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1. NOTE Technical changes in this issue of the manual compared with its previous issue are identified with a vertical change bar on the lefthand side of columns Air Top 2000 List of Contents List of Contents 1 Introduction 1 1 sScopeand Purpose seis A Gd i t en telat dee nt det e ru e da Da tada pad 101 Td Use Al Heaters top m dtes i diim t ER 101 1 2 Meaning of Warnings Cautions and Notes ooooocconoccccnonoccccnononcnncnnoncnnnnnnnnnnnnnonnnnnnnr nn nnno nennen nennen nennen 101 1 3 Additional Documentation to be used re eee senses enne nnne nnne nnn 101 1 4 Safety Information and Regulations sss eee enne tente een nen 101 1 4 1 General Safety Notes esses enses tenen then a aa a aie aatia aieas ia gaia 101 1 5 Legal Provisions for Installation eene enne tenente nennen rris nnne nnne 102 1 6 Gorrections and Improvemients 5 b geret ertet teg Le tede dore ra b eden 103 2 General Description 2 1 Combustion and Heating Air Fan siririn ainiaan iai aaeei aae iaaa deiae Aaa aa nennen nennen nen tenens 201 2 2 Heat Exch inc hee tet id sad 202 2 3 Burner Insert with Combustion Tube sssssssssssessseseses enne eene sn trnn entren nen sn nen tn ten nen ins 202 2 4 Control Unit Control Circuit Board iriiringa enne ennt en nene enn nnn nri aa tren tren nennen 202 2 5 Elame Sensor o A A dire E cert e roe Mare eee dede renes eoe rere a 203 226 Glow Pl g 4i sede NO a 2
2. 2_0 5mm gn ws H9 H7 0 5mm bi 3 2 Pa 6 0 5mm ws 5 4 1 P1 X11 12 nio x6 ETETTESETTETE TE TS Td CAUTION vilws x4 vi ge x4 ge xa br X9 x2 b xs Jbl Pin 4 no ground connection wi br i 2 A M E B1 B2 T B3 E HEE amp 83 x8 ib Y2 S2 Y1 amp n Item Nomenclature Remark A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temperature Limiter E Glow Plug Wire Gauges F2 Fuse 24V 10A Flat Fuse SAE J 1284 E RETO H6 Light at least 1 2 W Operation indication _ 0 75 mm 15mm conveyor facility EE LEER us ES SATA RETA 1 5 2 H7 LED red in item P Instant heat switch illumination L5 eu standy indication 40mm 60mm operating indicator light H8 Heating symbol in display in item P operating indicator light Wire Colours overheat indication bl blue H9 Light in item P Symbol illumination EM css M Motor gn green P1 Combination Timer 1531 3 STS S2 Disconnect Switch 1 or 2 pole Emergency off Switch rt red electr or pneum sw black vi violet S3 Switch Instant heating remote control we white S4 Switch Conveyor facility X1 X5 Connection 2 pole of item A2 n with plus from terminal 15 75 to connection 10 X6 Connection 8 pole of item A2 permanent operation during X8 Connection 2 pole instant heating as long as X9 Connection 2 pole of item A2 eee X11 Connection 6 pole of item A2 Mi plus to suat 10 3 A ting t X12 Connect
3. The temperature limiter protects the air heater against excessive operating temperatures Overheat protection is activated at temperature higher than 150 C to inter rupt the electrical circuit of the dosing pump and switch off the heater with run down operation After cooling down the electrical circuit is restored The air heater may be switched on again see 3 9 G C Temperature Limiter 2 8 Dosing Pump The dosing pump is a combined supply dosing and shut off system for the fuel supply of the heater out of the vehicle s fuel tank Dosing Pump DP 30 for Diesel operated Heaters 203 Air Top 2000 3 Functional Description 3 1 Functional Description Air Top 2000 without Diagnosis Fig 301 3 1 1 Control Element The control element is used to switch the air heater on and off set the desired room temperature air intake tem perature between 10 C and 45 and to unlock a failure interrupt condition The green LED indication is used to indicate the opera ting condition LED permanently on and an overheat condition LED flashes NOTE After application of power upon switch on of the battery switch and selecting the control element ON the con trol unit enters the error lockout condition Prior to a re activation the control element has to be placed to OFF 3 1 2 Switch On The control element is set to the desired room tempera ture When switching the air heater on
4. 2000 Diagnosis 12 Volt and 24 Volt may also be operated with an external temperature sen sor see 9 1 2 Minimum inside diameter of the heating air duct is 55 mm Standard diameter is 60 mm NOTE For heating air ducting only materials may be used which are temperature proof to at least 130 C Maximum loss of pressure between suction and delivery side of the heating air duct 1 0 mbar 10 mm water column When exceeding this value the temperature limiter is very likely to respond The heating air hose is to be se cured at its joints 801 8 Servicing The air heater when used in the ventilation mode of operation may also be employed for heating air ducting without any further accessories A short circuit of the heating air flow is to be avoided 8 6 2 Fuel Supply Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel container The rated pressure at the fuel tapping location is shown in Fig 801 Permissible fuel feed At max permissible height H m overpressure bar in fuel line 0 00 0 2 1 00 0 11 2 00 0 03 Permissible fuel suction At max permissible low height S m pressure bar in fuel tank 0 00 0 10 0 50 0 06 1 00 0 02 8 6 2 1 Fuel Tapping Vehicles with Diesel Engine Fuel tapping must be from the fuel reservoir or from a separate tank Figs 802 803 and 804 This separate fuel tapping avoids an influence on the pressure Vehicles with
5. 806 812 Control EleMe Nts weenie o Rte td edendi er e deut va Pa ep c reta A ne ee e ad 806 813 Pullingthe Plg order oie SR e te e PRO OR RR RR SR RS 806 814 Example of an installation a ea aia deep Eee ee oe A Dad aa Dex eda 807 815 Replacement of Control Unit and Temperature Limiter Air Top 2000 without Diagnosis 809 816 Replacement of Control Unit and Temperature Limiter Air Top 2000 Diagnosis 810 901 Removal of Housing Components Covers ines nennen nennen snnt enter rennen einen en 903 902 Replacement of Combustion Air Fan Removal sse ener entente nnns 904 903 Replacement of Combustion Air Fan Disassembly sssssssss sese 905 904 Disassembly of Heat Exchanger ssssssssssssseesseseee ennemi en ANEA innen ns intres etre nnns nnns en enn 907 Air Top 2000 1 Introduction 1 1 Scope and Purpose This repair shop manual is intended to support famil iarized personnel in the repair of air heaters Air Top 2000 of the fuel and Diesel type as well as of Air Top 2000 Diagnosis with serial no 30 000 and up 1 1 1 Use of Air Heaters The air heaters Air Top 2000 and Air Top 2000 Diag nosis are used to heat the cabin defrost the windscreens They are not cleared for heating a transportation com partment for dangerous goods The heaters operate independent from the vehicle en gine and
6. 9 Switch Off upon Failure a pii rye adden Gee Ga ea Hee a 306 4 Technical Data sa AAA ee edv eee DIRETA a To Bhs Tada ee So OA td an a E ee 401 List of Contents Air Top 2000 5 Troubleshooting AS A PETER 501 5 2 General Failure Symptoms aeiia iia iaaa aeiia iaaa Taa aa WAI an anna arara arena trennt 501 5 3 Failure Symptoms during Operation esses eene nennen area tenens nnne en nens 502 5 4 Error Code Output Air Top 2000 Diagnosis sse eene nennen nennen nnne nens 503 Functional Tests 6 1 6 2 6 3 Cee univ ia ci ia A a Ad a a ld cd 601 precum ada di A de la toa 601 6 2 1 Adjustment of the CO Contents non nn corn esent nennen 601 Components Testing RM 602 6 3 1 Glow Plug Resistance Test ener tenent nennen rint n 602 6 3 2 Flame Sensor Resistance Test esee entente nnne nennt nnne nens 602 Circuit Diagrams Pall GENE Caiana E 701 Servicing 81 Generale ga iria a DMA devis ACTUA AT du re Be duda DER US A 801 82 Work onthe Air Heater AAA gire en ern Fern kno dnTesa das a LE gon a EVE Fas aka ken dado danada da 801 83 Workon the Vehicl aiii AAN QU Ve DA ceo ee CU SD aula d Ga 801 8 4 ArrHeat r TesERUS aires A P EUNT Sa E A ed MEER NIU EET nde 801 NEC UM Ee 801 8 6 Visual Inspections and Installation Regulations serena aaa 801 8 6 1 Heating Air System esa aee Rd
