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Webasto Air Top Evo 3900 Workshop Manual

Summary of Air Top Evo 3900

  • Page 1

    Luft-heizgeräte air heaters 03/2003 workshop manual air top evo 3900 air top evo 5500 type air top evo 3900/5500 b (petrol) type air top evo 3900/5500 d (diesel/pme) visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 2

    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 t...

  • Page 3: Air Top Evo 3900/5500

    Air top evo 3900/5500 table of contents i table of contents 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 1.1 contents and purpose. . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 4: Table of Contents

    Table of contents air top evo 3900/5500 ii 6 function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 6.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 5: Air Top Evo 3900/5500

    Air top evo 3900/5500 table of contents iii 9 repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901 9.1 general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 6: List of Illustrations

    List of illustrations air top evo 3900/5500 iv list of illustrations fig. 201 air top evo 3900/5500 air heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 fig. 202 air top evo 3900/5500 air heater without casing . . . . . . . . . . ....

  • Page 7: Air Top Evo 3900/5500

    Air top evo 3900/5500 introduction 101 1 introduction 1.1 contents and purpose this workshop manual is designed to assist trained person- nel, with repairing both the petrol and the diesel versions of the air top evo 3900/5500 air heaters. 1.1.1 use of the air heaters the webasto air top evo 3900 an...

  • Page 8: Introduction

    Introduction air top evo 3900/5500 102 2. / 5.3. (part i) vehicle installation require- ments 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. (...

  • Page 9: Air Top Evo 3900/5500

    Air top evo 3900/5500 introduction 103 1.4.2 general safety information the mouth of the exhaust pipe should be installed upwards, to the side or, if the exhaust pipe passes under the floor of the vehicle, to the side or rear limit of the driver’s cab or the vehicle. The function of important parts ...

  • Page 10: Introduction

    Introduction air top evo 3900/5500 104 note if any damage or leaks are found on the fuel line, the heater must not be used until the damage has been rectified by an authorised webasto workshop. Put the heater out of action by removing the fuse. Overheating keep the hot air inlet and hot air outlet f...

  • Page 11: Air Top Evo 3900/5500

    Air top evo 3900/5500 general description 201 2 general description the air top evo 3900 and air top evo 5500 air heaters are based on the evaporator principle and essentially consist of the following – the drive unit with a combustion and hot air blower – the heat exchanger – the burner insert with...

  • Page 12: General Description

    General description air top evo 3900/5500 202 2.2 heat exchanger the heat generated by the combustion process is trans- ferred to the air transported by the combustion and hot air blowers in the heat exchanger. Fig. 204 heat exchanger 2.3 burner insert with combustion cham- ber the fuel is distribut...

  • Page 13: Air Top Evo 3900/5500

    Air top evo 3900/5500 general description 203 2.5 glow plug / flame monitor the glow plug also acts as a flame monitor. The mixture of fuel and air is ignited by the glow plug when the heater is started. The glow plug takes the form of an electrical resistor and is positioned in the burner on the si...

  • Page 14: General Description

    General description air top evo 3900/5500 204 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 15: Air Top Evo 3900/5500

    Air top evo 3900/5500 function description 301 3 function description 3.1 control element the control element is designed to switch the heater on and off, adjust the required room temperature (intake tempera- ture between approx. 5 °c and 35 °c) and to reset the heat- er after a fault. In addition, ...

  • Page 16: Function Description

    Function description air top evo 3900/5500 302 automatic restart 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 blower will be set to approx. 50% of its maximum speed. Af...

  • Page 17: Air Top Evo 3900/5500

    Air top evo 3900/5500 function description 303 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)! 3.8.2 initial installation/initial operation installation 1. Installation of the heaters according to installation instructio...

  • Page 18: Function Description

    Function description air top evo 3900/5500 304 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 ...

  • Page 19: Air Top Evo 3900/5500

    Air top evo 3900/5500 function description 305 3.10.2 reset a fault lock-out the various fault statuses can be reset as follows. Fault lock-out: switch off heater with heater control, wait at least 2 seconds and switch back on. Heater fault lock-out: when heater is switched on fault code f12 is disp...

  • Page 20: Function Description

    Function description air top evo 3900/5500 306 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 21: Air Top Evo 3900/5500

    Air top evo 3900/5500 technical data 401 4 technical data except where limit values are specified, the technical data listed in the table refer to the usual heater tolerances of ±10% at an ambient temperature of +20 °c and at the rat- ed voltage and in rated conditions. Electrical components: the co...

