Webasto Air Top Evo 40 User manual

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Operating instructions
Air heater
Air Top Evo 40 | Air Top Evo 55
GB

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1 About this document
1.1 Purpose of the document
This operating instruction is part of the product and provides the user with infor-
mation on the safe operation of the unit.
1.2 Using this document
 Before operating the unit, read this operating instruction, the operating instruc-
tions of the control element and the supplementary sheet "Important notes on
the operating and installation instructions".
 Keep this operating instruction ready to hand.
 Hand this operating instruction on to the following owner or user of the unit.
1.3 Use of symbols and highlighting
WARNING
Type and source of the risk
Result: non-observance can lead to severe or mortal injuries.
 Actions to protect yourself against risks.
CAUTION
Type and source of the risk
Result: non-observance leads to minor injuries.
 Actions to protect yourself against risks.
ATTENTION
Type and source of the property damage
Result: non-observance leads to property damage.
 Actions in order to avoid property damage.

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Highlight Explanation
3Requirements for the following necessary action
 Necessary action
1.4 Warranty and liability
Webasto shall not assume liability for defects or damage that are the result that
the installation and operating instructions as well as the instructions contained
therein being disregarded.
This liability exclusion particularly applies for:
■improper use
■repairs not carried out by a Webasto service workshop
■use of non-original spare parts
■conversion of the unit without permission from Webasto
2 Safety
2.1 Intended use
The heater is only approved for installation in vehicles. The heater is suitable for
heating:
■engines
■cabins
■aggregates
■cargo areas
The heater is not approved for the direct heating of the cargo area of ADR
vehicles (Accord européen relatif au transport international des marchandises Dan-
gereuses par Route, English: European Agreement concerning the International
Carriage of Dangerous Goods by Road).

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2.2 Regulations and safety instructions
 Regulations on the supplementary sheet "Important notes on the operating
and installation instructions" must be observed.
2.3 Safety instructions
Risk of explosion in environments with combustible vapours, flamma-
ble dust and hazardous goods (e.g., petrol stations, tank facilities, fuel
store, coal bunkers, timber yard or grain warehouses)
 Do not switch on or operate the heater.
Risk of intoxication and suffocation from exhaust fumes in closed rooms
without exhaust gas extraction
 Do not switch on or operate the heater.
Risk of fires from flammable substances in the hot air flow
 Keep the hot air flow free.
 Remove flammable substances from the hot air flow.
Risk of injury from the defective unit
 Do not operate a defective heater.
 Contact a Webasto service workshop.
2.4 Avoiding property damage
Overheating caused by insulated cold air inlet and hot air outlet
 Keep the cold air inlet and hot air outlet clear of dirt and objects.
Incorrect handling
 Protect the unit against mechanical loading (e.g., falling down, impacts, knocks
or vibrations).
 Do not place heavy objects on top of the unit.
 Do not step on the unit.
Switching off incorrectly, without after-run
The fan of the heater keeps running approx. 40 to 120 seconds after switching off

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via the control element. Switching off incorrectly, without after-run leads to the
unit over-heating.
 Always switch off the heater via the control element.
 If a battery circuit breaker is fitted: switch off the heater via the battery
circuit breaker only in case of danger.
3 Unit description
3.1 Type label
The type label is applied to the heater or clearly visibly as a duplicate on the vehic-
le. The year of installation is found on the type label.
3.2 Function description
The heater heats the vehicle cabin, cargo area, interior of the vehicle, or defrosts
the vehicle windscreen. The heater operates independent from the vehicle engine
and is connected to the electric system of the vehicle.
4 Operation
WARNING
Risk of explosion from vapours, dust and hazardous goods
Severe burns
 Switch off the heater at petrol stations and tank facilities as well
as in the vicinity of fuel stores, coal bunkers, timber yards or grain
warehouses.
WARNING
Breathing exhaust fumes in closed rooms
Intoxication and suffocation
 Never operate the heater in closed rooms such as garages or work-
shops that do not have an exhaust extraction unit, not even with
programmed heating start.

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4.1 Operating the heater
 See the enclosed operating instruction of the control element.
4.2 Use suitable fuels
The heater is connected to the fuel tank of the vehicle or to a separate fuel tank.
 Use suitable fuels (see "Technical Data").
4.3 Change to fuel resistant to cold temperatures
3Fuel resistant to cold temperatures is filled.
 Switch on the heater for approx. 15 minutes.
The fuel system is completely filled with fuel resistant to cold temperatures.
4.4 Using the heater in vehicles for transporting hazardous goods
WARNING
Risk of explosion from explosive and flammable hazardous
goods
Severe burn injuries
 The heater must not be operated during loading and unloading as
well as at the loading points.
Switching the heater on and off
 Switch the heater on and off via the control element.
Switching the heater on after automatic switch-off
If the vehicle engine is turned off or the pumping device of the vehicle is put into
operation, the heater switches off automatically. The combustion air supply is
interrupted after max. 40 seconds and the heater switches to fault lock-out.
 Make sure that the pumping device is out of operation.
 Wait until the heater switches to fault lock-out.
 Switch off the heater via the control element.
 Switch the heater back on via the control element.

