Webasto Type Air Top 2000 ST B Workshop Manual
  1. Manuals
  2. Brands
  3. Webasto Manuals
  4. Heater
  5. Air Top 2000 ST B
  6. Workshop manual

Webasto Type Air Top 2000 ST B Workshop Manual

Hide thumbs Also See for Type Air Top 2000 ST B:
Table of Contents

Advertisement

Quick Links

See also: Instruction and Installation Manual , Installation Manual
Luft-Heizgeräte
Air Heaters
03/2003
Workshop Manual
Air Top 2000 ST
Type Air Top 2000 ST B (petrol)
Type Air Top 2000 ST D (diesel)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Type Air Top 2000 ST B and is the answer not in the manual?

Questions and answers

Related Manuals for Webasto Type Air Top 2000 ST B

Summary of Contents for Webasto Type Air Top 2000 ST B

  • Page 1 Luft-Heizgeräte 03/2003 Air Heaters Workshop Manual Air Top 2000 ST Type Air Top 2000 ST B (petrol) Type Air Top 2000 ST D (diesel)
  • 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.

  • Page 3: Table Of Contents

    Air Top 2000 ST Table of Contents Table of Contents Introduction ................101 Contents and purpose.
  • Page 4 Table of Contents Air Top 2000 ST Function Tests ............... . 601 General .
  • Page 5 Air Top 2000 ST Table of Contents Repair ................901 General.
  • Page 6 Webasto tank connector ........

  • Page 7: Introduction

    1.1.1 Use of the air heaters passages of the procedures. The Webasto Air Top 2000 ST air heaters are designed 1.4.1 Statutory regulations governing – to heat cabins, boats, trucks, minibuses, vans,...
  • Page 8 Introduction Air Top 2000 ST 2.2. / 5.3.2. (Part I) Positioning of heater 2.6. / 5.3.6. (Part I) Heating air inlet 2.2.1. / 5.3.2.1. (Part I) Body sections and any other 2.6.1. / 5.3.6.1. (Part I) The heating air supply may be components in the vicinity of the heater must be pro- fresh or recirculated air and must be drawn from a tected from excessive heat and the possibility of fuel...
  • Page 9 Webasto-trained per- that dripping or evaporating fuel cannot collect or ignite sonnel. Claims can only be made if it can be verified that the on hot parts or on electrical equipment.
  • Page 10 Webasto workshop. After this the heater lockout can be cancelled by switching it off and then on again. If this action does not produce the required success (if the heater overheats again) take it to a Webasto-authorised workshop.

  • Page 11: Fig. 201 Air Top 2000 St Air Heater

    Air Top 2000 ST General description General description If a fault occurs, an error code will be output in the display of the combination or standard timer. If the heater has a control element, the ON control light will flash. In addition The Air Top 2000 ST air heaters are based on the evaporator the heater can be checked using a personal computer (see principle and essentially consist of the following...

  • Page 12: Fig. 204 Heat Exchanger

    General description Air Top 2000 ST Heat exchanger Control unit The heat generated by the combustion process is The control unit is the central component for ensuring the transferred to the air transported by the combustion and function is maintained and for monitoring the heater’s hot air blowers in the heat exchanger.

  • Page 13: Fig. 208

    Air Top 2000 ST General description Glow plug Metering pump The mixture of fuel and air is ignited by the glow plug when The metering pump is a combined transport, metering and the heater is started. The glow plug takes the form of an shut-off system for supplying fuel from the vehicle’s tank to electrical resistor and is positioned in the burner insert on the heater.
  • Page 14 General description Air Top 2000 ST Page for notes...

  • Page 15: Description Of Operation

    Air Top 2000 ST Description of operation Description of operation Automatic restart If no flame is detected, the starting procedure will be Control element repeated. The glow plug will be switched on again (cycled). The motor for the hot and combustion air blower will be set to approx.

