Webasto Air Top Evo 3900 Series Manual

Luftheizgeräte
Air heaters
Luchtverwarmingsapparaten
03/2009
1314543A
Einbau- und Bedienungsanweisung
Installation and Operating Instructions
Montage- en gebruikshandleiding
Air Top Evo 3900 AM
Air Top Evo 5500 AM
Handelsbezeichnungen / Trade names / Handelsnamen:
Air Top Evo 3900 D AM (Diesel/PME) (diesel/PME)
Air Top Evo 5500 D AM (Diesel/PME) (diesel/PME)
Ergänzung zur Standard Einbau- und Bedienungsanweisung
Addition to standard Installation and Operating Instructions
Toevoeging aan standard montage- en gebruikshandleiding
Air Top Evo 3900 / Air Top Evo 5500

Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer
verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder töd-
liche Verletzungen hervorgerufen werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines
Webastotrainings, technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
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 Per-
sonal 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.
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 3900/5500 AM
I
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau.......................... 7
2 Mitgeltende Unterlagen......................................................... 7
3 Verwendung Luftheizgeräte System .................................... 8
3.1 Aufbau des Systems ......................................................... 8
3.2 Heizleistung Gesamtsystem ............................................. 9
4 Anschlussschema / Schaltpläne ........................................... 10
5 Legende für Schaltpläne ...................................................... 15
6 Erstinstallation / Erstinbetriebnahme ................................. 17
7 Rücksetzen Master - Slave System ...................................... 18
8 Störabschaltung.................................................................... 18
Table of contents
1 Statutory regulations governing installation......................19
2 Other Applicable Documents................................................19
3 Using Air Heater Unit System...............................................20
3.1 System Design ................................................................20
3.2 Heating Capacity of Entire System ..................................21
4 Connection Diagram / Wiring Diagrams..............................22
5 Legend for circuit diagrams ..................................................27
6 Initial Installation/Initial Operation .....................................29
7 Resetting Master/Slave System............................................30
8 Fault lock-out .........................................................................30

Air Top Evo 3900/5500 AM Statutory regulations governing installation
19
1 Statutory regulations governing installation
The Air Top Evo 3900 AM and Air Top Evo 5500 AM 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:
e1*72/245*2006/28*035529
ECE R10*035529
e1*72/245*2006/119*000255
e1*72/245*2006/119*000256
ECE R122*000255
ECE R122*000256
2 Other Applicable Documents
– Installation Instructions for Air Top Evo 3900 / Air Top Evo 5500
– Operating Instructions for Air Top Evo 3900 / Air Top Evo 5500
– Workshop Manual for Air Top Evo

Using Air Heater Unit System Air Top Evo 3900/5500 AM
20
3 Using Air Heater Unit System
The Air Top Evo 3900 AM and Air Top Evo 5500 AM air heaters are
designed
– to heat large cabins, lorry bodies, boats, minibuses and tents
– to heat cargo
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)!
3.1 System Design
The variants Air Top Evo 3900 AM and Air Top Evo 5500 AM enable up to
4 heater units to be operated in one system.
Here Unit 1 is defined as the master heater unit and others as slave heater
units. The heater control and an external temperature sensor (T) are
connected to the master heater unit (see wiring diagram in Figure 3, 4, 5).
The slave heater unit is connected in accordance with the wiring diagram
(see Figure 6). The units communicate with each other via a serial bus
system.
This system can therefore be individually adapted to the applications by
combining several heater units.
Fig. 1: System design
Bus System
Unit 1 Unit 2 Unit 3 Unit 4

Air Top Evo 3900/5500 AM Using Air Heater Unit System
21
3.2 Heating Capacity of Entire System
NOTE:
It is only permitted to install heating systems with Air Top Evo heater units
of the same output type.
Heating Capacity Range Heater Number of Units
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

Connection Diagram / Wiring Diagrams Air Top Evo 3900/5500 AM
22
4 Connection Diagram / Wiring Diagrams
Fig. 2: Connection diagram of Air Top Evo 3900/5500 AM (connection of combination timer 1531 and setpoint generator possible)
MC04 heater control
Connection for
Webasto Thermo Test
diagnosis
Observe coloured markings
Heater units
wiring
harness
... Connection to additional heater
units
Control line
W-Bus +
Connection for
Webasto Thermo Test
diagnosis
Heater unit 1
Heater unit 2

Air Top Evo 3900/5500 AM Connection Diagram / Wiring Diagrams
23
Fig. 3: System wiring diagram for Air Top Evo 3900/5500 AM “Master Heater Unit”, 12 V/24 V diesel with heater control,
for legend, see Page 27 and 28

Connection Diagram / Wiring Diagrams Air Top Evo 3900/5500 AM
24
Fig. 4: System wiring diagram for Air Top Evo 3900/5500 AM “Master Heater Unit”, 12 V/24 V diesel with combination timer,
for legend, see Page 27 and 28

Air Top Evo 3900/5500 AM Connection Diagram / Wiring Diagrams
25
Fig. 5: System wiring diagram for Air Top Evo 3900/5500 AM “Master Heater Unit”, 12 V/24 V diesel with MC04 Multi Control,
for legend, see Page 27 and 28

Connection Diagram / Wiring Diagrams Air Top Evo 3900/5500 AM
26
Fig. 6: System wiring diagram for Air Top Evo 3900/5500 AM “Slave Heater Unit”, 12 V/24 V diesel, for legend, see Page 27 and 28

