • Page 39: Electrical Connections

    Air Top Evo 3900/5500 8 Servicing work 8.6.8 Electrical connections 8.6.8.3 Control element connection The wiring harness is prepared for connection to the control element. 8.6.8.1 Heater connection, control element Simply pull on connector housing to disconnect the The electrical connection is to be made as shown in the connector (fig.
  • Page 40 8 Servicing work Air Top Evo 3900/5500 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: Removal And Installation

    Air Top Evo 3900/5500 8 Servicing work Removal and installation Start-up After you have installed the heater, bleed the fuel supply IMPORTANT When the heater is installed it must not be dismantled. system carefully. NOTE As a result of the low fuel consumption the heater must be 8.7.1 Heater, removal and installation...
  • Page 42 8 Servicing work Air Top Evo 3900/5500 Page for notes...

  • Page 43: General

    9.1.2.1 Installation of an external temperature sensor General General The Air Top Evo 3900 or Air Top Evo 5500 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 44: Dismantling And Assembling

    9 Repair Air Top Evo 3900/5500 1. Ensure that the insulating mat (7) is properly Dismantling and assembling 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...
  • Page 45 Air Top Evo 3900/5500 9 Repair 1 Cover, electrical connection 2 Top shell 3 Cover, hot air outlet 4 Bottom shell 5 Cover, hot air inlet 6 Grate 7 Insulators (4) Insulator positioning Insulator Widening of corner rib Fig. 901 Remove / fit the casing parts...

  • Page 46: Change The Control Unit

    9 Repair Air Top Evo 3900/5500 9.2.3 Change the control unit 9.2.5 Change the combustion and hot air blower (drive unit) 9.2.3.1 Removal IMPORTANT 1. Remove the heater (see 8.7.1.1). Replace the drive unit (1, fig. 902) only with a drive unit 2.
  • Page 47 Air Top Evo 3900/5500 9 Repair 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 Overheating sensor Detail A Fig. 902 Change the control unit, overheating sensor and the combustion and hot air blower (drive unit)

  • Page 48: Change The Combustion Pipe And The Heat Exchanger

    9 Repair Air Top Evo 3900/5500 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).
  • Page 49 Air Top Evo 3900/5500 9 Repair 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 50 9 Repair Air Top Evo 3900/5500 Page for notes...

  • Page 51: Packaging, Storage And Shipping 10.1 General

    Air Top Evo 3900/5500 10 Packaging, storage and shipping Packaging, storage and shipping 10.1 General If the heater or its components are sent to Webasto AG 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 52 Webasto AG Kraillinger Strasse 5 82131 Stockdorf GERMANY http://dealers.webasto.com http://www.webasto.com Subject to modification © 2008 All Rights Reserved...

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Air top evo 5500Air top evo 5500

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