Webastoto Air Top 5000 Wartungshandbuch PDF herunterladen

Table of Contents

1. Introduction

1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Meaning of Warning, Caution and Notation Headings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Additional Documentation to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4.1 General Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. General Description

2.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Functional Description

3.1 Operating the Air Top 5000 with Self Diagnostic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Heater Control Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 2 Switch-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.3 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.4 Switch-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.5 Switch-Off upon Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 7-Day Digital Timer Model 1531 with 3 Time-Settings and Temperature Selector . . . . . . . . . . . . . . . 3-3

4. Technical Data

4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5. Installation

5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Mounting the Air Top 5000 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6.2 Fuel System Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6.3 Fuel Standpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.6.4 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.6.5 Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.6.6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

AIR TOP 5000 TABLE OF CONTENTS

Page

1 2 3 4 5 6 ... 31 32

Inhaltsverzeichnis

Seite 1 - Table of Contents

Table of Contents1. Introduction1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seite 2 - Contents

3FUNCTIONAL DESCRIPTION AIR TOP 50003-4GeneralThe 7-day digital “Combination” timer enables you to preset the start of the heater operation up to 7 da

Seite 3 - AIR TOP 5000 1INTRODUCTION

AIR TOP 5000 4TECHNICAL DATA4-14. Technical Data4.1 General InformationUnless tolerances are shown within the technical data table, a tolerance of ± 1

Seite 4 - 1INTRODUCTION AIR TOP 5000

4TECHNICAL DATA AIR TOP 50004-2423151>80>45Ø24Ø25148>20014847.5251234568794.2 DimensionsThe mounting dimensions as well as the space required

Seite 5 - 2. General Description

AIR TOP 5000 4TECHNICAL DATA4-356 mm (2-13/64 in.)38 mm (1-1/2 in.)30 mm (1-3/16 in.)Fig. 4-3: Control Element (Rheostat) - Air Top 2000 / 3500 / 5000

Seite 6

4TECHNICAL DATA AIR TOP 50004-4

Seite 7 - 3. Functional Description

AIR TOP 5000 5INSTALLATION5-1WARNINGDue to the confined spaces within marine vehicles, an increased risk of carbon monoxide poisoning causing death or

Seite 8

5INSTALLATION AIR TOP 50005-25.3 Mounting the Air Top 5000 HeaterA mounting template has been included with the heater kit. The template details all

Seite 9

AIR TOP 5000 5INSTALLATION5-3Basic Kit InstallationAfter selecting the heater location, temporarily tape the provided template in place and center pun

Seite 10

WARNINGDue to the risk of carbon monoxide poisoning causing death or serious injury to personnel, the exhaust tube must be sorouted that the possibili

Seite 11 - AIR TOP 5000 4TECHNICAL DATA

AIR TOP 5000 5INSTALLATION5-55.5 Combustion Air SupplyWARNINGDue to the risk of carbon monoxide poisoning causing death or serious injury to personnel

Seite 12 - 4TECHNICAL DATA AIR TOP 5000

Contents5.7 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seite 13

5INSTALLATION AIR TOP 50005-6Fuel is drawn from the vehicle’s fuel tank through the use of a standpipe provided in the heater installation kit.The fue

Seite 14

AIR TOP 5000 5INSTALLATION5-75.6.4 Fuel Metering PumpThe fuel metering pump forms a combined delivery/metering and shutoff system and is subject to ce

Seite 15 - AIR TOP 5000 5INSTALLATION

5INSTALLATION AIR TOP 50005-85.6.6 Fuel FilterA fuel filter may be supplied with your heater depending on kit model and application.If the heater kit

Seite 16 - 5INSTALLATION AIR TOP 5000

AIR TOP 5000 5INSTALLATION5-95.7 Wiring Connections5.7.1 General InformationThe Air Top 5000 heater may be operated using the standard rheostat switch

Seite 17

5INSTALLATION AIR TOP 50005-105.7.3 Wiring Diagram - Air Top 5000, 12 and 24 VoltFig. 5-13: Wiring Diagram - Air Top 5000

Seite 18

AIR TOP 5000 5INSTALLATION5-11ITEM DESCRIPTIONA1 Heater - Air Top 5000A2 Control UnitB2 Temperature SensorB3 Temperature LimiterE Ceramic Igniter / Fl

Seite 19

5INSTALLATION AIR TOP 50005-1238 mm (1.5 in.)30 mm (1.2 in.)56 mm (2.2 in.)Fig. 5-17: Control Element DimensionsThe heater control harness must be plu

Seite 20

AIR TOP 5000 5INSTALLATION5-135.9.1 General InformationNOTE: Additional ducting components are available through Webasto distributors and dealers.Wher

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5INSTALLATION AIR TOP 50005-145.10 Initial Start UpBefore starting heater, check your installation for:- routing and securing of wiring, fuel line, ex

Seite 22

6.1 Heater MaintenanceThe Webasto Air Top 5000 heater is designed for minimal maintenance. Under normal circumstances it should beinspected for prope

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AIR TOP 5000 1INTRODUCTION1-11. Introduction1.1 Scope and PurposeThis manual is intended to support authorized Webastotrained distributors, dealers an

Seite 24

6.2.2 Heater Emits Black Smoke from ExhaustCheck the combustion air intake tube and exhaust tube for obstructions or damage. Clear obstructions as ne

Seite 25

6.2.4 Diagnostic Code TableSymptomNo Function1X Flash (F 01)No combustion achieved afterstart and repeat start2X Flashes (F 02)Flame-out during operat

Seite 26

6MAINTENANCE/TROUBLESHOOTING AIR TOP 50006-4Please use this section for your notes and observations.

Seite 27

In the vicinity of the Air Top 5000 air heater, a temperatureof 185 °F (85 °C) must not be exceeded under anycircumstances (e.g. during body paint wor

Seite 28

2. General Description2.1 General DescriptionFig. 2-1: Webasto Air Top 5000 Air HeaterAIR TOP 5000 2GENERAL DESCRIPTION2-1World class technology with

Seite 29 - 6.2 Troubleshooting

2GENERAL DESCRIPTION AIR TOP 50002-2

Seite 30

AIR TOP 5000 3FUNCTIONAL DESCRIPTION3-13.1 Operating the Air Top 5000 with Self Diagnostic Control Unit3.1.1 Heater Control ElementThe heater control

Seite 31

3FUNCTIONAL DESCRIPTION AIR TOP 50003-2Once the heater control element has been turned on, the light on the control element will illuminate, and the c

Seite 32

AIR TOP 5000 3FUNCTIONAL DESCRIPTION3-33.1.5 Switch-Off upon MalfunctionThe control unit recognizes malfunctions of individual air heater components a