Webasto Air Top Evo 3900, Air Top Evo 3900 B, Air Top Evo 5500 B, Air Top Evo 3900 D, Air Top Evo 5500 D Installation Manual
Air Heater
Air Top Evo 3900 / 5500 B (Gasoline)
Air Top Evo 3900
Installation Manual
WARNING!
– 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.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools 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,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
– Improper installation or installation by untrained personnel voids all warranties on
this product.
/ 5500 D (Diesel)
Air Top Evo 3900/5500 Table of Contents
Contents Page
1. Safety and General Information 5
1.1 Warning Symbols in this Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Regulation for Installation in the Vehicle 6
2.1 Legal Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Position of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Combustion Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Hot Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Hot Air Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Automatic Control of the Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Purpose of the Air Heater 8
4. Installation 9
4.1 Recommended Installation and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Air Top EVO 3900/5500 Installation Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.4 To Install the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Optional Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Factory Plate / Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Installation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Hot Air System 13
5.1 External Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Fuel Supply 15
6.1 Vehicles with a Carburetor Equipped Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Vehicles with Fuel Injection Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Vehicles with Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.5 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Combustion Air Supply 19
8. Exhaust Pipe 20
9. Combustion Air Inlet and Exhaust Lines 21
10.Electrical Connections 22
10.1 Heater Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10.2 Supply Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
10.3 Control Element (Rheostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.4 Control Element (SmarTemp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.5 Control Element (MC04/05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.Circuit Diagrams 27
11.1 Legend for Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.Starting the Heater for the First Time 32
12.1 Control Element Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
13.Fault Lock-out 34
13.1 Error Code Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Table of Contents Air Top Evo 3900/5500
14.Technical Data 35
14.1 Electrical Components: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
14.2 Fuel for Air Top EVO 3900/5500 B (Gasoline): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
14.3 Fuel for Air Top EVO 3900/5500 D (Diesel/Heating Oil): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
15.Version 36
16.Drilling Template 37
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Air Top Evo 3900/5500 Safety and General Information
DANGER
WARNING
CAUTION
OR
1. Safety and General Information
1.1 Warning Symbols in this Installation Manual
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series
of symbols and signal words which are intended to convey the level of importance of the safety messages. The
progression of
symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a
substitute for proper accident prevention measures.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury or property damage.
It may also be used to alert against unsafe practices.
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 provide this installation manual with the AT 3900/5500 air heater.
When installed according to the guidelines stated in this manual, you can expect your customer to enjoy many years of
trouble-free heater operation.
This manual represents our latest effort to produce the best technical documentation possible.
In our efforts towards continuous, ongoing product improvement, we encourage our customers to write to us with
their comments or criticisms concerning this manual and the AT 3900/5500 air heating system.
Please write to us at:
Webasto Product North America, Inc.
Technical Documentation Group
15083 North Road
Fenton, MI 48430
You are also invited to fill out our online questionnaire concerning our technical documentation and web site at:
www.techwebasto.com
If you have any immediate questions concerning this manual, the installation procedures within or the product itself,
please call us at:
(800) 555-4518or send a fax to:(810) 593-6001
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Regulation for Installation in the Vehicle Air Top Evo 3900/5500
2. Regulation for Installation in the Vehicle
Read this installation manual in its entirety before installing this equipment.
2.1 Legal Provisions
2.1.1 The installation and service of Webasto heaters requires special expertise and training. Installations
and servicing of Webasto products by untrained, unauthorized personnel and end-users voids all
warranties and releases Webasto Product North America, Inc. and Webasto authorized distributors, dealers
and their personnel from responsibility for damage to Webasto products, any resulting collateral property
damage and personal injury.
2.1.2 Any use, operation, installation, modification or application of the product not described in Webasto manuals,
or subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics is
misuse of the product. Failure to comply with all installation instructions is a misuse of Webasto products. The same
applies for repairs without using genuine Webasto service parts. This will void the heaters “official Marks of
Conformity.”
IMPORTANT!
All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary
heating devices must be observed!
2.2 Position of the Heater
2.2.1 Parts of the vehicle body and other components in the immediate vicinity of the heater must be protected
against excessive heat and the danger of contamination by fuel or oil.
2.2.2 The internal combustion heater 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 ventilation and if fire-resistant materials or heat shields are used.
2.2.3 The model/ Serial plate or a duplicate there of (duplicate model/ Serial plate) must be fitted in such a way that
it is still clearly legible when the heater has been installed in the vehicle.
2.2.4 When positioning the heater, all reasonable precautions must be taken to minimize the risk of personal injury
or damage to items in the vehicle.
2.2.5 A clearly visible indicator within the user's field of vision must show when the heater is switched on or off.
2.3 Fuel Supply
2.3.1 Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by vehicle
and engine movement.
2.3.2 Fuel lines must be securely fastened to the vehicle every 12 inches (30 cm) or less along the total length from
heater to fuel tank.
2.3.3 Fuel-carrying components must be protected against excessive heat and are to be installed so that any
drippings or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment.
2.3.4 In buses, fuel lines are not to be located in the passenger area or in the driver’s compartment. Fuel supply must
not be by means of gravity or pressurization of the fuel tank.
2.3.5 The fuel tank must be equipped with a vent cap or ventilated in another way (vent line).
2.3.6 When a separate fuel supply is used the fuel filler neck must not be located in the passenger compartment and
must have a tightly fitting cap to prevent any fuel leaks.
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Air Top Evo 3900/5500 Regulation for Installation in the Vehicle
2.3.7 The type of fuel and the fuel filler neck must be clearly identified for liquid fuel heaters which have a fuel
supply separate from the vehicle fuel supply.
