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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 luchtverwarmingssystemen 05/2008 9010298c 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/pmu).

  • 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 3: Inhaltsverzeichnis

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

  • Page 4

    Air top 2000 st statutory regulations governing installation 39 1 statutory regulations governing installation 1.1. Statutory regulations governing installation the air top 2000 st heater unit has been type- tested and approved in accordance with directives 72/245/eec (emc), 2001/56/ec (heater) and ...

  • Page 5

    Statutory regulations governing installation air top 2000 st 40 2.2.4 / 5.3.2.4. The label referred to in paragraph 1.4 / annex 7 / article 1.4 (model plate), or a duplicate (duplicate model plate), must be positioned so that it can be easily read when the heater is installed in the vehicle. 2.2.5 /...

  • Page 6

    Air top 2000 st statutory regulations governing installation 41 (extract from directive 2001/56/ec annex ix) 3. Technical specifications for heater units for installation in dangerous goods transporters (annex 9) 3.1. General (ex/ii, ex/iii, at, fl and ox vehicles) 3.1.1. The combustion heaters and ...

  • Page 7

    Use of the air heaters air top 2000 st 42 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 to the fuel tank and ...

  • Page 8

    Air top 2000 st installation 43 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 hazardous substances. T...

  • Page 9

    Installation air top 2000 st 44 the heater must be installed in such a way that no water can ingress into it if the vehicle travels through a water hazard for which that vehicle is licensed. The openings for the combustion air inlet port, the exhaust outlet port and the fuel pipe must be sealed if t...

  • Page 10

    Air top 2000 st installation 45 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. Fig. 5: installation ensure that all moving parts can move ea.

  • Page 11

    Factory plate air top 2000 st 46 4 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

    Air top 2000 st installation example 47 5 installation example fig. 6: 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.

  • Page 13

    Hot air system air top 2000 st 48 6 hot air system note: the heater must not be integrated into the vehicle’s air system. Both recirculation and fresh air modes are possible. For fresh air mode it must be ensured that the hot air is taken from an area protected from splashing water and spray and in ...

  • Page 14

    Air top 2000 st hot air system 49 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 15

    Fuel supply air top 2000 st 50 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 9. Only for adr: the statutory regulation of adr (accord européen relatif au transport internat...

  • Page 16

    Air top 2000 st fuel supply 51 7.1. Vehicles with carburettor engines the fuel may only be extracted using the special webasto fuel extractor (see figure 10) 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 ...

  • Page 17

    Fuel supply air top 2000 st 52 note: the tank fitting must be made from metal! 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. Since the lines normally cann...

  • Page 18

    Air top 2000 st fuel supply 53 7.4.1. Connecting two pipes with a hose the correct procedure for connecting fuel lines with hosing is illustrated in fig. 14. Ensure that there are no leaks. 7.5. Metering pump the metering pump is a combined delivery, metering and shutoff system and is subject to spe...

  • Page 19

    Fuel supply air top 2000 st 54 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). Fig. 16: fuel filter 0° - 90°.

  • Page 20

    Air top 2000 st combustion air supply 55 8 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. Note: an ...

  • Page 21

    Exhaust pipe air top 2000 st 56 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 example. See the statutory re...

  • Page 22

    Air top 2000 st combustion air inlet and exhaust lines 57 10 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. The lines must not point to the ...

  • Page 23

    Combustion air inlet and exhaust lines air top 2000 st 58 only for adr: the statutory regulation of adr (accord européen relatif au transport international des marchandises dangereuses par route) governing the routing of the exhaust line, part 9 para. 9.2.4.7, must be adhered to. Fig. 22: exhaust pi...

  • Page 24

    Air top 2000 st electrical connections 59 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 convenience. The connections m...

  • Page 25

    Electrical connections air top 2000 st 60 before using the heater for the first time fit the control unit cover to prevent the illegal escape of hot air (heater overheating). The cable passage can be placed at either the left or right side. To ensure that the cable passage in the control unit cover ...

  • Page 26

    Air top 2000 st electrical connections 61 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 62 fig. 29: air top 2000 st with combination timer connection diagram adapter wiring harness red: terminal 30 grey: terminal 58 black: terminal 15 brown: terminal 31 combination timer 1531.

  • Page 28

    Air top 2000 st electrical connections 63 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 64 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 31 30 x2/x3/x4/x5 1 2 x10 1 2 2 1 x11 1 2 0,5mm² 0,5mm² 0,5mm² 0,5mm² ws/r ws/sw t sw/rt 15 30 f3 s4 s5 30 85 86 87 87a 2 3...

  • Page 30

    Air top 2000 st electrical connections 65 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 66 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.

  • Page 32

    Air top 2000 st legend for circuit diagrams: 67 12 legend for circuit diagrams: ➀ with positive from terminal (15/75) to connection 10: permanent operation for immediate heat as long as the ignition is switched on without positive at connection 10: heating time is variably programmable (10 min to 12...

  • Page 33

    Legend for circuit diagrams: air top 2000 st 68 item description comment a1 heater air top 2000 st a2 control module b1 flame sensor for petrol heater only b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug f1 fuse 24 v 15a/12v 20a flat ...

  • Page 34

    Air top 2000 st initial start-up 69 13 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 connec...

  • Page 35

    Fault lock-out air top 2000 st 70 14 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 36

    Air top 2000 st fault lock-out 71 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 ...

  • Page 37

    Technical data air top 2000 st 72 15 technical data except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °c and at the rated voltage and in rated conditions. 15.1. Electrical components: control unit, motor, mete...

  • Page 38

    Air top 2000 st technical data 73 heater operation air top 2000 st b air top 2000 st d type test permit emc heater e1*72/245*95/54*1085*00 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 fuel petrol diesel/pme fuel con...

  • Page 39

    Version air top 2000 st 74 16 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

    Air top 2000 st drilling template 75 17 drilling template fig. 34: drilling template 44 ø26 ø26 12 55 18 ø7,5 ø7,5 ø7,5 note: max. Base unevenness around the seal: 1 mm seal.

  • Page 41

    Webasto ag kraillinger strasse 5 82131 stockdorf germany tel: +49 (0)89 85794 - 0 fax: +49 (0)89 85794 - 448 http://dealers.Webasto.Com Änderungen vorbehalten subject to modification veranderingen voorbehouden © 2007 all rights reserved ide n t .-nr. 90 1029 8c die betriebsanweisung vor inbe- triebn...