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Webasto Air Top Evo 3900 Installation Manual

Summary of Air Top Evo 3900

  • Page 1

    Air heater air top evo 3900 / 5500 b (gasoline) air top evo 3900 / 5500 d (diesel) 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 repa...

  • Page 3

    Air top evo 3900/5500 table of contents www.Webasto.Us 3 webasto thermo & comfort n.A., inc. Contents page 1. Safety and general information 5 1.1 warning symbols in this installation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Table of contents air top evo 3900/5500 www.Webasto.Us 4 webasto thermo & comfort n.A., inc. 14.Technical data 35 14.1 electrical components: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 14.2 fuel for ...

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    Www.Webasto.Us 5 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 safety and general information 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 ...

  • Page 6

    Webasto thermo & comfort n.A., inc. 6 www.Techwebasto.Com 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 ser...

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    Www.Webasto.Us 7 webasto thermo & comfort n.A., inc. 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 ...

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    Webasto thermo & comfort n.A., inc. 8 www.Techwebasto.Com 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 window...

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    Www.Webasto.Us 9 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 installation 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 over...

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    Webasto thermo & comfort n.A., inc. 10 www.Techwebasto.Com installation air top evo 3900/5500 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 ...

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    Www.Webasto.Us 11 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 installation 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 mou...

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    Webasto thermo & comfort n.A., inc. 12 www.Techwebasto.Com installation air top evo 3900/5500 4.7 installation example figure 7. Installation example with heater in stalled under-bunk. (recirculation mode) 1 2 3 4 5 6 7 1 control element (rheostat) 2 a t 3900/5500 evo heater 3 fuel metering pump 4 f...

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    Www.Webasto.Us 13 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 hot air system 5. Hot air system note: the heater must not be integrated into the vehicle’s air system. Both recirculation and fresh air modes are possible. For fresh air mode it must be ensured that the inlet (hot) air is t...

  • Page 14

    Webasto thermo & comfort n.A., inc. 14 www.Techwebasto.Com hot air system air top evo 3900/5500 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. Note: the installation must be checked for: – air short circuit between ...

  • Page 15

    Www.Webasto.Us 15 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 fuel supply 6. Fuel supply the fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in figure 11. A sign must be affixed to the fue...

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    Webasto thermo & comfort n.A., inc. 16 www.Techwebasto.Com fuel supply air top evo 3900/5500 6.2 vehicles with fuel injection engines when installing the heater in a vehicle with fuel injection system, it is important to establish whether the fuel pump is located inside or outside the tank. If the f...

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    Www.Webasto.Us 17 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 fuel supply 6.4.1 connecting two fuel lines with a coupler hose the correct procedure for connecting fuel lines with hosing is shown in figure 16. Ensure that there are no leaks. Figure 16. Fuel line / coupler hose connectio...

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    Webasto thermo & comfort n.A., inc. 18 www.Techwebasto.Com fuel supply air top evo 3900/5500 6.5.2 installation and attachment the metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in figure 18 in order to ensure effective automatic bleedi...

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    Www.Webasto.Us 19 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 combustion air supply 7. Combustion air supply under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be loc...

  • Page 20: 6.5

    Webasto thermo & comfort n.A., inc. 20 www.Techwebasto.Com exhaust pipe air top evo 3900/5500 8. Exhaust pipe rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm (3/64 in.) or flexible piping of alloyed steel only must be used as exhaust line. The exhaust pipe is secure...

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    Www.Webasto.Us 21 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 combustion air inlet and exhaust lines 9. Combustion air inlet and exhaust lines both lines are to be installed falling away from the heater. If this is not possible, a condensate drain hole with a diameter of 4 mm (5/32 in....

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    Webasto thermo & comfort n.A., inc. 22 www.Techwebasto.Com electrical connections air top evo 3900/5500 10. Electrical connections all the cables and wires that are not required must be insulated against accidental shorting or grounding. Note: the electrical connection is made as shown in the system...

