Webasto Air Top Evo 3900 B, Air Top Evo 3900 D, Air Top Evo 5500 D, Air Top Evo 5500 B Installation Instructions
Luftheizgeräte
Einbauanweisung
Air heaters
Luchtverwarmingsapparaten
Installation Instructions
Montagehandleiding
Air Top Evo 3900
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 5500 D (Diesel/PME) (diesel/PME)
Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer
verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder tödliche Verletzungen hervorgerufen werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines
Webastotrainings, technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
Es dürfen nur Originalteile von Webasto verwendet werden. Siehe dazu auch Zubehörkatalog Luft- und
Wasserheizgeräte von Webasto.
Versuchen Sie NIEMALS, Webasto Heiz- oder Kühlsysteme einzubauen oder zu reparieren, wenn Sie das
Webastotraining nicht erfolgreich abgeschlossen und dabei die notwendigen technischen
Fähigkeiten erworben haben und die für einen sachgerechten Einbau und Reparatur nötigen
technischen Dokumentationen, Werkzeuge und Ausrüstungen nicht zur Verfügung stehen.
Befolgen Sie IMMER alle Webasto Einbau- und Reparaturanleitungen, und beachten Sie alle
Warnhinweise.
Webasto übernimmt keine Haftung für Mängel und Schäden, die auf einen Einbau durch ungeschultes Personal zurückzuführen sind.
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.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto
training course, you do not have the necessary technical skills and you do not have the technical
documentation, tools and equipment available to ensure that you can complete the installation and
repair work properly.
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.
Air Top Evo 3900 / Air Top Evo 5500
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . 1
2 Verwendung / Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Typschild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Einbaubeispiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Heizluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Abgasleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Brennluftansaug- und Abgasleitungen. . . . . . . . . . . . . . . . 22
11 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Anschlussschema / Schaltplan . . . . . . . . . . . . . . . . . . . . . . . 28
13 Legende für Schaltpläne . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
14 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
15 Störabschaltung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
6 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
10 Combustion air inlet and exhaust lines . . . . . . . . . . . . . . . .72
11 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
12 Connection diagram/Circuit diagram. . . . . . . . . . . . . . . . . .78
13 Legend for circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . .87
14 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
15 Fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
16 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
17 Drilling templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
I
Air Top Evo 3900 / Air Top Evo 5500 Statutory regulations governing installation
1 Statutory regulations governing installation
The Air Top Evo 3900 and Air Top Evo 5500 heaters have been type-tested
and approved in accordance with Directives ECE R10 and EC 72/245/EEC
(EMC) and ECE R122 and 2001/56/EC (heater) with the following EC permit numbers:
EMC: e1*72/245*2006/96*5529*__ (Air Top Evo 3900 / 5500)
E1 03 5529 (Air Top Evo 3900 / 5500)
Heater: e1*2001/56*2006/119*0255*__ (Air Top Evo 3900)
E1 00 0255 (Air Top Evo 3900)
e1*2001/56*2006/119*0256*__ (Air Top Evo 5500)
E1 00 0256 (Air Top Evo 5500)
Primarily the regulations of Annex VII of the Directive 2001/56/EC and Part
I and Annex 7 of the directive ECE R122 must be observed for the installation.
NOTE:
The specifications of this Directive are binding in the scope of the
Basic Directive EEC/70/156 and/or EC/2007/46 (for new vehicle
models from 29/04/2009) and should also be observed in countries
in which no special regulations exist.
See chapter 1.2, "Extract from directives 2001/56/EC Annex VII and
ECE R122 Part I and Annex 7" and chapter 1.3, "Extract from directives 2001/56/EC Annex IX and ECE R122 Annex 9".
IMPORTANT
Failure to follow the installation instructions and the notes contained
therein will lead to all liability being refused by Webasto. The same applies
if repairs are carried out incorrectly or with the use of parts other than genuine spare parts. This will result in the invalidation of the type approval for
the heater and therefore of its homologation / EC type licence .
NOTE:
For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.
1.1. Application of combustion heaters in vehicles for transporting dangerous goods
Vehicles for the purpose of transporting dangerous goods will be type tested in accordance with the standard ECE R105. The following measures are
derived for our combustion heaters:
• The electrical cable/wiring harness must be sufficiently dimensioned to
prevent overheating. The electrical cable/wiring harness must be sufficiently insulated. All power circuits must be protected with fuses or automatic circuit-breakers.