  • Page 16: Fault Lock-Out

    Description of operation Air Top 2000 ST If, at minimum heat output, the intake temperature set on • No repeated or incorrect start the control element is exceeded, the metering pump is shut • Temperature sensor defective down and the combustion process ended. To burn off the •...

  • Page 17: Reset A Fault Lock-Out

    Air Top 2000 ST Description of operation If the FAZ reaches a value of 6, the heater will go into fault lock-out mode and the permanent flame failure counter FAZP will be incremented by 1. In control mode the permanent flame failure counter FAZP will be decremented by 1.
  • Page 18 Description of operation Air Top 2000 ST Page for notes...

  • Page 19: Fig. 401 Technical Data Air Top 2000 St

    Air Top 2000 ST Technical data Technical data Fuel for Air Top 2000 ST B (petrol): The fuel specified by the manufacturer must be used. Fuel for Air Top 2000 ST D (diesel/PME): Except where limit values are specified, the technical data The diesel fuel specified by the manufacturer in accordance listed in the table refer to the usual heater tolerances of with DIN EN590 must be used Class EL heating oil (not L...

  • Page 20: Fig. 402 Setpoint Values For Resistance Values Of Components

    Technical data Air Top 2000 ST Setpoint values: 12 V 24 V Glow plug At 25 ºC red marking Green marking Test current: < 5 mA 0.263 - 0.323 ohms 1.125 - 1.375 ohms Drive unit Outside < 6 ohms Overheating temperature sensor at 25 ºC 2- 2.5 ohms.

  • Page 21: Fig. 501 General Error Symptoms

    Air Top 2000 ST Troubleshooting Troubleshooting IMPORTANT The troubleshooting guide is restricted to the localisation of defective components. The following potential sources of General malfunctions are not taken into account and should always be checked so that they can then be excluded as the cause of the particular fault: This section describes how to identify and remedy faults on the Air Top 2000 ST air heater.

  • Page 22: Fig. 502 Error Symptoms During Function

    Troubleshooting Air Top 2000 ST Error symptoms during function 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 The following table (Fig.

  • Page 23: Fig. 503

    Air Top 2000 ST Troubleshooting 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 If the heater is fitted with a combination timer, an error code indicator/error code indicator flashing.
  • Page 24 Troubleshooting Air Top 2000 ST Error Error (group) Additional information during PC Troubleshooting code diagnostic F 05 Flame monitor 1A Flame monitor circuit Replace flame monitor interrupt or short The switched cable of the element has a circuit short circuit to earth (only petrol heater) 9A Flame monitor circuit Replace flame monitor...
  • Page 25 Air Top 2000 ST Troubleshooting Error Error (group) Additional information during PC Troubleshooting code diagnostic F 12 Heater unit lock-out 07 The permanent heater fault lock-out Remove the fuse and reinsert it has been activated NOTE The following error has occurred several times: Fault counter more than 3 times...
  • Page 26 Troubleshooting Air Top 2000 ST Page for notes...

  • Page 27: Function Tests

    – 3 MB of free memory on the hard disk – a free COM port (RS232C) or a free USB port – Optional: Internet connection (for software updates) – Webasto Thermo Test does not run under Windows 3.1 with Win32s...

  • Page 28: Settings

    Function Tests Air Top 2000 ST Settings 6.3.1 Setting CO content The CO content in the emissions is set using the adjustment knob on the control element. At a constant blower speed the volume of fuel is controlled by changing the metering pump cycle.

  • Page 29: Testing Individual Components

    Webasto within the warranty period. Repair/replace component if necessary and put heater [vol. %] into operation. min. tolerance for operation [vol. %] Repair/replace component. Only send defective max. tolerance for operation [vol. %] component (not entire heater) to Webasto within warranty period.

  • Page 30: Burner Insert Component

    – CO measuring Check function on heater reference heater. unit test bench Set reference unit – Webasto to nominal CO Diagnosis Adapter value locally after – PC (personal 5 minutes of full- computer) load operation in – Reference heater...

