Webasto Air Top 2000 ST B Installation Instructions Manual
Air heaters
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Summary of Contents for Webasto Air Top 2000 ST B
- Page 1 Luftheizgeräte Einbauanweisung Air Heaters Installation Instructions Luchtverwarmingssystemen Montagehandleiding Air Top 2000 ST Handelsbezeichnungen/Trade names/Handelsnamen: Air Top 2000 ST B (Benzin/Petrol/benzine) Air Top 2000 ST D (Diesel/PMU) 05/2008 9010298C...
- Page 2 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 3: 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 4: Statutory Regulations Governing Installation
Failure to follow the installation instructions and the notes contained even in the case of overheating. This requirement shall be deemed to therein will lead to all liability being refused by Webasto. The same be fulfilled if the installation ensures an adequate distance to all parts... -
Page 5: Statutory Regulations Governing Installation
Statutory regulations governing installation Air Top 2000 ST 2.2.4 / 5.3.2.4. The label referred to in paragraph 1.4 / annex 7 / article 2.6. / 5.3.6. Heating air inlet 1.4 (model plate), or a duplicate (duplicate model plate), must be 2.6.1 / 5.3.6.1. - Page 6 Air Top 2000 ST Statutory regulations governing installation (Extract from Directive 2001/56/EC Annex IX) 3. Technical specifications for heater units for installation in 3.2. EX/II and EX/III vehicles dangerous goods transporters (Annex 9) Combustion heaters using gaseous fuels are not permitted. 3.1.
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Page 7: Use Of The Air Heaters
Use of the air heaters Air Top 2000 ST 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 to the fuel tank and the electrical system of the vehicle. -
Page 8: Installation
Air Top 2000 ST Installation Installation IMPORTANT 3.1. Air Top 2000 ST installation situation The statutory regulations governing installation on pages 1 and 2 must NOTE: be adhered to. The requirements of the latest version of the ADR must Check the installation situation of the relevant vehicle type. also be observed for the installing the heater into vehicles used to transport hazardous substances. - Page 9 Seal The installation dimensions and space requirement for service access A special tools can be purchased from Webasto to drill the holes and, if are shown in the installation drawing (Figure 1). The specified horizontal necessary, smooth the support area. The seal can compensate for and axial angles must not be exceeded (Figure 2).
- Page 10 Air Top 2000 ST Installation IMPORTANT After installation, check that the casing is not in contact with any parts of the vehicle body. A failure to do this may result in the hot air fan blocking. Ensure that all moving parts can move ea Fig.
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Page 11: Factory Plate
Factory plate Air Top 2000 ST Factory plate 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 12: Installation Example
Air Top 2000 ST Installation example Installation example Control element Heater Metering pump Fuel filter (accessory) Tank connector Exhaust silencer (accessory) Fuse Maximum water passage height Fig. 6: Installation example for air heater in recirculation mode... -
Page 13: Hot Air System
Hot air system Air Top 2000 ST Hot air system NOTE: IMPORTANT The heater must not be integrated into the vehicle’s air system. In vehicles used to transport people, the air outlet opening is to be directed in such a way that it is at least 20 cm away from all body parts. Both recirculation and fresh air modes are possible. - Page 14 Air Top 2000 ST Hot air system 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 with the heater must be used at all times.
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Page 15: Fuel Supply
Fuel supply Air Top 2000 ST 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 9. Permissible fuel inflow At max. - Page 16 (see Figure 11 for details of the minimum distance from the bottom of the tank). If this is not the case Webasto fuel extractor (see Figure 11, 12 and 13) may be used.
- Page 17 Fuel supply Air Top 2000 ST 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- stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines.
- Page 18 Installation location to ensure effective auto-bleeding. As a result of the risk of corrosion, only genuine Webasto parts may be It is advisable to install the metering pump in a cool place. The maximum used for the plug connections between the metering pump and the ambient temperature must not exceed +20 °C for petrol heaters at any...
- Page 19 Air Top 2000 ST 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 20: Combustion Air Supply
Air Top 2000 ST Combustion air supply Combustion air supply Under no circumstances may the combustion air be taken from areas occupied 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 21: Exhaust Pipe
Exhaust pipe Air Top 2000 ST Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness The exhaust silencer should ideally be installed near the heater. of 1.0 mm or flexible piping of alloyed steel only must be used as The heater may also be operated without a silencer. -
Page 22: Combustion Air Inlet And Exhaust Lines
Air Top 2000 ST Combustion air inlet and exhaust lines Combustion air inlet and exhaust lines Both lines are to be installed falling away from the heater. If this is not possible, a condensate drain hole with a diameter of 4 mm must be made at its lowest point. - Page 23 Combustion air inlet and exhaust lines Air Top 2000 ST 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° Fig.
