Webasto 40 Air Top Evo Diesel Vehicle Kit Instruction Manual

: June 13, 2024
: Webasto

Table of Contents

Webasto 40 Air Top Evo Diesel Vehicle Kit
General information
Safety
General safety information
Operation
Fuel
Cleaning
Malfunctions
Service signal
Maintenance
Disposal
Service and customer services
Declaration of Conformity
UK-Declaration of Conformity
Type approval
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Webasto 40 Air Top Evo Diesel Vehicle Kit

General information

Purpose of the document

These operating instructions provide the user with information on the safe operation of the Air Top Evo 40 | 55.

NOTE
The actual availability of these functions depends on each installed heater.

Using this document

Before operating the Air Top Evo 40 | 55, carefully read these operating instructions as well as the operating instructions for the control element.
Hand these operating instructions on to the following owner or user of the Air Top Evo 40 | 55.

Warranty and liability
Webasto shall not assume liability for defects or damages that are the result of disregarding the installation and operating instructions. This liability exclusion particularly applies to:

Installation or maintenance by untrained personnel.
Improper use.
Repairs not carried out by a Webasto service workshop.
Use of non-genuine parts.
Conversion of the unit without permission from Webasto.
Mechanical damage to the equipment.
Failure to comply with service instructions.

Use of symbols and highlighting

DANGER
This signal word denotes a hazard with a high degree of risk which, if not avoided, may lead to death or serious injury.

WARNING
This signal word denotes a hazard with a moderate degree of risk which, if not avoided, may lead to minor or moderate injury.

CAUTION
This signal word denotes a hazard with a low degree of risk which, if not avoided, may lead to minor or moderate injury.

NOTE
This symbol denotes a special technical feature, or (if not observed) potential damage to the product.

This symbol refers to separate documents which may be enclosed or can be requested from Webasto.

Safety

Intended use

WARNING
The heater is used exclusively for comfort purposes. Due to its installation, it must not become a safety-relevant component for the proper functioning of the vehicle.

NOTE
The heater is not approved for the purpose of directly heating the cargo area of ADR vehicles (hazardous substance transportation). The heater works independently of the vehicle engine and is integrated in the electrical system of the vehicle.

The heater is approved for the following applications:

Car, light truck (LCV)
Trucks, and buses in EU vehicle classes M, N, and O.
Caravans, motor homes, boats, pleasure craft
Earth-moving machinery
Construction machines
Vehicles that can be used in commercial, light-industrial, and industrial environments
Agriculture and forestry machines

General safety information

Safety information on the operation

DANGER
Risk of injury from the defective unit Do not operate a defective Air Top Evo 40 | 55 and put it out of service by removing the fuse:

prolonged heavy smoke development
unusual burner noise
smell of fuel
permanent fault switch-offs with error messages (flash code)
damaged heater.
- Contact a Webasto service workshop.

DANGER
Risk of burn injuries due to the insufficient distance between the hot air outlet and person Burn injuries

Make sure that persons are protected from the direct hot air flow from the heater and from contact with surfaces that will become hot.
Heat-sensitive parts must be protected from the direct hot air flow.

DANGER

Danger of explosion
In environments with combustible vapors, flammable dust, and hazardous goods (e.g., petrol stations, tank facilities, fuel stores, coal bunkers, timber yard,s or grain warehouses).

Do not switch on or operate the heater.

DANGER
Risk of explosion from explosive and flammable hazardous goods For hazardous material vehicles, restriction of the heater operation (ADR) is required to prevent severe burns.

Do not operate the heater at hazardous material loading points.
Do not operate the heater when loading and unloading hazardous materials.

DANGER
The danger of poisoning and suffocation Do not operate the heater in closed rooms that do not have an exhaust extraction unit.

Do not switch on or operate the heater, also not with programmed heating start.

DANGER
Danger of fire

Flammable materials or liquids in the hot air flow. u Keep the hot air flow free.