  • Page 31: Glow Plug Resistance Test (Only Petrol Heater)

    Air Top 2000 ST Function Tests 6.4.2 Glow plug resistance test (only petrol heater) See Fig. 904, Item 1 If you conduct this test with a digital multimeter, the flame monitor must have the values shown as following: Cold testing: Resistance at 25 °C: 2.6 - 3.4 ohms.
  • Page 32 Function Tests Air Top 2000 ST Procedure Testing and Visual measuring Flame monitor equipment Contacts detached? Visual inspection Cables damaged? Visual inspection Ceramic broken? Visual inspection Resistance outside Resistance Digital 2.5 - 3.8 ohms? measurement multimeter Ceramic broken by effects Visual inspection of force?

  • Page 33: Glow Plug Component

    Air Top 2000 ST Function Tests 6.4.3 Glow plug component See Fig. 904, Item 6 NOTE The resistance test must be carried out with an ohmmeter suitable for small resistance values. A resistance test with a simple digital multimeter is too inaccurate to find the precise values.
  • Page 34 Function Tests Air Top 2000 ST Procedure Testing and Visual measuring Glow plug equipment Contacts detached? Visual inspection Cables damaged? Visual inspection Ceramic broken? Visual inspection Resistance outside Resistance Digital 1.1 - 1.6 ohms? measurement multimeter Ceramic broken by effects Visual inspection of force?

  • Page 35: Combustion Air Fan Component (Drive)

    Air Top 2000 ST Function Tests 6.4.4 Combustion air fan component (drive) See Fig. 903, Item 5 Procedure Testing and Visual measuring equipment Combustion air fan (drive) Externally damaged? Visual inspection Installation of component in unit => short circuit to metal Continuity Digital parts (heat exchanger etc.)?

  • Page 36: Overheating Sensor Component

    Function Tests Air Top 2000 ST 6.4.5 Overheating sensor component See Fig. 903, Item 8 If you conduct this resistance test with a digital multimeter, the overheating sensor must have the values shown in the following diagram (Fig. 601). Temperature in °C Fig.

  • Page 37: Control Unit Component

    – Heater test Fault-free operation in test with the bench reference heater? reference unit, – PC mount the (personal control unit to be computer) tested in the – Webasto reference heater Diagnosis and conduct the Adapter function test – Reference again heater...

  • Page 38: Heater Component

    Function Tests Air Top 2000 ST 6.4.7 Heater component Description Procedure Testing and measuring Complete heater equipment Remove upper shell from heater and pull component connector off control unit PCB. Wire colours of Testing of all electrical individual components: components Glow plug (yellow), Flame monitor (brown), Drive unit (purple),...
  • Page 39 Burning hours, number of starts, errors Send printouts of diagnosis with component to Webasto (for contact, see beginning of paragraph 6.4) Function test – Heater test bench Fault-free operation? – PC (personal computer) – Webasto Diagnosis Adapter...
  • Page 40 Function test – Heater test continue bench – CO measuring unit Reinstalling control unit – PC (personal in heater to be tested computer) – Webasto Diagnosis Adapter – Reference heater value within tolerance? measurement Set CO value in permissible range with...
  • Page 41 CO value unit locally after 5 minutes of – PC (personal full-load operation in computer) accordance with – Webasto value adjustable in graphic, install burner to Diagnosis tolerance in reference be tested in reference measurement Adapter heater? unit and measure CO –...
  • Page 42 Function Tests Air Top 2000 ST Page for notes...

  • Page 43: Fig. 701 Plug Assignment

    Air Top 2000 ST Circuit diagrams Circuit diagrams The circuit diagrams (Fig. 702 to Fig. 705) show the possible circuits for 12 or 24 Volt with General • Control element and vehicle blower • Combination timer and vehicle blower • ADR operation with control element The Air Top 2000 ST heater units can be operated with the •...

