Webasto Air Top 2000 ST B Installation Instructions Manual
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- Workshop manual (70 pages) ,
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Summary of Contents for Webasto Air Top 2000 ST B
- Page 1 Luftheizgeräte Einbauanweisung Air Heaters Installation Instructions Luchtverwarmingsapparaten Montagehandleiding Air Top 2000 ST Handelsbezeichnungen/Trade names/Handelsnamen: Air Top 2000 ST B (Benzin/Petrol/benzine) Air Top 2000 ST D (Diesel/PME)
- Page 2 Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.
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Page 4: Table Of Contents
Air Top 2000 ST Inhaltsverzeichnis Table of Contents Gesetzliche Bestimmungen für den Einbau ... . . 1 Statutory regulations governing installation ... 39 Verwendung der Luftheizgeräte . -
Page 5: Statutory Regulations Governing Installation
Failure to follow the installation instructions and the notes contained • The combustion heater may only be switched on manually. Program- therein will lead to all liability being refused by Webasto. The same applies ming devices shall be prohibited. The combustion heater may be... - Page 6 Statutory regulations governing installation Air Top 2000 ST Requirement for basic unit: 5.3.2.4 The label referred to in Annex 7, paragraph 4, or a duplicate, must be positioned so that it can be easily read when the combustion heater is A maximum run-on period of 40 seconds is permitted when the combus- installed in the vehicle.
- Page 7 Air Top 2000 ST Statutory regulations governing installation 5.3.6.2 The inlet duct must be protected by mesh or other suitable means. 1.3. Extract from directive ECE-R 122 Annex 9 Start of extract. 5.3.7 Heating air outlet Additional provisions applicable to certain vehicles as specified in the ADR. 5.3.7.1 Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it 3.
- Page 8 Statutory regulations governing installation Air Top 2000 ST 3.3 FL vehicles 3.3.1 The combustion heaters shall be put out of operation by at least the following methods: Intentional manual switching off from the driver’s cab; Stopping of the vehicle engine; in this case the heating device may be restarted manually by the driver;...
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Page 9: Use Of The Air Heaters
Air Top 2000 ST Use of the air heaters Use of the air heaters The Webasto Air Top 2000 ST air heaters are designed – to heat cabins, boats, trucks, minibuses, vans and motorhomes – to defrost vehicle windows The heaters operate independently of the engine and are connected direct- ly to the fuel tank and the electrical system of the vehicle. -
Page 10: Installation
A special tools can be pur- cause the heater to overheat). chased from Webasto to drill the holes and, if necessary, smooth the sup- port area. The seal can compensate for unevenness of max. 1 mm. - Page 11 Air Top 2000 ST Installation 3 5 4 Hot air inlet Fuel intake Hot air outlet Space requirement for hot air inlet Combustion air intake Space requirement for removing the heater Exhaust fume outlet Cable outlet (either right or left) Fig.
- Page 12 Installation Air Top 2000 ST Air Top 2000 ST - diesel: Air Top 2000 ST - petrol: horizontally Fig. 3: Seal Ensure that all moving parts can move easily! Fig. 2: Permitted installation positions for heaters Fig. 4: Installation...
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Page 13: Type Label
Air Top 2000 ST Type label Type label The model plate must be positioned so that it cannot be damaged and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used). Inapplicable years must be erased from the model plate. -
Page 14: Installation Example
Installation example Air Top 2000 ST Installation example Control element Heater Metering pump Fuel filter (accessory) Tank connector Exhaust silencer (accessory) Fuse Maximum water passage height Fig. 5: Installation example for air heater in recirculation mode... -
Page 15: Hot Air System
The points table for air guide parts in the Webasto catalogue may be used to design the hot air system. NOTE: For fresh air mode an external temperature sensor must be fitted in the ap- The hot air hose must be secured at its connection points. - Page 16 Hot air system Air Top 2000 ST IMPORTANT 6.1.1. To install the external temperature sensor If you use the heater without a hot air inlet hose, the inlet grille supplied The external temperature sensor must be installed at medium height in the with the heater must be used at all times.
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Page 17: Fuel Supply
Air Top 2000 ST Fuel supply Fuel supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in Figure 8. Permissible fuel inflow At max. - Page 18 If the fuel pump is located inside the tank, fuel can only be extracted from The fuel extractor must be fitted in such a way that any air or gas bubbles the return line using the Webasto fuel extractor (see Figure 9), in which are automatically discharged towards the tank (see Figure 9).
- Page 19 Air Top 2000 ST Fuel supply NOTE: The tank fitting must be made from metal! Plastic tank 7.4. Fuel lines Only steel, copper and plastic lines of plasticised, light and temperature- stabilised PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines.
- Page 20 Fuel supply Air Top 2000 ST 7.4.1. Connecting two pipes with a hose Air Top 2000 ST 12 V - petrol The correct procedure for connecting fuel lines with hosing is shown in Fig- ure 13. Ensure that there are no leaks. Correct Preferably 15°...
- Page 21 7.6. Fuel filter Only a Webasto filter, order no. 487 171, is allowed to be used if the fuel is expected to be contaminated. Install vertically if possible, however at least horizontally (check flow direction). 0° - 90°...