7. Air Top 2000 Diagnosis The control unit control circuit board is the central con trolling unit for functional sequencing and monitoring of the combustion operation A temperature sensor located on the control unit is used for temperature control All heaters may have the temperature sensor replaced against an external temperature sensor The combustion and heating air fan may be set by means of a poten tiometer A malfunction in air heaters Air Top 2000 Diagnosis out puts an error code to the display of the combination or standard timer When equipped with a control element the operating indicator flashes In addition a heater chec kout may be performed using a personal computer refer to operating instructions PC air heater diagnosis Air Top 2000 Potentiometer c Y Temperature Sensor 5 Control Unit Air Top 2000 Diagnosis 2 5 Flame Sensor The flame sensor is a low Ohm PTC resistor changing its resistance dependent on its heating by the flame The signals are routed to the control unit for processing The flame sensor monitors the flame operating condition over the complete duration of heater operation Flame Sensor 2 6 Glow Plug The glow plug ignites the fuel air mixture at the start of the air heater operation The glow plug is acting as an electrical resistor and is located in the burner insert opposed to the flame side Glow Plug 2 General Description 2 7 Temperature Limiter
8. Replacement of Control Unit 812 Air Top 2000 24 Volt TRS Remove control unit according to 8 7 2 1 Remove leaf spring contacts of grey and violet wire from connector X6 contacts 4 and 6 Arrest leaf spring contacts in connector X11 as follows grey wire in contact 3 violet wire in contact 2 Install new control unit according to 8 7 2 2 Connect connector X6 and X11 Perform functional check Test TRS switch off as required stopping engine and starting auxiliary drive Air Top 2000 8 9 First Operation After installation of the air heater the fuel supply system must be bled thoroughly NOTE Due to low fuel consumption several switch ons are required to prime the fuel supply line to the air heater During the test run of the air heater all connections are to be checked for no leakage and tight fit Should the air heater during operation assume an error lockout condi tion perform troubleshooting Air Top 2000 9 Repair 9 1 General This section describes the repairs that may be per formed on the air heater Air Top 2000 and Air Top 2000 Diagnosis serial no 30 000 and up when removed Any further disassembly will void the warranty For reassembly only components of the proper spare kits are to be used 9 1 1 Work on Components after Disassembly CAUTION All gaskets located between disassembled components as well as the exhaust outlet seal must always be re placed and discarded 9 1 1 1 Clean
9. item A2 vi violet X6 Connection 8 pole of item A2 we white X7 Connection 4 pole of item S X8 Connection 2 pole X10 Connection 8 pole X11 Connection 2 pole for manufacturer s installations only Y Dosing Pump Fig 712 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element and Timer 712 Air Top 2000 S2 Circuit Diagrams 30 15 D 61 B2 A2 E B1 B3 jm i Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit ae a B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor a 25mm 2 5mm 4 0 mm B3 Temperature Limiter 40mm 60mm E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 wire colours H1 LED green in item S1 Operation indication s ane M Motor ge yellow S1 Rated Value Setting Switch Control Element A dei S2 Disconnect Switch 1 or 2 pole Emergency off Switch or orange electr or pneum n red X1 X5 Connection 2 pole of item A2 ok X6 Connection 8 pole of item A2 ws white X7 Connection 4 pole of item S X8 Connection 2 pole X11 Connection 2 pole for manufacturer s installations only Y Dosing Pump Fig 713 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element TRS 713 7 Circuit Diagrams S2 30 a D 61 0 5mm rt 0 5mm bl vi sw ws X
10. may be achieved by installation of an external temperature sensor Order No 85049A in the relevant living area Procedure 1 Remove control unit see 8 7 2 1 2 Using a suitable tool e g cutting pliers or similar remove temperature sensor from control unit Control unit 12 Volt type only e Remove temperature sensor 3 Select adequate installation location for external temperature sensor NOTE Temperature sensor should not directly be exposed to heated air flow For installation of the sensor in the motorcar we recommend to locate the sensor on the window spar of the windshield or in the vicinity of the air intake in the air flow for air circulation operation Forinstallation of the sensor in the lorry we recom mend to locate the sensor on the window spar of the windshield or on the underside of the roof con sole 4 Mount external temperature sensor and route cable to heater 5 Install control unit 902 Air Top 2000 6 Arrest leaf spring contacts in empty compartments of connector X6 contacts 4 and 6 Polarity is irrele vant 7 Connect connector X6 and fit cover 8 Perform test run and check control behaviour External Temperature Sensor Cover 9 2 Disassembly and Assembly 9 2 1 Removal of Housing Components Covers 9 2 1 1 Cover for Electrical Connection Dependent on the type of installation the cable loom exits the air heater either on the left or
11. right The cover may be levered off using a blunt blade in the areas marked Go 9 2 1 2 Covers for Heating Air Inlet and Outlet Both covers 3 and 5j Fig 901 may be removed by a slight side lift and a slide to Teff or right out of the locked position 9 2 1 3 Upper Housing Shell NOTE The covers for the heating air inlet and outlet must be removed By simultaneously exerting pressure on the catches of the upper housing shell 2 Fig 901 in the areas Y the shell disengages an can be lifted off 9 2 1 4 Lower Housing Shell By simultaneously exerting a light pull to the lower hous ing shell 4 Fig 901 jin the areas the catch is released and the shell may be separated from the motor housing 9 Repair Air Top 2000 gl E O 3 o EXCEL D ogOsg O c c On oO DODO cccc He Oe 322823 UTITI SoS amp lD 00000 gt Qa gt 25 oocog8o0o 09040 T ON CO TWO Fig 901 Removal of Housing Components Covers 903 9 Repair Air Top 2000 9 2 2 Replacement of Control Unit 9 2 3 Replacement of Temperature Limiter NOTE NOTE The procedure for replacement of the control unit is The procedure for replacement of the temperature limiter identical for the air heater in installed or removed condi is identical for the air heater in installed or removed con tion dition Replacement is to be performed in accordance with Replacement is to be performed in accordance with 673 NOTE Air heater Air Top 20
12. the operating indi cator is illuminated and the glow plug is activated cycled The motor of the combustion and heating air fan starts high speed operation for 1 second break away moment and is then under slow down control NOTE Should the temperature of the intake air be above the se lected rated temperature only the motor of the combus tion and heating air fan will operate control idle Start operation will be initiated with a heating air temperature below the rated temperature After approx 20 seconds for fuel operated heaters after approx 15 seconds the fuel dosing pump is activated After another 25 seconds the speed of the combustion and heating air fan is continuously increased to a higher rate and combustion begins As soon as a flame is detected combustion will be stabilized see 3 1 3 Should no normal combustion be achieved within 120 seconds for fuel operated heaters after approx 115 seconds the speed of the combustion and heating air fan is increased for approx 30 sec and there will be an automatic repeat start with the glow plug activated and fuel dosing pump deactivated no fuel supply Should the no combustion condition persist after an other 80 seconds for fuel operated heaters after approx 85 seconds there will be a switch off by error lockout see 3 1 9 with a run down of the combustion and heat ing air fan lasting 120 seconds at 2 3 of its max speed 3 Functional Description 3 1 3 Sta
