Air heater air top evo 40 / 55 installation/operation manual warning! – when heater is in use, the surface of the hot air outlet may become hot to the touch. Contact with skin may cause burns. – improper installation or repair of webasto heating and cooling systems can cause fire or the leakage of d...
Air top evo 40/55 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1...
Table of contents air top evo 40/55 www.Webasto.Us 4 webasto thermo & comfort n.A., inc. 12.Technical data 34 12.1 heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 12.2 elect...
Www.Webasto.Us 5 webasto thermo & comfort n.A., inc. Air top evo 40/55 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 seri...
Webasto thermo & comfort n.A., inc. 6 www.Techwebasto.Com regulation for installation in the vehicle air top evo 40/55 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...
Www.Webasto.Us 7 webasto thermo & comfort n.A., inc. Air top evo 40/55 regulation for installation in the vehicle 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 p...
Webasto thermo & comfort n.A., inc. 8 www.Techwebasto.Com purpose of the air heater air top evo 40/55 3. Purpose of the air heater the webasto air top evo 40/55 air heaters are designed – to heat vehicle cabins, boats (diesel only), trucks, minibuses, vans and motor homes – to defrost vehicle window...
Www.Webasto.Us 9 webasto thermo & comfort n.A., inc. Air top evo 40/55 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 overheat...
Webasto thermo & comfort n.A., inc. 10 www.Techwebasto.Com installation air top evo 40/55 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 ...
Www.Webasto.Us 11 webasto thermo & comfort n.A., inc. Air top evo 40/55 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 mountin...
Webasto thermo & comfort n.A., inc. 12 www.Techwebasto.Com installation air top evo 40/55 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 ...
Www.Webasto.Us 13 webasto thermo & comfort n.A., inc. Air top evo 40/55 cold and hot air system 5. Cold and hot air system when heater is in use, the surface of the hot air outlet may become hot to the touch. Contact with skin may cause burns. Note: the heater must not be integrated into the vehicle...
Webasto thermo & comfort n.A., inc. 14 www.Techwebasto.Com cold and hot air system air top evo 40/55 figure 8. Avoid air crossover between cold air inlet and hot air outlet) important! If no cold air ducts is used: install mesh guard over intake. Note: – make sure that the installation location sati...
Www.Webasto.Us 15 webasto thermo & comfort n.A., inc. Air top evo 40/55 cold and hot air system 5.1 external temperature sensor for fresh air mode, an external temperature sensor must be installed in the area to be heated. 5.1.1 to install the external temperature sensor the external temperature sen...
Webasto thermo & comfort n.A., inc. 16 www.Techwebasto.Com fuel supply air top evo 40/55 6. Fuel supply figure 11. 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 below. A sign must b...
Www.Webasto.Us 17 webasto thermo & comfort n.A., inc. Air top evo 40/55 fuel supply if the fuel pump is located inside the tank, fuel can only be extracted from the return line using the webasto fuel extractor (see figure 13), in which case it must be ensured that the return line continues almost to...
Webasto thermo & comfort n.A., inc. 18 www.Techwebasto.Com fuel supply air top evo 40/55 figure 12. Webasto fuel standpipe figure 13. Webasto fuel extractor * 25 minimum distance 25 mm (1 in.) only use this standpipe on fuel tanks constructed from metal hole pattern a= 6 Ø 8 Ø 10 Ø 12 Ø 0-60° Ø 5 0-...
Www.Webasto.Us 19 webasto thermo & comfort n.A., inc. Air top evo 40/55 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 connection 6....
Webasto thermo & comfort n.A., inc. 20 www.Techwebasto.Com fuel supply air top evo 40/55 figure 18. Fuel filter a Ø 5 0° - 90°.
Www.Webasto.Us 21 webasto thermo & comfort n.A., inc. Air top evo 40/55 combustion air system and exhaust system 7. Combustion air system and exhaust system under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the d...
Webasto thermo & comfort n.A., inc. 22 www.Techwebasto.Com combustion air system and exhaust system air top evo 40/55 length of the combustion air inlet and exhaust lines in total: with muffler: max. 2.0 m without muffler: max. 5.0 m note: if the exhaust line is over 2 m in length the lines must be ...
Www.Webasto.Us 23 webasto thermo & comfort n.A., inc. Air top evo 40/55 electrical connections 8. 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 circuit d...
Webasto thermo & comfort n.A., inc. 24 www.Techwebasto.Com electrical connections air top evo 40/55 important! The air top evo 40/55 requires 6.25 amps @ 12 volts or 12.5 amps @ 24 volts during start-up. The main power connection has to be made at a circuit designed to sustain this load without volt...
Www.Webasto.Us 25 webasto thermo & comfort n.A., inc. Air top evo 40/55 electrical connections note: as an option an external temperature sensor may be installed in the passenger cabin (see page15). See installation instructions included with the sensor or see the service instructions in the worksho...