  • Page 22: Technical Data

    Technical data air top evo 3900/5500 402 setpoint values: volume flow of hot air against 0.5 mbar max. 132 (139) m 3 /h max. 200 (220) m 3 /h max. 132 (139) m 3 /h max. 200 (220) m 3 /h co 2 in exhaust gas (permitted function range) 1.7 kw: 5.0 - 8.0 % 3.5/5.0 kw: 9.0 - 12.5 % 1.5 kw: 6.5 - 8.0 % 3....

  • Page 23: Air Top Evo 3900/5500

    Air top evo 3900/5500 troubleshooting 501 5 troubleshooting 5.1 general this section describes how to identify and deal with errors on the air top evo 3900 and air top evo 5500 heaters. If a fault occurs, an error code will be output in the display of the combination timer. If the heater has a contr...

  • Page 24: Troubleshooting

    Troubleshooting air top evo 3900/5500 502 5.3 error symptoms during function the following table (fig. 502) lists the possible error symptoms in the order in which they may occur during operation. In the event of a fault, the error is to be located using this table and rectified. It is important tha...

  • Page 25: Air Top Evo 3900/5500

    Air top evo 3900/5500 troubleshooting 503 5.4 error code output if the heater is fitted with a combination timer, an error code output will appear on the display of the timer after a fault occurs. Note the error code is output if the heater is fitted with a control element after an error has occurre...

  • Page 26: Troubleshooting

    Troubleshooting air top evo 3900/5500 504 error code error (group) additional information during pc diagnostic troubleshooting f 07 metering pump interrupt or metering pump short-circuit 88 break or short circuit to +ub 08 short circuit to earth check cables, replace metering pump check cables, repl...

  • Page 27: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 601 6 function tests 6.1 general this section describes the tests conducted on the heater when it is installed and not installed to verify that it is in working order. Warning the heater must not be operated in enclosed areas such as garages and workshops without...

  • Page 28: Function Tests

    Function tests air top evo 3900/5500 602 6.3 settings 6.3.1 setting co 2 content the co 2 content in the emissions is set using the temperature selector on the control element. Activate any desired heating mode (eco, normal or plus) in the process with the mc04/05 heater control. Important the co 2 ...

  • Page 29: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 603 6.3.2 co 2 setting of reference heater the reference heater is set to 10.3 vol. % co 2 at a geodetic altitude of 0 metres at the factory. For later resetting, a co 2 value must be set in accordance with the following table as per the geodetic altitude. Also s...

  • Page 30: Function Tests

    Function tests air top evo 3900/5500 604 6.4.1 burner component see fig. 904, item 33 and item 7 2 2 1 1 burner burner mechanically damaged? No yes no blockages in the fuel pipe? No check function on heater test bench can co 2 value be adjusted with to the correct value? No yes procedure testing and...

  • Page 31: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 605 6.4.2 combustion and hot air fan component see fig. 903, item 1 6.4.3 glow plug component see fig. 904, item 8 note the resistance test must be carried out with an ohmmeter suitable for small resistance values. A resistance test with a simple digital multimet...

  • Page 32: Function Tests

    Function tests air top evo 3900/5500 606 a 2 2 2 1 2 1 a glow plug contacts detached? No yes procedure testing and measuring equipment visual visual inspection visual inspection visual inspection resistance measurement digital multimeter visual inspection no yes no yes no yes cables damaged? Ceramic...

  • Page 33: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 607 6.4.4 drive component see fig. 903, item 1 1 2 1 2 1 1 drive unit externally damaged? No yes procedure testing and measuring equipment visual visual inspection continuity measurement digital multimeter motor start-up voltage source subjective test important e...

  • Page 34: Function Tests

    Function tests air top evo 3900/5500 608 6.4.5 overheating sensor component see fig. 903, item 8 if you conduct this resistance test with a digital multimeter, the overheating sensor must have the values shown in the following diagram: fig. 601 characteristic resistance values of a pt 2000 overheati...

  • Page 35: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 609 6.4.6 control unit component see fig. 701 and fig. 903, item 3 2 1 2 control unit externally damaged? No yes procedure testing and measuring equipment visual visual inspection conduct function test with the reference unit, mount the control unit to be tested ...

  • Page 36: Function Tests

    Function tests air top evo 3900/5500 610 6.4.7 heater component 3 3 2 3 3 b complete heater testing of all electrical components description procedure testing and measuring equipment remove upper shell from heater and pull component connector off control unit pcb. Wire colours of individual componen...

