Webasto Air Top Evo 55 Bedienungsanleitung

Air Heaters

Fault Codes / Troubleshooting

Air Top Evo 55

Air Top Evo 55 B (Petrol)

Air Top Evo 55 D (Diesel)

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Troubleshooting Air Top Evo 40 / Air Top Evo 55

501

5 Troubleshooting

5.1 General information

If a malfunction occurs, a flashing code is displayed on the

operating indicator or a fault code F .. on the combination

timer.

In addition, the heater can be checked using a personal com-

puter (see Webasto PC Thermo Test PC Diagnosis operating

manual).

IMPORTANT

Troubleshooting work demands precise knowledge of the

structure and theory of operation of the various components

and must be carried out by trained personnel only. The func-

tional relationships are described in Chapter 2 and 3.

IMPORTANT

The troubleshooting guide is restricted to the localisation of

defective components.

The following fault causes should always be checked or a

fault should be excluded for the following reasons:

• Corrosion on connector

• Loose connection on connector

• Poor crimp contacts on plugs

• Corrosion on lines and fuses

• Corrosion on battery terminals

If you wish to check individual components, the electrical

plug connectors on the control unit must be disconnected.

Conduct a function test in the vehicle after rectifying each

fault.

A direct operation of the individual components (with volt-

age) is not permitted.

5.2 General error symptoms

The following table (Fig. 501) lists possible fault symptoms.

Error symptom Possible cause Remedy

Heater cuts out automatically No combustion after starting and restarting

Operating display flashes

Switch heater off and then on again

Flame extinguishes during operation

Operating display flashes

Switch heater off and then on again

Heater overheated

Operating display flashes

Check the hot air guide for free passage, al-

low the heater to cool down, then briefly

switch the heater off and then on again

Vehicle voltage too low

Operating display flashes

Charge battery

Switch heater off and then on again

Heater emits black smoke Combustion air and/or exhaust system

blocked

Check that the combustion air and exhaust

systems are clear

Fig. 501 General error symptoms

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Air Top Evo 40 / Air Top Evo 55 Troubleshooting

502

5.3 Error symptoms during function

The following table (Fig. 502) lists the possible error symp-

toms in the order in which they may occur during operation.

In the event of a fault, the error is to be located using this ta-

ble and rectified. It is important that the error symptom is cor-

rectly identified.

If the error symptom is not included in this table or if the fault

is not found under the specific error symptom heading, in an

emergency you can contact our technicians on our service

hotline.

NOTE

Every fault is indicated by the flashing LED on the control el-

ement after the slow down time has finished. If the other

components are OK, a defective control unit may be the

cause of all the faults.

There are states which are equivalent to faults.

Error symptom Occurrence Possible causes

No start and no illumination of the LED

on the control element

immediate Incorrect cabling, defective fuse

No start but LED is lit immediate The unit immediately goes into a control break when

switched on; the control break speed is 0 rpm when an

external temperature sensor is used.

Fig. 502 Error symptoms during function

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Troubleshooting Air Top Evo 40 / Air Top Evo 55

503

5.4 Fault code displayed in control element

If serious malfunctions, such as overheating or failure to start,

occur with increasing frequency, then the heater is

permanently locked out and can only be returned to

operation following repairs by Webasto-trained

professionals.

When equipped with a combination timer, a fault code

output appears on the display after a malfunction occurs until

the heater malfunction has been eliminated.

In case of equipment with a rotary selector or an Air Top Evo

Multi Control the fault code is displayed by means of a

flashing operating indicator after a malfunction occurs .

After five short signals, the long flashing pulses are counted.

The flashing pulses match the number in the table below (e.g.

F 04 = 4 long flashing pulses).

NOTE

For equipment with combination timer:

Fault codes F 01 to max. F 15 are displayed.

After this the faults are displayed with "- -".

Fault

code

Fault (group) Additional information during PC di-

agnostic

Troubleshooting

F 00 Control unit defective/

heater lock-out/

internal room temperature sensor

defective

01 Control unit error

81 EOL checksum error

11 Incorrectly coded control unit or incorrect

heater (fuel type) installed (the heater will not

work if this error occurs)

91 Neutrally coded or disabled control unit

(the heater will not work if this error occurs)

92 Maintain command failed (no operation if

fault occurs)

18 Customer bus defective

Replace control unit

07 Heater lock-out active Delete heater lock-out:

Switch on unit and remove fuse.