NOTE

Do not operate the heater without the control unit cover in place.

Avoiding damage to property

NOTE
Protect the Air Top Evo 40 | 55 against mechanical stress:

e.g. dropping, impacts, or knocks.
Do not place any objects on top of the heater.
Do not stand on the heater.

NOTE
The fan of the heater keeps running for approx. 240 seconds after switching off via the control element (40 s for ADR). Switching off incorrectly, without afterrun, can cause damage to the Air Top Evo 40 | 55.

Always switch off the Air Top Evo 40 | 55 via the control element.

Regulations and legal requirements

The Air Top Evo 40 | 55 heater has been type-tested and approved in accordance with ECE-R 10 (EMC) and ECE-R 122 (heater).
Read and comply with warnings in these Installation instructions and in the Operating instructions.

Operation

DANGER
Hazardous material vehicles (ADR) must not be switched on or off using a timer control or remote control.

Control elements

Rotary switch
MultiControl or SmartControl
ThermoCall TC4 and ThermoConnect with mobile app
UniControl

Observe additional requirements from the operating and installation instructions for the Air Top Evo 40 | 55 and the control element. The Air Top Evo 40 | 55 can be fitted with various control elements. A combination of control elements is possible.

Switch the heater on and off
The heater is switched on and off by different switch signals. Depending on the system equipment, the switch signals are produced by a switch, control element, or a climate control system.

See the operating and installation instructions for the control element. If the documents are not available, these can be requested from Webasto.

DANGER

Overheating possible
A battery disconnector (emergency off switch) may only be actuated in the event of danger since the heater will be switched off without an after-running period.

Always switch on/off the heater via the control element.

Heater operation

NOTE
In order to ensure that the batteries are recharged while traveling, follow this rule of thumb: the traveling time should be greater than or equal to the preheating time. In order to protect the batteries, the heater has an undervoltage trip.

Using the heater in hazardous material vehicles (ADR)

It is not possible to set a preselection time in hazardous material vehicles (ADR). The SmartControl (if present) shows how much heater operation time is left (remaining operation time).

NOTE
An ADR after-running period is applied in the following cases:

the generator signal (D+, light machine) is discontinued.
the pumping device (auxiliary drive) belonging to the vehicle is put into operation. After the end of the ADR after-running period, the heater is in ADR locking mode.

NOTE

Release ADR lock:

put the pumping device belonging to the vehicle out of operation
restart the heater by switching it off and on again using the control element

Switching the heater on after automatic switch-off

ATTENTION
Possible loss of heating function

Following an automatic switch-off, the heater may need to be manually switched back on in some circumstances. The heater can be restarted by switching it off and on again using the control element.