13. upon switch on of the battery switch and selecting the control element ON the con trol unit enters the error lockout condition Prior to a re activation the control element has to be placed to OFF 3 2 2 Switch On The control element is set to the desired room tempera ture When switching the air heater on the operating indi cator is illuminated and the glow plug is activated cycled The motor of the combustion and heating air fan starts high speed operation for 1 second break away moment and is then under slow down control to approx 30 Diesel or 50 fuel of full speed NOTE Should the temperature of the intake air be above the se lected rated temperature only the motor of the combus tion and heating air fan will operate control idle Start operation will be initiated with a heating air temperature below the rated temperature The flame sensor function is checked If the flame sen sor at this time already signals flame there will be a 120 second run down and an error lockout of the control unit A malfunction of any other component monitored causes an error lockout without run down After approx 20 seconds for fuel operated heaters after approx 15 seconds the fuel dosing pump is activated After another 25 seconds the speed of the combustion and heating air fan is continuously increased to a higher rate and combustion begins As soon as a flame is detected combustion will be stabilized s
14. voltage above 15 Volt in excess of 20 seconds for 12 Volt heaters low voltage below 20 Volt or high voltage above 30 Volt in excess of 20 seconds for 24 Volt heaters A switch off like in switch off will be performed In case of overheating there will be no fuel supply After run down the control unit is in the error lockout mode The operation indication outputs a flash code For error unlock the air heater has to be switched off momentarily at least 2 seconds to be switched on 306 Air Top 2000 4 Technical Data 4 Technical Data Electrical Components As Hish l Control unit combustion air fan dosing pump timer s long as no threshold values are given the following glow plug and control element are for 12 or 24 Volts technical data are understood to include tolerances of operation 10 usual for heaters at an ambient temperature of 20 C and at nominal voltage and conditions The components temperature limiter and flame detector are independent of voltage not for TRS Mark of conformity Heater type Air heater with evaporator burner Heat flow Control range 1 1 2 0 kW 0 9 2 0 kW Type of fuel Fuel Diesel Fuel oil EL Fuel consumption Control range 0 1 0 2 kg h 0 16 0 27 I h 0 1 0 21 kg h 0 12 0 24 1 h Nominal voltage 12 Volt 12 Volt 24 Volt Operation voltage 10 15 Volt 10 15 Volt 20 30 Volt Rated power consumption Control range Permitte
15. 00 Di agnosis 24 Volt not TRS the modifications per 8 8 2 must be incorporated CAUTION Not performing the modification may result in a short cif cuit 8 Servicing When replacing the control unit Air Top 2000 TRS 24 Volt with a control unit Air Top 2000 Diagnosis TRS 24 Volt perform modifications pe WARNING Failure to perform modifications will result in a potential safety risk In all cases there will be no possibility for diagnosis after replacement as the wiring harness installed in the vehicle is not provided with a diagnosis connector 8 8 1 Replacement of Control Unit Air Top 2000 12 Volt with External Temperature Sensor 1 Remove control unit according to 8 7 2 1 2 Remove leaf spring contacts 4 and 6 from connector X6 NOTE The following step is not applicable when installing a new temperature sensor 3 Position leaf spring contacts order no 880 39A must be ordered and arrest in connector X9 order no 881 97A must also be ordered Polarity is irrele vant 4 Install new control unit according to 8 7 2 2 5 Connect connectors X6 and X9 o LP gt Cag PA 8 8 2 Replacement of Control Unit Air Top 2000 24 Volt not TRS 1 Remove control unit according to 8 7 2 1 2 Remove leaf spring contacts of grey and violet wire from connector X6 contacis 4 and 6 3 Install new control unit according to 8 7 2 2 4 Connect connector X6 811 8 Servicing 8 8 3
16. 00 without Diagnosis shown Figure is also applicable for replace ment of combustion air fan or Air Top 2000 Di agnosis 1 Heating Air Intake 2 Insulation 3 Seal Fig 902 Replacement of Combustion Air Fan Removal 904 Air Top 2000 9 2 4 Replacement of Combustion Air Fan 9 2 4 1 Removal on gt Remove air heater se Remove control unit see 8 7 2 1 Remove seal 3 Fig 902 from lower housing shell and discard Remove air heater from lower housing shell Remove heating air intake 1 Eig 902 and remove insulation 2 Remove screws 1 Withdraw combustion air fan 3 and remove gasket 2 Perform work on components after disassembly see 9 2 4 2 Installation 1 2 Ensure that sealing surfaces on combustion air fan and on heat exchanger are not damaged Place new gasket 2 Fig 903 bnto flange of combustion air fan 3 1 Screw 5 2 Gasket 3 Combustion Air Fan Combustion air fan must not be disassembled any further 9 Repair NOTE Apply Loctite to screws 1 3 6 7 8 9 Bring combustion air fan into assembly position and mount using screws 1 Torque screws 1 to 4 Nm Place air heater with heating air intake 1 Fig 902 and insulation 2 into lower housing shell and on side lock in position in housing Fit new seal 3 to lower housing Install control unit see 8 7 2 2 Install air heater seg 8 7 1 2 Check CO setting and adjust as re
17. 000 without Diagnosis 24V with Control Element and Timer sese arara ne arara na arara eren nennen nennen nnns 712 713 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element TRS indt eet rer ve EV Ix av a ae d e n d 713 714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Control Element in Vehicles without Auxiliary Drive sss 714 715 Connection Diagram Air Top 2000 Diagnosis with Combination Timer not TR 715 801 Euel SUpply 5i nit oit e edo Fu ob E Ee OD e iere eee dens 802 802 Webasto Fuel Tank Tap aiii enn eri needy C ee rice Ate idee Urea dde eva a edd eee 803 803 Fuel Tapping from Plastic Tank tapping via fuel drain plug 803 804 Fuel Tapping from Plastic Tank tapping via fitting plate essen 803 805 Pipe Hose Connection ARM 804 806 Dosing Pumpe Installation Position and Attachment sss sess 804 807 A NO 804 808 Exhaust Muffier Dir ction of FOW 2 irren iene i rii re i d a e n a e i re i d a i da data 805 809 Exhaust Pipe Outlet Installation Position oooonoonccnonoccccnnnoccccnanonnncnononcnnnnnn occ nnnnrnnnn ener nennen nennen nnne 805 810 Removal of Fuse Holder Attachment Plate esses esee eene eene nennen nnne en 806 811 Fuse Holder Installation Position ococcccccninininininoninininoninoninininononononana nono nnne enne nennen enne
18. 03 21 Temperature Eimiter uti tada ad pate 203 2 9 DOSIMO P MP sia O Tie sos sa ndd ada bp Eine odd 203 3 Functional Description 3 1 Functional Description Air Top 2000 without Diagnosis Fig 301 301 3 1 0 Control Element it eda e TER tae a P Et e VARA A i aaa 301 3iL2 SWIN ORe A atten atn bec iiec ta dodi eee t Ue d a bas e da deba e ed og sao 301 31 39 ICE P 301 3 14 Heating Operatlonz eee tre e ee Get ede e DR dive e Y ee opcm dene 301 3 1 5 Control Operation iie ii inre Ea Rie dede 302 EM Control Ale e dad quad 302 TT 302 3 1 8 Functions of the Air Heater in TRS Vehicles conan rn narran 302 3 1 9 Switch Off upon Failure sopas eat casei Joga AA iria 302 3 2 Functional Description Air Top 2000 Diagnosis erre rama emana 304 3 21 Control Elemlepnt inert A oe lene ati ei a NV quao i dou yd pa 304 3 2 25 SWIC ON ice atn e Gre A cased cea eda esed ut eek TOP Ru et ne Get eet e IS RUBER NER HA aa 304 3 2 9 SIabilIZatlOr iden ath decree a Ya hd dac y ea dA D o dan vedo da y a 304 3 2 4 Heating Operation sess enne rin tenete aaa neri trennen tenens 305 3 2 5 Control Operation viene aid aie ie sog e e See ELI A Ee tee Cb Ed 305 LO COMO A A M 305 BARI SWIN OTT erc ore ea ee a ac CET UG A 305 3 2 8 Functions of the Air Heater in TRS Venhicles aerea 305 3 2
