Webasto Air Top 3500 ST - User Manual

Operating instructions
Air Top 00 ST35
Air Top 5000 ST
Servicing and safety instructions
Servicing and safety instructions
1. The heater has been type-tested and approved in
accordance with EC Directives 72/245/EEC (EMC) and 2001/56/EC (heater) with the
following EC permit numbers:
e1*72/255*95/54*1221*00
e1*2001/56*0021*00
2. The year in which the heater was used for the first time must be permanently displayed
on the factory plate be deleting the inapplicable years from the plate.
To install the Air Top 3500 ST D / 5000 ST D heater in hazchem vehicles, the
requirements of ADR must be satisfied in addition to the Road Traffic Registration
Directive.
4. Claims can only be made if it can be verified that the claimant has complied with the
servicing and safety instructions.
7. The heater must be checked by an expert at the latest at the start of the cold weather
period.
8. In the event of long-lasting heavy smoke development, unusual combustion noises or a
smell of fuel or if the heater suffers continuous fault cut-outs with error messages (flashing
code), it must be put out of service be removing the fuse and must not be reused until it
has been nspected by Webasto-trained personnel.
Air Top 3500 ST / 5000 ST
NOTE:
The provisions of these Directives are binding within the territory governed by EU
Directive 70/156/EEC and should similarly be observed in countries without specific
regulations.
3. The heaters are not designed for heating hazardous substance transport
compartments.
5. The heater must be switched off at filling stations and tank farms as a result of
the risk of explosion.
6. The heater may not be operated in enclosed spaces (such as garages) as a result
of the risk of poisoning and asphyxiation, even if a timer or Telestart remote is
used.
9. Wherever inflammable vapours or dust may form (for example in the vicinity of
fuel, carbon, wood dust or cereal stores or the like), the heater must be switched
off as a result of the risk of explosion.
Air Top
e1*2001/56*0020*00
Air Top
10. The heat transfer unit on air heaters is exposed to very high thermal stress and
must be replaced by a genuine Webasto spare part ten years after it is used for the
first time.
If exhaust lines pass through areas used by personnel, they must also be replaced
by genuine spare parts after ten years.
11. The fuel specified by the vehicle manufacturer is suitable for combusting in
Air Top 3500 ST B / Air Top 5000 ST B. Both leaded and unleaded fuel may be used.
The diesel fuel specified by the vehicle manufacturer must be used for the Air Top 3500
ST D / Air Top 5000 ST D heater (diesel). Class EL heating oil (not L heating oil) may also
be used as long as it complies with the normal quality available on the German market
pursuant to DIN 51603.
The Air Top 3500 ST D / Air Top 5000 ST D heater is also licensed for use with PME
(bio-diesel), which complies with DIN EN 14214.
We know of no negative influences due to additives.
If fuel is extracted from the vehicle's tank, follow the additive instructions issued by the
vehicle manufacturer.
If you change to low-temperature fuel, the heater must be operated for approx.
15 minutes so that the fuel system is filled with the new fuel.
12. The temperature in the area around the heater must not exceed 85 °C (storage
temperature). If the temperature exceeds this level there is a risk of permanent damage to
the electronics systems.
13. Failure to follow the installation instructions and the notes contained therein will lead
to all liability being refused by Webasto. The same applies if repairs are carried out
incorrectly or with the use of parts other than genuine spare parts. This will result in the
invalidation of the type approval for the heater and therefore of its homologation / EC type
licence.
14. Keep the hot air inlet and hot air outlet free of dirt and foreign bodies.
Contaminated or blocked hot air lines may cause overheating and thus result in the
overheating cut-out tripping.
15. To prevent mechanical parts seizing, the heater should be operated for approx.
10 minutes every four weeks.
16. Do not stand on the heater and do not place any heavy items on the heater or throw
items at the heater.
17. Do not place any items of clothing, textiles or similar materials over the heater or in
front of the hot air inlet and the hot air outlet.
18. The current of hot air in the heater must not be restricted or blocked by highly
inflammable substances or materials such as rags, cleaning wool, etc.
19. The heater must not be cleaned with a high pressure cleaner.
Ident-Nr. 90 103 14A 5/0404
Webasto Thermosysteme International GmbH
Postfach 80 - D-82132 Stockdorf -
http://www.webasto.de
https://webasto-russia.ru

Summary

Operating Instructions and Safety

General Safety and Servicing Procedures

Covers EC directives, year display, hazardous substance compartments, ADR, filling stations, enclosed spaces, expert checks, fault cut-outs, and flammable vapours.

