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  5. Installation Instructions Manual

Webasto Air Top 2000 STC Installation Instructions Manual

Other manuals for Air Top 2000 STC: Workshop Manual

Summary of Air Top 2000 STC

  • Page 1

    Luftheizgeräte air heaters luchtverwarmingsapparaten einbauanweisung installation instructions montagehandleiding air top 2000 stc handelsbezeichnungen/trade names/handelsnamen: air top 2000 stc b (benzin/petrol/benzine) air top 2000 stc d (diesel/fame) 9032312a_ii_at2000stc.Book page 1 thursday, se...

  • 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 stc i inhaltsverzeichnis 1 gesetzliche bestimmungen für den einbau . . . . . . . . . . . . . 1 2 verwendung der luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 5 3 einbau. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 typschild. . . . . . ....

  • Page 4

    Air top 2000 stc statutory regulations governing installation 41 1 statutory regulations governing installation the air top 2000 stc heater has been type-tested and approved in accord- ance with ece-r 10 (emc) and ece-r 122 (heater). For approval number see chapter 16, "technical data". Primarily, t...

  • Page 5

    Statutory regulations governing installation air top 2000 stc 42 requirements relating to the basic unit: when switched off, it is permissible for combustion heaters to continue running for max. 40 seconds. Only combustion heaters are to be used with heat exchangers that are not damaged during their...

  • Page 6

    Air top 2000 stc statutory regulations governing installation 43 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 c...

  • Page 7

    Statutory regulations governing installation air top 2000 stc 44 3.1.2 the combustion heater shall be switched on manually. Programming devices shall be prohibited. 3.2 ex/ii, ex/iii and memu vehicles combustion heaters using gaseous fuels are not permitted. 3.3 fl vehicles 3.3.1 the combustion heat...

  • Page 8

    Air top 2000 stc use of air heaters 45 2 use of air heaters the webasto air top 2000 stc air heaters are designed – to heat cabins, boats, commercial vehicles, minibusses, vans/transporters and motor homes – to defrost vehicle windows. The heaters operate independently of the engine and are connecte...

  • Page 9

    Installation air top 2000 stc 46 3 installation attention: comply with the legal requirements for installation on page 41 and 42. The requirements stipulated in the latest version of the adr must be additionally observed for the installation of the heater in vehicles used to transport dangerous good...

  • Page 10

    Air top 2000 stc installation 47 fig. 1: heater dimensions a b c 120 121 >155 29 >30 120 310 2 >20 >20 >20 Ø22 Ø22 1 2 3 4 5 6 cold air inlet cable outlet (optionally on right or left) hot air outlet exhaust gas outlet fuel inlet combustion air inlet a space requirements for hot air outlet b space r...

  • Page 11

    Installation air top 2000 stc 48 fig. 2: permissible heater installation positions diesel: petrol: horizontal fig. 3: seal fig. 4: installation ensure ease of movement of all moving parts! 9032312a_ii_at2000stc.Book page 48 thursday, september 29, 2016 1:21 pm.

  • Page 12

    Air top 2000 stc type label 49 4 type label if the type label is not visible with the heater in installed position, a duplicate of the type plate must be displayed in a position where it is clearly visible and protected from damage. Year figures that do not apply must be removed from the type label....

  • Page 13

    Installation example air top 2000 stc 50 5 installation example fig. 5: installation example of air heater in recirculated air mode 1 2 3 4 5 6 7 10 9 8 control element heater fuse tank extracting device fuel filter (accessory) fuel pump exhaust silencer (accessory) combustion air intake line combus...

  • Page 14

    Air top 2000 stc hot air system 51 6 hot air system note: it is not permitted to integrate the heater into the vehicle's air circulation system. A temperature sensor, which measures the room temperature, is mounted on the inside of the control unit. The required interior temperature is selected at t...

  • Page 15

    Hot air system air top 2000 stc 52 attention: suitable grilles must be fitted on the cold air inlet and hot air outlet if the heater is used without air guides. Note: the installation must be checked for: – excessively high cold air intake temperature due to the vehicle heating system – for air shor...