Reinstall fuse after more than 2 s and switch

on unit again

F 01 No start/no flame formation 02 Even after the restart, no flame has

formed

82 No start in test

83 Maximum feed rate exceeded

Check fuel supply

(tank empty, lines blocked).

Check exhaust temperature sensor for

deposits from outside through exhaust fitting

and clean carefully if necessary.

Check evaporator mount and replace if

necessary.

F02 Flameabort 03 The flame has gone out during operation

and has not reformed after a restart attempt

Check fuel supply

(tank empty, lines blocked).

Check exhaust temperature sensor for

deposits from outside through exhaust fitting

and clean carefully if necessary.

Check evaporator mount and replace if

necessary.

F 03 Undervoltage or overvoltage 84 The voltage was less than 10.5 V or 20.5

V for longer than 20 seconds

04 The voltage was more than 16 V or 32 V

for longer than 6 seconds

F 04 Premature flame detection 05 The exhaust temperature sensor

recognised a flame before combustion had

started

Check exhaust temperature sensor and

replace if necessary.

Fig. 503 Faults and error remedies (Page 1 of 2)

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Air Top Evo 40 / Air Top Evo 55 Troubleshooting

504

F 05 Not available

F 06 Not available

F 07 Fuel pump defective 88 Open circuit in fuel pump Check electrical wiring and fuel pump and

replace if necessary

08 Short circuit in fuel pump

F 08 Open circuit/short circuit/

overloading/blockage in drive motor

09 Short circuit in drive motor

89 Open circuit in drive motor

15 Blocking guard in drive motor

95 Overload protection in drive motor

Eliminate cause of blockage/sluggishness

Check magnets of heating air fan and replace

drive unit (drive motor with combustion and

heating air fan) if necessary

F 09 Glow plug defective 19 Short circuit in glow plug

99 Open circuit in glow plug

Check glow plug and replace if necessary.

F 10 Overheating 06 Heater overheated - blow-out

temperature sensor

5B Heater overheated - PCBs - temperature

sensor

17 Temperature gradient exceeded - blow-

out temperature sensor

5C Temperature gradient exceeded - PCBs -

temperature sensor

Find and eliminate cause of overheating in

hot air guide.

Possible causes:

Pressure loss too high, line kinked, air outlet

closed, soiling of blow-out temperature

sensor

F 11 Not available

F 12 Not available

F 13 Not available

F 14 Blow-out temperature sensor

defective

1B Short circuit in blow-out temperature

sensor

AB Open circuit in blow-out temperature

sensor

Check blow-out temperature sensor and

replace if necessary.

F 15 Not available

F 16 Exhaust temperature exceeded 4F Upper limit of exhaust temperature

exceeded

Check free through-flow of combustion air

and exhaust system, check CO2setting, clean

soot from heat exchanger if necessary

F 17 Exhaust gas temperature sensor

defective

1A Short circuit to ground in exhaust

temperature sensor

9A Open circuit in exhaust temperature

sensor

Replace exhaust temperature sensor

F 18 Setpoint generator defective 9B Open circuit or short circuit to +Ub in

setpoint generator

Check wiring and replace control element if

necessary

F 19 Plausibility of sensors incorrect 93 Plausibility check not passed Check exhaust temperature sensor/blow-out

temperature sensor for plausibility and

replace defective sensor

Fault

code

Fault (group) Additional information during PC di-

agnostic

Troubleshooting

Fig. 503 Faults and error remedies (Page 2 of 2)

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Troubleshooting Air Top Evo 40 / Air Top Evo 55

505

5.5 Maintenance display in control element

The maintenance signal is displayed when an operating

period of more than 3,000 operating hours has been reached

or the heater is in a restricted operating mode.

In case of restricted operation, either the automatic altitude

adjustment or the external room temperature sensor

(optional) may be defective. The heater can continue to be

operated, however with a considerable reduction in comfort

in some cases.

The heater should be inspected by trained professionals as

soon as possible.

The maintenance signal is displayed with equipment with a

rotary selector or an Air Top Evo Multi Control (MC04) by

means of flashing of the operating indicator for 60 seconds

each time the heater is started. Flashing signal 1 second on,

1 second off.

With equipment with combination timer, "- -" appears on the

display.

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