Advanced Safety and Servicing Procedures

Details heat transfer unit replacement, fuel types, temperature limits, installation liability, air inlet/outlet, mechanical parts, and operational precautions.

Control Element Operation

Basic Operation and Notes

Explains how to switch the heater on/off using the rotary knob and notes for ADR operation.

Ventilation Mode

Describes the use of a separate switch for heating and ventilation modes.

Combination Timer Functions

Timer Setup and Operation

Details setting time/date, program start times, viewing/deleting programs, and operating time.

ADR Vehicle and Error Code Information

Covers limitations for ADR vehicles and how error codes are displayed on the timer.

Troubleshooting and Error Codes

Heater Automatic Cut-Outs and Remedies

Lists common causes for automatic cut-outs and provides remedies.

Black Smoke and ADR Mode Faults

Addresses issues like black smoke, blocked systems, and specific steps for ADR mode restarts.

Error Code Interpretation

Provides a table of error codes and their meanings for combination timers or control elements.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

This document serves as an operating manual for the Webasto Air Top 3500 ST and Air Top 5000 ST heaters, providing essential information on their function, usage, and maintenance.

Function Description

The Webasto Air Top 3500 ST and Air Top 5000 ST are type-tested and approved heaters designed to provide warmth. They operate by combusting fuel to generate heat, which is then distributed as hot air. These heaters are equipped with a control element that allows users to switch them on and off, set the desired room temperature, and reset the device after a fault cut-out. An indicator/error code display provides visual feedback on the heater's status and any issues that may arise.

For enhanced control, the heaters can be integrated with a combination timer. This timer enables users to program start times for up to seven days in advance, with the option to set three different cut-in times. It also features a temperature setpoint generator, allowing for precise temperature control. The timer displays the current time and day, and when the heater is operating, the display and buttons are illuminated. In vehicles equipped for ADR (Accord Dangereuses Routier) operation, the display remains blank, and certain functionalities are restricted for safety.

A ventilation option is also available, allowing the user to switch between heating and ventilation modes using a separate switch. In ventilation mode, the fan speed can be adjusted based on the position of the control element, providing flexibility for air circulation without heat.

Usage Features

To operate the heater, the rotary knob on the control element should be set to the required temperature. Before switching on, it is crucial to ensure that there are no objects blocking or scraping the hot air and combustion air fan to prevent damage.

For ADR operation, the Air Top 3500 ST and Air Top 5000 ST heaters must be switched on and off manually using a dedicated switch; automatic control systems are not permitted. In class FL vehicles, these heaters are prohibited during loading and unloading procedures or at loading points. They automatically switch off, and the combustion air supply is interrupted for a maximum of 40 seconds if the vehicle's engine is at a standstill or a pumping device that is part of the vehicle is started. In such cases, the control unit enters a fault lock-out mode, and the ON/OFF switch must be set to OFF before the heater can be restarted.

The combination timer offers several usage features:

• Switching on/off: Manual operation is initiated by pressing the button for permanent heating mode or automatically by programming a start time. To switch off, press the button again for manual operation or allow the operating period to conclude for automatic shutdown.
• Setting time/date: Press the button for more than two seconds to make the time flash, then use the and buttons to set the time. The day will then flash, allowing it to be set.
• Viewing time: When the ignition is off, press the button to view the time.
• Program start time: Press the P button to make the program number flash, then use the and buttons to set the start time and day. Multiple presses of the P button allow setting program numbers 2 and 3 or returning to time mode.
• Viewing/deleting selected times: Press the button multiple times until the desired program number is displayed. To delete a selected time, press the P button until the time is displayed with no program numbers.
• Program operating time: With the heater switched off, press the button for three seconds to make the operating duration flash. Use the and buttons to set the desired duration (10 to 120 minutes).
• Setting remaining time: While the heater is operating and the ignition is off, use the and buttons to set the remaining operating time (1 to 120 minutes). This feature allows adjustment of how long the heater will continue to operate.