19. 1 Terminal Pin Assignment Air Top 2000 Diagnosis eee nennen nnn nennen 701 702 Terminal Pin Assignment Air Top 2000 without Diagnosis sess 702 703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Control Element 703 704 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Combination Timer 704 705 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Control Element and Standard Timer ssssssssssssssseeeenennene nee enne 705 706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Control Element sess ener enne ernst nn 706 707 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Combination Timer assesses enne enne nn 707 708 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Combination Timer and 2 Auxiliary Drives 708 709 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 12V with Control Element 709 710 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 12V with Control Element and Timer ssssssssssessseseeeee nennen enne rene ne rennen nennen nnns 710 711 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element 711 712 Circuit Diagram Automatic Control Air Top 2
20. 2 Pipes with Hose The proper connection of fuel lines with hoses is shown in Fig 805 correct wrong bubble Fig 805 Pipe Hose Connection 8 6 3 Dosing Pump The dosing pump is a combined delivery dosing and shut off system and is subject to certain installation crite ria see Figs 801 land 804 AT 2000 D 12 Volt and 24 Volt Diesel DP 30 Installation Position only Horizontal Fig 806 Dosing Pump Installation Position and Attachment Air Top 2000 8 6 3 1 Installation Location Itis advantageous to mount the dosing pump in a cool location The ambient temperature must never exceed 20 C during operation Dosing pump and fuel lines must not be installed in loca tions exposed to heat radiated by hot vehicle compo nents A heat shield is to be provided as required 8 6 3 2 Installation and Attachment The dosing pump is to be attached with anti vibration mounts The installation location is limited according to Fig 806 to ensure sufficient self venting capability Due to the danger of corrosion the plug connection between dosing pump and dosing pump cable loom may only use Webasto original parts 8 6 4 Fuel Filter If there is the probability of contaminated fuel only the Webasto filter Order No 487 171 may be used Installa tion possibly vertical up to horizontal at the most observe direction of flow O 90 gt 05 Fig 807 Fu
21. 5 y E S2 i 15 D 61 Air Top 2000 B2 A2 E B1 B3 A2 31 gt O Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit ae poe B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor ee ie 2 5mm 4 0 mm B3 Temperature Limiter 40mm 60mm E Glow Plug F2 Fuse 10A Flat Fuse SAE J 1284 Mire Colours H1 LED green in item S1 Operation indication in M Motor ge yellow 81 Rated Value Setting Switch Control Element m pha S2 Disconnect Switch 1 or 2 pole Emergency off Switch or orange electr or pneum n red X1 X5 Connection 2 pole of item A2 A d X6 Connection 8 pole of item A2 ws white X7 Connection 4 pole of item S1 X8 Connection 2 pole X9 Connection 2 pole of item A2 X11 Connection 2 pole of item A2 X12 Connection 1 pole Diagnosis K wire Y1 Dosing Pump 714 Fig 714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Control Element in Vehicles without Auxiliary Drive Air Top 2000 Terminal 15 0 75 mm SW Terminal 30 1 0 mm 7 Circuit Diagrams Terminal 31 1 0 mm 2 br Fig 715 Connection Diagram Air Top 2000 Diagnosis with Combination Timer not TRS 715 Air Top 2000 8 Servicing 8 1 General This section describes the servicing procedures that may be performed with the air heat
22. Carburettor Engine Fuel tapping in motorcars may only be performed using the special Webasto fuel tap e g Ident No 470 910 possibly in the vicinity of the fuel tank Connection to the supply or return line is optional the return line must be routed almost to the tank floor otherwise the return line may be extended The fuel tap is to be mounted so that air or gas bubbles can escape towards the fuel tank The fuel tap should be located in the engine compart ment because the radiation of engine heat may cause gas bubbles to build up in the fuel lines causing malfunc tions in the combustion operation Vehicles with Fuel Injection Engines When installing the heater in vehicles with fuel injection system the fuel pump s location within or outside the fuel tank must be investigated first If the fuel pump is fitted inside the fuel tank the fuel may be tapped only from the return line using the Webasto fuel tap only e g Ident No 470 910 ensuring that the return line is routed almost to the tank floor If this is not 802 Air Top 2000 ES mnm T CEN max 3 m l2 io2mm ig2mm H pL lo E ai S a XE l4 B im Hh l2 lt 10m l1 lt 1 2 m l2 lt 8 8 m Fig 801 Fuel Supply the case the Webasto fuel tap see Fig 802 803 land may be used In case of a fuel pump mounted externally to the tank the fuel tap be
23. Diagram Automatic Control Air Top 2000 without Diagnosis 12V with Control Element 709 7 Circuit Diagrams 0 5mm rt 0 5mm sw 0 5mm bl Air Top 2000 30 58 15 75 B2 A2 E B1 B3 EE SR Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 ER TS A2 Control Unit 075mm 15mm B1 Flame Sensor 3 3 mm Ls E B2 Temperature Sensor 25mm 40mm B3 Temperature Limiter m 4 0mm 60mm B4 Temperature Sensor Wire Colours E Glow Plug bi lug F2 Fuse 15A Flat Fuse SAE J 1284 br brown H1 LED green in item S1 Operation indication i Den H4 Light in item P Symbol illumination gr grey M Motor or orange rt red P Timer 1529 for pre timed operation sw black S1 Rated Value Setting Switch Control Element E Md X1 X5 Connection 2 pole of item A2 X6 Connection 8 pole of item A2 X7 Connection 4 pole of item S X8 Connection 2 pole X10 Connection 8 pole Y Dosing Pump 710 Fig 710 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 12V with Control Element and Timer Air Top 2000 7 Circuit Diagrams it B2 A2 E B1 B3 X1 2 3 4 5 1 Item Nomenclature Remar
24. TION When installing a new control unit in heaters Air Top 2000 without diagnosis it is mandatory to observe the remarks in 8 8 NOTE During installation avoid the build up of static charge i e do not touch strip conductors 1 Locate control unit 2 in installation position and secure with screws 3 Ensure control unit en gages in arrester groove 6 Torque screws to 0 5 Nm 2 Connect plug connections to terminal Fig 701 or Plug on upper housing shell and fix in position 4 Slide on covers for heating air inlet and outlet and fix in position 5 Connect plug of cable loom to control unit 6 Fitcover and fix in position 8 7 3 Replacement of Temperature Limiter 8 7 3 1 Removal 1 Withdraw cover from upper housing shell according tj92 1 1 Disconnect plug of cable loom from control unit Withdraw covers for heating air inlet and outlet accord ing to 9 2 1 2 Remove upper housing shell according to 9 2 1 3 Disconnect plugged connection blue from terminal Remove lock washers 4 Fig 815 or Fig 816 Remove temperature limiter 5 on NOOR 8 7 3 2 Installation 1 Locate temperature limiter 5 Fig 815 orFig 816 lin installation position and secure with lock washers 4 Ensure that temperature limiter rests properly on heat exchanger Connect plug connections blue to terminal Plug on upper housing shell and fix in position Slide on covers for heating air inlet and outlet and fi
25. aee ci t Ud A aue A Sana de Eae 801 8 6 2 gt Fuel Supply ace Rhe A ege do der do d pt a e E a 802 8 6 3 DOSING PUMP sit iure IE dee ge rte ete Pa ee wien eden ter ne med in Geena edhe eine 804 8 0 4 Fuel FER a c EP 804 8 6 5 Combustion Air Supply sse enne enne ana etre neni a ar tn enn neni 805 8 6 6 Exhaust Line tea AAA ve dna A dar ead ua 805 8 6 7 Combustion Air Intake and Exhaust Lines sss seen 805 8 6 8 Electrical Connections auch nd nagd teca etes Lee Va Aa Doa anna Tea dE da 806 8 nemovaland Installation iss assess RA NAAA due cte tr De a ee eu OT de d ad 808 8 7 1 Air Heater Removal and Installation eese nnne 808 8 7 2 Replacement of Control Unit renata ara tenerent enne en 808 8 7 8 Replacement of Temperature Limiter sess enne nennen 808 8 8 Installation of new Control Units oooonccconncccconoccconononcconononcnnnononncnnono nn E rn rn rra nn cnn nennen nennen nennen neni 811 8 8 41 Replacement of Control Unit Air Top 2000 12 Volt with External Temperature Sensor ssssssssssesseseeeee ener nennen nnne nens 811 8 8 2 Replacement of Control Unit Air Top 2000 24 Volt not TRS sss sss 811 8 8 8 Replacement of Control Unit Air Top 2000 24 Volt TRS sse 812 8 9 First Operation i eg a PUR RE RU a Ree egeta eda A a ae cea afe a aguda CUR dae 812 Air Top 2000 List of Contents 9 Re