  • Page 37: Air Top Evo 3900/5500

    Air top evo 3900/5500 function tests 611 2 3 c b check function on heater test bench description procedure testing and measuring equipment function test – heater test bench – co 2 measuring unit – pc (personal computer) – webasto diagnosis adapter – reference heater function test reading out control...

  • Page 38: Function Tests

    Function tests air top evo 3900/5500 612 2 2 3 2 c reinstalling control unit in heater to be tested description procedure testing and measuring equipment conduct function test with reference heater.Set reference unit to nominal co 2 value locally after 5 minutes of full-load operation in accordance ...

  • Page 39: Air Top Evo 3900/5500

    Air top evo 3900/5500 7 circuit diagrams 701 7 circuit diagrams 7.1 general the air top evo 3900 and air top evo 5500 heater units can be operated with the heater control (setpoint generator/ switch), a combination timer or the mc04/05 heater con- trol. The circuit diagrams (fig. 702 to fig. 708) sh...

  • Page 40: 7  Circuit Diagrams

    7 circuit diagrams air top evo 3900/5500 702 fig. 702 system circuit diagram 12v/24v with control element and vehicle blower fig. 703 system circuit diagram 24v adr operation with control element visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 41: Air Top Evo 3900/5500

    Air top evo 3900/5500 7 circuit diagrams 703 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 visit www.Butlertechnik.Com for more technical information & ...

  • Page 42: 7  Circuit Diagrams

    7 circuit diagrams air top evo 3900/5500 704 fig. 706 system circuit diagram (diesel) 12v/24v with control panel mc04/05 and vehicle blower fig. 707 system wiring diagram air top evo 3900 / 5500 am “master heater unit”, 12v/24v diesel with controls visit www.Butlertechnik.Com for more technical info...

  • Page 43: Air Top Evo 3900/5500

    Air top evo 3900/5500 7 circuit diagrams 705 fig. 708 system wiring diagram air top evo 3900 / 5500 am “slave heater unit”, 12v/24v diesel fig. 709 schematic connection of the combination timer combination timer 1531 black: terminal 15 red: terminal 30 brown: terminal 31 grey: terminal 58 adapter wi...

  • Page 44: 7  Circuit Diagrams

    7 circuit diagrams air top evo 3900/5500 706 fig. 710 schematic connection of the control panel mc04/05 fig. 711 connection diagram of air top evo 3900/5500 am (connection of combination timer 1531 and setpoint generator possible) observe coloured markings control panel mc04/05 optional connection f...

  • Page 45: Air Top Evo 3900/5500

    Air top evo 3900/5500 7 circuit diagrams 707 7.2 legend for circuit diagrams cable cross-sections 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet whi...

  • Page 46: 7  Circuit Diagrams

    7 circuit diagrams air top evo 3900/5500 708 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 47: Air Top Evo 3900/5500

    Air top evo 3900/5500 8 servicing work 801 8 servicing work 8.1 general this section describes the servicing work that can be carried out on the heater when it is installed. 8.2 work on the heater disconnect the main power cable from the vehicle’s battery before carrying out any work on the heater. ...

  • Page 48: 8  Servicing Work

    8 servicing work air top evo 3900/5500 802 the heater can be used with grills on the air inlet and outlet side if it is used in an air circulation system. Do not short cir- cuit the current of hot air. Minimum internal diameter of the main section of hot air line: 80 mm for the air top evo 3900 90 m...

  • Page 49: Air Top Evo 3900/5500

    Air top evo 3900/5500 8 servicing work 803 vehicles with carburettor engines the fuel may only be extracted on cars using the special we- basto 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 t...

  • Page 50: 8  Servicing Work

    8 servicing work air top evo 3900/5500 804 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 ris- ing ...

  • Page 51: Air Top Evo 3900/5500

    Air top evo 3900/5500 8 servicing work 805 8.6.4 fuel filter only a webasto filter, ident. No. 487 171, is allowed to be used if the fuel is expected to be contaminated. Install verti- cally if possible, however at least horizontally (check flow di- rection). Fig. 807 fuel filter 8.6.5 combustion ai...

  • Page 52: 8  Servicing Work

    8 servicing work air top evo 3900/5500 806 fig. 809 exhaust pipe ends, installation position warning if the exhaust pipe ends is other than as shown in the fig. 809 it will pose a fire risk. 8.6.8 electrical connections 8.6.8.1 heater connection, control element the electrical connection is to be ma...

  • Page 53: Air Top Evo 3900/5500

    Air top evo 3900/5500 8 servicing work 807 8.6.8.3 control element connection the wiring harness is prepared for connection to the control element. Simply pull on connector housing to unplug the connector (fig. 813). Fig. 812 control element note the fibre optic cable must be in contact with the rot...