  • Page 44: Fig. 702 System Circuit Diagram Air Top 2000 St, 12V/24V With Control Element And Vehicle Blower

    Circuit diagrams Air Top 2000 ST Fig. 702 System circuit diagram Air Top 2000 ST, 12V/24V with control element and vehicle blower Fig. 703 System circuit diagram Air Top 2000 ST, 12V/24V with combination timer and vehicle blower...
  • Page 45 Air Top 2000 ST Circuit diagrams Fig. 704 System circuit diagram Air Top 2000 ST, 12V/24V ADR operation with control element Fig. 705 System circuit diagram Air Top 2000 ST, 12V/24V with combination timer and electrical battery isolation switch...

  • Page 46: Fig. 706 Air Top 2000 St With Combination Timer Connection Diagram

    Circuit diagrams Air Top 2000 ST Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig. 706 Air Top 2000 ST with combination timer connection diagram...

  • Page 47: Legend For Circuit Diagrams

    Air Top 2000 ST Circuit diagrams Legend for circuit diagrams Cable cross-sections Cable colours < 7.5 m 7.5 - 15 m blue brown 0.75 mm 1.0 mm yellow green 1.0 mm 1.5 mm grey 1.5 mm 2.5 mm orange 2.5 mm 4.0 mm black violet...
  • Page 48 Circuit diagrams Air Top 2000 ST Page for notes...

  • Page 49: Servicing Work

    Do not short checked at regular intervals, at the latest at start of the circuit the current of hot air. heating period (the time after which the heater will be used due to adverse weather conditions) by Webasto-trained personnel.

  • Page 50: Fuel Supply

    (for example Part No. 470 910), in which case it must be ensured that the return line continues almost to the bottom of the tank. If this is not the case Webasto fuel 8.6.2 Fuel supply extractor (see Fig. 802, Fig. 803 or Fig. 804) may be used.

  • Page 51: Fig. 801 Fuel Supply

    Sealing ring Hole pattern Tank fitting NOTE Only use a tank extractor with metal fuel tanks Fig. 802 Webasto tank connector NOTE The fitting must be made from metal! Fig. 804 Fuel extractor from the plastic tank (extraction through tank fitting)

  • Page 52: Fig. 805 Pipe/Hose Connections

    Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness. 8.6.4 Fuel filter Only a Webasto filter, ident. no. 487 171, is allowed to be Correct Wrong used if the fuel is expected to be contaminated. Install Fig.

  • Page 53: Fig. 809 Exhaust Silencer

    Air Top 2000 ST Servicing work 8.6.5 Combustion air supply 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 or a connection Under no circumstances may the combustion air be taken element with a condensate drain used.

  • Page 54: Fig. 811 Remove The Fastening Plate On The Fuse Holder

    Servicing work Air Top 2000 ST 8.6.8 Electrical connections The wiring harness is prepared for connection to the control element (setpoint generator). Simply pull on connector housing to unplug the connector 8.6.8.1 Heater connection, control element (Fig. 813). The electrical connection is to be made as shown in the appropriate circuit diagram (see section 7).

  • Page 55: Fig. 815 Installation Example For Heater In Recirculation Mode

    Air Top 2000 ST Servicing work 1 Control element 2 Heater 3 Metering pump and damper 4 Fuel filter (accessory) 5 Tank connector 6 Exhaust silencer 7 Fuse Fig. 815 Installation example for heater in recirculation mode...

  • Page 56: Removal And Installation

    1. Place the heater with a new seal on the exhaust outlet in the installation position and secure it with 4 nuts and locking washers (use only genuine Webasto nuts). 2. Tighten the nuts to 6 +1 Nm. 3. Secure the connection for the combustion air inlet on the heater.