2.3.8 A label must be affixed to the fuel filler neck warning that the heater must be switched off before refuelling.
An identical warning must also be included in the manufacturer's operating instructions.
2.4 Exhaust System
2.4.1 The exhaust outlet must be positioned in such a way that exhaust fumes cannot get into the interior of the
vehicle through ventilation devices, hot-air inlets or open windows. Also note that exhaust should always point away
from the direction of travel.
2.4.2 Do not route exhaust components within 100 mm (4 inches) of flammable materials such as fuel system
components, polyurethane or similar 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 combustion chamber of the heater must not be extracted from the passenger cabin of the
vehicle.
2.5.2 The air inlet must be positioned in such a way that it cannot be obstructed by other objects.
2.6 Hot Air Inlet
2.6.1 The supply of heating air must consist of either fresh air or recirculated air and must be taken from a clean area
which cannot be contaminated by exhaust fumes from the engine, the internal combustion heater or any other source
in the vehicle.
2.6.2 The inlet line must be protected by a grating or other suitable means.
2.7 Hot Air Outlet
2.7.1 Hot air lines within the vehicle must be positioned or protected in such a way as to exclude all risk of injury or
damage caused by direct contact.
2.7.2 The air outlet must be positioned or protected so that it cannot be obstructed by other objects.
2.8 Automatic Control of the Heating System
When the engine stops, the heating system must cut out automatically and the fuel supply must be stopped within 5
seconds.
The heating system may remain in operation if a manual unit has already been activated.
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Purpose of the Air Heater Air Top Evo 3900/5500
3. Purpose of the Air Heater
The Webasto Air Top EVO 3900/5500 air heaters are designed
– 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 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 designed for heating hazardous substances.
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Air Top Evo 3900/5500 Installation
9
1
25 24
ØØ
4
151
45
6
423 80
47.5
200
162
8
148
25
3
5
2
7
1. Hot air inlet
2. Hot air outlet
3. Combustion air inlet
4. Exhaust gas outlet
5. Fuel intake
6. Space required for hot air inlet
7. Space required for hot air outlet
8. Space required for removing the heater (service)
9. Cable outlet/Control unit cover (either right or
left)
4. Installation
IMPORTANT!
The regulations governing installation on pages 4 and 5 must be adhered to.
The heater must not be operated without the control unit cover (#9 below) (this will cause the heater to
overheat).
4.1 Recommended Installation and Service Tools
• Digital Multi-Meter - Should be a good quality VAO meter.
• 1/2 Heavy-Duty, low speed drill with good quality, sharp drill bits and a selection of hole saws.
• Mounting/ Drilling Templates.
4.2 Air Top EVO 3900/5500 Installation Situation
NOTE:
Check the installation situation of the relevant vehicle type.
4.3 Installation Location
The heater may be fitted both in the interior or on the exterior of the vehicle.
If it is installed 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 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 line must be sealed if the heater is
installed in the interior. The seal designed and supplied for this purpose must be used (see Figure 4). The same applies
when using the optional mounting plate and closed cell foam gasket (see Figure 5).
Figure 1. Dimensions of the Heater
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Installation Air Top Evo 3900/5500
Gasoline Heaters
Diesel Heaters
0 - 90°
0 - 90°
0 - 90°
0 - 90°
0 - 90°
0 - 3 0°
WARNING
Ø7.5
Ø7.5
Ø7.5
Ø26
Ø26
18
12
44
55
4.4 To Install the Heater
The M6 nuts used to install the heater must be tightened with a torque of 6 Nm ±1 Nm (4.4 lb.-ft ± 74 lb.-ft).
The installation dimensions and space requirement for service access are shown in the installation drawing (Figure 1).
The specified horizontal and axial angles must not be exceeded (Figure 2).
Figure 2. Recommended Installation 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 the heater foot must be flat. A special tools can be purchased from Webasto to
drill the holes and, if necessary, smooth the support area. The seal can compensate for unevenness of max. 1 mm
.
The seal or foam gasket or both must be replaced each time the heater is removed and reinstalled.
Figure 3. Hole Pattern
Figure 4. Seal
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Air Top Evo 3900/5500 Installation
1
2
3
1. Seal - Heater to vehicle floor or optional
mounting plate.
2. Mounting plate - Facilitates installation on
corrugated vehicle floors.
3. Closed Cell Foam Gasket - Seals area
between mounting plate and vehicle floor.
The seal or foam gasket or
both must be replaced
each time the heater is
removed and re-installed.
A mounting plate template is provided in the
installation kit for locating the heater on the floor
of the vehicle. All recommended hole locations
and sizes are included.
WARNING
CAUTION
Ensure that all moving part can move freely
4.5 Optional Mounting Plate
Figure 5. Mounting with optional mounting plate
When using the optional mounting plate and closed cell foam gasket, do not over tighten
the mounting bolts. Doing so will cause the mounting plate to warp and result in stress
damage to the heater and fan motor.
IMPORTANT!
After installation, check that the heater casing is not in contact with any parts of the vehicle body.
A failure to do this may result in the hot air fan binding internally (Figure 6).
Figure 6. Installation
4.6 Factory Plate / Label
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).
Inapplicable years must be erased from the model plate.
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Installation Air Top Evo 3900/5500
1
2
3
4
5
6
7
1 Control Element (Rheostat)
2 AT 3900/5500 EVO Heater
3 Fuel Metering Pump
4 Fuel Filter (Optional)
5 Fuel Satndpipe
6 Exhaust Muffler (Optional)
7 Fuse Block
4.7 Installation Example
Figure 7. Installation example with heater in stalled under-bunk. (Recirculation mode)
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