1. Introduction
This manual provides essential information for the safe and efficient operation, installation, and maintenance of your Webasto Air Top EVO 40 Diesel Air Heater. This unit is designed to provide reliable heating for RVs, trucks, and other vehicles. Please read this manual thoroughly before installation and use to ensure proper function and safety.
2. Product Overview and Components
The Webasto Air Top EVO 40 kit includes the main heater unit and various components necessary for installation and operation. Familiarize yourself with all parts before proceeding.
Figure 2.1: Overview of the Webasto Air Top EVO 40 Diesel Air Heater kit, showing the main heater unit, exhaust pipes, fuel pump, wiring harness, air ducts, and mounting hardware.
Key components typically include:
- Air Top EVO 40 Heater Unit
- Fuel Pump
- Fuel Line
- Exhaust Pipe and Silencer
- Combustion Air Intake Pipe
- Wiring Harness
- Mounting Plate and Hardware
- Air Ducting Components
3. Technical Specifications
The following table details the technical specifications for the Webasto Air Top EVO 40 diesel air heater. These values are crucial for proper installation and operation.
Figure 3.1: Technical data for Webasto Air Top EVO 40 and EVO 55 models, including heat output, fuel type, voltage, power consumption, and dimensions.
| Parameter | Air Top EVO 40 D |
|---|---|
| Type approval: EMC | E1 00 0385 |
| Heat flow over control range [kW] | 1.5 to 3.5 (4.0) |
| Fuel | Diesel / biodiesel DIN EN 590 / DIN EN 14214 |
| Fuel consumption over control range [l/h] | 0.18 to 0.43 (0.49) l/h |
| Rated voltage [V] | 12 / 24 |
| Operating voltage range [V] | 10.5 to 16 / 20.5 to 31 |
| Rated power consumption over control range [W] | 15 to 40 (55) |
| Permissible ambient temperature (operation/storage): Heater [°C] | -40 to +40 / -40 to +85 |
| Permissible ambient temperature (operation/storage): Fuel pump [°C] | -40 to +20 |
| Permissible combustion air intake temperature [°C] | -40 to +20 |
| Setpoint temperature range [°C] | +5 to +35 |
| Volumetric flow rate with pressure loss in cold/hot air system 0.5 hPa [m³/h] | max. 132 (140) |
| CO₂ in exhaust gas: Rated heating capacity VL [vol%] | 9.2 |
| Heater length [mm] | 423 ± 2 |
| Heater width [mm] | 148 ± 1 |
| Heater height [mm] | 162 ± 1 |
| Heater weight [kg] | 5.9 |
| IP class: Heater | IP5K4K |
| IP class: Fuel pump | IPX6 / IPX7 / IP6K9K |
| Max. length of combustion air line and exhaust line with exhaust silencer [m] | 2 |
| Max. length of combustion air line and exhaust line without exhaust silencer [m] | 5 |
| Max. permissible pressure loss in cold and hot air system [hPa] | 2.0 |
4. System Functionality
The Webasto Air Top EVO 40 operates as a forced-air diesel heater. It draws in fresh air, heats it using a combustion process, and then circulates the warm air into the vehicle's interior. The system includes a glow plug for ignition, a fuel pump for precise fuel delivery, and a control unit to manage the heating process.
Figure 4.1: Cross-section view of the air heating system, illustrating key internal components such as the glow plug, combustion chamber, heat exchanger, impellers, control unit, and various sensors.
Key functional components include:
- Heater Housing: Encloses all internal components.
- Combustion Air Blower: Supplies air for the combustion process.
- Tubular Combustion Chamber: Where fuel is ignited and burned.
- Heat Exchanger: Transfers heat from the combustion gases to the circulating air without mixing.
- Hot Air Blower: Circulates the heated air into the vehicle.
- Control Unit: Manages all heater functions, including ignition, fuel delivery, and temperature regulation.
- Fuel Pump: Delivers precise amounts of diesel fuel to the combustion chamber.
- Glow Plug: Ignites the fuel-air mixture during startup.
5. Installation Guidelines
Proper installation is critical for the safe and efficient operation of your Webasto Air Top EVO 40 heater. It is recommended that installation be performed by a qualified technician. Always adhere to local regulations and manufacturer guidelines.