  • Page 57: Fig. 901 Installation Of An External Temperature Sensor

    Air Top 2000 ST Repair Repair 9.1.2.1 Installation of an external temperature sensor General General The heater optimally regulates the desired temperature when its temperature sensor is loaded with the air temper- ature of the area mainly occupied. In certain circumstances, This section describes the repair work that may be carried this is not always possible using the temperature sensor out on the Air Top 2000 ST heater after it has been removed...

  • Page 58: Dismantling And Assembling

    Repair Air Top 2000 ST Dismantling and assembling 9.2.2.2 Top shell 1. Place the top shell (2, Fig. 902) on the heater and secure 9.2.1 Remove the casing parts it in the grooves in the bottom shell. 9.2.1.1 Cover for electrical connection 9.2.2.3 Cover for hot air inlet and outlet The cover (1,Fig.

  • Page 59: Fig. 902 Remove/Fit The Casing Parts

    Air Top 2000 ST Repair 1 Cover, electrical connection 2 Top shell 3 Cover, hot air outlet 4 Bottom shell 5 Grille 6 Cover, hot air inlet 7 Insulators Insulator positioning Insulator Widening of corner rib Fig. 902 Remove/fit the casing parts...

  • Page 60: Replace Control Unit

    Repair Air Top 2000 ST 9.2.3 Replace control unit 3. Ensure that overheating sensor is correctly positioned in heat exchanger (7). 9.2.3.1 Removal 4. Connect plug connection X5 to the control unit (3). Ensure parallel routing of the cable duct between the 1.

  • Page 61: Replace Flame Sensor (Petrol Heater Only)

    Air Top 2000 ST Repair 9.2.6 Replace flame sensor (petrol heater only) 9.2.6.1 Removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the combustion air fan (see 9.2.5.1). 5.

  • Page 62: Fig. 903 Change Control Unit, Combustion Air Fan And Overheating Sensor

    Repair Air Top 2000 ST Detail A Hot air blower Torx screw (3) Control unit Torx screw (5) Combustion air fan (drive) Seal Heat exchanger Overheating sensor Insulator (4) Fig. 903 Change control unit, combustion air fan and overheating sensor...

  • Page 63: Change Glow Plug

    Air Top 2000 ST Repair 9.2.7 Change glow plug 5. Introduce the burner insert (5) in the heat exchanger (9). Make sure that the cable of the flame sensor (1) (only present with petrol heater) is positioned under the fuel 9.2.7.1 Removal line.

  • Page 64: Fig. 904 Change The Glow Plug, Flame Sensor, Burner Insert And Heat Exchanger

    Repair Air Top 2000 ST Flame sensor (only petrol heater) Grommet Torx screw (4) Heat exchanger Air baffle 10 Cable grommet Securing strap 11 Cable grommet (only petrol heater) Burner insert 12 Seal Glow plug 13 Combustion chamber Screw Fig. 904 Change the glow plug, flame sensor, burner insert and heat exchanger...

  • Page 65: Change Burner Insert, Combustion Pipe And Heat Exchanger

    Air Top 2000 ST Repair 9.2.8 Change burner insert, combustion pipe and heat exchanger 9.2.8.1 Removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the overheating sensor (see 9.2.4.1). 5.

  • Page 66: Fig. 905 Starting Air Hole In Burner Insert

    Repair Air Top 2000 ST Starting air hole Fig. 905 Starting air hole in burner insert...

  • Page 67: Packing, Storage And Shipping

    Packing, Storage and Shipping Packing, Storage and Shipping 10.1 General If the heater or its components are sent to Webasto AG for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, transport and storage.
  • Page 68 Packing, Storage and Shipping Air Top 2000 ST Page for notes 1002...
  • Page 70 Webasto AG Postfach 80 D - 82132 Stockdorf Germany National: Hotline: 01805 93 22 78 (€ 0,14 aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com www.webasto.de International: www.webasto.com...

This manual is also suitable for:

Air top 2000 st b (petrol)Air top 2000 st d (diesel)Hot air system 2000

Table of Contents