Air Heaters Installation instructions

Air Top 3500

Air Top 5000
Type Air Top 3500 B (Petrol
Type Air Top 3500 D (Diesel)
Type Air Top 5000 B (Petrol)
Type Air Top 5000 D (Diesel)

12/1998
Air Top 3500/5000

Table of Contents
Page
Installation Instructions

Legal Provisions for Installation 1

Installation 3
Installation Example 5
Heating Air System 6
Fuel Supply 7
Combustion Air Supply 10
Exhaust Pipe 10
Electrical Connections 12
Circuit Diagrams 15
Initial Operation 22
Shut-Down on Faults 22
Technical Data 23
Drilling Template 25
Webasto Service Phone 27

II
 Air Top 3500/5000

Installation Instructions
Legal Provisions for Installation The effectiveness of the design certification (homologa- Extracting the combustion air from the interior of the ve-
tion) is dependent on this certificate. The approval certifica- hicle is not permissible.
For testing the heater in accordance with §§ 19, 20 or 21 tion is to be kept in the vehicle.
StVZO (German Road Licensing Regulations) the follow- “Combustion air pipe: The combustion air required
ing regulations are primarily to be observed (§ 22 a The year of the initial operation must be durably marked must be drawn in from the outside of the vehicle.
StVZO): on the type plate of the heater by the installer by removing Inside passenger areas the combustion air lines are per-
the years that do not apply. mitted to have a maximum of four joints and must be pro-
NOTE: vided with a splash-proof opening leading through the out-
These provisions are binding within the scope of the The heat exchanger of the air heater is not to be used side wall. These joints must be so sealed that a total leak-
StVZO and should also be observed in countries for longer than ten years and must thereafter be re- age rate of 200 l/h at an overpressure of 0.5 mbar is not ex-
where no special regulations are in effect! placed by the manufacturer or one of its authorised ceeded.
dealers with a genuine replacement part. The pipe including lead-through, joints, material and type
Within the scope of the StVZO (German Road Licensing If exhaust pipes lead through passenger areas, these of construction must be specified in the installation instruc-
Regulations) “General Design Certifications” have been pipes must also be replaced with genuine replacement tions.
granted by the Federal Office for Motor Traffic for the Air parts after ten years. Mounting and removal of the pipe must be possible with
Top 3500/5000 air heaters with the following design appro- tools only, the pipe must be protected against damage and
val numbers: Whenever the heater is removed it is imperative that be permanently vibration-proof.
~ S 305 Air Top 3500 B the gasket located underneath be replaced.
~ S 306 Air Top 3500 D “Exhaust gas pipe”: The heaters must be so designed
~ S 304 Air Top 5000 B The heaters are approved for heating the passenger com- that the exhaust fumes are discharged to the atmosphere.
~ S 303 Air Top 5000 D partment and the driver’s cabin, not however, the cargo Exhaust pipes must be so routed that the possibility of ex-
space for the transport of hazardous materials. haust gases penetrating the interior of the vehicle is
The installation of the heaters must be performed in ac- When using the heater in special vehicles (e.g. “TRS” ve- remote. The functioning of any parts of the vehicle essen-
cordance with these Installation Instructions. The installa- hicles for the transport of hazardous materials) or in ve- tial for its operation must not be impaired. Any condensate
tion must be checked hicles not subject to StVZO regulations (e.g. ships) all regu- or water that may have entered must not be able to collect
a) upon the homologation of the vehicles in accordance lations that may be locally applicable are to be complied in the exhaust gas line. Drain holes are permissible; these
with § 20 StVZO with. must discharge the liquid to the atmosphere via lines that
b) upon any individual test in accordance with When installing the Air top 3500/5000 D heater in ve- are leakproof in relation to the interior of the vehicle.
§ 21 StVZO, or hicles for the transport of hazardous materials the require- The discharge opening of the exhaust pipe is to point up-
c) upon any examination in accordance with ments laid down in TRS 002 and TRS 003 (Technical Gui- ward, sideways or, in the case of routing the exhaust pipes
§ 19 StVZO by a registered expert or examiner for delines relating to the ordinance of transporting hazardous on the underside of the bottom of the vehicle, it must be po-
motor traffic, an expert for automotive vehicles, materials on the road) must be fulfilled in addition to those sitioned near the lateral or rear edge of the driver’s cab or
or any other authorised official, in accordance with of the StVZO. vehicle.
paragraph 7.4 a of Appendix VIII to the StVZO Inside areas where people are present, exhaust pipes may
and in the case of item c) the proper installation must be “Heating air system”:Heating air intake openings must have a maximum of one joint, and their lead-through
certified on the approval certificate contained on the de- be so arranged that the possibility of exhaust fumes from through the outer wall/bottom of the vehicle must be
sign certification stating the following: the vehicle engine and the heater being drawn in is remote splash-proof. It is permissible to connect a drain pipe pro-
- vehicle manufacturer under normal operating conditions. vided with a leak-proof metal joint to discharge the water
- vehicle type and penetrated into the exhaust pipe. The drain pipe is to be
- vehicle identification number passed through the outside wall or the bottom of the ve-

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Air Top 3500/5000

hicle through a sealed bush. their operation, and must be located such that dripping or
The heat exchanger, the connected exhaust pipe as well evaporating fuel can neither collect nor be ignited by hot
as any drain pipe that may be connected must be so components or electrical equipment.
sealed that in the event of an overpressure equivalent to In the case of buses, fuel lines and fuel tanks may be lo-
the twofold overpressure of the exhaust gas at maximum cated neither in the passenger area nor in the driver’s com-
permissible exhaust pipe length – however, at a minimum partment. In these vehicles the fuel tanks must be located
overpressure of 0.5 mbar – a leakage rate of a total of 30 such that they do not pose a direct hazard to the exits in
l/h is not exceeded. the event of a fire. The fuel must not be supplied by means
The pipe including lead-through, joints, material and type of gravity or gauge pressure in the fuel tank.
of construction must be specified in the installation instruc-
tions. Mounting instructions for Webasto fuel tanks for fuel sup-
Mounting and removal of the pipe must be possible with ply of heating units in vehicles:
tools only, it must be protected against damage and be per- In the case of buses, installation must not be performed in
manently vibration-proof. the passenger area or in the driver’s compartment.
Only metal pipes may be used. These must not exceed a The fuel filler neck must not be located inside the pas-
temperature of 110 °C if the possibility of accidental con- senger area or the driver’s compartment in any vehicle.
tact in the vehicle’s interior exists. It is permissible to install Petrol fuel tanks must not be located directly behind the
a protection against accidental contact. front panelling of the vehicle.
They must be separated from the engine in such a manner
“Combustion Air Inlet” and “Exhaust Gas Outlet”: that the possibility of fuel inflammation is remote even in
During installation it must be ensured that the openings of the event of an accident. This does not apply to tractor ve-
the combustion air inlet and exhaust gas outlet pipes are hicles with open cabs.
so designed that a spherical object of 16 mm diameter can-
not be introduced. The operating state of the heater at any given time – i.e. at
least whether it is on or off – must be easily recognizable.
Electric lines, switchgear and controlgear of the heater
must be so arranged in the vehicle that their functioning Webasto will not assume any liability if the installation in-
cannot be impaired under normal operating conditions. structions and the notes contained therein are not ob-
served. The same applies to improperly performed repairs
All tubes leading from the heater toward the outside must or those where others than genuine replacement parts
be routed through splashwater-proof openings. have been used. In those cases, the heater’s General De-
sign Certification and thus the vehicle’s General Operating
In the case of buses, the heater must be installed neither Permit (homologation) will be invalidated as a conse-
in the driver’s compartment nor in the passenger area. quence.

For the routing of fuel lines and the installation of additional

fuel tanks, articles 45 and 46 StVZO are to be adhered to.
The most important excerpts therefrom are as follows:
Fuel lines are to be designed in such a way that their sta-
bility remains unaffected by torsional stresses in the ve-
hicle, engine movement and the like. They must be pro-
tected against mechanical damage. All parts of the fuel sys-
tem must be protected against heat which would impair

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 Air Top 3500/5000

Scope of Application of the Air Heaters

The Webasto Air Top 3500/5000 air heaters are designed

to provide the following features:
- for the heating of driver’s cabs, boats, trucks, small
buses, vans and ambulance vehicles
- defrosting the vehicle’s windows.

The heaters operate independently of the vehicle engine

and are connected to the fuel tank and the electrical sys-
tem of the vehicle.

They can be used in vehicles with water-cooled or air-

cooled engines.

1 Heating air inlet 6 Space required for heating air inlet

Installation 2 Heating air outlet 7 Space required for heating air outlet
3 Combustion air inlet 8 Space required for removal of heater
CAUTION: 4 Exhaust gas outlet 9 Cable outlet (optionally on the right or left)
The legal provisions 1 and 2 relating to the installation are 5. Fuel inlet
to be adhered to.
It is not permitted to operate the heater without control unit Fig. 1: Dimensions of the Heater
cover (results in overheating of the heater).

Installation Details for Air Top 3500/5000

NOTE:
The different vehicle-specific installation conditions should
be taken into account.

Installation Location

The heater can be fitted both inside and outside the ve-
hicle. When installed on the outside, care must be taken
that the heater is fitted in a location that is protected
against splashwater and spray.

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Air Top 3500/5000

If installed in the vehicle’s interior, the lead-through open- A gasket (Fig. 4) must be fitted between heater and car
ings for combustion air inlet, exhaust gas outlet and fuel body. The gasket must be renewed prior to each re-
pipe must be splash-water protected. installation. The support surface for the heater mounting
foot must be level. A special tool is available from the
For this purpose, the special gasket supplied with the manufacturer for drilling the holes and levelling the support
heater must be used (see Fig. 4). The gasket must be surface, if necessary. Surface irregularities of up to max. 1
renewed prior to each re-installation. mm can be compensated for by means of the gasket.

Diesel-fuelled heaters
CAUTION:
After the installation has been performed, a check must be
0 - 90° 0 - 90° 0 - 90° carried out to verify that no part of the housing is in contact
with any surrounding parts. Non-compliance could result in
a blockage of the heater fan.

Fig. 3: Hole Pattern

Name Plate

The type plate must be located at a place where it is pro-

petrol-fuelled heaters
tected against damage and be easily accessible once the
heater has been installed (or else, a type plate duplicate is
to be used).
0 - 90° 0 - 90°
0 - 30° The years not applicable are to be removed from the type
plate.

Fig. 2: Permissible Installation Positions Fig. 4: Gasket

Unobstructed installation to be ensured!

Mounting the Heater

When mounting the Air Top 3500/5000 heater, the M 6 nuts

must be tightened to a torque of 6 Nm +1 Nm.

The mounting dimensions as well as the space required Fig. 5: Installation

for the performance of servicing work are shown in the in-
stallation drawing (Fig. 1). The specified horizontal and
axial angles of inclination must not be exceeded (Fig. 2).

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 Air Top 3500/5000

1 Heater control dial

2 Heater
3 Metering pump and damping device
4 Fuel filter (accessory)
5 Tank extracting device
6 Exhaust silencer (accessory)
7 Fuse

7
2

4 5
3

Fig. 6: Installation example of air heater in the recirculating air mode

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Air Top 3500/5000

Heating Air System Maximum air pressure drop between intake and delivery
side of the heating air line:
NOTE: Air Top 3500 2,0 mbar (20 mm WH)
It is not permissible to integrate the heater into the vehi- Air Top 3500 Volume Plus 3,0 mbar (30 mm WH)
cle’s air ducting system. Air Top 5000 3,0 mbar (30 mm WH)

Both recirculated-air and fresh-air operation is permissible. The test can also be performed by measuring the tempera-
In the case of fresh-air operation, care must be taken that ture directly at the heater:
the heating air is extracted from an area that is protected temperature difference between heating air inlet and hot
against splashwater and spray. air outlet max. 130 K.
If this value is exceeded, the temperature limiter is ex-
NOTE: pected to trip. The heating air hose is to be secured at the
In the case of fresh-air operation, an external temperature joints. Fig. 7a: Heating air inlet with intake grille
sensor must be mounted within the space to be heated.
The hot air stream must be prevented from re-entering the
A temperature sensor is installed in the heater on the heat- heater, if the heater is operated in the recirculating mode If an installation housing is used, the area around the air
ing air intake side which, in conjunction with the heater con- without any hot air ducting discharge nozzle must be tightly sealed so that no hot air
trol element and dependent upon the intake temperature can enter the installation box.
and position of the setpoint transmitter, operates the
heater within the appropriate heat output range. Heat out-
put is so adjusted that after a quick reaching of the preset External Temperature Sensor
interior temperature the same will be maintained at the
preset value. The installation of an external temperature sensor is rec-
Minimum inside diameter of heating air pipe is ommended if the heater is installed in an installation hous-
90 mm at Air Top 5000 ing or in location with poor ventilation (e.g. under-neath
80 mm at Air Top 3500 bunks). Extremely short cycle times of the heater can thus
may be decreased to 75mm subject to prior approval by be avoided.
Fig. 7: Heating air inlet and heating air outlet
the manufacturer.