  • Page 54: 8  Servicing Work

    8 servicing work air top evo 3900/5500 808 fig. 814 installation example for heater in recirculation mode 1 control element 2 heater 3 metering pump 4 fuel filter (accessory) 5 tank connector 6 exhaust silencer 7 fuse 5 4 3 7 2 6 1 visit www.Butlertechnik.Com for more technical information & downloa...

  • Page 55: Air Top Evo 3900/5500

    Air top evo 3900/5500 8 servicing work 809 8.7 removal and installation important when the heater is installed it must not be dismantled. 8.7.1 heater, removal and installation 8.7.1.1 removal 1. Disconnect the battery. 2. Pull the cover off the top shell as described in 9.2.1.1 3. Disconnect the wi...

  • Page 56: 8  Servicing Work

    8 servicing work air top evo 3900/5500 810 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 57: Air Top Evo 3900/5500

    Air top evo 3900/5500 9 repair 901 9 repair 9.1 general this section describes the repair work that may be carried out on the air top 3900/5500 heater after it has been re- moved from the vehicle. Any further dismantling will invalidate the warranty. Only use the spare parts from the appropriate spa...

  • Page 58: 9  Repair

    9 repair air top evo 3900/5500 902 9.2 dismantling and assembling 9.2.1 remove the casing parts 9.2.1.1 cover for electrical connection the cover (1, fig. 902) can be carefully levered off using a blunt blade in the areas marked “x”. 9.2.1.2 grill for hot air inlet and outlet the grill (6, fig. 902)...

  • Page 59: Air Top Evo 3900/5500

    Air top evo 3900/5500 9 repair 903 y y x x x 1 2 3 5 4 6 1 cover, electrical connection 2 top shell 3 cover, hot air outlet 4 bottom shell 5 cover, hot air inlet 6 grill 7 insulators (4) 7 6 insulator positioning insulator widening of corner rib 7 fig. 902 remove/fit the casing parts visit www.Butle...

  • Page 60: 9  Repair

    9 repair air top evo 3900/5500 904 9.2.3 change the control unit 9.2.3.1 removal 1. Remove heater (see 8.7.1.1). 2. Remove casing parts (see 9.2.1). 3. Disconnect plug connections on control unit (3, fig. 903). 4. Remove screws (4). 5. Slide the control unit (3) towards the hot air fan and re- move ...

  • Page 61: Air Top Evo 3900/5500

    Air top evo 3900/5500 9 repair 905 fig. 903 change control unit, overheating sensor and combustion and hot air fan (drive unit) 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 1 2 3 4 ...

  • Page 62: 9  Repair

    9 repair air top evo 3900/5500 906 9.2.6 change burner and glow plug/flame sensor 9.2.6.1 removal 1. Remove heater (see 8.7.1.1). 2. Remove casing parts (see 9.2.1). 3. Remove control unit (see 9.2.3.1). 4. Remove combustion and hot air fan (see 9.2.5.1). 5. Remove 2 screws (1, fig. 904) and take of...

  • Page 63: Air Top Evo 3900/5500

    Air top evo 3900/5500 9 repair 907 fig. 904 change burner, glow plug/flame sensor, combustion chamber and heat exchanger 1 torx screw (4) 2 clamping bar 3 diesel burner 4 combustion chamber 5 round sealing ring 6 heat exchanger 7 petrol burner 8 glow plug/flame monitor 9 retaining clip 1 2 3 6 5 4 7...

  • Page 64: 9  Repair

    9 repair air top evo 3900/5500 908 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 65: Air Top Evo 3900/5500

    Air top evo 3900/5500 10 packaging, storage and shipping 1001 10 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 s...

  • Page 66: Air Top Evo 3900/5500

    10 packaging, storage and shipping air top evo 3900/5500 1002 page for notes visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 67: Air Top Evo 3900/5500

    Air top evo 3900/5500 10 packaging, storage and shipping 1003 visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 68

    Visit www.Butlertechnik.Com for more technical information & downloads. Www.Butlertechnik.Com.

  • Page 69

    Ident . N o . 1 3 1 356 0b • 11/ 09 • err o rs an d omiss ions except ed • prin ted in ger m any • © w e b a st o ag, gcs 2 009 webasto ag postfach 80 d - 82132 stockdorf germany national: hotline: 01805 9 3 22 78 ( € 0,14 aus dem deutschen festnetz) hotfax: 0395 5592 353 hotmail: technikcenter@weba...