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Page 22: Combustion Air Supply
Combustion air supply Air Top 2000 ST Combustion air supply Under no circumstances may the combustion air be taken from areas oc- cupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt. -
Page 23: Exhaust Pipe
Air Top 2000 ST Exhaust pipe Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of The exhaust silencer should ideally be installed near the heater. 1.0 mm or flexible piping of alloyed steel only must be used as exhaust line. The heater may also be operated without a silencer. -
Page 24: Combustion Air Inlet And Exhaust Lines
Combustion air inlet and exhaust lines Air Top 2000 ST Combustion air inlet and exhaust lines Both lines are to be installed falling away from the heater. If this is not pos- sible, a condensate drain hole with a diameter of 4 mm must be made at its lowest point. - Page 25 Air Top 2000 ST Combustion air inlet and exhaust lines An attachment is required no further than 150 mm from the end of the exhaust pipe to ensure that the angle of 90° 10° is achieved Discharge direction almost vertical 90° 10°...
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Page 26: Electrical Connections
Electrical connections Air Top 2000 ST Electrical connections All the cables that are not required must be insulated. IMPORTANT In accordance with the regulations of the act governing the road/rail haul- NOTE: age of hazardous materials, heaters are only allowed to be taken into serv- If the combination timer is used, a touch-sensitive switch may be installed ice with a special manually operated switch fitted in the cab. - Page 27 Air Top 2000 ST Electrical connections The cable passage can be placed at either the left or right side. F = 15 A To ensure that the cable passage in the control unit cover seals perfectly, (12 and 24V) the cable grommet is to be adjusted appropriately on the wiring harness. 11.3.
- Page 28 Electrical connections Air Top 2000 ST 11.4. Control element connection The wiring harness is prepared for connection to the control element. Simply pull on connector housing to unplug the connector. The connector housing can be locked (self-locking action) by simply pulling on the wiring harness.
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Page 29: Connection Diagram/Circuit Diagram
Air Top 2000 ST Connection diagram/Circuit diagram Connection diagram/Circuit diagram Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig. 29: Air Top 2000 ST with combination timer connection diagram... - Page 30 Connection diagram/Circuit diagram Air Top 2000 ST Fig. 30: System wiring diagram for the Air Top 2000 ST, 12V/24V with control element and vehicle fan, for legend see pages 68 and 69...
- Page 31 Air Top 2000 ST Connection diagram/Circuit diagram Fig. 31: System wiring diagram for the Air Top 2000 ST, 12V/24V with combination timer and vehicle fan, for legend see pages 68 and 69...
- Page 32 Connection diagram/Circuit diagram Air Top 2000 ST Fig. 32: System wiring diagram for the Air Top 2000 ST D, 12/24V ADR operation with control element, for legend see pages 68 and 69...
- Page 33 Air Top 2000 ST Connection diagram/Circuit diagram Fig. 33: System wiring diagram for the Air Top 2000 ST, 12 V/24 V with combination timer and electrical battery isolation switch, for legend see pages...
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Page 34: Legend For Circuit Diagrams
Legend for circuit diagrams Air Top 2000 ST Legend for circuit diagrams Cable cross-sections < 7.5 m 7.5 - 15 m 0.75 mm 1.0 mm 1.0 mm 1.5 mm 1.5 mm 2.5 mm 2.5 mm 4.0 mm 4.0 mm 6.0 mm Cable colours blue brown... - Page 35 Air Top 2000 ST Legend for circuit diagrams Item Description Comment Item Description Comment Heater Air Top 2000 ST Combination Timer 1531 Timer and setpoint generator Control module Control unit 1574 Resistor With internal temperature sensor only Flame sensor for petrol heaters only Basic heater control On/Off switch and setpoint gene- Temperature sensor...
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Page 36: Initial Start-Up
Initial start-up Air Top 2000 ST Initial start-up After you have installed the heater, bleed the fuel supply system carefully. NOTE: As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line. Until the fuel lines have been filled the heater may switch into a fault lock- out for safety reasons - see chapter 15, "Fault lock-out". -
Page 37: Fault Lock-Out
Air Top 2000 ST Fault lock-out Fault lock-out The control unit has identified errors on individual heater components and Rectify the cause of the fault. faults during the operation. To reset the fault switch the heater on and off briefly (at least 2 seconds). If serious malfunctions such as overheating or failure to start reoccur, the The heater is shut down (fault lock-out) if: heater is locked (F 12) and can be put back into service by disconnecting... - Page 38 Fault lock-out Air Top 2000 ST 15.1. Error code output NOTE: The error code is output if the heater is fitted with a control element after an error has occurred by the switch-on indicator/error code indicator flash- ing. After 5 seconds of fast flashing, the error code will be output by a se- quence of long flash pulses, the number of flashes is shown in the table below.
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Page 39: Technical Data
The timer, overheating sensor and temperature sensor component are not dependent on voltage. 16.2. Fuel for Air Top 2000 ST B (petrol): The fuel specified by the manufacturer must be used. 16.3. Fuel for Air Top 2000 ST D (diesel/ EL heating oil): The diesel fuel specified by the manufacturer in accordance with DIN EN590 must be used. - Page 40 Technical data Air Top 2000 ST Heater Operation Air Top 2000 ST B Air Top 2000 ST D Type test permit E1 10R- 04 1085 heater E1 122R- 00 0216 Model Air heater with evaporator burner Heat output Control range 1.0 - 2.0 kW...
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Page 41: Version
Air Top 2000 ST Version Version Air Top 2000 ST-B (petrol) Air heater for petrol (12 V) Air Top 2000 ST-D (diesel) Air heater for diesel/EL heating oil (12 or 24 V) -
Page 42: Drilling Template
Drilling template Air Top 2000 ST Drilling template Seal NOTE: Max. base unevenness around the seal: 1 mm Fig. 34: Drilling template... - Page 44 In multilingual versions the German language is binding. 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. De gebruiksaanwijzing moet beslist voor inbedrijfstelling van het verwarmingstoestel gelezen worden.
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