26. air intake temperature set with the control element a new start procedure is launched with out break away 3 1 7 Switch Off Switching the heater off extinguishes the operation indi cation of the control element If no fuel has been delivered within 20 seconds for Die sel operated heaters or within 15 seconds for fuel oper ated heaters after switch on or if the air heater is in control idle the air heater is deactivated immediately without run down If fuel supply has commenced it will be immediately stopped at switch off The fan speed decreases within 35 seconds to 2 3 of maximum Subsequently or if the flame sensor detects no flame the fan speed is increased to maximum for 60 seconds and run down is initiated to last 120 seconds Run down is automatically halted NOTE Re activation of the heater during run down is permitted Run down will be completed first with a subsequent re start 3 1 8 Functions of the Air Heater in TRS Vehicles NOTE Applicable only for Air Top 2000 D Air Heaters installed in vehicles for the transportation of dangerous goods TRS If the heater is deactivated using the control element run down will not change 302 Air Top 2000 A short run down max 40 seconds is automatically activated if the vehicle engine is turned off aconveyor facility is put into operation The short run down time depends on the operational condition at which TRS switch off occurs A 40 s
27. and 46 of the StVZO are to be adhered to The most important regulations are Fuel lines are to be designed in such a way that they remain unaffected by torsional stresses in the vehicle engine movement and the like They must be protected against mechanical damage Fuel carrying parts are to be protected against ex cessive heat and are to be arranged so that any dripping or evaporating fuel can neither accumulate nor be ig nited by hot components or electrical equipment In busses fuel lines and fuel tanks may be located neither in the passenger area nor in the driver s compart ment In these type of vehicles the fuel tanks must be lo cated such that they do not pose a direct hazard to the exits in the event of a fire Fuel supply must not be by means of gravity or pressurization of the fuel tank Installation Rules for Webasto Fuel Tanks for the Fuel Supply of Heaters in Vehicles In busses the installation is not permitted in the pas senger or driver compartment The fuel fill neck must in no vehicle be located within any of these compartments Fuel containers for carburettor fuel must not be located immediately behind the front panelling of the vehicle They must be sparate from the engine so that even in case of an accident the inflammation of fuel is unlikely to be expected This does not apply for towing vehicles with an open cockpit The operational state of the heater i e an indication on or off must be easily and
28. are connected to the fuel tank and to the electri cal system of the vehicle Their use is possible in vehicles with water or air cooled engines 1 2 Meaning of Warnings Cautions and Notes WARNINGS CAUTIONS and NOTES in this manual have the following meaning WARNING This heading is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel CAUTION This heading is used to highlight that non compliance with instructions or procedures may cause damage to equipment NOTE This heading is used to highlight and draw specific atten tion to information 1 3 Additional Documentation to be used This workshop manual contains all information and pro cedures necessary for the repair of heaters Air Top 2000 and Air Top 2000 Diagnosis The use of additional documentation is normally not necessary Operating instructions installation instructions and the vehicle specific installation proposal may be used as complementary information as necessary 1 Introduction 1 4 Safety Information and Regulations The general safety regulations for the prevention of acci dents and the relevant operating safety instructions have to be observed at all times General Safety Regulations beyond the scope of these regulations are detailed in the following The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings Cautions and No
29. ashers i4 Fia 815 and pull off temperature limiter 5 9 Perform work on components after disassembly see 9 2 7 2 Installation 1 Incase a new heat exchanger is fitted secure tem perature limiter 5 Fig 815 with lock washers 4 2 Fitnew gasket 7 3 Bring combustion tube 6 in assembly position NOTE The burner insert will be secured when installing flame sensor and glow plug CAUTION When performing the following step ensure that the fuel connection is not bent Install glow plug see 9 2 6 2 Install flame sensor see 9 2 5 2 Mount combustion air fan see 9 2 4 2 Install control unit see B 7 2 2 Install air heater se No a E 9 Repair 909 Air Top 2000 10 10 Packaging Storage and Shipping 10 1 General The air heater and its components shipped to Webasto Thermosysteme GmbH for inspection or repair are to be cleaned and packaged so that they are protected against damage during handling transportation and storage In storage an ambient temperature of 85 C and 40 C must not be exceeded 1001 Packaging Storage and Shipping 02 2002
30. ature Motor operates momentarily 1 Glow plug or flame sensor short or open circuit or and then stops control unit defective Stoppage without run down 5 Fan motor obstructed binding Run down after 1 Flame detection erroneous Run down after 20 Voltage to control unit too low Run down after 120 Cabling to dosing pump pump itself or overheat and dosing pump does not cycle protection defective Run down after 40 to 120 Intermittent disconnect of connection to dosing pump or to overheat protection Run down after 230 No flame wrong fuel supply quantity defective or slow fan coked burner in particular pilot flame outlet bore combustion air exhaust ducting obstructed or heat exchanger coked dosing pump seized Run down during combustion Overheating or operation voltage too low or component error flame sensor glow plug overheat sensor dosing pump burner or no fuel supply or obstructed combustion air exhaust ducting Stoppage without run down during combustion Fan motor failure or seizure operation Interruption of dosing pump during combustion Flame out by gas bubbles in fuel delivery or strong cycling and max speed for operation wind against exhaust outlet or defective no flame 30 sec with subsequent re start detection 502 Fig 502 Failure Symptoms during Operation Air Top 2000 5 4 Error Code Output Air Top 2000 Diagnosis When equipped with a combination or standard timer a malfunction will cause an error code output to the di
31. bilization Diesel Operated Heaters With the glow plug activated the operating speed of the combustion and heating air fan is increased After an other 20 seconds the speed of the combustion and heat ing air fan is continuously increased within 17 seconds to full load for full heat A flame out during the speed rise control period causes a repeat start Fuel Operated Heaters With the glow plug activated the operating speed of the combustion and heating air fan is continuously increased within 4 seconds to full load for full heat A flame out dur ing the speed rise control period causes a repeat start 3 1 4 Heating Operation During operation the combustion exhaust gasses flow through the heat exchanger charging its walls with com bustion heat which in turn is taken up by the heating air delivered by the heating air fan to be routed to the vehicle interior The temperature of the heating air sucked in is measured by means of a temperature sensor fitted to the air intake side of the air heater or in case of 12 Volt heaters also by means of an externally located tempera ture sensor A temperature below the one set with the control element increases the heater performance up to maximum heat In order to extend the burner idle period of Diesel oper ated heaters during permanent operation with a heating performance in excess of 1 2 kW the fuel dosing pump delivery rate is reduced every 30 minutes for 20 seconds A heating perfor
