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  4. Air Top 2000 ST B
  5. Installation Instructions Manual

Webasto Air Top 2000 ST B Installation Instructions Manual

Summary of Air Top 2000 ST B

  • Page 1

    Luftheizgeräte air heaters luchtverwarmingsapparaten einbauanweisung installation instructions montagehandleiding air top 2000 st handelsbezeichnungen/trade names/handelsnamen: air top 2000 st b (benzin/petrol/benzine) air top 2000 st d (diesel/pme) at2000st_installation_instructions.Book page 1 wed...

  • Page 2

    Das unsachgemäße einbauen oder reparieren von webasto heiz- und kühlsystemen kann feuer verursachen oder zum austritt von tödlichem kohlenmonoxid führen. Dadurch können schwere oder tödliche verletzungen hervorgerufen werden. Für den einbau und die reparatur von webasto heiz- und kühlsystemen bedarf...

  • Page 4

    Air top 2000 st i inhaltsverzeichnis 1 gesetzliche bestimmungen für den einbau . . . . . . . . . . . . . 1 2 verwendung der luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 5 3 einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 typschild . . . . ...

  • Page 5

    Air top 2000 st statutory regulations governing installation 39 1 statutory regulations governing installation type approvals according to ece-r 10 (emc) and ece-r 122 (heater) exist for the air top 2000 st heater. See chapter 16, "technical data" for the approval number. Primarily the regulations o...

  • Page 6

    Statutory regulations governing installation air top 2000 st 40 requirement for basic unit: a maximum run-on period of 40 seconds is permitted when the combus- tion heater is switched off. Only combustion heaters with heat exchangers that are approved for this reduced run-on time of 40 seconds may b...

  • Page 7

    Air top 2000 st statutory regulations governing installation 41 5.3.6.2 the inlet duct must be protected by mesh or other suitable means. 5.3.7 heating air outlet 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 ca...

  • Page 8

    Statutory regulations governing installation air top 2000 st 42 3.3 fl vehicles 3.3.1 the combustion heaters shall be put out of operation by at least the following methods: a) intentional manual switching off from the driver’s cab; b) stopping of the vehicle engine; in this case the heating device ...

  • Page 9

    Air top 2000 st use of the air heaters 43 2 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 fue...

  • Page 10

    Installation air top 2000 st 44 3 installation important the statutory regulations governing installation on pages 1 and 2 must be adhered to. The requirements of the latest version of the adr must also be observed for the installing the heater into vehicles used to transport haz- ardous substances....

  • Page 11

    Fig. 1: dimensions of the heater 1 hot air inlet 2 hot air outlet 3 combustion air intake 4 exhaust fume outlet 5 fuel intake 6 space requirement for hot air inlet 7 space requirement for removing the heater 8 cable outlet (either right or left) 1 2 3 5 4 7 8 6 air top 2000 st installation 45 at2000...

  • Page 12

    Fig. 2: permitted installation positions for heaters air top 2000 st - diesel: air top 2000 st - petrol: horizontally fig. 3: seal fig. 4: installation ensure that all moving parts can move easily! Installation air top 2000 st 46 at2000st_installation_instructions.Book page 46 wednesday, may 29, 201...

  • Page 13

    Air top 2000 st type label 47 4 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. At2000st_installation_instruct...

  • Page 14

    Installation example air top 2000 st 48 5 installation example fig. 5: installation example for air heater in recirculation mode 1 control element 2 heater 3 metering pump 4 fuel filter (accessory) 5 tank connector 6 exhaust silencer (accessory) 7 fuse maximum water passage height 1 2 3 5 4 7 6 at20...

  • Page 15

    Air top 2000 st hot air system 49 6 hot air system note: the heater must not be integrated into the vehicle’s air system. Inside the control unit there is a temperature sensor, which operates the heater in the appropriate heat output range in conjunction with the control element depending on the int...

  • Page 16

    Hot air system air top 2000 st 50 important if you use the heater without a hot air inlet hose, the inlet grille supplied with the heater must be used at all times. Note: the installation must be checked for: – air short circuit between the vehicle’s heating system and the heater air inlet – air sho...

  • Page 17

    Air top 2000 st fuel supply 51 7 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 height h (m) at max. Perm. Pressure (bar) in fuel line 0,00 0,2 1,00...

  • Page 18

    Fuel supply air top 2000 st 52 7.1. Vehicles with carburettor engines the fuel may only be extracted using the special webasto fuel extractor (see figure 9) as close to the tank as possible. The connect may be made in either the supply or return line, in which case the return line must lead almost t...

  • Page 19

    Fig. 11: fuel pick-up from the plastic tank (pick-up via tank drain screw) sealing ring plastic tank fig. 12: fuel pick-up from the plastic tank (pick-up via tank fitting) sealing ring tank connector tank fitting air top 2000 st fuel supply 53 note: the tank fitting must be made from metal! 7.4. Fue...