NOTE: CAUTION: Mounting of External Temperature Sensor

For heating air ducts only materials capable of withstand- If the heater is operated without heating air intake hose, it
ing a temperature of at least 150° may be used. is imperative that the air intake grille supplied with the The external temperature sensor must be mounted on sur-
The hot air discharge opening is to be located so that the heater be mounted! faces as vertical as possible, at mid-height in the vehicle
hot air is not directed onto parts that are not resistant to cab in the area to be heated.
heat. NOTE:
The installation must be checked for the following: The temperature sensor must not
CAUTION: - “closed circuit” of air between the vehicle heater and the - be located directly in the hot air stream (vehicle’s or
In vehicles designed for the transportation of passengers, heater air inlet heater’s heating air).
the air outlet openings must be arranged in such a way - “closed circuit” of air between heater air inlet and heater - be mounted in the vicinity of heat sources
that they cannot be obstructed by passengers. air outlet (fig. 7) (e.g. vehicle’s heating system).
- adequate space for taking in heating air (heating air to be - be exposed to direct sun radiation (e.g. on the
extracted from the cool space of the cabin, e.g. in the dashboard).
case of installation underneath a bunk) - be mounted behind curtains or the like.

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 Air Top 3500/5000

Fuel Supply

Fuel is extracted from the vehicle’s fuel tank or a separate

fuel tank. The values relating to the permissible pressure
at the fuel extraction point are shown in Fig. 8.

permissible fuel feed height at max. permissible

H (m) overpressure (bar) in fuel
line
0.00 0.2
1.00 0.11
2.00 0.03
l2
permissible fuel suction at max. permissible
height S (m) underpressure (bar) in fuel
tank
0.00 -0.10
0.50 -0.06
1.00 -0.02

l1

l2

l1 + l2 ≤ 10 m l1
l1 ≤ 1,2 m
l2 ≤ 8,8 m

Fig. 8: Fuel Supply

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Air Top 3500/5000

Vehicles with Carburetor Engines Vehicles with Fuel Injection Engines

hole pattern
In passenger cars, fuel may only be extracted with the spe- When installing the heater in vehicles with petrol injection
cial Webasto fuel pickup (see Fig. 8) and as close to the systems it must be determined whether the fuel pump is
tank as possible. The connection can be made either in mounted inside or outside the tank.
the flow or the return pipe whereby it must be ensured that
the return pipe reaches almost to the bottom of the tank. Where the fuel pump is located inside the tank, the fuel
Failing this, the return pipe can be extended. can only be drawn from the return pipe and only by using
the Webasto fuel pickup (see Fig. 8) whereby it must be
The fuel pickup is to be so mounted that any air or gas ensured that the return pipe reaches almost to the bottom
bubbles are automatically discharged into the tank (see of the tank (minimum distance to tank bottom, see Fig. 10). minimum distance 25 mm
Fig. 9). Failing this, the Webasto tank extracting device (see Figs.
9, 10 and 11) can be used.

Where the fuel pump is mounted outside the tank, the fuel Fig. 10: Webasto Tank Extracting Device
may only be extracted between the tank and the fuel pump
and also only by using the Webasto fuel pickup (see Fig. 8). * tank extracting device only to be used with
metal fuel tanks

Vehicles with Diesel Engines

Fuel must be drawn from the fuel tank or a separate tank plastic tank
(see Figs. 9, 10 and 11). With this method of fuel being
supplied from a separate tank, no pressure-related in-
fluence is possible.

to engine
sealing ring
from tank

to metering pump Fig. 11: Fuel Extraction From the Plastic Tank
Fig. 9: Webasto Fuel Pickup (Extraction Via Tank Drain Plug)

Fuel should not be extracted in the vicinity of the engine

since here gas bubbles are likely to form in the lines owing
to the heat radiation of the engine, which may result in mal-
functions of the combustion operation.

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 Air Top 3500/5000

the inside diameter must not exceed a given dimen- Metering Pump
sion.Starting with an inside line diameter of 4mm, air or
gas bubbles will accumulate resulting in malfunctions of The metering pump is a combined delivery/metering and
fuel extracting sealing ring the combustion operation if lines sag or are routed with a shutoff system and is subject to certain installation criteria
device downward pitch. When the diameters shown in Fig. 8 are (see Figs. 8, 14 and 15).
used, you can be sure that no unwanted bubbles will be
formed.
Air Top 3500/5000, 12-volt Petrol
The lines leading from the metering pump to the heater
should not be routed in a downward pitch.

To prevent the fuel lines from sagging, freely suspended

lines must be secured. Mounting should be performed in
tank fitting such a manner that the lines are protected against flying
stones and thermal influence (exhaust pipe). preferably
To prevent the fuel lines from slipping off they are to be se- 15°-90°
cured at the joints by means of hose clamps.

Connecting Two Pipes Using a Hose

The proper connection of fuel lines using a hose is shown

in Fig. 13.
Check for leakage!
Fig. 14: Metering Pump DP 2
Installation Position
correct
Air Top 3500/5000 D. 12-volt and 24-volt Diesel
Fig. 12: Fuel Extraction From the Plastic Tank
(Extraction Via Tank Fitting) clamp

incorrect
NOTE:
The fitting must be made of sheet steel!

bubble bubble
Fuel Lines

Only steel, copper and plastic pipes made of plasticized,

light-resistant and temperature-stabilized PA 11 or PA 12
(e.g. Mecanyl RWTL) in accordance with DIN 73378 may Fig. 15: Metering Pump DP 30
be used as fuel lines. As in the majority of cases it is not Installation Position
possible to route the lines in a continuous upward pitch, Fig. 13: Pipe/Hose Connection

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Air Top 3500/5000

Installation Location Combustion Air Supply The exhaust pipe is to be secured to the heater, e.g. by
means of a clamp. For further regulations refer to the
The metering pump must be mounted in a cool location as On no account may the combustion air be extracted from Legal Provisions.
close to the tank as possible (see Fig. 8). The permissible areas where persons are present. The combustion air in-
ambient temperature must not exceed a temperature of + take opening must not point in the direction of travel. It
20°C at any given operating state. must be so located that the possibility of clogging due to
Metering pump and fuel lines must not be mounted within contamination n is remote. The exhaust silencer is preferably to be mounted in the vi-
the radiation range of hot vehicle parts. If necessary, a radi- cinity of the heater.
ation protection is to be provided. NOTE: Operation of the heater is also permissible without exhaust
With an intake duct length < 0.6 m, it is compulsory that an silencer.
Installation and Mounting intake silencer be mounted.

The metering pump is to be attached by a vibration-damp- NOTE:

ing suspension device (e.g. rubberized clamp). The instal- Combustion air must be drawn from a splash-water pro-
lation position is restricted as shown in Figs. 14 and 15 in tected location that is as cool as possible. A combustion air
order to ensure proper self-bleeding of the system. line is to be used, if necessary.
Owing to the hazard of corrosion, only genuine Webasto
parts may be used for the plug connection between meter- Exhaust gas pipes must not be used as combustion air
ing pump and metering pump cable harness. lines as this would cause damage to the metering pump
cable emerging from the combustion air intake fitting.

Fuel Filter For further regulations refer to the Legal Provisionsfor the
installation.
Combustion Air Intake and Exhaust Pipes
If dirt in the fuel must be reckoned with, only Webasto filter,
order no. 487 171, should be used. The filter is preferably
Both pipes leading away from the heater are to be routed
be installed in vertical position, where this is not possible, it
in a downward pitch. If this is not possible, a ø 4mm con-
may also be installed horizontally (direction of flow to be Exhaust Pipe
densate drain hole is to be provided at the lowermost point.
observed).
Rigid pipes made of unalloyed or alloyed steel with a mini-
mum wall thickness of 1.0 mm, or flexible tubes of alloyed
steel only are to be used as exhaust pipes.

0 - 90°

Fig. 17: Exhaust Silencer Fig. 18: Prevent condensation from forming
Direction of flow optional
Fig. 16: Fuel Filter

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 Air Top 3500/5000

The lines must not point into the direction of travel.

To ensure an angle of discharge of 90° ± 10°, it is re-
quired that the pipe clamp be attached no more than
150 mm, from the exhaust pipe end

Fig. 19: Pipe discharge openings not in direction of

travel
The lines must be so arranged that any clogging due to
contamination is not to be expected.

direction of discharge approximately vertical 90° ± 10°

Fig. 21: Exhaust Pipe Discharge Opening
Installation Position

NOTE:
Fig. 20: Avoid areas exposed to water, mud or snow For exhaust pipes lengths of 2 m and more, insulated ex-
haust pipes are to be used (dew point not reached)

Inside diameter of pipes:

CAUTION: Combustion air pipe: 25 mm
A fire hazard exists if the installation position of the ex- Exhaust pipe (metal): 24 mm
haust pipe discharge opening differs from that shown in
Fig. 21. Smallest bending radius: 50 mm

Length of combustion air intake and exhaust pipes: Total angle of all bends:
with exhaust gas silencer: max. 2.6 m Combustion air pipe: max. 270°
without exhaust gas silencer: max. 5.6 m Exhaust pipe: max. 270°

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Air Top 3500/5000

Electrical Connections CAUTION: Connection to Supply Voltage

In accordance with the Technical Guidelines relating to the
All pipes that are not required must be insulated! ordinance of transporting hazardous materials on the road, Preferably to be supplied from the vehicle central electrical
heaters may only be switched on by means of a special system.
NOTE: switch installed in the driver’s cabin and are to be actuated
When using the combination or standard digital timer a manually. If the heater is equipped with a combination or To provide the heater with adequate protection, an ad-
remote-control pushbutton may be provided near the bunk standard digital timer, it must ensured that pin 4 on the ditional flat fuse holder is to be installed (supplied
for added convenience. The connection is to be performed combination or standard digital timer remains unassigned. with the heater). The fuse holder may only be installed
in accordance with wiring diagram 30 and 31. The heater can therefore only be started up by means of in the vehicle interior.
the instant heating button.
The electrical connection is to be performed in accordance No other digital timers are allowed to be used in TRS ve-
with the system circuit (Fig. 29, 30, 31, 32, 33). hicles.

Connection in Vehicles for the Transportation of Dan- Connection of the Heater

gerous Goods (TRS)
To connect the cable harness, remove the control unit
When installing the Air Top 3500/5000 D heaters in ve- cover on the heater and connect the cable harness con-
hicles for the transport of hazardous materials, the require- nectors with the control unit.
ments laid down in TRS 002 and TRS 003 (Technical Gui-
delines relating to the ordinance of transporting hazardous
materials on the road) must be fulfilled in addition to those
of the StVZO. The electrical connection is to be performed Fig. 23: Removal of Mounting Plate of Fuse Holder
in accordance with wiring diagrams Fig. 32 or 33.
On vehicles without auxiliary drives, electrical connection
is to be performed in accordance with the system circuit di-
F = 15A (24V)
agram Fig. 33.
F = 20A (12V)
NOTE:
Switch S3 must be so installed that in the event of a pump-
ing device being put into operation, a plus potential is ap- Fig. 22: Removal of Control Unit Cover
plied across the corresponding input of the electronic con- NOTE:
trol unit. Lift off control unit cover applying a blunt edge at its side
(see arrows in Fig. 22)
CAUTION: Be sure not to touch the printed conductors of the
If no voltage to ground is present at the control unit input Fig. 24: Fuse Holder, Installation Position
control unit.
X6/1 upon start-up all TRS functions will be inoperative. Prior to starting up the heater for the first time, reinstall the
After the plus potential has been applied across the control control unit cover to prevent any undue escaping of heat-
unit input X6/1 (auxiliary drive ON) a short after-run period ing air (overheating of heater).
of 20 seconds takes place and subsequently the control Cable lead-through can optionally be located on the left or
unit is in its “fault lock-out” state.
right.
To ensure that the cable lead-through in the control unit
cover provides a tight seal, the cable grommet on the
cable harness must be displaced accordingly.

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 Air Top 3500/5000

Connection of Heater Control Element

The cable harness is prepared for connection to the heater

control.
To withdraw the connector pull at the connector housing
only.
If the cable harness is pulled, the connector housing is
locked (self-locking).

NOTE:
The optical fiber must be in contact with the rotary knob.

NOTE:
As an option, an external temperature sensor can be in-
stalled in the passenger area (see page 6)

Fig. 25: Heater Control Knob

Correct!
Fig. 26: Mounting of Heater Control Knob

Incorrect!
Fig. 27: Mounting of Heater Control Knob (incorrect)

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Air Top 3500/5000

Jumper Terminal 15

Terminal 30
Terminal 58

Terminal 31

to isolate

Fig.28: Connection diagram Air Top 3500/5000 ; only connection featuring a combination timer is shown.