32. clearly visible Telefax 1 Introduction 1 6 Corrections and Improvements Deficiencies improvements or proposals for correction of this workshop manual are to be mailed to Webasto Thermosysteme GmbH Abt Technische Dokumentation D 82131 Stockdorf Telephone 0 89 8 5794 542 0 89 8 57 6410 108 Air Top 2000 2 General Description The air heater Air Top 2000 and Air Top 2000 Diagnosis with serial no 30 000 and up operating to the evaporator principle basically consist of combustion and heating air fan heat exchanger burner insert with combustion tube control unit Air Heater Air Top 2000 For control and monitoring a control unit control circuit board flame sensor glow plug temperature limiter temperature sensor are located within the unit 12 Volt heaters Air Top 2000 without Diagnosis may be controlled by means of an external temperature sensor All heaters of air Top 2000 Diagnosis may be controlled by means of an external temperature sensor Fuel supply is provided externally by a fuel dosing pump Air Heater Air Top 2000 without Diagnosis covers removed 2 General Description A malfunction in air heaters Air Top 2000 Diagnosis out puts an error code to the display of the combination or standard timer When equipped with a control element the operating indicator flashes In addition a heater chec kout may be performed using a personal computer refer to o
33. control unit will be in error lockout Prior to reactivation the control element must be set to OFF or the instant heat switch on the combination or standard timer be operated 5 Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components The following causes for trouble are not considered and should always be checked for to exclude them as cause for trouble corrosion on connector loose contact on connector wrong crimping on connector corrosion on electrical wiring and fuses corrosion on battery terminals If individual components are checked the control unit electrical connections must be disconnected After any correction of a failure a functional test has to be performed in the vehicle 5 2 General Failure Symptoms The following table Fig 501 lists the possible failure symptoms Failure Symptom Probable Cause Remedy Air heater switches off automatically start operation Heater overheats Vehicle electrical No combustion after start or repeat Flame extinguishes during Operation indication flashes system voltage too low Switch off heater momentarily and switch on once again Switch off heater momentarily and switch on once again Check heat air ducting for obstructions allow heater to cool down switch off heater momentarily and switch on once again Charge battery Switch off heater momentarily and switch on once again Hea
34. d ambient temp Heater operation 40 C 40 85 C Dosing pump i 40 20 C 40 85 C Control element i 40 75 C storage 40 85 C Permitted combustion air intake temperature 40 20 C Setting range for indoor iemper tilte Control range 10 45 C Volume flow of heating air against 0 5 bar Max 70 ms h CO in exhaust perm functional range Max Dimensions air heater Length 322 2 mm Width 130 X 1 mm Height 122 1 mm Weight heater Do 2 6 kg 401 Air Top 2000 5 Troubleshooting 5 1 General This section describes troubleshooting procedures for the Air Heater Air Top 2000 and Air Top 2000 Diagnosis A malfunction in air heaters Air Top 2000 Diagnosis out puts an error code to the display of the combination or standard timer When equipped with a control element the operating indicator flashes In addition a heater chec kout may be performed using a personal computer refer to operating instructions PC air heater diagnosis CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of heater components and may only be performed by skilled personnel In cases of doubt refer to Sections 2 or 3 for functional interrelations NOTE Only for TRS operation After a TRS switch off or power application by vehicle main power switch operation and the control element to ON the
35. e Remove four screws 3 and spoiler 2 Tilt and withdraw burner insert 5 carefully NOTE Ensure that burner insert 5 has separated from burner tube 6 906 Air Top 2000 CAUTION The glow plug has to be pulled out with utmost care and must under no circumstances be twisted danger of breaking After a long period of combustion operation the glow plug may be caked by fuel deposits In this case allow creep oil to react long enough to free glow plug for withdrawal 7 Loosen screw 13 and withdraw and remove glow plug 11 from burner insert 8 Perform work on components after disassembly see ot 1 9 2 6 2 Installation 1 Insert new gasket 7 Fig 904 into heat exchanger and bring combustion tube 6 in assembly position Ensure that starting air bore is not clogged If required clean with wire approx 1 mm see Detail A 2 CAUTION During glow plug installation observe twist lock see De tail B That means that the glow has to be inserted so that the contacts point towards the heat exchanger Otherwise there will be the danger of a short circuit 3 Feed glow plug 11 into burner insert 5 and arrange cable protective sleeve in slot of burner insert CAUTION When performing the following step ensure that glow plug is inserted in burner insert fully against stop 4 Secure glow plug 11 with screw 13 Torque screw 13 with 0 5 Nm 5 Locate burner insert 5 in heat exchanger 8
36. each other 6 3 1 Glow Plug Resistance Test During electrical testing of the glow plug using a digital multimeter the following readings should be obtained Glow plug 12 Volt red 24 Volt green Resistance at 25 C 0 324 0 360 0 1 3 1 44 0 Test current lt 5 mA lt 5 mA 6 3 2 Flame Sensor Resistance Test During electrical testing of the flame sensor using a digi tal multimeter the following readings should be obtained Cold test Resistance at 25 C 26 340 Test current 5mA Hot test Resistance at 800 1000 C 12 150 ceramic rod red hot over a length of approx 20 mm Test current lt 5mA 602 Air Top 2000 Air Top 2000 7 Circuit Diagrams 7 Circuit Diagrams The air heater Air Top 2000 without Diagnosis may be operated using the control element rated value transmit ter switch or with the control element and a timer The 7 1 General circuit diagrams Figs 709 to 713 show the possible cir cuits 12 or 24 Volt with The air heater Air Top 2000 Diagnosis may be operated using the control element rated value transmitter switch or with the control element and a combination or standard timer The circuit diagrams Figs 703 to 708 and 714 show the possible circuits 12 or 24 Volt with control element control element and timer control element for TRS Fig 702 shows the terminal pin assignment control element combination timer control element and standard timer control e
37. econd run down with maximum speed is initiated TRS switch off when air heater is still in the start phase stabilization not yet achieved air heater is in normal run down air heater is in control idle A 20 second run down is switched on in normal combus tion operation with the fuel delivery immediately halted maintaining the fan speed for 5 seconds Then the speed is increased for 30 seconds within another 5 sec onds For all heaters after July 1995 the short run down out of all operating conditions is a max of 20 sec onds After a TRS switch off the control unit is in the error lockout condition Prior to resuming operation the control element has to be set to OFF 3 1 9 Switch off upon Failure The control unit recognises failures of individual air heater components and malfunctions in the start se quence and in normal operation The air heater is deactivated and enters the error lockout mode under the following conditions flame sensor resistance out of tolerance temperature sensor resistance out of tolerance glow plug glow plug trigger defective fan speed too low short circuit or open circuit error in dosing pump electrical circuit or of overheat protection in start phase only low voltage below 10 Volt and in excess of 20 seconds for 12 Volt heaters low voltage below 20 Volt and in excess of 20 seconds for 24 Volt heaters control unit defective In case of overheating the