Fuel

The heater is connected to the fuel tank of the vehicle or to a separate fuel tank.

```
* Suitable fuels:
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Air Top Evo 40 | 55 B: Petrol DIN EN 228
Air Top Evo 40 | 55 D: Diesel DIN EN 590, biodiesel DIN
14214, HVO DIN EN 15940

Converting from operation with summer diesel to winter diesel

The tank is filled up with winter diesel (cold-resistant fuel). However, the fuel system for the heater may still contain residues of summer diesel.
Switch on the heater for approx. 15 minutes (the fuel system is completely filled with cold-resistant fuel).

Cleaning

NOTE
Do not clean the Air Top Evo 40 | 55 with a high-pressure cleaner. Carefully clean the heater using water and a cleaning agent suitable for cleaning vehicles. With the intake filter fitted on the cold air inlet clean the intake filter.

Malfunctions

In the event of a malfunction, the control element can indicate a malfunction. If an error occurs, the unit outputs a fault code via the control element.

On control elements with display, the fault codes F01 to F15 are output via the display. The fault codes F16 to F19 are shown with “- -”.
On control elements without display, the fault code is output by flashing pulses of the indicator lamp. The pulses are short or long. The number of long pulses corresponds to the number of the fault code. F00 is just rapid flashing.
In the event of an error occurring, check the fuse and plug connectors.
Determine the measure using the following fault code table.
If the fault cannot be rectified by the measure described, contact your Webasto service workshop.

Cod e	Hex code	Possible cause	Action

The heater switches off automatically
F00| H: 01 /

07 / 11 /

18 / 81 /

91 / 92

| Control unit defective / heater lock-out / eternal room temperature sensor defective| Contact a Webasto service workshop.
F01| H: 02 /

82 / 83

| No start| 1. Switch off heater.

2. Switch on the heater.

F02| H: 03| The flame goes out during the operation| 1. Switch off heater.

2. Switch on the heater.

Cod e	Hex code	Possible cause	Action
F03	H: 04 / 84	On-board power supply too low / under-voltage or overvoltage

1. Charge the vehicle battery.

2. Switch off heater.

3. Switch on the heater.

F04| H: 05| Flame was detected prior to combustion| Contact a Webasto service workshop.
F07| H: 08 / 88| Fuel pump defective
F08| H:

09 /15 /

89 / 95

| Combustion air fan de- fective
F09| H: 19 / 99| Glow plug defective
F10| H: 5B /

5C / 06 /

17

| Heater overheats| 1. Check the cold and hot air lines for free passage.

2. Switch off heater.

3. Allow the heater to cool down.

4. Switch on the heater.

The vehicle engine switched off / pumping device in operation

| 1. Make sure that the pumping device is out of operation.

2. Wait until the heater switches to fault lock-out.

3. Switch off the heater via the control element.

4. Switch the heater on via the control element.

| | The heater produces black smoke
–| | Combustion air and exhaust gas guide blocked| Check combustion air and exhaust gas routing for free passage.
In case of any other error messages not listed, contact the Webasto service workshop.

Service signal

In the event of service information, the service signal is shown via the control element when the heater is switched on.

In the case of the MultiControl / SmartControl control element, a service symbol is displayed.
On control elements without display: operating indicator flashes for 60 s: on for 1 s, off for 1 s
- Have the heater checked by a professional.

The heater can continue to be used with limited operation.

Maintenance

Put the heater into operation every 4 weeks in order to prevent mechanical parts from seizing.
At the beginning of the heating period, have the heater checked by a professional.

Disposal

The Air Top Evo 40 | 55 must not be disposed of in domestic waste. Observe the regional regulations for the disposal of electronic products.

Service and customer services

Do you have any technical questions or problems with the device? National phone numbers of our representatives are provided on: www.webasto.com

Declaration of Conformity

Hersteller / Webasto Thermo & Comfort SE
Manufacturer
- 82205 Gilching Germany

For the use of the Webasto heating system

Air Top Evo 40

Richtlinie	Ausgewählte Normen
Directive	Designated Standards

Follow the installation instruction
- 9026757
and operating instruction
- 9026767

Webasto-40-Air-Top-Evo-Diesel-Vehicle-Kit-fig-8

Original in German version.
This declaration of conformity is issued under the sole responsibility of the manufacturer.

UK-Declaration of Conformity

Hersteller
- Webasto Thermo & Comfort SE
Manufacturer
- 82205 Gilching Germany

Air Top Evo 55

Richtlinie	Ausgewählte Normen
Directive	Designated Standards

Follow the installation instruction
- 9026757
and operating instruction
- 9026767

Webasto-40-Air-Top-Evo-Diesel-Vehicle-Kit-fig-9

Original in German version.
This declaration of conformity is issued under the sole responsibility of the manufacturer.

Type approval

Type approval Air Top Evo 40

Webasto-40-Air-Top-Evo-Diesel-Vehicle-Kit-fig-2

Type approval Air Top Evo 55

Webasto-40-Air-Top-Evo-Diesel-Vehicle-Kit-fig-5

These are the original instructions. The German language is binding. You can request your language if it is missing. The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country.