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 Air Top 3500/5000

ϑ ϑ

Fig.29: System circuit diagram Air Top 3500/5000, 12V/24V with Control Knob, legend see page 20 and 21

15
Air Top 3500/5000

ϑ ϑ

Fig.30: System circuit diagram Air Top 3500/5000, 12V/24V with Combination Timer , legend see page 20 and 21

16
 Air Top 3500/5000

ϑ ϑ

Fig. 31: System circuit diagram Air Top 3500/5000, 12V/24V with Combination Timer and electrical battery disconnecting switch, legend see page 20 and 21

17
Air Top 3500/5000

ϑ ϑ

Fig.32: System circuit diagram Air Top 3500/5000 D, 24V TRS-Operation with Heater Control Knob , legend see page 20 and 21

18
 Air Top 3500/5000

ϑ ϑ

Fig. 33: System circuit diagramAir Top 3500/5000 D, 24V TRS-Operation with Heater Control Knob without auxiliary drive , legend see page 20 and 21

19
Air Top 3500/5000

Legende for circuit diagrams:

➀ Positive voltage from terminal (15/75) to pin 10:

Min. wire cross sections per circuit Colour of cables
continuous operation in the instant heating mode as
long as ignition is switched on bl blue
< 7.5 m 7.5 - 15 m
2 2
br brown
No positive voltage at pin 10: 0.75 mm 1.5 mm ge yellow
variable heating times can be programmed 2 2 gn green
1.0 mm 1.5 mm gr gray
(10 min up to 120 min),
2 2 or orange
basic setting: 120 min 1.5 mm 2.5 mm
2 2
rt red
➁ Diagnostic K conductor 2.5 mm 4.0 mm sw
vi
black
violet
2 2
4.0 mm 6.0 mm
➂ Diagnostic L conductor ws white

➃ Input pin (pin 7/connector X7, cable color in cable harness: white/red):
“Ventilation” (blower speed is dependent on the heater control position)

➄ CO2 setting (see Workshop Manual)

➅ NOTE:
If connection is made to terminal 30, continuous heating operation is
possible with the ignition turned off! In this case, no connection to
terminal 15/75 must be made!

➆ NOTE:
For TRS function, gray and purple wires are required.

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 Air Top 3500/5000

Pos. Designation Remarks Pos. Designation Remarks

A1 Heater Air Top 3500/5000 S6 Switch Ventilation
A2 Electronic control unit S7 Push-button switch Instant heating button remote control
B2 Temperature sensor S8 Battery disconnecting switch.
B3 Temperature sensor (limiter) Overheating protection V1 Diode
E Glow plug / Flame detector V2 Diode
F1 Fuse24V 15A/12V 20A flat fuse SAE J 1284 X1 Connector 2pole atPos. A2 (ST B)
F2 Fuse20A flat fuse SAE J 1284 X2 Connector 2pole at Pos. A2 (ST V)
F3 Fuse max. 15A flat fuse SAE J 1284 X3 Connector 2pole at Pos. A2 (ST U)
H1 LED green (in Pos. S1) operation indicator X4 Connector 2pole at Pos. A2 (ST Z)
H3 LED red (in Pos. P) Display illumination instant heating button X5 Connector 2pole at Pos. A2 (ST Y)
Operation indicator Operation indicator X6 Connector 2pole at Pos. A2 (ST X)
light X7 Connector 12pole at Pos. A2 (ST1)
H4 Heating symbol in display (in pos. P) Operation indicator X8 Connector 2pole
H5 Lamps (in pos. P) Illumination of display and buttons X9 Connector 4pole at Pos. S1
H6 Lamp (min. 1.2W) Operation indicator light pumping device X10 Connector 2pole
M1 Motor Combustion and heating air fan X11 Connector 2pole at Pos. Y1
M3 Motor Vehicle fan X12 Connector 12pole at Pos. P
P Combination timer (1531) Digital timer and setpoint generator Y1 Metering pump,
S1 Control element Setpoint generator switch Y2 Solenoid valve for pumping device
S2 Disconnecting switch 1 or 2 poles. Emergency Stop switch
S3 Switch at or for pumping device

21
Air Top 3500/5000

Initial Operation Shut-Down on Faults Fault Code Display

After the heater has been installed, the fuel supply system Faults related to individual heater components and mal- If the heater is equipped with a combination or standard
is to be bled thoroughly. functions during the start-up sequence are detected in the digital timer, a fault code is indicated on the display of the
control unit. digital timer whenever a malfunction has occurred:
NOTE:
Owing to the low fuel consumption it is required that the The heater is shut down (fault lock-out) in the following F 00 Control unit failure / incorrect parameter set /
heater be turned on repeatedly to fill the fuel line leading to cases: warm start detection
the heater. - no or unsuccessful start-up F 01 No start-up (after 2 start-up attempts)
- temperature sensor defective no formation of flames
- temperature limiter (interruption or short-circuit) F 02 Flame extinguished (repeated >5)
During a test run of the heater all connections are to be - glow plug defective F 03 Undervoltage or overvoltage
checked for leakage and security. Should a malfunction of - insufficient fan speed, short circuit or interruption F 04 Premature flame detection
the heater occur during operation, fault isolating measures - fault in the metering pump circuit or overheat protection F 06 Temperature sensor interruption or
are to be performed. circuit (during start-up phase only) temperature sensor short-circuit
- undervoltage of less than 10 volts or overvoltage of F 07 Metering pump interruption or
more than 15 volts and for longer than 20 seconds metering pump short-circuit
(aplies to 12-volt heaters) F 08 Fan motor interruption or
- undervoltage of less than 20 volts or overvoltage of fan motor short-circuit or
more than 32 volts and for longer than 20 seconds fan motor incorrect speed
(on 24-volt heaters) F 09 Pencil-type glow plug interruption or
- control unit defective pencil-type glow plug short-circuit
- overheating F 10 Overheating
F 11 Temperature limiter interruption or
temperature limiter short-circuit
Fuel supply will be interrupted in the event of overheating. F 12 Setpoint transmitter (interruption / short-circuit)
An after-run cycle is performed as is the case when the
heater is shut down manually.
After the after-run cycle has been terminated, the control
unit is in the fault lock-out state.
An overheating condition is indicated by 10 flashing light
signals of the operation indicator.
Eliminate cause of malfunction.
To deactivate the fault lock-out, the heater is to be briefly
(min. 2 seconds) turned off and then switched back on
again one time.

22
 Air Top 3500/5000

Heater Operation Air Top Air Top Air Top Air Top Air Top
Technical Data 3500 B 3500 D 3500 D
Volume
5000 B 5000 D
Plus
Unless tolerances are shown within the technical data
table, a tolerance of ± 10% applies at an ambient tempera- Mark of approval ~S 305 ~S 306 ~S 306 ~S 304 ~S 303
ture of +20°C and at the rated voltage and conditions. Type air heater with vaporizing type burner
Electrical Components: Heat output control range 1,5 – 3,5 kW 1,5 – 3,5 kW 1,5 – 5,0(5,5)* kW
*booster setting for max.
Control unit, motor, fuel metering pump, light bulb in the 30 min.
digital timer* and pencil-type glow plug/flame detector are
designed either for 12-volt or 24-volt operation. Fuel petrol Diesel petrol Diesel
control range 0,17 – 0,46 0,17 – 0,42 l/h 0,19 – 0,66 0,17 – 0,60
The digital timer*, temperature limiter and temperature sen- Fuel consumption l/h l/h l/h
sor are voltage-independent components. *booster setting for max. 30 min. (0,73)* l/h (0,66)* l/h
Rated voltage 12 volts 12/24 volts 12 volts 12/24 volts
* Presetting of heater operating times is not possible for
TRS-operation Operating voltage range 10,5 – 15 10,5–15/21–30 volts 10,5 – 15 10,5–15/21–30
volts volts volts
Fuel for AT 3500/5000 B (Petrol): Rated power consumption control range 15 – 36 W 15 – 36 W 15 – 90 W 15 – 90 W 15 – 90 W
The fuel specified by the vehicle manufacturer is suitable Permissible ambient temperature:
as fuel for the heater. Heater: - operation -40°... +40°C
- storage -40°... +85°C
Fuel for AT 3500/5000 D (Diesel/Fuel Oil EL): Metering pump- operation -40°... +20°C
- storage -40°... +85°C
The Diesel fuel specified by the vehicle manufacturer is Heater control - operation -40°... +75°C
suitable as fuel for the heater. Also EL class fuel oil – not, - storage -40°... +85°C
however, L type fuel oil – can be used provided it conform-
Perm. combustion air intake -40°... +20°C
s to the usual quality on the German market in accordance temperature
with DIN 51603.
Setting range for interior +10 ... + 45 °C
Any negative effect caused by additives is not known. temperature
When the fuel for the heater
Flow rate of heating air against 139 m3/h 139 m3/h 218 m3/h 218 m3/h 218 m3/h
is drawn from the vehicle’s fuel tank, the vehicle manufac- 0.5 mbar
turer’s specifications concerning additives are to be ob-
CO2 content in exhaust gas 1,5 kW:5,0-8,0% 1,5 kW:5,0-8,0%
served. (permissible operating range) 3,5 kW:9,0-12,5% 5 kW:9,0-12,5%
When to changing to cold-resistant fuels, the heater must Dimensions of heater length 425 ± 2 mm
width 148 ± 1 mm
be operated for approx. 15 minutes to ensure that the fuel height148 ± 1 mm
pump is filled with the new fuel.
Weight of heater 5,9 Kg

23
Air Top 3500/5000

Version
Air Top 3500/5000 B (Petrol)
Type Air Top 3500/5000 B
Air heaters for petrol fuel
(12 volts)

Air Top 3500/5000 D (Diesel)

Type Air Top 3500/5000 D
Air heaters for
“Diesel/EL Fuel Oil EL”
(12 or 24 volts)

Air Top 3500 Volume Plus D

(Diesel)
Type Air Top 3500 D
Air heaters for
“Diesel/EL Fuel Oil EL”
(12 or 24 volts)

24
 Air Top 3500/5000

Gasket

NOTE:
Max. floor unevenness in the
vicinity of the gasket: 1mm

Fig. 34: Drilling template

25
Air Top 3500/5000

26
subject of modification Webasto Thermosysteme GmbH
82131 Stockdorf . Kraillinger Str. 5 . Telefon (089) 85794-0
Telefax (089) 8 57 94-448 . Telex 5 23 647 webas d
Air Top 3500/5000 2 General Description

2 General Description The heater may be controlled by means of an external

temperature sensor instead of the internal temperature
The air heaters Air Top 3500 and Air Top 5000 working to sensor.
the evaporator principle of operation basically consist of Fuel supply is provided by an external dosing pump.
the:
In case of a heater malfunction an error code is output to
– combustion and heating air fan the display of the combination timer. When equipped with
– heat exchanger a control element, the operating indicator light will flash.
– burner The heater may be additionally checked using a personal
– combustion tube computer (refer to operating instructions for PC heater
– control unit fault diagnosis).

For control and monitoring the following components are

located inside the air heater:

– control unit
– glow plug / flame sensor
– analogue temperature limiter
– temperature sensor

Air Heater Air Top 3500/5000

201
2 General Description Air Top 3500/5000

2.1 Combustion and Heating Air Fan 2.3 Burner with Combustion Tube

The combustion and heating air fan delivers the air Inside the burner insert fuel is distributed across the
necessary for combustion from the combustion air inlet combustion tube fuel cross section. Combustion of the
into the burner. The fan also supplies heating air to the fuel/air mixture takes place within the combustion tube to
heating air outlet. heat the heat exchanger.

Combustion tube

Burner

2.2 Heat Exchanger

Within the heat exchanger the air delivered by the

combustion and heating air fan is charged with the heat
generated by combustion.
or

Combustion tube

Burner with shield

202
Air Top 3500/5000 2 General Description

2.4 Control Unit 2.6 Analogue Temperature Limiter

The control unit ensures control and monitoring of The analogue temperature sensor protects the heater
combustion operation. A temperature sensor plugged on against undue high operating temperatures. For
the control unit is used for temperature control. On all protection against overheating the temperature limiter
heaters this temperature sensor may be substituted with responds at a heating air temperature higher than
an externally mounted temperature sensor. 150° C. The control unit disconnects the dosing pump
circuit and deactivates the heater with a run-down. After
In case of a heater malfunction an error code is output cooling down the circuit is re-established. The heater may
to the display of the combination timer. When equipped be reactivated by switching the heater off and on again
with a control element, the operating indicator light will using the control element.
flash.
The heater may be additionally checked using a personal
computer (refer to operating instructions for PC heater
fault diagnosis).

2.7 Dosing Pump

The dosing pump is a combined delivery, dosing and

shut-off system for the fuel supply of the heater out of the
vehicle fuel tank.

2.5 Glow Plug / Flame Sensor

The glow plug also functions as flame sensor.