38. ee 3 2 3 Should no normal combustion be achieved within 120 seconds for fuel operated heaters after approx 115 seconds the speed of the combustion and heating air fan is increased for approx 30 sec and there will be an automatic repeat start with the glow plug activated and fuel dosing pump deactivated no fuel supply 304 Air Top 2000 Should no proper combustion develop within 120 sec onds for fuel operated within 115 seconds the combus tion and heating air fan speed is increased to full load for approx 30 seconds 15 seconds for fuel operated heaters with the glow plug on and the dosing pump off no fuel delivery with a subsequent automatic restart Should the no combustion condition persist after an other 80 seconds for fuel operated heaters after approx 85 seconds there will be a switch off by error lockout sed3 2 9 win a run down of the combustion and heat ing air fan lasting 120 seconds at 2 3 of its max speed 2 Start automatic restart Fan speed is again reduced to approx 30 for fuel operated heaters to approx 50 and fuel is delivered During the next 20 seconds fan speed is increased to ap prox 60 for fuel operated heaters to approx 75 of full speed As soon as a flame is detected within the next 55 seconds combustion will be stabilized Should there be no flame condition after a total fuel delivery period of 180 seconds fuel delivery will be stopped and the glow plug deactivated The c
39. ehicles e g vehicles for the transportation of dangerous goods TRS or ve hicles not subject to the StZVO e g ships are ruled by partially regional regulations For the installation of the AT 2000 D in vehicles used for the transportation of dangerous goods in addition to the StVZO the requirements in TRS 002 and TRS 003 Technical Guidelines for the Transportation of Dan gerous Goods on Roads must be met 101 1 Introduction The heater must not be installed in the passenger or driver compartments of busses Should the heater never theless be installed in such a compartment the installa tion box must be sealed tight against the vehicle interior There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum tem perature of 40 C in the installation box At filling stations and fuel depots the heater must be switched off as there is a potential danger of explo sion Where flammable fumes or dust may build up e g in the vicinity of fuel coal wood cereal depots or similar installations the heater must be switched off to prevent explosions Due to the danger of poisoning and suffocation the heater must not be operated in enclosed areas such as garages or workshops without exhaust venting not even if the start up is activated by the timer or telestart device When removing the heater the gasket below must be re placed The heat exchanger of the air heater remain
40. el Filter Air Top 2000 8 6 5 Combustion Air Supply Combustion air must under no circumstances be ex tracted from rooms with persons The combustion air inlet must not point towards the forward direction of mo tion It must be located so that no clogging by contamina tion is to be expected NOTE For fuel operated heaters the combustion air tap must be located in a possibly cool and splash water proof posi tion using a combustion air line If the air heater is located in a closed installation box combustion air must be taken in from and the exhaust routed to the exterior The feedthroughs must not allow exhaust fumes to enter the vehicle interior If a contamniated combustion air supply is expected a combustion air filter Ident No 21963A can be fitted Air Top 2000 D only 8 6 6 Exhaust Line Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1 0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only The exhaust pipe is secured to the air heater e g with a clamp The exhaust muffler is preferably mounted near the air heater The direction of flow is optional Fig 808 Exhaust Muffler Direction of Flow Operation of the air heater is also permitted without muffler 8 6 7 Combustion Air Intake and Exhaust Lines In order to avoid damage to the dosing pump cable no exhaust line may be used for the elongation of the com bustion air intake line Length o
41. em Nomenclature Remark A1 Air Heater Air Top 2000 Wire Gauges A2 Control Unit B1 Flame Sensor dome Po B2 Temperature Sensor 10 mm 18 mm B3 Temperature Limiter EI rmm E Glow Plug 4 0 mm 6 0 mm F2 Fuse 24V 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication sodes ui H6 Light at least 1 2 W Operation indication vid conveyor facility ge yellow M Motor gn green gr grey S1 Rated Value Setting Switch Control Element or orange S2 Disconnect Switch 1 or 2 pole Emergency off Switch B E electr or pneum SEE S4 Switch Conveyor facility ws white X1 X5 Connection 2 pole of item A2 X6 Connection 8 pole of item A2 X7 Connection 4 pole of item S1 X8 Connection 2 pole X9 Connection 2 pole of item A2 X11 Connection 6 pole of item A2 X12 Connection 1 pole Diagnosis K wire Y1 Dosing Pump Y2 Solenoid valve for conveyor facility Il 706 Fig 706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Control Element Air Top 2000 7 Circuit Diagrams s2 30 07 15 15 B2 A2 E B1 B3 58 58 Te D 61 D 61 IN a Li F2 A2 O 1 0 mm a X6 x3 z E mo Ex x13 3 To E xo Lx 1 10 11 A2 o 0 5mm rt 23 9 E vi 355 43 alle 3 0 5mma x12 D i gt
42. er conditions 8 Servicing For reasons of the air heater s functional reliability per form the following servicing check heating air inlet and outlet for foreign matter and contamination Contaminated or clogged heat ing air ducts may lead to overheating and thus response of the temperature limiter Clean air heater exterior prevent the ingress of water Examine electrical connections for corrosion of con tacts and for security Check combustion air and exhaust ducts for damage and obstructions Checkfuel lines and fuel filter for leakage Replace fuel filter if installed 8 6 Visual Inspections and Installation Regulations 8 6 1 Heating Air System CAUTION The integration of the air heater into the vehicle s own air system is not permitted due to the system s high press ure The air heater can only be operated in the ventilation mode of operation Fitted in the air heater on the heating air intake side is a temperature sensor which operates the heater in the relevant range of performance in conjunction with the control element dependent on the air intake temperature and position of the rated value transmitter Heating per formance is selected so that after quickly reaching the preselected indoor temperature it is maintained at this value 12 Volt heaters Air Top 2000 without Diagnosis m e operated with an external temperature sensor av D see 9 1 2 Air heaters Air Top
43. er installed 8 2 Work on the Air Heater Prior to performing any work it is mandatory to discon nect the vehicle battery main lead As long as the air heater is in operation or in run down the battery main supply must not be disconnected due to the danger of overheating resulting in a response of the overheat pro tection When performing extensive repairs on the heater a com plete removal is advisable When performing repairs re quiring a relocation of the installation position the relevant installation instructions and the vehicle specific installation proposal have to be observed 8 3 Work on the Vehicle CAUTION In the vicinity of the air heater a temperature of 85 C must not be exceeded under any circumstances e g during body paint work 8 4 Air Heater Test Run WARNING The air heater must not be operated not even with timer in enclosed areas like garages or workshops not equipped with an exhaust venting facility CAUTION Operation of the heater without the control unit cover is not permitted and causes overheating 8 5 Servicing NOTE In order to avoid the seizure of mechanical components the air heater should be operated every 4 weeks for at least 10 minutes The air heater does not require maintenance It should however be checked by Webasto trained skilled person nel in regular intervals the latest before the heating sea son begins point of time when the heater is more frequently in use due to weath