For vehicles with ADR equipment, setting a time on the timer is not possible. The remaining time will be displayed while the heater is operating and can be adjusted. Remote control is also possible using an external optional immediate heat button.

Maintenance Features

Regular maintenance is crucial for the safe and efficient operation of the heater.

• Heat transfer unit replacement: The heat transfer unit on air heaters is exposed to very high thermal stress and must be replaced with a genuine Webasto spare part ten years after its initial use. If exhaust lines pass through areas used by personnel, they must also be replaced with genuine spare parts after ten years.
• Fuel compatibility: The heater is designed to operate with specific fuels. For Air Top 3500 ST B / Air Top 5000 ST B, both leaded and unleaded fuel specified by the vehicle manufacturer are suitable. For Air Top 3500 ST D / Air Top 5000 ST D, diesel fuel specified by the vehicle manufacturer or Class EL heating oil (complying with DIN 51603) can be used. The Air Top 3500 ST D / Air Top 5000 ST D is also licensed for use with PME (bio-diesel) complying with DIN EN 14214. If fuel is extracted from the vehicle's tank, follow the vehicle manufacturer's additive instructions. When switching to low-temperature fuel, the heater should be operated for approximately 15 minutes to fill the fuel system with the new fuel.
• Temperature limits: The temperature around the heater must not exceed 85 °C (storage temperature) to prevent permanent damage to the electronics systems.
• Air inlet/outlet cleanliness: Keep the hot air inlet and hot air outlet free of dirt and foreign bodies. Contaminated or blocked air lines can cause overheating and trigger the overheating cut-out.
• Regular operation: To prevent mechanical parts from seizing, the heater should be operated for approximately 10 minutes every four weeks.
• Physical handling: Avoid standing on the heater, placing heavy items on it, or throwing items at it. Do not place clothing, textiles, or similar materials over the heater or in front of the hot air inlet and outlet.
• Airflow restriction: The current of hot air in the heater must not be restricted or blocked by highly inflammable substances or materials such as rags or cleaning wool.
• Cleaning: The heater must not be cleaned with a high-pressure cleaner.
• Safety checks: The heater must be checked by an expert at the latest at the start of the cold weather period.
• Troubleshooting: In case of long-lasting heavy smoke, unusual combustion noises, fuel smell, or continuous fault cut-outs with error messages, the heater must be put out of service by removing the fuse and inspected by Webasto-trained personnel before reuse.
• Explosion risk: The heater must be switched off at filling stations, tank farms, and wherever inflammable vapours or dust may form (e.g., near fuel, carbon, wood dust, or cereal stores) due to the risk of explosion.
• Enclosed spaces: The heater must not be operated in enclosed spaces (such as garages) due to the risk of poisoning and asphyxiation, even with a timer or Telestart remote.

In case of an error, first check the fuse and plug connections. If the issue persists, have the heater checked by Webasto-trained personnel. Error codes are displayed on the combination timer or control element to indicate specific faults, such as control unit errors, no start, flame failure, undervoltage/overvoltage, premature flame recognition, sensor interrupts/short circuits, metering pump interrupts/short circuits, fan motor interrupts/short circuits/overload/blocked, glow plug interrupts/short circuits, overheating, and heater lock-out. Frequent serious errors may lead to a permanent fault lock-out, requiring repair by Webasto-trained personnel.

Webasto Air Top 3500 ST Specifications

General

Heating Power	3.5 kW
Fuel Type	Diesel
Heat Output	3500 W
Voltage	12 V
Operating Temperature Range	-40°C to +40°C