The glow plug ignites the fuel/air mixture during heater
start. The glow plug represents an electrical resistance
and is located on the side of the burner exposed to the
flame.
When operating as a flame sensor the glow plug behaves
like a low Ohm PTC resistor changing its resistance
dependent on its heat-up by the flame.
The signals are routed to the control unit for processing.
The flame sensor monitors the flame-up condition
throughout the heater time of operation.

203
 Operating Instructions Maintenance and Safety Information
15. Webasto will not assume any liability if the installation instructions and the notes
Air Top 3500 / 5000 Webasto Thermosysteme GmbH
contained therein are not observed. The same applies to improperly performed repairs or
those where others than genuine replacement parts have been used. In those cases, the
Heaters 82131 Stockdorf’Kraillinger Str. 5’Telefon (089)8 57 94-0
Telefax (089) 8 57 94-448’Telex 5 23 647 webas d
heater’s General Design Certification and thus the General Operating Permit
(homologation) will be invalidated as a consequence.
16. Heating air inlet and outlet openings must be kept clear of dirt and objects.
Maintenance and Safety Information Contaminated or obstructed heating air ducts can result in overheating and thus tripping
1. Within the scope of the StVZO (German Road Licensing Regulations) General Design of the temperature limiter.
Certifications have been granted by the Federal Office for Motor Traffic for the Air Top 17. To prevent mechanical parts from seizing, the heater should be operated every 4
3500 / 5000 air heaters. weeks for approx. 10 minutes.
2. The installation of the heaters must be performed in accordance with the Installation
Instructions. If available, the approval certification is to be kept in the vehicle.
3. The year of the initial operation must be durably marked on the type plate of the
heater by removing the years that are not applicable.
4. The heaters are not approved for use in the cargo space of vehicles carrying
hazardous materials. When installing the AT 3500 / 5000 D heater in vehicles for the
Heater Control
transport of hazardous materials, the requirements laid down in TRS 002 and TRS 003 Any changes in the

!
(Technical Guidelines relating to the ordinance of transporting hazardous materials on
the road) must be fulfilled in addition to those of the StVZO.
settings adjusted at the
5. Claims can only be asserted if the claimant can prove that the maintenance and heater control will take
safety notes were adhered to. effect with some delay
6. Due to the danger of explosion the heater must be switched off at filling stations
and tank farms.
7. Due to the danger of poisoning or asphyxiation the heater must not be operated Rotary dial for:
in enclosed spaces (e.g. garages) without adequate exhaust extraction. This - turning on/off
should be considered when pre-setting heater operating times or using the - setting the desired room temperature
Telestart remote control. - deactivating any fault lock-out
8. The heater must be inspected by a qualified expert annually, preferably prior to the
heating season commencing. Operation indicator/fault code display
9. In the case of severe smoke development, unusual combustion noises or fuel smell,
the heater must be placed out of operation by removing the fuse and may only be
restarted after it was inspected by Webasto-trained personnel. Start-Up
10. At locations where combustible vapours or dust may accumulate (e.g. in the
Set the heater control to the desired temperature
vicinity of fuel, coal, sawdust and grain depots or the like) the heater must be
switched off due to the danger of explosion.
NOTE:

!
11. Whenever the heater is removed it is mandatory that the gasket located
underneath be replaced. To prevent any obstruction or chafing of the heating and combustion air fans make
12. The heat exchanger of the air heater is not to be used for longer than 10 years sure that no objects are deposited on the heater nor rest against it, before putting
and must thereafter be replaced by the manufacturer or one of the authorised the heater into operation.
3/9708

workshops with a genuine replacement part.

If exhaust pipes lead through passenger areas, these pipes must also be replaced
with genuine replacement parts after 10 years. Ventilation option
13. The fuel specified by the vehicle manufacturer is suitable as fuel for the heater . Both
A separately fitted switch provides you with the possibility to select between the "heating"
Ident-Nr. 776 247

leaded and unleaded fuel may be used.

14. The heater should not be exposed to temperatures greater than 85°C (storage and "ventilation" operating modes.
temperature). Exposure to such temperatures will cause permanent damage to the The fan speed in the ventilation operating mode depends on the heater control position.
electronics.
 Switching the Manually: by pressing the button (continuous heating mode)
Standard Timer / Automatically: by programming the heater starting time
heater on
Combination Timer Switching the Manually: by pressing the button
heater off Automatically: after the programmed operating time has elapsed
With the heater running: by programming the remaining operating time
day of the week heater "on" indicator temperature
selection Setting time/ Press the button for more than 2 seconds - time of the day is
time display flashing - and set the clock using the and buttons. Day of the
day of the
memory combination digital
week
week is flashing - adjust the day of the week.
location timer with temperature
selection only for Viewing With the ignition switched off: press the button
Air Top 2000/3500/ the time
alarm 5000 Programming Press the button - the memory location is flashing - using the
indicator and buttons set start of the heater operating time. Day of the week
Standard Timer with heater starting
is flashing - set the day of the week. By repeatedly pressing the
time alarm function time button, memory locations 2 and 3 can be programmed or the time
display mode can be reached.
program instant reverse forward Recalling/ Repeatedly press the button until the desired memory location is
selection heating erasing preset displayed. To erase the preset time, press the button several
times until the time of the day is displayed instead of the memory
times
Programming The heater must be switched off. Press the button for 3 seconds -
duration of operating time is flashing - and set the desired operating time (10 to
General The standard digital timer/combination timer enables you to preset 120 minutes) using the and buttons.
the start of the heater operation up to 7 days in advance. operating time
It is possible to program 3 different starting times, only one of which Setting the Set the desired remaining operating time (1 to 120 minutes) using
can be activated. remaining the and buttons. The remaining operating time refers to the
The standard digital timer features a wakeup alarm function. The time the heater still continues to remain in operation. It can only be
combination timer has a temperature controller. The combination operating time changed while the heater is in operation and the ignition switched off.
timer can only be used on Air Top 2000/3500/5000 heaters which
allow the temperature to be preselected. Setting the A wakeup time can only be programmed on the standard digital
When the ignition switched on, the timer displays the current time wakeup time timer. The wakeup time is not bound to a specific day of the week.
and the day of the week. When the heater is switched on, the display Repeatedly press the button until the bell symbol appears on
and the buttons are illuminated. the display. Set the desired wakeup time using the and
After the power supply has been connected, all symbols on the buttons.The alarm clock turns off after 5 minutes or when one of the
buttons is pressed.
display will flash. The current time and weekday must be set. No
display occurs in TRS vehicles.

Operation The timer can be operated in that all flashing symbols can be Recalling/ Repeatedly press the button until the bell symbol appears on
adjusted by means of the and buttons. If the buttons are not the display - read off wakeup time. To erase the wakeup time: press
pressed within 5 seconds, the time displayed will be stored. If the erasing the
the button until the bell symbol is no longer visible on the
and buttons are pressed for more than 2 seconds, the fast wakeup time display.
time-setting mode is activated.
If the ignition is switched off while the heater is operating in the
continuous mode, the remaining operating time of 15 minutes is Remote control Possible by means of an optional external "instant heating" button
displayed and the heater continues to operate for this period of time.
Air Top On heaters equipped with a fault diagnosis system (Air Top 3500/ Vehicles On TRS vehicles it is not possible to program a preset starting time.
3500/5000 5000), a number, i.e. the error code, may be flashing on the display. with TRS The remaining time is shown on the display while the heater is in
In this case, please consult your Webasto dealer. operation. The clock can be set. The alarm clock function can be
equipment programmed on the standard digital timer.
Troubleshooting Fault Codes on the Display of the Combination or Standard Digital Timer
In the event of a malfunction, fuses and electrical connections should be checked for
condition and security.
NOTE:

!
If the actions described below do not correct the malfunction, consult your authorized
Webasto dealer. If the heater is equipped with a heater control, the fault codes are signalled by a
flashing operation indicator/fault code indicator. The coded flashing signals
Heater turns itself off automatically correspond to the numbers in the table below. After every fast pulse sequence, a
fault code follows.
Cause Remedy
Combustion was not established Switch heater briefly off and on again one time
during start-up and repeated
start-up sequence F 00 Control unit failure

Flame extinguishes during operation Switch heater briefly off and on again one time F 01 No start-up (after 2 start-up attempts)

Heater overheats Check heating air ducts for unobstructed passage, F 02 Flame extinguished (at least > 5)
Operation indicator is flashing allow heater to cool,
switch heater briefly off and on again one time F 03 Undervoltage or overvoltage

F 04 Premature flame detection

Vehicle voltage insufficient Charge battery
Switch heater briefly off and on again one time F 05 Flame detector interruption or
Heater emits black smoke flame detector short-circuit

Cause Remedy F 06 Temperature sensor interruption or

Combustion air and/or Check combustion air and exhaust gas ducts for temperature sensor short-circuit
exhaust gas ducts obstructed unobstructed passage
F 07 Metering pump interruption or
metering pump short-circuit

F 08 Fan motor interruption or

fan motor short-circuit or
NOTE for "TRS" mode of operation only:

!
incorrect fan motor speed
Following a "TRS" fault lock-out situation or upon applying the operating voltage by
turning on the vehicle main switch and moving the heater control to the "ON" F 09 Pencil-type glow plug interruption or
position, the control unit is in the "fault lock-out" state. pencil-type glow plug short-circuit
Before the heater can be restarted, the heater control must be turned to the "OFF"
position or the instant heat button on the combination or standard digital timer must F 10 Overheating
be pressed.
F 11 Temperature limiter interruption or
temperature limiter short-circuit

F 12 Setpoint transmitter (interruption / short-circuit)

Fault Code Display
If the heater is equipped with a combination or standard digital timer, a fault code is
indicated on the display of the digital timer whenever a malfunction has occurred.

The meanings of the fault codes are listed on the last page.
Air Top 3500/5000 5 Troubleshooting

5 Troubleshooting CAUTION
Troubleshooting is normally limited to the isolation of
defective components. The following possible causes for
5.1 General trouble have not been taken into consideration and must
always be excluded as a possible cause or reason for
This section describes the troubleshooting for the heater malfunctions:
Air Top 3500 and Air Top 5000.
• corrosion on connectors
After heater malfunction an error code is output to the • loose contacts on connectors
display of the combination or standard timer. When • wrong crimping on connectors
equipped with a control element the operating indicator • corrosion on wiring and fuses
light will flash. The heater may also be checked with a • corrosion on battery terminals
personal computer (refer to Operating Instructions PC
Heater Fault Diagnosis). For checking individual components the electrical
connectors on the control unit must be disconnected.
CAUTION
Troubleshooting requires profound knowledge about After any fault correction a functional checkout in the
components and their theory of operation and may only be vehicle has to be performed.
performed by trained personnel. In case of doubt
functional interrelations may be derived from Sections 5.2 General Failure Symptoms
2 and 3.
The following table (Fig. 501) lists possible failure
NOTE symptoms of general nature.
For ADR operation only
When applying electrical power with the control element
still set to "on", e.g. by closing the battery switch, as well
as after a ADR switch-off, the control unit will go in error
lockout. For re-activation the control element must be
momentarily switched off and on again or the instant heat
switch on the combination timer be operated.

Symptom Probable Cause Remedy

Heater does not switch off No combustion after start and Switch off heater momentarily and
automatically restart switch on once again

Flame-out during operation Switch off heater momentarily and

switch on once again

Heater overheats Check heating air ducting for

Operating indicator light flashes obstructions, allow heater to cool
down,
switch off heater momentarily and
switch on once again

Vehicle electrical system power Charge vehicle battery

supply underpowered Switch off heater momentarily and
switch on once again

Heater develops black smoke Combustion air and/or exhaust Check combustion air and exhaust
ducting obstructed ducting for obstructions

Fig. 501 General Failure Symptoms

501
5 Troubleshooting Air Top 3500/5000

5.3 Failure Symptoms during Operational Should the symptom not be listed in the table or the fault
Sequence of a symptom listed, cannot be isolated our technicians
are available in emergencies
(service telephone 0 89 / 8 57 94 - 5 12).
The following table (Fig. 502) lists possible failure
symptoms in the time pattern of the functional sequence.
NOTE
Overheating and dosing pump failure are always and
In case of a malfunction this table is to be used for
additionally indicated by a flashing LED of the control
isolation and removal of the malfunction. It is important to
element after run-down.
clearly identify the failure symptoms.
In all cases of malfunction, a faulty control unit could be
the cause should the remaining components be
serviceable.