• The cables must be securely fastened and routed so that they are suffi-
ciently protected against mechanical and thermal loading.
• The combustion heaters must be type-tested in accordance with the
standard ECE R122 (equivalent to EC/2001/56 in the version EC/2006/
119) and comply with the Appendix 9 – Additional regulations for vehicles for transporting dangerous goods.
• The combustion heaters and their exhaust gas routing shall be de-
signed, located, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load.
• In the event of any leakage of the fuel line, the fuel shall drain to the
ground without coming into contact with hot parts of the vehicle or the
load;
• The exhaust system as well as the exhaust pipes shall be so directed or
protected to avoid any danger to the load through heating or ignition.
Parts of the exhaust system situated directly below the fuel tank shall
have a clearance of at least 100 mm or be protected by a thermal shield.
51
Statutory regulations governing installation Air Top Evo 3900 / Air Top Evo 5500
• The combustion heater may only be switched on manually. Programming devices shall be prohibited. The combustion heater may be
switched on again manually after the vehicle engine has been switched
off.
Requirement for basic unit:
A maximum run-on period of 40 seconds is permitted when the combustion heater is switched off. Only combustion heaters with heat exchangers
that are approved for this reduced run-on time of 40 seconds may be used.
1.2. Extract from directives 2001/56/EC Annex VII and ECE R122
Part I and Annex 7
Start of extract.
ANNEX VII
REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR
INSTALLATION
1. GENERAL REQUIREMENTS
1.7.1. / 7.1. (Annex 7) A clearly visible tell-tale in the operator's
field of view shall inform when the combustion heater is switched
on or off.
2. / 5.3. (Part I) VEHICLE INSTALLATION REQUIREMENTS
2.1. / 5.3.1. (Part I) Scope
2.1.1. / 5.3.1.1. (Part I) Subject to paragraph 2.1.2. / 5.3.1.2. (Part
I) combustion heaters shall be installed according to the requirements of this Annex.
2.1.2. / 5.3.1.2. (Part I) Vehicles of category O having liquid fuel
heaters are deemed to comply with the requirements of this Annex.
2.2. / 5.3.2. (Part I) Positioning of heater
2.2.1. / 5.3.2.1. (Part I) Body sections and any other components
in the 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 case of overheating. This requirement
shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation, by the use of
fire resistant materials or by the use of heat shields.
2.2.3. / 5.3.2.3. (Part I) In the case of M2 and M3 vehicles, the
heater must not be positioned in the passenger compartment.
However, an installation in an effectively sealed envelope which
also complies with the conditions in paragraph 2.2.2. / 5.3.2.2.
(Part I) may be used.
2.2.4. / 5.3.2.4. (Part I) The label referred to in paragraph 1.4 / Annex 7 paragraph 1.4. or a duplicate, must be positioned so that it
can be easily read when the heater is installed in the vehicle.
2.2.5. / 5.3.2.5. (Part I) Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property.
2.3. / 5.3.3. (Part I) Fuel supply
2.3.1. / 5.3.3.1. (Part I) The fuel filler must not be situated in the
passenger compartment and must be provided with an effective
cap to prevent fuel spillage.
2.3.2. / 5.3.3.2. (Part I) In the case of liquid fuel heaters, where a
supply separate to that of the vehicle is provided, the type of fuel
and its filler point must be clearly labelled.
52
Air Top Evo 3900 / Air Top Evo 5500 Statutory regulations governing installation
2.3.3. / 5.3.3.3. (Part I) A notice, indicating that the heater must
be shut down before refuelling, must be affixed to the fuelling
point. In addition a suitable instruction must be included in the
manufacturer's operating manual.
2.4. / 5.3.4. (Part I) Exhaust system
2.4.1. / 5.3.4.1. (Part I) The exhaust outlet must be located so as
to prevent emissions from entering the vehicle through ventilators,
heated air inlets or opening windows.
2.5. / 5.3.5. (Part I) Combustion air inlet
2.5.1. / 5.3.5.1. (Part I) The air for the combustion chamber of the
heater must not be drawn from the passenger compartment of
the vehicle.
2.5.2. / 5.3.5.2. (Part I) The air inlet must be so positioned or
guarded that blocking by rubbish or luggage is unlikely.