Webasto thermo & comfort n.A., inc. 26 www.Techwebasto.Com electrical connections air top evo 40/55 notes: – always make sure there are no obstacles behind the mounting location prior to drilling. – ensure good readability when selecting installation location. – observe information on adhesive label...
Www.Webasto.Us 27 webasto thermo & comfort n.A., inc. Air top evo 40/55 electrical connections notes: – control panel is only intended for installation in passenger compartment – ensure good readability when selecting installation location – observe information on adhesive labels and colored marking...
Webasto thermo & comfort n.A., inc. 28 www.Techwebasto.Com pre-start checklist air top evo 40/55 9. Pre-start checklist this checklist is provided as a technical aid to technicians for final heater installation guidance. Heater mounting complete (yes/no/comments) 1 is the heater installation safely ...
Www.Webasto.Us 29 webasto thermo & comfort n.A., inc. Air top evo 40/55 pre-start checklist if you have any questions, contact our technical support team at (800) 860-7866 or via email at: info-us@webasto.Com . Exhaust systems complete (yes/no/comments) 1 is the muffler and clamps securely tightened...
Webasto thermo & comfort n.A., inc. 30 www.Techwebasto.Com operation instructions air top evo 40/55 10. Operation instructions 10.1 starting heater for the first time - make sure the control unit cover is fitted in position. - install contact guard if necessary. - bleed the fuel supply system carefu...
Www.Webasto.Us 31 webasto thermo & comfort n.A., inc. Air top evo 40/55 operation instructions 10.2.3 mc-04 figure 37. Control element (mc-04) 10.3 product registration - register the product on the internet under: http://techwebasto.Com - hand over the registration document to the next owner or use...
Webasto thermo & comfort n.A., inc. 32 www.Techwebasto.Com troubleshooting air top evo 40/55 11. Troubleshooting 11.1 error code output - if an error occurs, the unit outputs a fault code via the control element. - you will find further information in the operating instructions and in the heater wor...
Www.Webasto.Us 33 webasto thermo & comfort n.A., inc. Air top evo 40/55 troubleshooting to reset the fault, switch the heater on and off briefly (at least 2 seconds). If serious faults, such as overheating or no start, occur frequently, the heater will be set to fault lock-out (f 12) and can be rest...
Webasto thermo & comfort n.A., inc. 34 www.Techwebasto.Com technical data air top evo 40/55 12. Technical data 12.1 heater figure 38. Technical data table heater air top evo 40 b air top evo 40 d air top evo 55 b air top evo 55 d type approval: emc e1 03 5529 type approval: heating e1 00 0385 e1 00 ...
Www.Webasto.Us 35 webasto thermo & comfort n.A., inc. Air top evo 40/55 technical data the technical data apply under the following conditions: - ambient temperature: +20 °c - geodetic height: 0 m above sea level - rated voltage the standard tolerances of ±10 % for heaters shall apply if no limits a...
Webasto thermo & comfort n.A., inc. 36 www.Techwebasto.Com version air top evo 40/55 13. Version air top evo 40/55 b (gasoline) air heater for gasoline (12 v) air top evo 40/55 d (diesel) air heater for diesel/heating oil (12 or 24 v).
Www.Webasto.Us 37 webasto thermo & comfort n.A., inc. Air top evo 40/55 annex 14. Annex 14.1 drilling template: heater figure 39. Drilling template for heater installation (dimensions in millimeters) Ø 7.5 Ø 29 Ø 28 Ø 7.5 12 Ø 7.5 18 55 44 0 1 02 03 04 05 0
Webasto thermo & comfort n.A., inc. 38 www.Techwebasto.Com annex air top evo 40/55 figure 40. Drilling template for mc04 control panel 98 r2 63.
Www.Webasto.Us 39 webasto thermo & comfort n.A., inc. Air top evo 40/55 annex 14.2 legends to the wiring diagrams legend to wiring diagram item description remarks a1 heater air top evo 40 / 55 a2 control unit control unit 1580 a3 unibox – b2 room temperature sensor inside b3 overheat temperature se...
Webasto thermo & comfort n.A., inc. 40 www.Techwebasto.Com annex air top evo 40/55 legend to remarks in wiring diagrams connector x7 pin assignments item remarks 1 positive from terminal 15/75 to connection 10: continuous heating mode is possible in connection with quick heating function provided th...
Www.Webasto.Us 41 webasto thermo & comfort n.A., inc. Air top evo 40/55 annex 14.3 wiring diagrams figure 41. Air top evo 40/55, 12v / 24v with rheostat.
Webasto thermo & comfort n.A., inc. 42 www.Techwebasto.Com annex air top evo 40/55 figure 42. Air top evo 40/55, 12v/24v with multicontrol (mc04) control element.
Www.Webasto.Us 43 webasto thermo & comfort n.A., inc. Air top evo 40/55 annex figure 43. Air top evo 40/55, 12v/24v with smartemp.
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. 4/2015 rev. N/a p/n: 5011187a.