Symptom Symptom shows after ...s Probable Causes

No start-up and no illumination of immediately Wrong wiring, defective fuse

LED of control element

No start-up but LED comes on immediately Fan or control unit defective or fan blocked

Very low speed without start immediately Control idle operation: wrong manual setting
(selected temperature on control element below
air intake temperature) or wrong heater
integration (excessive air intake temperature)

Motor starts to run up but then 1 Glow plug/flame sensor open or short circuit or
stops control unit defective

Stop without run-down 5 Fan motor seized or not moving freely

Run-down after 1 Wrong flame detection

Run-down after 20 Control unit electrical supply underpowered

Run-down after 120 Wiring to dosing pump, pump itself or

and dosing pump does not cycle temperature limiter defective

Run-down after 40 to 120 Short time interruption of connection to dosing

pump or to temperature limiter

Run-down after 230 No flame: wrong fuel quantity, defective fan or

fan too slow, coked burner, combustion air/
exhaust ducting obstructed or heat exchanger
coked, dosing pump seized

Run-down during combustion Overheating or voltage too low or component

operation failure (glow plug/flame sensor, temperature
limiter, dosing pump, burner) or no fuel supply
or combustion air/exhaust ducting obstructed

Stop without run-down during combustion Fan motor failure or seizure

operation

Interruption of dosing pump cycle during combustion Flame-out by gas bubbles in fuel supply or
and max. speed for 30 sec with operation strong head wind at exhaust outlet or no flame
subsequent restart detection erroneous

Fig. 502 Failure Symptoms during Operational Sequence

502
Air Top 3500/5000 5 Troubleshooting

5.4 Error Code Output

When equipped with a combination timer a malfunction

will output an error code to the timer display.

NOTE
When equipped with a control element the error code
output after a malfunction will be a flashing operating
indicator light/error code indication. The flash pulses
correspond to the number of the table below. After a rapid
pulse train there will always be an error code output.

Error code output on display of combination timer

F 00 control unit malfunction / wrong parameter set /

warm start detection

F 01 no start (after 2 start attempts) / no flame-up

F 02 flame-out (repeated > 5)

F 03 voltage too low or too high

F 04 premature flame detection

F 06 temperature sensor open circuit or

temperature sensor short circuit

F 07 dosing pump open circuit or

dosing pump short circuit

F 08 fan motor open circuit or

fan motor short circuit or
fan motor wrong speed

F 09 glow plug/flame sensor open circuit or

glow plug/flame sensor short circuit

F 10 overheating

F 11 temperature limiter open circuit or

temperature limiter short circuit

F 12 control element (open circuit/short circuit)

503
Air Top 3500/5000 7 Circuit Diagrams

7 Circuit Diagrams

7.1 General

The heater Air Top 3500 and Air Top 5000 may be
operated with the control element (rated value setting/
switch) or with a combination timer.
The circuit diagrams (Fig. 702 to 706) show possible 12 V
or 24 V circuits with:

• control element
• combination timer
• combination timer and battery switch
• control element for ADR
• ADR operation for vehicles without secondary drive

Fig. 701 shows the control unit pin assignment.

Wiring harness
Temperature sensor

Dosing pump Wiring harness

10
12
2
4
6

8
1

11
9
3
5

7
2
1

2
1

2
1

Control unit

Glow plug /
flame sensor
2
1

Combustion and
heating air fan
2
1

2
1

Temperature limiter

Fig. 701 Control Unit Pin Assignment, Air Top 3500/5000

701
7 Circuit Diagrams Air Top 3500/5000

ϑ ϑ

2 Diagnosis line K Wire Colours

Wire Gauges
3 Diagnosis line L bl blue
< 7.5 m 7.5 - 15 m
br brown
4 Input pin (pin 7/connector X7), wire colour on wiring harness: ws/rt): 0.75 mm2 1.5 mm2
ge yellow
"ventilate" (fan speed is dependent on control element position) 1.0 mm2 1.5 mm2
gn green
1.5 mm2 2.5 mm2
5 CO2 adjustment gr grey
2.5 mm2 4.0 mm2
or orange
4.0 mm2 6.0 mm2
rt red
sw black
vi violet
ws white

Item Nomenclature Remark

Item Nomenclature Remark
A1 Heater Air Top 3500/5000
X7 Connection 12-pole on item A2 (ST 1)
A2 Control unit
X8 Connection 2-pole
B2 Temperature sensor
X9 Connection 4-pole on item S1
B3 Temperature limiter Overheat protection
X10 Connection 2-pole
E Glow plug / flame sensor
X11 Connection 2-pole on item Y1
F1 Fuse 24V 15A / 12V 20A Flat fuse SAE J 1284
Y1 Dosing pump
H1 LED green (in item S1) Operating indicator light
M1 Motor Combustion and heating air fan
S1 Control element Rated value transmitter-switch
S6 Switch Ventilate
X1 Connection 2-pole on item A2 (ST B)
X2 Connection 2-pole on item A2 (ST V)
X3 Connection 2-pole on item A2 (ST U)
X4 Connection 2-pole on item A2 (ST Z)
X5 Connection 2-pole on item A2 (ST Y)
X6 Connection 2-pole on item A2 (ST X)

Fig. 702 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Control Element
Air Top 3500/5000 7 Circuit Diagrams

30 30
15 15
58 58
X1/X2
1 6

5 2
F3 F1 1 2 X8
1,0 mm²

2
1

0,5mm²

0,5mm²
gn/ws
X3/X4/X5/X6

br
X7 3

rt
1 10 11
4 9 10 12
2 A2 2
1
2 0,5mm² sw 6 3
X7
H4 0,5mm² ge/rt
7 4
H5 H3 8 1
0,5mm² bl
6 11
2
11
8 9
0,5mm² ws 7
5
P 1 3
9 5 1
12 7 4
X6 X8
X12 1 1 2 1 2 2 2
2 1 1

0,5mm² ws/rt
AT 3500: rt X1 br ge X2 ge ws X3 ws X4 X5
AT 5000: sw K
M ϑ ϑ 2 1
M1 E B3 B2 X10/X11
A1
1 2

0,6mm²

0,6mm²
sw

sw
1,0 mm²

S7 X10 1 2
S6
br

br
bl
3 2 X12
X11 1

6, 5, 4
9, 8, 7
Y1
12, 11, 10

31

1 With plus from terminal (15/75) to connection 10: Wire Colours

continuous operation in instant heating as long as ignition is on
Wire Gauges
Without plus to connection 10: bl blue
< 7.5 m 7.5 - 15 m
heating time programmable as required (10 min to 120 min), br brown
default setting 120 min 0.75 mm2 1.5 mm2
ge yellow
1.0 mm2 1.5 mm2
gn green
2 Diagnosis line K 1.5 mm2 2.5 mm2
gr grey
2.5 mm2 4.0 mm2
3 Diagnosis line L or orange
4.0 mm2 6.0 mm2
rt red
4 Input pin (pin 7/connector X7), wire colour on wiring harness: ws/rt):
sw black
"ventilate" (fan speed is dependent on control element position)
vi violet
5 CO2 adjustment ws white

6 NOTE
Connection to terminal 30 enables continuous heating operation with ignition off!
In this case no connection to terminal 15/75 must be made!

Item Nomenclature Remark Item Nomenclature Remark

A1 Heater Air Top 3500/5000 X2 Connection 2-pole on item A2 (ST V)
A2 Control unit X3 Connection 2-pole on item A2 (ST U)
B2 Temperature sensor X4 Connection 2-pole on item A2 (ST Z)
B3 Temperature limiter Overheat protection X5 Connection 2-pole on item A2 (ST Y)
E Glow plug / flame sensor X6 Connection 2-pole on item A2 (ST X)
F1 Fuse 24V 15A / 12V 20A Flat fuse SAE J 1284 X7 Connection 12-pole on item A2 (ST 1)
F3 Fuse max. 15A Flat fuse SAE J 1284 X8 Connection 2-pole
H3 LED red (in item P) Instant heat switch illumination, X10 Connection 2-pole
standby indication, X11 Connection 2-pole on item Y1
operating indicator light
X12 Connection 12-pole on item P
H4 Heating symbol in display Operating indication
Y1 Dosing pump
(in item P)
H5 Lights (in item P) Display and push button switch
illumination
M1 Motor Combustion and heating air fan
P Combination timer Timer and rated value
transmitter
S6 Switch Ventilate
S7 Push button switch Instant heat switch remote
control
X1 Connection 2-pole on item A2 (ST B)

Fig. 703 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer

703
7 Circuit Diagrams Air Top 3500/5000

58 58
15 15
30 30
X1/X2
1
88 86a
S8 5 2
F3 86 F1 1 2 X8
1,0 mm²

2
1

0,5mm²

0,5mm²
gn/ws
V1 V2 X3/X4/X5/X6

br
X7 3

rt
1 10 11
4 9 10 12
2 A2 2
1
2 0,5mm² sw 6 3
X7
H4 0,5mm² ge/rt
7 4

0,5mm² sw/rt
H5 H3 8 1
0,5mm² bl
6 11
2
11
8 9
0,5mm² ws 7
5
P 1 3
9 5 1
12 7 4
X6 X8
X12 1 1 2 1 2 2 2
2 1 1

0,5mm² ws/rt
AT 3500: rt X1 br ge X2 ge ws X3 ws X4 X5
AT 5000: sw M ϑ ϑ 2 1
M1 E B3 B2 X10/X11
A1
1 2
0,6mm²

0,6mm²
sw

sw
1,0 mm²

S7 X10 1 2
S6
br

br
bl

X11 3 2 X12
1

6, 5, 4
Y1 9, 8, 7
12, 11, 10
31

1 With plus from terminal (15/75) to connection 10: Wire Colours

continuous operation in instant heating as long as ignition is on Wire Gauges
Without plus to connection 10: bl blue
heating time programmable as required (10 min to 120 min), < 7.5 m 7.5 - 15 m
br brown
default setting 120 min 0.75 mm2 1.5 mm2
ge yellow
1.0 mm2 1.5 mm2
2 Diagnosis line K gn green
1.5 mm2 2.5 mm2
gr grey
2.5 mm2 4.0 mm2
3 Diagnosis line L or orange
4.0 mm2 6.0 mm2
rt red
4 Input pin (pin 7/connector X7), wire colour on wiring harness: ws/rt):
"ventilate" (fan speed is dependent on control element position)
sw black
vi violet
5 CO2 adjustment ws white

Item Nomenclature Remark Item Nomenclature Remark

A1 Heater Air Top 3500/5000 V1 Diode
A2 Control unit V2 Diode
B2 Temperature sensor X1 Connection 2-pole on item A2 (ST B)
B3 Temperature limiter Overheat protection X2 Connection 2-pole on item A2 (ST V)
E Glow plug / flame sensor X3 Connection 2-pole on item A2 (ST U)
F1 Fuse 24V 15A / 12V 20A Flat fuse SAE J 1284 X4 Connection 2-pole on item A2 (ST Z)
F3 Fuse max. 15A Flat fuse SAE J 1284 X5 Connection 2-pole on item A2 (ST Y)
H3 LED red (in item P) Instant heat switch illumination, X6 Connection 2-pole on item A2 (ST X)
standby indication, X7 Connection 12-pole on item A2 (ST 1)
operating indicator light
X8 Connection 2-pole
H4 Heating symbol in display Operating indication
X10 Connection 2-pole
(in item P)
X11 Connection 2-pole on item Y1
H5 Lights (in item P) Display and push button switch
illumination X12 Connection 12-pole on item P
M1 Motor Combustion and heating air fan Y1 Dosing pump
P Combination timer (1631) Timer and rated value transmitter
S6 Switch Ventilate
S7 Push button switch Instant heat switch remote
control
S8 Battery switch

Fig. 704 Automatic Switching Circuit Air Top 3500/5000, 12 V/24 V with Combination Timer and Battery Switch

704
Air Top 3500/5000 7 Circuit Diagrams

ϑ ϑ

2 Diagnosis line K Wire Colours

Wire Gauges
3 Diagnosis line L bl blue
< 7.5 m 7.5 - 15 m
br brown
4 Input pin (pin 7/connector X7), wire colour on wiring harness: ws/rt): 0.75 mm2 1.5 mm2
ge yellow
"ventilate" (fan speed is dependent on control element position) 1.0 mm2 1.5 mm2
gn green
1.5 mm2 2.5 mm2
5 CO2 adjustment gr grey
2.5 mm2 4.0 mm2
or orange
4.0 mm2 6.0 mm2
7 NOTE rt red
Grey and violet wires required for ADR function
sw black
vi violet
ws white

Item Nomenclature Remark Item Nomenclature Remark

A1 Heater Air Top 3500/5000 X4 Connection 2-pole on item A2 (ST Z)
A2 Control unit X5 Connection 2-pole on item A2 (ST Y)
B2 Temperature sensor X6 Connection 2-pole on item A2 (ST X)
B3 Temperature limiter Overheat protection X7 Connection 12-pole on item A2 (ST 1)
E Glow plug / flame sensor X8 Connection 2-pole
F1 Fuse 24V 15A / 12V 20A Flat fuse SAE J 1284 X9 Connection 4-pole on item S1
H1 LED green (in item S1) Operating indicator light X10 Connection 2-pole
H6 Light (min. 1.2W) Operating indicator light X11 Connection 2-pole on item Y1
conveyor installation Y1 Dosing pump
M1 Motor Combustion and heating air fan Y2 Solenoid valve
S1 Control element Rated value transmitter-switch
S2 Disconnect switch 1- or 2-pole Emergency off switch
S3 Switch On or for conveyor installation
S6 Switch Boost or Ventilate
X1 Connection 2-pole on item A2 (ST B)
X2 Connection 2-pole on item A2 (ST V)
X3 Connection 2-pole on item A2 (ST U)