  • Page 16

    Air top 2000 stc fuel supply 53 7 fuel supply the fuel is taken from the vehicle's fuel tank or from a separate fuel tank. Refer to chapter 7.1.4, "pipe lengths and delivery head" for the permissible pressure at the fuel take-off point. A notice, indicating that the heater must be shut down before r...

  • Page 17

    Fuel supply air top 2000 stc 54 fig. 9: webasto tank extracting device fig. 10: extracting fuel from plastic fuel tank (fuel take-off via tank drain plug) hole pattern minimum distance 25 mm use tank extracting device only with metal fuel tanks seal plastic fuel tank fig. 11: extracting fuel from pl...

  • Page 18

    Air top 2000 stc fuel supply 55 7.1.4. Pipe lengths and delivery head when installing the fuel line make sure that it is kept as short as possible. See fig. 12. The pipe must be installed such as to protect it from being damaged. The fuel line must be installed in cool areas to avoid bubbles being f...

  • Page 19

    Fuel supply air top 2000 stc 56 the fuel lines must be secured using state-of-the-art fastening elements. Do not damage the fuel line. Intake side: d 1 : inside diameter of fuel line = 2 mm. H 1 : fuel level (tank above fuel pump) [m] s 1 : fuel level (tank below fuel pump) [m] l 1 : length of fuel ...

  • Page 20

    Air top 2000 stc fuel supply 57 – secure the line at regular intervals to prevent sagging. Avoid kinks. – keep away from heat sources. Use heat shield if necessary! 7.2. Fuel pump the fuel pump is a combined delivery, metering and a shut-off system and is subject to certain installation criteria (se...

  • Page 21

    Combustion air supply air top 2000 stc 58 8 combustion air supply under no circumstances may the combustion air be taken from areas occupied by persons. The combustion air intake opening must not face in the direction of travel. It must be arranged in such a way that it cannot become clogged with di...

  • Page 22

    Air top 2000 stc exhaust pipe 59 9 exhaust pipe rigid pipes made from unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm or flexible piping made of alloyed steel must be used for the exhaust pipe. The exhaust pipe is secured to the heater with the supplied exhaust pipe clamp. See sta...

  • Page 23

    Combustion air intake and exhaust pipes air top 2000 stc 60 10 combustion air intake and exhaust pipes both pipes must be installed falling away from the heater. If this is not possible, make a ø 4 mm condensation drain hole at the lowest point. The pipes must not face in the direction of travel. Th...

  • Page 24

    Air top 2000 stc combustion air intake and exhaust pipes 61 fig. 21: end of exhaust pipe installation position attachment no further than 150 mm from the end of the exhaust pipe is required to achieve the required angle of 90° ±10°. Outflow direction almost vertical 90° ±10° 9032312a_ii_at2000stc.Bo...

  • Page 25

    Electrical connections air top 2000 stc 62 11 electrical connections all lines that are not required must be insulated! 11.1. Connection for installation in a vehicle for transporting dangerous goods (adr) the requirements stipulated in the adr/rid part 9, 9.2.4.7 combustion heaters must be addition...

  • Page 26

    Air top 2000 stc electrical connections 63 an additional blade terminal fuse holder is to be installed to protect the heater (supplied with the heater). The fuse holder must only be installed in the vehicle interior. Fig. 23: removing mounting plate on fuse holder fig. 24: fuse holder, installation ...

  • Page 27

    Electrical connections air top 2000 stc 64 11.4. Control element connection the wiring harness is prepared for connection to the control element. Only pull on the connector housing to unplug the connector. The connector housing will lock (self-locking action) by pulling on the wiring harness. Note: ...

  • Page 28

    Air top 2000 stc connection diagram/wiring diagram 65 12 connection diagram/wiring diagram fig. 28: system wiring diagram air top 2000 stc, 12 v/24 v with multicontrol, see page 70 for legend 9032412a02 9032312a_ii_at2000stc.Book page 65 thursday, september 29, 2016 1:21 pm.