2.6. / 5.3.6. (Part I) Heating air inlet
2.6.1. / 5.3.6.1. (Part I) The heating air supply may be fresh or recirculated 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 vehicle source.
2.6.2. / 5.3.6.2. (Part I) The inlet duct must be protected by mesh
or other suitable means.
2.7. / 5.3.7. (Part I) Heating air outlet
2.7.1. / 5.3.7.1. (Part I) Any ducting used to route the hot air
through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched.
2.7.2. / 5.3.7.2. (Part I) The air outlet must be so positioned or
guarded that blocking by rubbish or luggage is unlikely.
2.8. / 5.3.8. (Part I) Automatic control of the heating system
2.8. / 5.3.8.1. (Part I) The heating system must be switched off automatically and the supply of fuel must be stopped within five seconds when the vehicle's engine stops running. If a manual device
is already activated, the heating system can stay in operation.
End of extract.
53
Statutory regulations governing installation Air Top Evo 3900 / Air Top Evo 5500
1.3. Extract from directives 2001/56/EC Annex IX and ECE R122
Annex 9
Start of extract.
ANNEX IX / 9
3. Technical specifications for heater units for installation in
dangerous goods transporters (Annex 9)
3.1. General (EX/II, EX/III, AT, FL and OX vehicles)
3.1.1. The combustion heaters and their exhaust gas routing shall
be designed, located, protected or covered so as to prevent any
unacceptable risk of heating or ignition of the load. This requirement shall be considered as fulfilled if the fuel tank and the exhaust system of the appliance conform to the provisions set out in
the points 3.1.1.1 and 3.1.1.2. Compliance with those provisions
shall be verified on the completed vehicle.
3.1.1.1. Any fuel tanks for supplying the appliance shall meet the
following requirements:
a) in the event of any leakage, the fuel shall drain to the
ground without coming into contact with hot parts 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 enabling the opening to be kept hermetically sealed.
3.1.1.2. The exhaust system as well as the exhaust pipes shall be
so directed or protected to avoid any danger to the load through
heating or ignition. Parts of the exhaust system situated directly
below the fuel tank (diesel) shall have a clearance of at least
100 mm or be protected by a thermal shield.
3.1.2. The combustion heater shall be switched on manually. Programming devices shall be prohibited.
3.2. EX/II and EX/III vehicles
Combustion heaters using gaseous fuels are not permitted.
3.3. FL vehicles
3.3.1. The combustion heaters shall be put out of operation by at
least the following methods:
a) intentional manual switching off from the driver’s cab;
b) stopping of the vehicle engine; in this case the heating de-
vice may be restarted manually by the driver;
c) start-up of a feed pump on the motor vehicle for the dan-
gerous goods carried.
End of extract.
54
Air Top Evo 3900 / Air Top Evo 5500 Use / version
2 Use / version
2.1. Use of the air heaters
The Webasto Air Top Evo 3900 and Air Top Evo 5500 air heaters are designed
– to heat cabins, boats, trucks, minibuses, vans, ambulances and mo-
torhomes
– to defrost vehicle windows
– to heat cargo
The heaters operate independently of the engine and are connected directly 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 which dangerous goods are
transported.
2.2. Version
Air Top Evo 3900 B (petrol)
Air Top Evo 5500 B (petrol)
Air Heater for "Petrol" Fuel (12 V)
Air Top Evo 3900 D (diesel)
Air Top Evo 5500 D (diesel)
Air Heater for "Diesel" Fuel (12 or 24 V)
55
Installation Air Top Evo 3900 / Air Top Evo 5500
3Installation
IMPORTANT
The statutory regulations governing installation (see chapter 1, "Statutory
regulations governing installation") must be adhered to. The requirements
of the latest version of the ADR must also be observed for the installing the
heater into vehicles used to transport hazardous substances.
The heater must not be operated without the control unit cover (this will
cause the heater to overheat).
3.1. Air Top Evo 3900 / Air Top Evo 5500 installation situation
NOTE:
Check the installation situation of the relevant vehicle type.
3.2. Installation location
The heater may be fitted both in the interior or on the exterior of the vehicle.
When using the vehicle in normal road traffic, the heater may only
be installed with contact protection if it is located within reach of
the driver.
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 pipe must be sealed if the heater is installed in the interior. The seal
designed and supplied for this purpose must be used (see Figure 3).
3.3. To install the heater
The M6 nuts must be tightened with a torque of 6 Nm (-0 Nm,+1 Nm) for
installing the Air Top Evo 3900 or Air Top Evo 5500 heater.
