1314543A Installation Operating Instructions Air Top Evo AM en

Luftheizgeräte
Air heaters
Luchtverwarmingsapparaten
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)
03/2009
1314543A
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 tödliche 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 Personal 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
Inhaltsverzeichnis
Table of contents
1
Gesetzliche Bestimmungen für den Einbau .......................... 7
1
Statutory regulations governing installation......................19
2
Mitgeltende Unterlagen......................................................... 7
2
Other Applicable Documents................................................19
3
Verwendung Luftheizgeräte System .................................... 8
3.1 Aufbau des Systems ......................................................... 8
3.2 Heizleistung Gesamtsystem ............................................. 9
3
Using Air Heater Unit System...............................................20
3.1 System Design ................................................................20
3.2 Heating Capacity of Entire System ..................................21
4
Anschlussschema / Schaltpläne ........................................... 10
4
Connection Diagram / Wiring Diagrams..............................22
5
Legende für Schaltpläne ...................................................... 15
5
Legend for circuit diagrams ..................................................27
6
Erstinstallation / Erstinbetriebnahme ................................. 17
6
Initial Installation/Initial Operation .....................................29
7
Rücksetzen Master - Slave System ...................................... 18
7
Resetting Master/Slave System ............................................30
8
Störabschaltung .................................................................... 18
8
Fault lock-out .........................................................................30
I
Air Top Evo 3900/5500 AM
Statutory regulations governing installation
1
2
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:
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
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
19
Using Air Heater Unit System
3
Air Top Evo 3900/5500 AM
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.
Bus System
Unit 1
Fig. 1:
20
System design
Unit 2
Unit 3
Unit 4
Air Top Evo 3900/5500 AM
3.2
Using Air Heater Unit System
Heating Capacity of Entire System
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
NOTE:
It is only permitted to install heating systems with Air Top Evo heater units
of the same output type.
21
Connection Diagram / Wiring Diagrams
4
Air Top Evo 3900/5500 AM
Connection Diagram / Wiring Diagrams
MC04 heater control
Observe coloured markings
Control line
W-Bus +
Connection for
Webasto Thermo Test
diagnosis
Connection for
Webasto Thermo Test
diagnosis
... Connection to additional heater
units
Heater units
wiring
harness
Heater unit 2
Heater unit 1
Fig. 2:
22
Connection diagram of Air Top Evo 3900/5500 AM (connection of combination timer 1531 and setpoint generator possible)
Air Top Evo 3900/5500 AM
Fig. 3:
Connection Diagram / Wiring Diagrams
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
23
Connection Diagram / Wiring Diagrams
Fig. 4:
24
Air Top Evo 3900/5500 AM
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
Fig. 5:
Connection Diagram / Wiring Diagrams
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
25
Connection Diagram / Wiring Diagrams
Fig. 6:
26
Air Top Evo 3900/5500 AM
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
5
Legend for circuit diagrams
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.
Cable cross-sections
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) CO2 adjustment (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
< 7.5 m
7.5 - 15 m
0.75 mm2
1.0 mm2
1.0 mm2
1.5 mm2
1.5 mm2
2.5 mm2
2.5 mm2
4.0 mm2
4.0 mm2
6.0 mm2
Cable colours
bl
br
ge
gn
gr
or
rt
sw
vi
ws
blue
brown
yellow
green
grey
orange
red
black
violet
white
27
Legend for circuit diagrams
Air Top Evo 3900/5500 AM
Item Description
Comment
Item Description
Comment
A1
Heater
Air Top Evo 3900/5500
X2
Plug connector, 2-pin
To item A2 (ST V)
A2
Control module
X3
Plug connector, 2-pin
To item A2 (ST U)
B2
Temperature sensor
In control unit
X4
Plug connector, 2-pin
To item A2 (ST Z)
B3
Overheating sensor
Overheating guard
X5
Plug connector, 2-pin
To item A2 (ST Y)
B4
Temperature sensor
External
X6
Plug connector, 2-pin
To item A2 (ST X)
E
Glow plug / Flame monitor
X7
Plug connector, 12-pin
To item A2 (ST 1)
F1
Fuse 24 V 15A/12V 20A
Flat fuse SAE J 1284
X8
Plug connector, 1-pin
F3
Fuse max. 5A
Flat fuse SAE J 1284
X9
Plug connector, 4-pin
F4
Fuse 1A
Flat fuse SAE J 1284
X10
Plug connector, 2-pin
H1
Green LED
Indicator
X11
Plug connector, 2-pin
to item Y1
H3
LED red (in item P)
Light in immediate heat button,
ready indicator,
switch-on indicator
X12
Plug connector, 12-pin
to item P
Y1
Metering pump
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 Ω
With 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
CO2 setting
S7
Momentary-contact switch
Immediate heat button remote
control
X1
Plug connector, 2-pin
To item A2 (ST B)
28
to item S1
Air Top Evo 3900/5500 AM
6
Initial Installation/Initial Operation
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
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").
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
29
Resetting Master/Slave System
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").
30
Air Top Evo 3900/5500 AM
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.
http://dealers.webasto.com
http://www.webasto.com
In multilingual versions the German language is binding.
Änderungen vorbehalten
Subject to modification
Wijzigingen voorbehouden
Bij een meertalige versie is de Duitse versie bindend.
© 2009 All Rights Reserved
Im Fall einer mehrsprachigen Version ist Deutsch verbindlich.
IDENT.-NR. 1314543A
Webasto AG
Kraillinger Strasse 5
82131 Stockdorf
GERMANY
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