  • Page 29

    Connection diagram/wiring diagram air top 2000 stc 66 fig. 29: system wiring diagram air top 2000 stc, 12 v/24 v with control element and vehicle fan, see page 70 for legend 9032487a01 9032312a_ii_at2000stc.Book page 66 thursday, september 29, 2016 1:21 pm.

  • Page 30

    Air top 2000 stc connection diagram/wiring diagram 67 fig. 30: system wiring diagram air top 2000 stc, 12 v/24 v with standard timer/combination timer, see page 70 for legend 9032490a01 9032312a_ii_at2000stc.Book page 67 thursday, september 29, 2016 1:21 pm.

  • Page 31

    Connection diagram/wiring diagram air top 2000 stc 68 fig. 31: system wiring diagram air top 2000 stc d, 12 v/24 v adr-operation with smartcontrol, see page 70 for legend 9032489a01 9032312a_ii_at2000stc.Book page 68 thursday, september 29, 2016 1:21 pm.

  • Page 32

    Air top 2000 stc connection diagram/wiring diagram 69 fig. 32: system wiring diagram air top 2000 stc, 12 v/24 v adr-operation with control element, see page 70 for legend 9032488a01 9032312a_ii_at2000stc.Book page 69 thursday, september 29, 2016 1:21 pm.

  • Page 33

    Legend to wiring diagrams air top 2000 stc 70 13 legend to wiring 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 white...

  • Page 34

    Air top 2000 stc legend to wiring diagrams 71 h4 bulb/led (in item p) display and button lighting h5 bulb/led on indicator, pumping device (max. 500 ma) h6 led (green, blue, white, red) operation indicator, ready indicator, on indicator, fault list h7 symbol on display - k relay with free-wheeling d...

  • Page 35

    Legend to wiring diagrams air top 2000 stc 72 13.1. Pin assignments plug connection x6, 18-pin item remarks positive from terminal 15/75 to connection 10: continuous heating mode is possible in connection with quick heating function provided the ignition is switched on. All heater versions: connecti...

  • Page 36

    Air top 2000 stc initial start-up 73 14 initial start-up carefully bleed the fuel supply system after installing the heater. Note: due to the low fuel consumption, it is necessary to switch on the heater several times to fill the fuel line. Due to the frequent faulty start attempts, the heater may a...

  • Page 37

    Fault switch-off air top 2000 stc 74 15 fault switch-off the control unit identifies faults in individual heater components and mal- functions during operation. The heater shuts down (fault lock-out) when: – no or faulty start – temperature sensor defective – overheating sensor interrupted or short-...

  • Page 38

    Air top 2000 stc fault switch-off 75 15.1. Fault code output note: after a fault has occurred in heaters with a control element, the fault code is output by the switch-on indicator/fault code indicator lamp flashing. After 5 fast flash pulses, the fault code is output by a sequence of long flash pul...

  • Page 39

    Technical data air top 2000 stc 76 16 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. 16.1. Electrical components: the control unit, motor, ...

  • Page 40

    Air top 2000 stc technical data 77 heater operation air top 2000 stc b air top 2000 stc d type approval emc heater e1 r10- 04 1085 e1 r122- 00 0216 design air heater with evaporator burner heat flow control range 1.0 - 2.0 kw 0.9 - 2.0 kw fuel petrol en 228 din 51625 diesel/fame en 590 din 51603 din...

  • Page 41

    Variants air top 2000 stc 78 17 variants air top 2000 stc b (petrol) air heater for petrol (12 v) air top 2000 stc d (diesel) air heater for diesel/fuel oil el (12 or 24 v) 9032312a_ii_at2000stc.Book page 78 thursday, september 29, 2016 1:21 pm.

  • Page 42

    Air top 2000 stc drilling template 79 18 drilling template fig. 33: drilling template note: max. Base unevenness in area of seal: 1 mm seal 9032312a_ii_at2000stc.Book page 79 thursday, september 29, 2016 1:21 pm.

  • Page 43

    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-landesvertre- tung. In multilingual versions the german language is binding. The telephone number o...