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).
A seal (Figure 3) 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
IMPORTANT
After installation, check that the casing is not in contact with any parts of
the vehicle body. A failure to do this may result in the hot air fan blocking.
.
56
Air Top Evo 3900 / Air Top Evo 5500 Installation
1Hot air inlet
2 Hot air outlet
3 Combustion air intake
4 Exhaust fume outlet
5 Fuel intake
Fig. 1 Dimensions of the heater
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 right or left)
57
Installation Air Top Evo 3900 / Air Top Evo 5500
Diesel heaters
Petrol heaters
Fig. 2 Approved installation position
Ensure that all moving parts can move easily.
Fig. 4 Installation
Fig. 3 Seal
58
Air Top Evo 3900 / Air Top Evo 5500 Type label
4Type label
The model plate 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.
59
Installation example Air Top Evo 3900 / Air Top Evo 5500
5 Installation example
1 Control element
2Heater
3 Metering pump
4 Fuel filter (accessory)
5 Tank connector
6 Exhaust silencer (accessory)
7Fuse
1
7
2
4
3
6
5
Maximum
water passage height
Fig. 5 Installation example for air heater in recirculation mode
60
Air Top Evo 3900 / Air Top Evo 5500 Installation example
5.1. Design as system
The variants Air Top Evo 3900 AM and Air Top Evo 5500 AM enable up to
4 heaters to be operated in one system.
Here Unit 1 is defined as the master heater and others as slave heaters. The
heater control and an external temperature sensor (T) are connected to the
master heater (see wiring diagram in Figure 34, 36 and 38). The slave heater 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 be individually adapted to the applications by
combining several heaters.
Bus System
Unit 1 Unit 2 Unit 3 Unit 4
IMPORTANT
The use of an Air Top Evo 3900 AM or Air Top Evo 5500 AM system is not
approved for dangerous goods transports (ADR)!
Fig. 6 System design
61
Installation example Air Top Evo 3900 / Air Top Evo 5500
5.2. Heating Capacity of Entire System
Heating Capacity
Range
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
1.5 - 16.5 kW Air Top Evo 5500 3
1.5 - 22.0 kW Air Top Evo 5500 4
NOTE:
It is only permitted to install heating systems with Air Top Evo heaters of
the same output type.
Heater Number of
Units
62
Air Top Evo 3900 / Air Top Evo 5500 Hot air system
6 Hot air system
NOTE:
The heater must not be integrated into the vehicle’s air system.
Inside the control unit there is a temperature sensor, which operates the
heater in the appropriate heat output range in conjunction with the control
element depending on the intake temperatures and the position of the setpoint generator. The heat output is controlled such that after the selected
interior temperature has been reached quickly, it is then kept at this selected value.
Both recirculation and fresh air modes are possible.
For fresh air mode it must be ensured that the hot air is taken from an area
protected from splashing water and spray and in such a way that no water
can ingress into the heater if the vehicle travels through a water hazard for
which that vehicle is licensed.
NOTE:
For fresh air mode an external temperature sensor must be fitted in the appropriate zone.
Recommended internal diameter of the main section of the hot air line:
90 mm for the Air Top Evo 5500 80 mm for the Air Top Evo 3900
NOTE:
Only materials that can permanently withstand temperatures of at least
130 °C may be used for the hot air line. The hot air opening is to be positioned 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 people, the air outlet opening is to be directed
in such a way that it is at least 20 cm away from all body parts.
Maximum pressure drop between the inlet and outlet side of the hot air
line:
Air Top Evo 3900 2.0 hPa
Air Top Evo 5500 3.0 hPa
1 hPa corresponds to 1 mbar corresponds to 10 mm water column.
The heaters check the internal temperature rise automatically each time
they are switched on. If this is above the specified limits, the start is cancelled and error messages F10 is displayed. To ensure that the heater functions stably, the flow resistance of the connected hot air system must be
reduced.
The points table for air guide parts in the Webasto catalogue may be used
to design the hot air system.
The hot air hose must be secured at its connection points.
If the heater is used in recirculation mode without a hot air guide, do not
short circuit the hot air flow.
Fig. 7 Hot air inlet and hot air outlet
IMPORTANT
If you use the heater without a hot air inlet hose, the inlet grille supplied
with the heater must be used at all times.
63
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