Fig. 705 Automatic Switching Circuit Air Top 3500/5000, 24 V ADR Operation with Control Element

705
7 Circuit Diagrams Air Top 3500/5000

ϑ ϑ

2 Diagnosis line K Wire Colours

Wire Gauges
3 Diagnosis line L bl blue
< 7.5 m 7.5 - 15 m
br brown
4 Input pin (pin 7/connector X7), wire colour on wiring harness: ws/rt): 0.75 mm2 1.5 mm2
ge yellow
"ventilate" (fan speed is dependent on control element position) 1.0 mm2 1.5 mm2
gn green
1.5 mm2 2.5 mm2
5 CO2 adjustment gr grey
2.5 mm2 4.0 mm2
or orange
7 NOTE 4.0 mm2 6.0 mm2
rt red
Grey and violet wires required for ADR function
sw black
vi violet
ws white

Item Nomenclature Remark Item Nomenclature Remark

A1 Heater Air Top 3500/5000 X7 Connection 12-pole on item A2 (ST 1)
A2 Control unit X8 Connection 2-pole
B2 Temperature sensor X9 Connection 4-pole on item S1
B3 Temperature limiter Overheat protection X10 Connection 2-pole
E Glow plug / flame sensor X11 Connection 2-pole on item Y1
F1 Fuse 24V 15A / 12V 20A Flat fuse SAE J 1284 Y1 Dosing pump
H1 LED green (in item P1) Operating indicator light
M1 Motor Combustion and heating air fan
S1 Control element Rated value transmitter-switch
S2 Disconnect switch 1- or 2-pole Emergency off switch
X1 Connection 2-pole on item A2 (ST B)
X2 Connection 2-pole on item A2 (ST V)
X3 Connection 2-pole on item A2 (ST U)
X4 Connection 2-pole on item A2 (ST Z)
X5 Connection 2-pole on item A2 (ST Y)
X6 Connection 2-pole on item A2 (ST X)

Fig. 706 Automatic Switching Circuit Air Top 3500/5000, 24 V ADR Operation with
Control Element and no Auxiliary Drive

706
Air Top 3500/5000 8 Servicing

8 Servicing To ensure functional reliability of the heater the following

servicing must be performed:

8.1 General • inspect heating air inlet and outlet for contamination
and foreign matter. (Contaminations or obstructions in
This section describes the servicing procedures allowed heating air lines may cause overheating and thus
on the heater when installed. response of the temperature limiter.)
• clean heater exterior (prevent the ingress of water).
• examine electrical connections for corrosion of
8.2 Work on the Heater
contacts and for security.
• inspect combustion air and exhaust ducting for
For any type of work on the heater the fuses for the heater damage and obstructions.
must be removed. As long as the heater is in operation or • inspect fuel lines and fuel filter for leakage.
in run-down the battery main power supply must not be • replace fuel filter, if installed.
disconnected to prevent the heater from overheating by
response of the overheat protection.
8.6 Visual Inspections and Installation
Repairs requiring a change of location the relevant Regulations
installation instructions and the vehicle specific heater
installation proposal have to be observed. 8.6.1 Heating Air System

8.3 Work on the Vehicle CAUTION

Integration of the heater in the vehicles own air ducting is
CAUTION not allowed due to the high pressure in the vehicle
In the vicinity of the heater a temperature of 85° C must system.
under no circumstances be exceeded (e.g. during paint
work on the vehicle). Both the circulation and ventilation mode of operation are
permitted. In fresh air ventilation mode ensure to use
heating air only from areas protected against splash and
8.4 Heater Test Run spray water.
On the air intake side of the heater a temperature sensor
WARNING is located, which in combination with the control element,
The heater must not be operated in enclosed areas like makes the heater operate with adequate heating
garages or workshops not provided with exhaust performance dependent on air intake temperature and
ventilation facilities. control element setting. Heating performance is set so
that after fast heat-up to the preselected indoor
CAUTION temperature this temperature will be maintained.
Operation of the heater without control unit cover is not
permitted and causes overheating. NOTE
In the fresh air ventilation mode of operation or when
8.5 Servicing installing the heater in an installation box, an external
temperature sensor must be mounted in the room area to
NOTE be under heat control!
To prevent seizure of mechanical components the heater
should be operated every 4 weeks for at least 10 minutes. The temperature sensor must not be mounted on exterior
walls without insulation. It must also be protected against
The heater does not require any maintenance. It should direct exposure to sun and draught wind.
however be inspected in regular intervals by Webasto
trained maintenance personnel, the latest date for Minimum inner diameter of heating air duct:
inspection being the start of the heating season (point of 80 mm Air Top 3500
time with increased use of heater). 90 mm Air Top 5000

NOTE
For heating air ducting only materials with a temperature
resistance of at least 150° C may be used. The heating air
opening is to be located so that components not
temperature resistant are exposed to the heating air flow.

801
8 Servicing Air Top 3500/5000

Maximum pressure drop between suction and pressure 8.6.2.1 Fuel Tapping
side of heating air duct:
2.0 mbar (20 mm water column) Air Top 3500 Diesel fuel tapping must be from the fuel tank or a
3.0 mbar (30 mm water column) Air Top 5000 separate fuel reservoir (Fig. 802, 803 and 804). This
separate fuel tapping avoids an influence on the pressure.
NOTE
Exceeding this value will cause the temperature limiter to
respond. The heating air hose connections must be
secured. HG
HG

In the air circulation mode the heater may be used without

any accessories for heating air ducting. A short circuit of
the heating air flow should be avoided.
max. 3 m
8.6.2 Fuel Supply
l2
Fuel supply is from the vehicle fuel tank or a separate fuel
reservoir. Fig. 801 lists the pressure permitted at the fuel
tapping location. i ø 2 mm

Permitted fuel feed height at max. permissible

(H) m overpressure (bar) in H
i ø 2 mm
fuel line
0.00 0.20
1.00 0.11
2.00 0.03 HG
HG
Permitted suction height at max. permissible l1
S (m) negative pressure (bar) in i ø 2 mm
fuel tank
l2
i ø 2 mm
0.00 –0.10
S
0.50 –0.06
1.00 –0.02
l1
l1 + l2 ≤ 10 m
l1 ≤ 1.2 m
l2 ≤ 8.8 m

Fig. 801 Fuel Supply

802
Air Top 3500/5000 8 Servicing

Hole Pattern Fuel Tank Tap

25
Gasket

Tank Fitting Plate

> 25 mm

Fig. 802 Webasto Fuel Tap*

*Fuel tap to be used only for metal fuel tanks

Fig. 804 Fuel Tapping from Plastic Tank

(tapping via fitting plate)

NOTE
Plastic tank Tank fitting plate to be made from sheet metal!

8.6.2.2 Fuel Lines

Fuel lines may only be steel, copper, or plastic lines made

of unhardened, light and temperature stabilised PA 11
or PA 12 (e.g. Mecanyl RWTL) according to DIN 73378.
A descending line routing from the dosing pump to the
heater should be avoided.
As a permanently rising fuel line routing cannot always be
ensured, the inner diameter must not exceed a certain
Gasket value. Too large inner diameters cause air or gas bubbles
to accumulate resulting in malfunctions should the lines
be descending or having sags. The diameters specified in
Fig. 801 ensure no disturbing formation of bubbles.

Loose fuel lines must be secured in order to avoid

sagging. The installation must ensure protection against
stone impacts and undue temperatures (exhaust line).
Fuel line connections must be secured against slippage
using hose clamps.
Fig. 803 Fuel Tapping from Plastic Tank
(tapping via fuel drain plug)

803
8 Servicing Air Top 3500/5000

Connection of 2 Pipes with Hose 8.6.3.1 Installation Position

The correct connection of fuel lines with hoses is shown in It is advantageous to mount the dosing pump in a cool
Fig. 805. location. The ambient temperature must never exceed
+20° C during operation.
Dosing pump and fuel lines must not be installed in
locations exposed to heat radiated by hot vehicle
correct
components (e.g. exhaust line). A heat shield is to be
provided as necessary.
hose clamp
8.6.3.2 Installation and Attachment

wrong The dosing pump is to be attached with an anti-vibration

mount. The installation location is limited according to
bubble bubble Fig. 806 to ensure sufficient self-venting capability. Due to
the danger of corrosion only Webasto original parts may
be used for the plug connection between dosing pump
and dosing pump wiring harness.

8.6.4 Fuel Filter

Fig. 805 Pipe/Hose Connection
If fuel contaminations are expected, only Webasto filter
order no. 487 171 may be used. The filter installation
8.6.3 Dosing Pump should be vertical and never exceed horizontal (observe
direction of flow).
The dosing pump is a combined delivery, dosing and
shut-off system and is subject to certain installation
criteria (Fig. 801 and 806).

0 - 90°

0 - 90° 0 - 90°
0° ø5

Fig. 807 Fuel Filter

12 Volt and 24 Volt
Installation position horizontal only

Fig. 806 Dosing Pump, Installation Position

804
Air Top 3500/5000 8 Servicing

8.6.5 Combustion Air Supply 8.6.7 Combustion Air Intake and Exhaust Lines

The combustion air must not be taken in from rooms Max. total length of the combustion air intake and exhaust
accommodating persons. The intake must not point in the line:
direction of forward motion. The combustion air intake with muffler: max. 2.6 m
must be located so that clogging by contamination is not without muffler: max. 5.6 m
to be expected.
The use of an air intake muffler or an equivalent air intake Both lines are to be routed away from the heater in a
extension is necessary. descent. If this is not possible, a condensate drain hole
with a diameter of 4 mm must be provided at the lowest
If the heater is contained in an installation box, the point.
combustion air must be taken in from and the exhaust
vented to the exterior. The line feedthroughs must not Inner diameter of the lines:
allow exhaust fumes to enter the vehicle interior. combustion air intake line: 25 mm
exhaust line (metal): 24 mm
In order to avoid damage to the dosing pump cable, no
exhaust line must be used for extension of the combustion NOTE
air supply line. Exhaust line lengths exceeding 2 m require the use of
insulated exhaust lines (dew point below minimum).

8.6.6 Exhaust Line Smallest bending radius: 50 mm

Rigid pipes of unalloyed steel with a minimum wall Sum of bends:

thickness of 1.0 mm or flexible hoses of alloyed steel only combustion air intake line: max. 270°
may be used as exhaust ducts. The exhaust line is exhaust line: max. 270°
fastened to the heater e.g. with a hose clamp.

The exhaust muffler is to be preferably mounted near the

heater, the direction of flow is optional.
Operation of the heater is also permitted without exhaust
muffler.

ø 6,5

Direction of exhaust
Fig. 808 Exhaust Muffler, Direction of Flow 10° 10° flow nearly vertical
90° ± 10°

Fig. 809 Installation Arrangement of Exhaust Pipe Outlet

In order to ensure an angle of 90° ± 10°, an attachment is

required away not more than 150 mm from the exhaust
pipe end.

WARNING
Any other installation of the exhaust pipe outlet as shown
in Fig. 809 will provoke the danger of fires.

805
8 Servicing Air Top 3500/5000

8.6.8 Electrical Connections 8.6.8.3 Connection of Control Element

8.6.8.1 Connection of Heater, Control Element The wiring harness is prepared for connection to the
control element (rated value transmitter).
The electrical connection is according to the circuit For disconnection of the connector simply pull on the
diagram (see Section 7). connector terminal (Fig. 813). Pulling on the wiring
For connection to the wiring harness the cover on the harness will lock the connector (self-locking).
heater must be removed and the wiring harness
connector be plugged onto the heater.

Prior to first operation of the heater the cover must be

fitted to avoid undue escape of heating air (heater
overheating). The cable passage may be on the left or
right.

8.6.8.2 Connection of Power Supply

Light guide
Preferably from the vehicle central electrics.

For heater protection an additional flat fuse holder

(included in the heater delivery) must be fitted. The fuse Fig. 812 Control Element
holder may only be installed in the vehicle interior.
NOTE
Light guide must contact rotary knob.

Fig. 810 Removal of the Fuse Holder Mounting Plate

F = 10A 24V
15A 12V

Fig. 811 Fuse Holder Installation Position

Fig. 813 Pulling the Connector

806
Air Top 3500/5000 8 Servicing

7
2

4
3 5
6

1 Control element
2 Heater
3 Dosing pump
4 Fuel filter (accessory)
5 Fuel tap
6 Exhaust muffler (accessory)
7 Flat fuse holder

Fig. 814 Sample Installation of Air Heater for Air Circulation Mode of Operation

807
8 Servicing Air Top 3500/5000

8.7 Removal and Installation 8.8 Initial Operation

CAUTION After heater installation the fuel supply system must be

With the heater installed no component removal or carefully bled.
disassembly procedures are permitted.
NOTE
Due to the low fuel consumption it is required to switch the
8.7.1 Heater, Removal and Installation heater several times on and off for priming the fuel line.