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5 Cleaning
 With intake filter fitted on the cold air inlet: clean the intake filter.
 Do not clean the heater with a high-pressure cleaner.
6 Troubleshooting
If an error occurs, the unit outputs a fault code via the control element.
■On control elements with display, the fault codes F01 to F15 are output via the
display. The fault codes F16 to F19 are shown with “- -”.
■On control elements without display, the fault code is output by flashing pulses
of the operating indicator. The number of pulses corresponds with the number
of fault codes. Example for fault code F03: ".....– – – ....."
 In event of an error occurring, check the fuse and plug connectors.
 Determine the measure using the following fault code table.
 If the error cannot be rectified by the measure described, contact your Webasto
service workshop.
Code Possible cause Measure
Heater switches off automatically
F00
Control unit defective / heater
lock-out / internal room tempera-
ture sensor defective
 Contact a Webasto service workshop.
F01 No starting  Switch off the heater for at least 2 seconds.
 Switch on the heater.
F02 Flame goes out during operation  Switch off the heater for at least 2 seconds.
 Switch on the heater.
F03 On-board power supply too low /
undervoltage or overvoltage
 Charge the vehicle battery.
 Switch off the heater for at least 2 seconds.
 Switch on the heater.
F04 Premature flame detection
 Contact a Webasto service workshop.
F07 Fuel pump defective
F08 Combustion air fan defective
F09 Glow plug defective
F10 Heater overheats
 Check the cold and hot air lines for free
passage.
 Allow the heater to cool down.
 Switch off the heater for at least 2 seconds.
 Switch on the heater.

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Code Possible cause Measure
F14 Blow out temperature sensor
defective
 Contact a Webasto service workshop.
F16 Exhaust gas temperature exceeded
F17 Exhaust gas temperature sensor
defective
F18 Setpoint sensor defective
F19 Plausibility check for sensor not
correct
–
On vehicles for transporting hazar-
dous goods:
Vehicle engine switched off /
pumping device in operation
 Make sure that the pumping device is out of
operation.
 Wait until the heater switches to fault
lock-out.
 Switch off the heater via the control element.
 Switch the heater on via the control element.
Heater produces black smoke
–Combustion air and exhaust gas
guiding blocked
 Check combustion air and exhaust gas
routing for free passage.
Service signal
T he service signal is shown via the control element when the heater is switched on .
■On control elements with display: "- -"
■On control elements without display: operating indicator flashes:
on for 1 second, off for 1 second
 Have the heater checked by a professional. The heater can continue to be used
with limited operation.
7 Maintenance
 Put the heater into operation every 4 weeks in order to prevent mechanical
parts from seizing.
 At the beginning of the heating period, have the heater checked by a profes-
sional.
 The heat exchanger must be replaced by a Webasto original spare part every
10 years after being put into service for the first time. See the type label for the
first time it was put into service.

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8 Disposal
The unit must not be disposed of in domestic waste.
 Observe the regional regulations for disposal of electronic products.
9 Service and customer services
Do you have any technical queries or a problem with your unit?
Country-specific telephone numbers for our branches can be found on the
Webasto service point flyer or under www.webasto.com.
10 Technical data
The values in brackets apply for the extended heating capacity that is activated
temporarily during each start.
Heater Air Top Evo 40 Air Top Evo 55
Diesel Petrol Diesel Petrol
Type approval EMC E1 03 5529 E1 03 5529 E1 03 5529 E1 03 5529
Heater E1 00 0385 E1 00 0385 E1 00 0386 E1 00 0386
Heating capacity (kW) 1.5–3.5 (4.0) 1.7–3.5 (4.0) 1.5–5.0 (5.5) 1.7–5.0 (5.5)
Fuel consumption (l/h) 0.18–0.43
(0.49)
0.25–0.51
(0.58) 0.18–0.61 (0.67) 0.25–0.73 (0.80)
Rated voltage (V) 12 / 24 12 12 / 24 12
Nominal power
consumption (W) 15–40 (55) 15–40 (55) 15–95 (130) 5–95 (130)
Fuel
Diesel / biodiesel
DIN EN 590
DIN EN 14214
Petrol
DIN EN 228
Diesel / biodiesel
DIN EN 590
DIN EN 14214
Petrol
DIN EN 228
Operating
temperatures (°C) –40 to +40 –40 to +40 –40 to +40 –40 to +40

Webasto Thermo & Comfort SE
Postfach 1410
82199 Gilching
Germany
Visiting Address:
Friedrichshafener Str. 9
82205 Gilching
Germany www.webasto.com
Ident. no. 9030680A • 05/14 • Errors and omissions excepted • Printed in Germany • © Webasto Thermo & Comfort SE, 2014
In case of mulitlingual versions the German version is binding.
The telephone number of the respective country can be obtained from
the Webasto service point flyer or the homepage of your respective
Webasto country representative.