5.1. Typical Applications
The Air Top EVO 40 is versatile and can be installed in various vehicle types, including:
- Recreational Vehicles (RVs)
- Trucks and Commercial Vehicles
- Boats (with marine-specific installation kits)
- Construction Equipment
Figure 5.1: Illustrative diagram of a Webasto heater installed in a van, showing the placement of the heater unit and the routing of warm air ducts within the vehicle interior.
Figure 5.2: Illustrative diagram of a Webasto heater installed in a loader vehicle, indicating the heater unit's position and the distribution of heated air within the cabin.
5.2. General Installation Considerations
- Mounting Location: Choose a dry, protected location, typically under the vehicle, in a storage compartment, or within the cabin, ensuring adequate clearance for air intake and exhaust.
- Fuel Supply: Connect the fuel pump to the vehicle's diesel tank or a dedicated fuel tank. Ensure all fuel lines are securely fastened and free from leaks.
- Electrical Connection: Connect the heater to a 12V or 24V DC power source as specified for your model. Ensure proper fusing and wiring according to the provided wiring diagram.
- Air Ducting: Install the warm air ducts to distribute heat effectively throughout the desired area. Ensure ducts are not kinked or obstructed.
- Exhaust System: Route the exhaust pipe safely away from flammable materials and passenger areas. Ensure proper sealing to prevent exhaust fumes from entering the vehicle.
- Combustion Air Intake: Ensure the combustion air intake is clear of obstructions and draws in fresh air from outside the vehicle.
6. Operation Instructions
Operating the Webasto Air Top EVO 40 is straightforward using the control unit. The specific control panel may vary, but general functions remain consistent.
Figure 6.1: Example of a Webasto control knob, typically used for turning the heater on/off and adjusting the desired temperature.
6.1. Starting the Heater
- Ensure the vehicle's battery is adequately charged and there is sufficient diesel fuel.
- Turn the control knob or press the power button on your control panel to the 'ON' position or desired temperature setting.
- The heater will initiate a startup sequence, which includes a self-test, glow plug activation, and fuel pump priming. This process may take a few minutes.
- Once combustion is stable, warm air will begin to flow from the air outlets.
6.2. Adjusting Temperature
Use the control knob or digital interface to set your desired temperature. The heater will automatically adjust its heat output to maintain the set temperature.
6.3. Shutting Down the Heater
- Turn the control knob or press the power button to the 'OFF' position.
- The heater will enter a cool-down cycle to prevent overheating and clear the combustion chamber. Do not disconnect power during this cycle.
- Once the cool-down cycle is complete (indicated by the fan stopping), the heater is safely shut down.
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Webasto Air Top EVO 40 heater. Perform these checks periodically.
- Annual Inspection: Have the heater inspected by a qualified technician at least once a year, preferably before the heating season.
- Air Intake and Exhaust: Regularly check that the combustion air intake and exhaust pipes are clear of obstructions (e.g., dirt, ice, debris).
- Air Ducts: Ensure the warm air ducts are clean and free from blockages.
- Electrical Connections: Check all electrical connections for tightness and corrosion.
- Fuel System: Inspect fuel lines for leaks or damage. Ensure the fuel filter (if installed) is clean.
- General Cleaning: Keep the exterior of the heater unit clean. Do not use harsh chemicals.
8. Troubleshooting
This section provides solutions for common issues you might encounter with your Webasto Air Top EVO 40 heater. For complex problems, contact Webasto authorized service.
| Problem | Possible Cause | Solution |
|---|---|---|
| Heater does not start | Low battery voltage No fuel Blown fuse Faulty wiring | Check battery charge Check fuel level Inspect and replace fuse Check wiring connections |
| Heater starts but shuts down quickly | Insufficient fuel supply Blocked exhaust or air intake Overheating | Check fuel lines and pump Clear obstructions from exhaust/intake Ensure proper ventilation around heater |
| No warm air output | Blower malfunction Air duct blockage | Contact service technician Check and clear air ducts |
| Excessive smoke or unusual odor | Improper combustion Fuel leak | Immediately shut down heater and contact service. Do not operate. |
9. Support & Warranty
For technical assistance, spare parts, or warranty claims, please contact Webasto customer support or an authorized Webasto service center. Refer to your purchase documentation for specific warranty terms and conditions.
Webasto Official Website: www.webasto-group.com
Always use genuine Webasto spare parts to ensure the safety and performance of your heater.