8.7.1.1 Removal During the heater test run inspect all connections for
leakage and security. Should the heater during operation
1. Disconnect vehicle battery. enter an error lockout condition, perform troubleshooting.
2. Remove cover from upper housing shell according to
9.2.1.1.
3. Disconnect wiring harness connector from heater.
4. Disconnect fuel supply line from heater.
5. Disconnect combustion air intake line and exhaust
line from heater.
6. Remove four nuts and washers from heater.
7. Remove heater and discard gasket.

8.7.1.2 Installation

1. Locate heater with new gasket for installation and

secure with four nuts and washers (use Webasto
original nuts only).
2. Tighten nuts with 6 + 1 Nm.
3. Connect and secure fuel supply line to heater.
4. Connect and secure combustion air intake line and
exhaust line to heater.
5. Route cable to dosing pump and connect to dosing
pump.
6. Connect wiring harness connector to control unit.
7. Plug on cover and arrest.
8. Reconnect vehicle battery.
9. Bleed fuel supply system.

808
Air Top 3500 / 5000
Sectional View

31.08.01 / a3010101 / WTI / ATT-T

Air Top 3500 / 5000
Heater dimensions

7 148

47,5 6
148 >200

ø25 ø24

25
4 1 2 5
151 3
>45 423 >80

1 Combustion air inlet

2 Exhaust gas outlet
3 Fuel inlet
4 Space requirement for heating air inlet
5 Space requirement for heating air outlet
6 Space requirement for removal of unit
7 Cable outlet (optionally right or left)
31.08.01 / a3070103 / WTI / ATT-T
Air Top 3500 / 5000
Permissible installation positions
Diesel-operated heaters

Check for proper clearances!

Petrol-operated heaters

31.08.01 / a3070102 / WTI / ATT-T

Air Top 3500 / 5000
Technical data
Heater Operation Air Top 3500 B Air Top 3500 D Air Top 5000 B Air Top 5000 D
Mark of approval ~~~ S 305 ~~~ S 306 ~~~ S 304 ~~~ S 303
Type Air heater with vaporising-type burner
Heat output control range 1.5 - 3.5 kW 1.5 - 5.0 (5.5) 1) kW
Fuel Petrol Diesel Petrol Diesel
Fuel consumption control range 0.19 - 0.46 l/h 0.17 - 0.42 l/h 0.19 - 0.66 l/h 0.17 - 0.60 l/h
(0.73) 1) l/h (0.66) 1) l/h
Rated voltage 12 V 12/24 V 12 V 12/24 V
Operating voltage range 10.5 - 15 V 10.5 - 15/ 10.5 - 15 V 10.5 - 15/
21 - 30 V 21 - 30 V
Rated power consumption control range 15 - 36 W 15 - 90 W
Permissible ambient temperatures:
Heater
– operation - 40 – + 40 °C
– storage - 40 – + 85 °C
Metering pump
– operation - 40 – + 20 °C
– storage - 40 – + 85 °C
Heater control
– operation - 40 – + 75 °C
– storage - 40 – + 85 °C
Perm. combustion air intake temperature - 40 – + 20 °C
Adjusting range for inside temperature + 10 – + 45 °C
Flow rate of heating air against 0.5 mbar max. 139 m3/h max. 218 m3/h
CO2 content in exhaust gas (perm. 1.5 kW: 5.0 – 8.0 % 1.5 kW: 5.0 – 8.0 %
operating range) 3.5 kW: 9.0 – 12.5 % 5.0 kW: 9.0 – 12.5 %
Dimensions of the heater length 425 ± 2 mm
width 148 ± 1 mm
height 148 ± 1 mm
Weight of the heater 5.9 kg
1) Booster stage, max 30 min

31.08.01 / a3070101 / WTI / ATT-T

Air Top 3500 / 5000
Overview

31.08.01 / a3010100 / WTI / ATT-T

Air Top 3500 / Air Top 5000
DELIVERY VOLUME Item Qty. Description
2
3 1 1 heater ** 12 or 24V
19 28 2 1 heater control element 12 or 24 V
27
18 3 1 panel with ventilation switch (part of ’boat’ delivery volume)
6 4 1 metering pump * 12 or 24 V (with mounting)
1 5 1 stand for metering pump (part of ’boat’ delivery volume)
6 1 wiring harness (heater) (part of ’boat’ delivery volume, 9.5 m)
7 7 1 wiring harness (metering pump) 7000 lg.
13 8 8 1 gasket
9 1 flexible pipe compl. 12 V: 1100 lg.; 24V: 800 lg.
(not part of ’boat’ delivery volume)
24 10 1 exhaust silencer leakproof 1500 lg.;
26 9 11 1 fitting (part of ’boat’ delivery volume)
22
23 12 1 fuel hose * 12 V: 5000 lg.; 24V: 8000 lg.
11 13 1 grid heater
14
10 14 1 air intake silencer Ø 25; 650 lg.
15 1 fuel extractor * (for 12 V)
12 (not part of ’boat’ delivery volume)
16 1 tank extracting device (for 24V)
(and part of 12 V ’boat’ delivery volume)
17 1 fuel filter * (part of ’boat’ delivery volume)
17 4 18 1 stand (part of ’boat’ delivery volume)
5
19 1 temperature sensor, external 20 m
18
25 (part of ’boat’ delivery volume)
21
1 bag (with mech. mounting hardware) consisting of:
16 21 8 hose clamp Ø 10
15 22 1 hose clamp Ø 28 - 35
* on boats, these components may only be used outside the 23 1 pipe clip Ø 34 (combustion air)
engine compartment. Inside the engine compartment, com- 24 1 pipe clip Ø 28 (exhaust)
ponents in acc. with EN ISO 7840 have to be used 25 4 fuel hose *
** The scopes of delivery for boats include heaters which - in the 26 1 hose clamp Ø 26 - 28
heating mode - do not deliver any heated air during the control 27 17 cable tie
idle period (on reaching the preset temperature). Operation of 28 2 angle bracket
these heaters is only permissible with the supplied external various washers, nuts, screws
temperature sensor

31.08.01 / a30L0101 / WTI / ATT-T

Air Top 3500
WARM AIR SYSTEM
Item Qty. Description Part no.
1 1 adapter heater - hose Ø 90 / 80 891 11A
2 1 reducer hose - hose Ø 90 / 80 890 75A
17
15 7 3 1 branch Ø 90 / 60 / 90 909 99A
10 4 1 grid Ø 90 891 41A
12 18 5 1 Y-piece Ø 90 / 80 / 80 910 00A
7 6 x flexible pipe PAK, (per mtr.) Ø 60 398 497
16
7 x flexible pipe PAK, (per mtr.) Ø 80 398 519
19 8 x flexible pipe PAK, (per mtr.) Ø 90 903 95A
5 9 1 air intake screen Ø 80 252 441
10 1 double pipe socket Ø 80; 75 lg. 495 646
11 1 hose clamp Ø 50 ... 70 139 645
8 6 11
12 1 hose clamp Ø 70 ... 90 139 610
3 hose clamp Ø 80 ... 95
14 13 1 915 65A
14 1 air outlet, adjustable 360° Ø 60 398 551
15 1 air outlet Ø 80; 90° 107 976
4 13 16 1 air outlet Ø 90 915 69A
17 1 hood 90° (exit) Ø 90 100 567
2 18 1 branch (Y-piece) Ø 80 x 60 x 60 252 727
9
1 19 1 coupling pipe Ø 90 720 22A

31.08.01 / a30L0103 / WTI / ATT-T

 Air Top 5000
WARM AIR SYSTEM
Item Qty. Description Part no.
3 1 branch Ø 90 / 60 / 90 909 99A
15 4 1 grid Ø 90 891 41A
7 16
5 1 Y-piece Ø 90 / 80 / 80 910 00A
6 x flexible pipe PAK, (per mtr.) Ø 60 398 497
12 17 7 x flexible pipe PAK, (per mtr.) Ø 80 398 519
5 8 x flexible pipe PAK, (per mtr.) Ø 90 903 95A
11 1 hose clamp Ø 50 ... 70 139 645
8 6 11 12 1 hose clamp Ø 70 ... 90 139 610
3 13 1 hose clamp Ø 80 ... 95 915 65A
14 14 1 air outlet, adjustable 360° Ø 60 398 551
4 15 1 air outlet Ø 80; 90° 107 976
13 16 1 air outlet Ø 90 915 69A
17 1 coupling pipe Ø 90 720 22A

31.08.01 / A30L0104 / WTI / ATT-T

Air Top 3500 / Air Top 5000
ACCESSORIES
Item Qty. Description Part no.
1 1 heater control element 828 19B
1 2 3 2 1 panel with ventilation switch
(for item 1) 922 40A
3 1 temperature sensor, external 5 m 932 05A
3 1 temperature sensor, external 20 m 926 50A
4 1 digital timer 1531,
Combination Timer, 12 V 882 06A
4 5 6 7 4 1 digital timer 1531,
Combination Timer, 24 V 882 05A
1 electrical connection parts
(for item 4) 881 91A
6 1 mounting kit (frame) 474 630
7 1 mounting kit (case)
heater control element 475 866

31.08.01 / A30L0105 / WTI / ATT-T

Air Top 3500 / Air Top 5000
COMBUSTION AIR- / EXHAUST SYSTEM
Item Qty. Description Part no.
COMBUSTION AIR SYSTEM
1 1 air intake silencer Ø 25; 650 lg. 904 16B
2 1 elbow Ø 25 915 63A
3 x flexible pipe, (per mtr.) Ø 25 915 62A
4 1 protecting cap 904 11A

EXHAUST SYSTEM
7 5 1 exhaust silencer Øa 24 903 78A
5 6 1 elbow 915 64A
7 1 protecting cap 921 61A
8 1 exhaust silencer leakproof
6 Øa 24; 1500 lg. 985 82A
3 2
8
4
1

31.08.01 / A30L0106 / WTI / ATT-T

Air Top 3500 / Air Top 5000
FUEL SUPPLY
Item Qty. Description Part no.

1 1 fuel tank 24 Ltr. 9001307A

1 1 fuel tank 12 Ltr. 862 27A
11 1 shut-off valve with filtering
screen (for 862 27A) 131 700
3 1 fuel tank, ca. 12 l; Øa 180;
496 lg.; H 258 125 016
9 4 1 base order 2 parts (to 125 016) 135 186
5 1 banjo Ø 12 x 5 289 566
6 1 gasket ring Cu, 2 required 151 173
8 7 1 Ø 12 x 17 487 171
7 1 8 1 fuel filter Ø 5 379 662
9 x hose clamp (steel) Ø 9
15 flexible pipe/heat insulation hose 155 70A
13
1 (per mtr.) Øi 14,5
3 fuel pipe kit assy; in acc. 669 58A
6 11 1 with EN ISO 7840
4 5 fuel hose; to EN ISO 7840; 648 92A
1 5000 lg.
fuel hose; to EN ISO 7840; 648 91A
13 1 50 lg. 363 022
1 hose clamp Ø 14
fuel hose screwed coupling assy 669 59A
15 1 tank extracting device Ø 5 353 20A

for mounting parts see

Accessories Catalog

31.08.01 / A30L0107 / WTI / ATT-T

Air Top 3500 / Air Top 5000
RECOMMENDED BOAT ACCESSORIES
Item Qty. Description Part no.
1 1 1 stand 922 23A
2 2 1 distance plate, thickness: 6 for
height comp. 822 27A

for air ducting parts see

Boat/Ship Accessories

MISCELLANEOUS

Item Qty. Description Part no.

1 2 3 4 1 1 elbow with condensation water
drain, Ø 25 915 64A
2 1 elbow without condensation
water drain, Ø 25 926 43A
3 1 condensation water drain 926 21A
5 6 7 4 1 exhaust thermal isolation 1,20 m 921 68A
5 1 exhaust insulation band 25 m 443 247
6 1 fitting Ø 24 922 82A
7 1 exhaust pipe adapter Ø 24/30 668 78A

for air ducting parts see

Boat/Ship Accessories
31.08.01 / A30L0108 / WTI / ATT-T
Air Top 3500 / 5000
Overview of subassemblies

1 Heating unit
2 Control unit
3 Temperature limiter
4 Temperatur sensor
5 Wiring harness 1
3
2

31.08.01 / a3020101 / WTI / ATT-T

Air Top 3500 / 5000
Overview- heating unit

1 Combustion and
heating air fan
2 Pencil-type glow plug/
flame detector
3 Combustion chamber
4 Heat exchanger
5 Burner

31.08.01 / a3020102 / WTI / ATT-T

Air Top 3500 / 5000
Control unit
1 (NTC) Function
Controls the operational sequence and
monitors the combustion operation.
Temperature sensor (1) plugged in.

Check
Combination or standard timer: Error code
on the display.
Heater control: Operation indicator light flashes
Test using PC diagnostics possible.