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Page 24: Electrical Connections
Air Top 2000 ST Electrical connections 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 NOTE: haulage of hazardous materials, heaters are only allowed to be taken If the combination timer is used, a touch-sensitive switch may be into service with a special manually operated switch fitted in the cab. - Page 25 Electrical connections Air Top 2000 ST Before using the heater for the first time fit the control unit cover to F = 15A (24V) prevent the illegal escape of hot air (heater overheating). F = 20A (12V) The cable passage can be placed at either the left or right side. To ensure that the cable passage in the control unit cover seals perfectly, the cable grommet is to be adjusted appropriately on the wiring harness.
- Page 26 Air Top 2000 ST Electrical connections 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.
- Page 27 Electrical connections Air Top 2000 ST 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 28 Air Top 2000 ST Electrical connections Fig. 30: System wiring diagram for the Air Top 2000 ST, 12V/24V with control element and vehicle fan, for legend see pages 67 and 68...
- Page 29 Electrical connections Air Top 2000 ST 0,5mm² sw/rt X2/X3/X4/X5 0,5mm² 0,5mm² 0,5mm² 0,5mm² ge br 12V rt 24V gn Fig. 31: System wiring diagram for the Air Top 2000 ST, 12V/24V with combination timer and vehicle fan, for legend see pages 67 and 68...
- Page 30 Air Top 2000 ST Electrical connections Fig. 32: System wiring diagram for the Air Top 2000 ST D, 24V ADR operation with control element, for legend see pages 67 and 68...
- Page 31 Electrical connections Air Top 2000 ST Fig. 33: System wiring diagram for the Air Top 2000 ST D, 24V ADR operation with control element without power take-off, for legend see pages 67 and 68...
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Page 32: Legend For Circuit Diagrams
Air Top 2000 ST Legend for circuit diagrams: Legend for circuit diagrams: ➀ With positive from terminal (15/75) to connection 10: Cable cross-sections Permanent operation for immediate heat as long as the ignition is switched on < 7.5 m 7.5 - 15 m Without positive at connection 10: Heating time is variably programmable (10 min to 120 min), 0.75 mm... - Page 33 Legend for circuit diagrams: Air Top 2000 ST Item Description Comment Item Description Comment Heater Air Top 2000 ST Switch Ventilation Control module Switch Flashover sensor Flame sensor for petrol heater only Switch setting Temperature sensor internal Momentary-contact switch Immediate heat button remote control Overheating sensor Overheating guard...
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Page 34: Initial Start-Up
Air Top 2000 ST Initial start-up 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. Conduct a trial of the heater to check all the connections for leaks and to ensure that they are secure. -
Page 35: Fault Lock-Out
Fault lock-out Air Top 2000 ST Fault lock-out The control unit has identified errors on individual heater components If serious malfunctions such as overheating or failure to start reoccur, and faults during the operation. the heater is locked (F 12) and can be put back into service by disconnecting the power supply with the heater switched on (e.g. - Page 36 Air Top 2000 ST Fault lock-out 14.1. 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 flashing. After 5 seconds of fast flashing, the error code will be output by a sequence of long flash pulses, the number of flashes is shown in the table below.
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Page 37: Technical Data
The timer, overheating sensor and temperature sensor component are not dependent on voltage. 15.2. Fuel for Air Top 2000 ST B (petrol): The fuel specified by the manufacturer must be used. 15.3. Fuel for Air Top 2000 ST D (diesel/ EL heating oil): The diesel fuel specified by the manufacturer must be used. - Page 38 Air Top 2000 ST Technical data Heater Operation Air Top 2000 ST B Air Top 2000 ST D Type test permit e1*72/245*95/54*1085*00 heater e1*2001/56*0022*00 E1*R122 00 0216*-- Model Air heater with evaporator burner Heat output Control range 1.0 - 2.0 kW 0.9 - 2.0 kW...
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Page 39: Version
Version Air Top 2000 ST 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 40: Drilling Template
Air Top 2000 ST Drilling template Drilling template Seal ø7,5 ø26 ø26 ø7,5 ø7,5 NOTE: Max. base unevenness around the seal: 1 mm Fig. 34: Drilling template... - Page 41 De gebruiksaanwijzing moet beslist voor inbedrijfstelling van het ver- warmingstoestel gelezen worden. Webasto AG Kraillinger Strasse 5 82131 Stockdorf GERMANY Tel: +49 (0)89 85794 - 0 Fax: +49 (0)89 85794 - 448 http://dealers.webasto.com...
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