Air Top Evo 3900/5500 AM Legend for circuit diagrams
27
5 Legend for circuit diagrams
1) With positive from terminal (15/75) to connection 10:
Continuous operation with immediate heating as long as the ignition
is switched on.
Without Positive on connection 10:
Heating time is variably programmable (10 min to 120 min),
default setting 120 min
2) Connection for Telestart*/Thermocall*/W-bus diagnosis
(only when using Control Panel MC04)
3) CO2adjustment (see workshop manual)
4) NOTE:
If the connection is made to terminal 30, permanent heating is possible
when the ignition is switched off!
In this case no connection must be made to terminal 15/75.
5) NOTE:
ADR operation is not permissible for a system consisting of several
heater units!
6) External temperature sensor
7) Fuse installed in vehicle
9) Connection of additional heater units via serial bus interface
Cable cross-sections
< 7.5 m 7.5 - 15 m
0.75 mm21.0 mm2
1.0 mm21.5 mm2
1.5 mm22.5 mm2
2.5 mm24.0 mm2
4.0 mm26.0 mm2
Cable colours
bl
br
ge
gn
gr
or
rt
sw
vi
ws
blue
brown
yellow
green
grey
orange
red
black
violet
white

Legend for circuit diagrams Air Top Evo 3900/5500 AM
28
Item Description Comment
A1 Heater Air Top Evo 3900/5500
A2 Control module
B2 Temperature sensor In control unit
B3 Overheating sensor Overheating guard
B4 Temperature sensor External
E Glow plug / Flame monitor
F1 Fuse 24 V 15A/12V 20A Flat fuse SAE J 1284
F3 Fuse max. 5A Flat fuse SAE J 1284
F4 Fuse 1A Flat fuse SAE J 1284
H1 Green LED Indicator
H3 LED red (in item P) Light in immediate heat button,
ready indicator,
switch-on indicator
H4 Heating symbol in the display
(in item P)
Indicator
H5 Lights Display or button illumination
M1 Motor Combustion and hot air fan
P Combination timer (1531) Timer and setpoint generator
R1 Resistor 620 ΩWith internal temperature sensor
only
S Control Panel MC04/05 Setpoint generator and selector
switch for additional functions
S1 Control element Setpoint generator switch
S5 Switch CO2setting
S7 Momentary-contact switch Immediate heat button remote
control
X1 Plug connector, 2-pin To item A2 (ST B)
X2 Plug connector, 2-pin To item A2 (ST V)
X3 Plug connector, 2-pin To item A2 (ST U)
X4 Plug connector, 2-pin To item A2 (ST Z)
X5 Plug connector, 2-pin To item A2 (ST Y)
X6 Plug connector, 2-pin To item A2 (ST X)
X7 Plug connector, 12-pin To item A2 (ST 1)
X8 Plug connector, 1-pin
X9 Plug connector, 4-pin to item S1
X10 Plug connector, 2-pin
X11 Plug connector, 2-pin to item Y1
X12 Plug connector, 12-pin to item P
Y1 Metering pump
Item Description Comment

Air Top Evo 3900/5500 AM Initial Installation/Initial Operation
29
6 Initial Installation/Initial Operation
Procedure for initial installation/initial operation of a master/slave system:
Installation
1. Installation of the heater units according to installation instructions for
Air Top Evo 3900/5500
2. Establishment of electrical contacts according to system wiring
diagram (Figure 2 to Figure 6)
3. Installation of heater control and external temperature sensor
Initial start-up
1. Start master heater unit with controls
=> Master heater unit "starts up"
2. Produce connection between Master and Slave 1
(see system wiring diagram)
=> Slave 1 heater unit switches into "Ventilation" state
3. Produce connection from Slave 1 to Slave 2
(see system wiring diagram)
=> Slave 2 heater unit switches into "Ventilation" state
4. Teach additional slave heater units (repeat Point 2 and 3)
5. Switch off master heater unit with controls
=> Initial start-up completed
NOTE:
Teaching a slave heater unit is only possible for a limited time (120 sec)!
If this time is exceeded, teaching is no longer possible and the system must
be reset (see Chapter 7, "Resetting Master/Slave System").

Resetting Master/Slave System Air Top Evo 3900/5500 AM
30
7 Resetting Master/Slave System
Resetting a master/slave system:
If for some reason (communication error, time expired, etc.) teaching has
not functioned, it is possible to reset the system.
Resetting Master/Slave System to Original State
1. Switch master heater unit into "Ventilation"
2. De-energise/pull fuse
NOTE:
All connected heater units must be disconnected from Terminal 30!
3. Connect voltage and repeat teaching process (see Chapter 6, "Initial
Installation/Initial Operation").
8 Fault lock-out
The displayed error codes (F00 - F15) for a master/slave system match an
error on the master heater unit. If an error occurs on the slave heater unit,
only the service code is output (operation indicator flashes with 1 sec. on
and 1 sec. off).
NOTE:
For the meaning and information on troubleshooting malfunctions, see
Installation and Operating Instructions for Air Top Evo 3900/Air Top Evo 5500.

Webasto AG
Kraillinger Strasse 5
82131 Stockdorf
GERMANY
http://dealers.webasto.com
http://www.webasto.com
Änderungen vorbehalten
Subject to modification
Wijzigingen voorbehouden
© 2009 All Rights Reserved
IDENT.-NR. 1314543A
Im Fall einer mehrsprachigen Version ist Deutsch verbindlich.
In multilingual versions the German language is binding.
Bij een meertalige versie is de Duitse versie bindend.