Temperature sensor (1): R25 = 10 kΩ ± 10%

Imax = 5mA

Comment
External temperatur sensor available.

31.08.01 / a3030103 / WTI / ATT-T

Air Top 3500 / 5000
Combustion and heating air fan
Function
Supplies combustion air.
Heating air is transported to the air outlet.

Test
Check for easy movement
with mains voltage applied (max.:)
AT 3500 12 V: 3.3 A
24 V: 1.65 A
AT 5000 12 V: 8.8 A
24 V: 4.4 A

Comment
Can only be replaced as a unit.
Repair not possible.

31.08.01 / a3030101 / WTI / ATT-T

Air Top 3500 / Air Top 5000
Burner with burner chamber
Function
The burner distributes the fuel across the
burner's cross-sectional area.
The combustion takes place in the combustion
chamber.
Check
Visual inspection: Check for damage and
signs of coking.

Comment
Upon every removal of the combustion cham-
ber, install a new gasket and check the CO2-
setting.

31.08.01 / a3030102 / WTI / ATT-T

Air Top 3500 / 5000
Pencil-type glow plug / flame detector
12 V 24 V Function
Evaporation of the fuel during the starting
phase.
Flame monitoring during the combustion
operation (PTC).
Check
Resistance measurement
12 volts (red) 24 volts (green)
R25 0.30 … 0.33 Ω 1.18 … 1.32 Ω
I < 5 mA < 5 mA

Comment
Do not use any external power source!

31.08.01 / a3030104 / WTI / ATT-T

Air Top 3500 / 5000
Heat exchanger
Function
Gives the generated heat off to the air
delivered by the heating air fan.

Check
Visual inspection: check for damage
Approved for 10 years of operation (only app-
lies to StVZO = German Motor Vehicle Safety
Standards)

Comment
During removal and reinstallation be careful
not to bend the fuel pipe connector.

31.08.01 / a3030107 / WTI / ATT-T

Air Top 3500 / 5000
Connector pin assignment on control unit
1 Temperature limiter
2 Glow plug/flame detector
3 4 5 6
3 Metering pump
4 Temperature sensor

10
12
5 Wiring harness

2
4
6
8
6 Wiring harness

11
1

7
3
5
1
2
1

2
1
9
7 Control unit
8 Combustion and
heating air fan
7

2
1
2

8
2
1

2
1
1

31.08.01 / a3030106 / WTI / ATT-T

Air Top 3500 / 5000
Analog temperature limiter
Function
Protection against overheating

Check
R25 = 1 kΩ (PTC)
Imax = 5mA

Comment
When installing, make sure the sensor
element points toward the heat exchanger.

31.08.01 / a3030105 / WTI / ATT-T

Air Top 3500 / 5000
Wiring harness
Extension to the metering pump
1

Wiring harness 4
with fuse holder

1 3

To: 2
1 Metering pump
2 Control unit
3 Diagnostic connector
4 Heater control 2
31.08.01 / a3050107 / WTI / ATT-T
Air Top 3500 / 5000
Circuit diagram, with heater control
30 30
15 15

X1/X2

5 2
F1 1 2 X8 2
1

0,5mm²

0,5mm²
X3/X4/X5/X6
X7 3

rt
X9 4 9 10 12
S1 3 2
0,5mm² A2 2
1
6 3
4 0,5mm² X7
H1 7 4
1
1 0,5mm² 11
2
2 0,5mm² 8
1
5
X6 X8
2 1 1 2 1 2 1 2 2 1
X1 X2 ge X3 X4 X5
M ϑ ϑ

0,5mm²
M1 E B3 B2
A1
X9

0,6mm²
0,6mm²
1 4

2 3
X10 S6

X11 X10/X11

Y1

31

31.08.01 / a3050101 / WTI / ATT-T

Air Top 3500 / 5000
Circuit diagram, with combination timer
and electr. battery disconnector
58 58
15 15
30 30
X1/X2
1
88 86a
S8 5 2 2
F3 86 F1 1 2 X8 1
1,0 mm²
X3/X4/X5/X6

0,5mm²
0,5mm²
V1 V2
1 10 11 X7 3
4 9 10 12
2
2 A2 1
2 0,5mm² 6 3 X7
0,5mm²
H4 7 4
H5 H3 8 1
0,5mm²

0,5mm²
6 11
2
0,5mm² 8
P 1
9 5
12 7 4 X8
X6
X12 2 1 1 2 1 2 1 2 2 1

X1 X2 X3 X4 X5
M ϑ ϑ

0,5mm²
M1 E B3 B2 X10/X11
A1

0,6mm²

0,6mm²
1,0 mm²

S7 X10 S6
X12
X11

Y1

31 31

31.08.01 / a3050105 / WTI / ATT-T

Air Top 3500 / 5000
Circuit diagram, TRS operation with heater control,
without auxiliary drive
S2
30 30
X1/X2
15 15
D+ D+

5 2 2
F1 1 2 X8 1

0,5mm²
X3/X4/X5/X6

0,5mm²

0,5mm²
X7 3
X9 4 9 10 12 2
S1 3 0,5mm² 2 A2 1
3 X7
4 6
0,5mm²
H1 7 4
1
1 0,5mm² 11
2
2 0,5mm² 8
7
1 0,5mm²
5
X8
X6
2 1 1 2 1 2 1 2 2 1
X1 X2 X3 X4 X5
M ϑ ϑ
M1 E B3 B2
A1
1 X9 4

0,6mm²

0,6mm²
2 3
X10

X10/X11
X11

S2
Y1

31
31.08.01 / a3050104 / WTI / ATT-T
Air Top 3500 / 5000
Circuit diagram, TRS operation with heater control
S2
30 X1/X2
15 15
D+ D+

5 2 2
1
F1 1 2 X8 X3/X4/X5/X6

0,5mm²
S3

0,5mm²

0,5mm²
X7 3
X9 4 9 10 2
12 1
S1 3 2
0,5mm² A2
X7
6 3
4 0,5mm²
H1 7 4
1
1 0,5mm² 11
2
2 0,5mm² 8 7
1 0,5mm² X8
5
X6
2 1 1 2 1 2 1 2 2 1
X1 X2 X3 X4 X5
M ϑ ϑ

0,5mm²
M1 E B3 B2 X9
A1 1 4

0,6mm²

0,6mm²
2 3

X10 S6
X10/X11
X11 H6
Y2

S2
Y1

31

31.08.01 / a3050103 / WTI / ATT-T

Air Top 3500 / 5000
Circuit diagram, with combination timer
30 30
15 15 X1/X2
58 58
1 6

5 2 2
F3 F1 1 2 X8 1

1,0 mm²
X3/X4/X5/X6

0,5mm²

0,5mm²
1 10 11 X7 3
4 9 10 12 2
2 A2 1
2 0,5mm² 6 3 X7
0,5mm²
H4 7 4
H5 H3 8 1
0,5mm²
6 11
2
0,5mm² 8
P 1
9 5
12 7 4 X8
X6
X12 1 1 1 2 2
2 2 2 1 1
X2 X3 ws X4 X5
X1 K
M ϑ ϑ

0,5mm²
M1 E B3 B2 X10/X11
A1

0,6mm²

0,6mm²
1,0 mm²

S7 X10 S6
X12
X11

Y1

31

31.08.01 / a3050102 / WTI / ATT-T

Air Top 3500 / 5000
Legend for circuit diagrams
Wire cross-sections Pos. Designation Comment
< 7.5 m 7.5 - 15 m A1 Heater Air Top 3500/5000
A2 Control unit
0.75 mm² 1.5 mm² B2 Temperature sensor
1.0 mm² 1.5 mm² B3 Temperature sensor (limiter) overheating protection
E Pencil-type glow plug/flame detector
1.5 mm² 2.5 mm² F1 Fuse 24V 15A/12V 20A flat fuse SAE J 1284
2.5 mm² 4.0 mm² F2 Fuse 20A flat fuse SAE J 1284
F3 Fuse max. 15A flat fuse SAE J 1284
4.0 mm² 6.0 mm² H1 LED green (in pos. S1) operation indicator
H3 LED red (in pos. P)
1 With positive voltage from terminal (15/75) to H4 'Heating' symbol on display (pos. P) operation indicator
pin 10: continuous operation if 'instant heating' H5 Lamps (in pos. P) display and pushbutton illumination
is selected, for as long as ignition is 'on' H6 Lamp (min. 1.2W) "on" indicator of pumping device
No positive voltage connected to pin 10: M1 Motor combustion and heating air fan
M3 Motor vehicle fan
Variable heating times can be programmed P Combination digital timer (1531) digital timer and setpoint transmitter
(10 min to 120 min), S1 Heater control element setpoint transmitter switch
Basic setting: 120 S2 Disconnector 1 or 2-pole Emergency Stop switch
S3 Switch on or for pumping device
2 Diagnostic K-lead S6 Pushbutton switch ventilation
3 Diagnostic L-lead S7 Battery disconnector 'instant heating' button, remote control
S8 Diode
4 Input pin (pin 7/connector X7, V1 Diode
cable color in wiring harness: ws/rt): V2 Connector 2-pole
"ventilation" (fan speed depends on the X1 Connector 2-pole at pos. A2 (ST B)
X2 Connector 2-pole at pos. A2 (ST V)
position of the heater control) X3 Connector 2-pole at pos. A2 (ST U)
5 CO2-setting (see workshop manual) X4 Connector 2-pole at pos. A2 (ST Z)
X5 Connector 2-pole at pos. A2 (ST Y)
6 NOTE: X6 Connector 12-pole at pos. A2 (ST X)
If connected to terminal 30, continuous X7 Connector 2-pole at pos. A2 (ST1)
X8 Connector 4-pole
heater operation is possible with the ignition X9 Connector 2-pole at pos. S1
switched off! In this case, no connection to X10 Connector 2-pole
terminal 15/75 must be made! X11 Connector 2-pole at pos. Y1
X12 Connector 12-pole at pos. P
7 NOTE: Y1 Metering pump
The gray and violet cables are required for the Y2 Solenoid valve for pumping device
TRS function.
31.08.01 / a3050106 / WTI / ATT-T
Air Top 3500 / 5000
Connection diagram, combination timer

1 2
0,75 mm² 0,75 mm²
1 Jumper
3 2 Terminal 15
5 1,0 mm² 3 Terminal 30
0,75 mm²
4 Terminal 31
4 5 Terminal 58
1,0 mm²

0,5 mm²

0,5 mm²

0,5 mm²

0,5 mm²

0,5 mm²
insulate

31.08.01 / a3050108 / WTI / ATT-T

Air Top 3500 / 5000
Heater control

When removing the connector, pull at

the connector housing only.
Pulling at the wiring harness will result in
locking the connector housing (self-locking)

31.08.01 / a3050109 / WTI / ATT-T

Air Top 3500 / 5000
Integration into the vehicle's fuel system

Fuel Supply

max.3m permissible fuel at max. perm. overpressure

I2 feed height H (m) (bar) in the fuel pipe
0.00 0.20
iO2mm
1.00 0.11
iO2mm H 2.00 0.03
permissible fuel at max. perm. underpressure
suction height S (m) (bar) in the fuel tank
iO2mm I1
0,00 – 0.10
I2
iO2mm

0,50 – 0.06
S
1,00 – 0.02
I1
l1 + l2 ≤ 10m
l1 ≤ 1.2 m
l2 ≤ 8.8 m

31.08.01 / a3060101 / WTI / ATT-T

Air Top 3500 / Air Top 5000
Resistance points
Heater max. number of min. diameter of
resistance points main conduit
Air Top 3500
Air Top 5000 250 80 mm resistance
Description Diameter Part-no points

flexible pipe 80 398 519 15

1 bend in the flex. pipe 80 6
flexible pipe 90 903 95A 10
1 bend in the flex. pipe 90 3
adapter 90/80 891 11A 13
reducer 90/80 890 75A 17
double pipe 80 495 646 6
wall pipe 80 495 425 3
warm air elbow 80 128 503 17
embellisher 80 252 441 12
embellisher 100 252 468 26
screen 90 891 41A 5
flap valve 80/80/80 100 548 27
junction fitting 80/80/80 495 700 17
junction fitting 90/60/90 909 99A 6
Y-piece 90/80/80 910 00A 41
junction fitting 80/80/60 252 778 5
junction fitting 80/80/80 252 786 14
junction fitting 80/80/55 495 719 4
distributor with flap valve 80/80/80 100 567 24
air outlet, turns 360° 80 264 091 50
air outlet, 90° 80 107 976 8
air outlet, 45° 80 107 984 50
air outlet 90 915 68A 25

31.08.01 / a3020104 / WTI / ATT-T

Air Top 3500 / 5000
Metering pump
DP 2

DP 2 R2 DP 30
Petrol Diesel

0-90°
(15-90°) 0-90° 0-90° 0-180° 0-180°

+ 0° + 0°

31.08.01 / a3060201 / WTI / ATT-T