  • Page 20

    Fuel supply air top 2000 st 54 7.4.1. Connecting two pipes with a hose the correct procedure for connecting fuel lines with hosing is shown in fig- ure 13. Ensure that there are no leaks. Fig. 13: pipe / hose connection clip bubble correct wrong bubble 7.5. Metering pump the metering pump is a combi...

  • Page 21

    Air top 2000 st fuel supply 55 7.5.2. Installation and attachment the metering pump must be secured with a vibration-damping mounting (for example a rubberised clip). Its installation position is limited as shown in figures 14 and 15 in order to ensure effective automatic bleeding. As a result of th...

  • Page 22

    Combustion air supply air top 2000 st 56 8 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. Note: a...

  • Page 23

    Air top 2000 st exhaust pipe 57 9 exhaust pipe rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm or flexible piping of alloyed steel only must be used as exhaust line. The exhaust pipe is secured to the heater using a clamping collar, for ex- ample. See the statutory ...

  • Page 24

    Combustion air inlet and exhaust lines air top 2000 st 58 10 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. Fig. 19: prevent the formation...

  • Page 25

    Fig. 22: exhaust pipe opening installation position an attachment is required no further than 150 mm from the end of the exhaust pipe to ensure that the angle of 90° r 10° is achieved discharge direction almost vertical 90° r 10° air top 2000 st combustion air inlet and exhaust lines 59 only for adr...

  • Page 26

    Electrical connections air top 2000 st 60 11 electrical connections all the cables that are not required must be insulated. Note: if the combination timer is used, a touch-sensitive switch may be installed in the sleeping section to act as a remote control and improved conven- ience. The connections...

  • Page 27

    Air top 2000 st electrical connections 61 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. 11.3. Supply voltage connection ideally fro...

  • Page 28

    Electrical connections air top 2000 st 62 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 29

    Air top 2000 st connection diagram/circuit diagram 63 12 connection diagram/circuit diagram adapter wiring harness red: terminal 30 grey: terminal 58 black: terminal 15 brown: terminal 31 combination timer 1531 fig. 29: air top 2000 st with combination timer connection diagram at2000st_installation_...

  • Page 30

    Connection diagram/circuit diagram air top 2000 st 64 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 at2000st_installation_instructions.Book page 64 wednesday, may 29, 2013 12:54 pm.

  • Page 31

    Air top 2000 st connection diagram/circuit diagram 65 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 at2000st_installation_instructions.Book page 65 wednesday, may 29, 2013 12:54 pm.

  • Page 32

    Connection diagram/circuit diagram air top 2000 st 66 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 at2000st_installation_instructions.Book page 66 wednesday, may 29, 2013 12:54 pm.

  • Page 33

    Air top 2000 st connection diagram/circuit diagram 67 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 and at2000st_installation_instructions.Book page 67 wednesday, may 29, 2013 12:54 pm.

  • Page 34

    Legend for circuit diagrams air top 2000 st 68 13 legend for circuit diagrams cable cross-sections 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet wh...

  • Page 35

    Item description comment a1 heater air top 2000 st a2 control module control unit 1574 b1 flame sensor for petrol heaters only b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug f1 fuse 15 a 12 v/24 v (max. 20 a) flat fuse sae j 1284 f2 ...

  • Page 36

    Initial start-up air top 2000 st 70 14 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 ...

  • Page 37

    Air top 2000 st fault lock-out 71 15 fault lock-out the control unit has identified errors on individual heater components and faults during the operation. The heater is shut down (fault lock-out) if: – no or incorrect start – temperature sensor defective – overheating sensor interrupt or short circ...

  • Page 38

    Fault lock-out air top 2000 st 72 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- que...

  • Page 39

    Air top 2000 st technical data 73 16 technical data except where limit values are specified, the technical data refer to the usual heater tolerances of r 10 % at an ambient temperature of + 20 °c and at the rated voltage and in rated conditions. 16.1. Electrical components: control unit, motor, mete...

  • Page 40

    Heater operation air top 2000 st b air top 2000 st d type test permit emc heater e1 10r- 04 1085 e1 122r- 00 0216 model air heater with evaporator burner heat output control range 1.0 - 2.0 kw 0.9 - 2.0 kw fuel petrol en 228 din 51625 diesel/pme en 590 din 51603 din en 14214 fuel consumption control...

  • Page 41

    Air top 2000 st version 75 17 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) at2000st_installation_instructions.Book page 75 wednesday, may 29, 2013 12:54 pm.

  • Page 42

    Drilling template air top 2000 st 76 18 drilling template fig. 34: drilling template note: max. Base unevenness around the seal: 1 mm seal at2000st_installation_instructions.Book page 76 wednesday, may 29, 2013 12:54 pm.

  • Page 43

    At2000st_installation_instructions.Book page 115 wednesday, may 29, 2013 12:54 pm.

  • Page 44

    Die betriebsanweisung vor inbetriebnahme des heizgerätes unbedingt lesen. Im fall einer mehrsprachigen version ist deutsch verbindlich. Die telefonnummer des jeweiligen landes entnehmen sie bitte dem webasto servicestellenfaltblatt oder der webseite ihrer jeweiligen webasto-landesvertretung. The ope...