  • Page 23

    Www.Webasto.Us 23 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 electrical connections 10.3 control element (rheostat) the wiring harness is prepared for connection to the control element. Simply pull on the connector housing to unplug the connector. The connector housing can be locked (...

  • Page 24

    Webasto thermo & comfort n.A., inc. 24 www.Techwebasto.Com electrical connections air top evo 3900/5500 10.4 control element (smartemp) the control panel should be installed in a suitable location on a flat surface if possible in a visible area. – connect control panel to existing connectors on heat...

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    Www.Webasto.Us 25 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 electrical connections figure 33. Air top 3900/5500 evo with smartemp control - connection diagram 10.5 control element (mc04/05) the control panel should be installed in a suitable location (on a flat surface if possible) i...

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    Webasto thermo & comfort n.A., inc. 26 www.Techwebasto.Com electrical connections air top evo 3900/5500 figure 35. Connection diagram for air top evo 3900/5500 with control element mc04/05 10.5.1 control element (1531 combi timer) figure 36. Air top evo 3900/5500 with combination timer 1531 - connec...

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    Www.Webasto.Us 27 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 circuit diagrams 11. Circuit diagrams 11.1 legend for circuit diagrams cable colors (where applicable) bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white item description comment a1 heat...

  • Page 28

    Webasto thermo & comfort n.A., inc. 28 www.Techwebasto.Com circuit diagrams air top evo 3900/5500 figure 37. Standard wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control element (rheostat).

  • Page 29

    Www.Webasto.Us 29 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 circuit diagrams figure 38. Standard wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control element (smartemp).

  • Page 30

    Webasto thermo & comfort n.A., inc. 30 www.Techwebasto.Com circuit diagrams air top evo 3900/5500 figure 39. Standard wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control element (mc04/05).

  • Page 31

    Www.Webasto.Us 31 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 circuit diagrams figure 40. Standard wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control element (1531 combi timer).

  • Page 32

    Webasto thermo & comfort n.A., inc. 32 www.Techwebasto.Com starting the heater for the first time air top evo 3900/5500 12. Starting the heater for the first time after you have installed the heater, bleed the fuel supply system carefully. Note: as a result of the low fuel consumption the heater mus...

  • Page 33

    Www.Webasto.Us 33 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 starting the heater for the first time 12.1.3 mc-04/05 figure 43. Control element (mc-04) the mc-05 control element has one additional function called “altitude” ( ). Altitude correction is used when operating the heater in ...

  • Page 34

    Webasto thermo & comfort n.A., inc. 34 www.Techwebasto.Com fault lock-out air top evo 3900/5500 13. Fault lock-out the control unit continuously monitors the heater operation. The control unit identifies errors on individual heater components and faults during operation. Should the control unit expe...

  • Page 35

    Www.Webasto.Us 35 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 technical data 14. Technical data except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10% at an ambient temperature of +20 °c (68 °f) and at the rated voltage and in rated co...

  • Page 36

    Webasto thermo & comfort n.A., inc. 36 www.Techwebasto.Com version air top evo 3900/5500 15. Version air top evo 3900/5500 b (gasoline) air heater for gasoline (12 v) air top evo 3900/5500 d (diesel) air heater for diesel/heating oil (12 or 24 v).

  • Page 37

    Www.Webasto.Us 37 webasto thermo & comfort n.A., inc. Air top evo 3900/5500 drilling template 16. Drilling template figure 45. Drilling template for heater installation (dimensions in millimeters) figure 46. Drilling template for mc04/05 control panel Ø 7.5 Ø 7.5 Ø 7.5 Ø 26 Ø 26 18 12 44 55 98 r2 63.

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    Notes air top evo 3900/5500 www.Webasto.Us 38 webasto thermo & comfort n.A., inc..

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    Air top evo 3900/5500 notes www.Webasto.Us 39 webasto thermo & comfort n.A., inc..

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    Webasto thermo & comfort n.A., inc. 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 555-4518 canada: (800) 667-8900 www.Webasto.Us www.Techwebasto.Com org. 05/2009 rev. 6/2013 p/n lit909385b.