44. f the combustion air intake and exhaust line with muffler max 2 0 m without muffler max 5 0m 8 Servicing Both lines must be routed away from the heater in a de scending attitude If this is not possible a condensate drain hole 4 mm must be provided at the lowest point Inner diameter of lines Combustion airline 22 mm Exhaust line 22 mm NOTE When exceeding an exhaust line length of 2 m insulated exhaust lines have to be used below minimum dew point Smallest bending radius 50 mm In order to ensure the angle of 90 10 an attachment is required not further than 150 mm away measured from the exhaust pipe end Exhaust exit direction nearly vertical 90 10 Fig 809 Exhaust Pipe Outlet Installation Position WARNING Any exhaust exit direction other than the one shown in Fig 809 may cause fires Sum of bends Combustion air line Exhaust max 270 max 270 805 8 Servicing 8 6 8 Electrical Connections 8 6 8 1 Connection Air Heater Control Element Electrical connection is according to Circuit Diagram Automatic Control see Section 7 For connection of the cable loom the cover see 9 2 1 1 of the air heater has to be removed for connecting the cable loom plug s to the control unit Avoid touching the control unit strip conductors Prior to first operation of the air heater the cover must be fitted to avoid the loss of heated air air heater overheat ing The cable feedthr
45. in is measured by means of a temperature sensor fitted to the air intake side of the air heater or by means of an ex ternally located temperature sensor A temperature below the one set with the control ele ment increases the heater performance up to maximum heat In order to extend the burner idle period of Diesel operated heaters during permanent operation with a heating performance in excess of 1 1 kW the fuel dos ing pump delivery rate is reduced every 15 minutes for 20 seconds A heating performance less than 1 1 kW causes the fuel delivery to the dosing pump to be interrupted every 30 minutes for 4 seconds Additionaly heating operation is briefly suspended every 9 hours like in control idle For Diesel operated heaters this is only applicable if at this time heating performance is less than 1 1 kW 3 2 5 Control Operation During control operation fan speed and dosing pump rate of delivery are subject to heating performance The glow plug is deactivated 3 2 6 Control Idle After reaching the temperature set with the control ele ment heating performance is controlled to decrease The speed of the combustion and heating air fan slows down and the fuel delivery rate to the dosing pump is re duced When exceeding the air intake temperature set with the control element during minimum heating perfor mance the dosing pump is deactivated after 5 seconds and combustion terminates Fan speed remains constant for 35 seconds and i
46. inadvertent loss of this position it is sufficient to restore its original position The manufacturer setting may be corrected by rotating the potentiometer A suitable tool like a small screw driver 2 5 mm tip is to be used 0000000000 Air Top 2000 Diagnosis 6 Functional Tests CAUTION Set potentiometer slowly observe end positions Adjustment may be performed at any electrical system voltage Clockwise rotation increases the fan speed and de creases the CO contents Counterclockwise rotation de creases the fan speed and increases the CO contents If the setting range is not sufficient e g after replace ment of the combustion and heating air fan the manufac turer s setting may be cancelled according to the procedure described in the following 6 2 1 2 New Basic Setting CAUTION The manufacturer s setting cannot be restored 1 Withdraw cover from upper shell according ta 9 2 1 1 2 Switch on air heater 3 Rotate potentiometer two times and with no interrupt through its complete setting range e g max min max Adjust desired CO2 contents Fig 601 Switch off air heater Plug on cover and secure ooa 0000000000 Air Top 2000 without Diagnosis Fig 601 Adjustment of CO2 Contents 601 6 Functional Tests 6 3 Components Testing CAUTION During electrical testing always ensure that the control unit and the component under test are electrically discon nected from
47. ing All components disassembled must be cleaned with cleaning spirit and subsequently dried with press urized air All sealing compound must be carefully removed from components using a suitable tool 9 1 1 2 Visual Inspection Examine all components for damages cracks defor mation wear etc and replace as necessary Examine connectors and wiring for corrosion loose contacts wrong crimping etc and repair as necess ary Checkterminals for corrosion and contacts for security Repair as required 9 1 2 Incorporation of Modifications NOTE The continous design improvement of the heaters is in tended to optimise their serviceability avoiding failures or malfunctions In general equipment in service may be retrofitted with available modification kits In the following that modifica tion which may be incorporated easily during maintenace installation of an external temperature sensor for opti mising temperature control Air Top 2000 Diagnosis seg 9 1 2 1 e installation of an external temperature sensor for opti mising temperature seg 9 1 2 2 only for 12 Volt heaters Air Top 2000 without Diagnosis 9 Repair 9 1 2 1 Installation of an External Temperature Sensor Air Top 2000 Diagnosis General The heater Air Top 2000 regulates the desired tempera ture best when its temperature sensor is exposed to the air temperature of the most probable surrounding in use This might not alwa
48. ion 1 pole Diagnosis K wire fequi 10 Win to 120 min X13 Connection 12 pole of item P default setting 120 min Y1 Dosing Pump Y2 Solenoid valve for conveyor facility II Fig 707 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Combination Timer 707 708 Fig 708 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 24V TRS Operation with Combination Timer and 2 Auxiliary Drives 7 Circuit Diagrams Air Top 2000 15 B2 A2 E Bi B3 Item Nomenclature Remark A1 Air Heater Air Top 2000 Wire Gauges A2 Control Unit B1 Flame Sensor mE E B2 Temperature Sensor 10 mms 18 mm DEC Limiter E smi umm ow Plug 4 0 mm 6 0 mm F2 Fuse 24V 10A Flat Fuse SAE J 1284 H7 LED red in item P Instant heat switch illumination standy indication Wire Colours operating indicator light ed a H8 Heating symbol in display in item P operating indicator light ge yellow overheat indication gn green i in item P Symbol illumination A ando otor rt red P1 Combination Timer 1531 e S2 Disconnect Switch 1 or 2 pole Emergency off Switch ws white electr or pneum S3 Switch Instant heating remote control S4 Switch Conveyor facility S5 Switch Conveyor facility X1 X5 Connection 2 pole of item A2 NOTE X6 Connection 8
49. ite P1 Combination Timer 1531 S3 Switch Instant heating remote control 3 with plus from terminal 15 75 X1 X5 Connection 2 pole of item A2 to connection 10 X6 Connection 8 pole of item A2 feta eb ee TRES X8 Connection 2 pole ignition on X9 Connection 2 pole Ot item A2 without plus to connection 10 X11 Connection 6 pole of item A2 heating time programmable as X12 Connection 1 pole Diagnosis K wire PU Ul seu He OU HE min X13 Connection 12 pole of item P Y1 Dosing Pump 2 Connection X11 2 and X11 3 for TRS function only Fig 704 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Combination Timer 704 Air Top 2000 30 58 7 Circuit Diagrams mt m B2 A2 E B1 B3 F2 1 0 mm X13 E 6 4 1 10 11 A2 X11 0 5mm rt 0 5mme gr 2259 48 y 3 lo 5mm vi O Es gt 2 0 5mm gn ws H8 o H9 H7 3 5 Y lo 6 4 z 1 p2 o 12 194 5 5 X6 ETE TESTE Ei 241 142 TE vilws x4 vi gel x4 ge x3lbr xo x2 bl x5 bl an o Wa ts X7 ar LM B1 B2 B3 a S1 3 D El salir a 3 e 1 1 om E x8 5 sl 3 1 2 vid 31 Item Nomenclature Remark A1 Air Heater Air Top 2000 Wire Gauges A2 Control Unit 75m 75 15m B1 Flame Sensor gt 07s s is imr O mm 9 mm B2 Temperature Sensor 15mm 25mm2 B3 Temperature Lim
50. item A2 D o X7 Connection 4 pole of item S vi violet X8 Connection 2 pole MS whe X9 Connection 2 pole of item A2 X11 Connection 6 pole of item A2 2 Connection X11 2 and X11 3 X12 Connection 1 pole Diagnosis K wire tor TRS funetion only Y1 Dosing Pump Fig 703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Control Element 703 7 Circuit Diagrams 30 58 Air Top 2000 B2 A2 E B1 B3 1 0 mm 1 X13 2 6 4 E 0 5mm rt 1 fe ad gr 2 2259 48 3 0 5mme vi x12 osm sw gt 2 DER gn ws H9 e osmm bi 3 S 5 4 6 0 5mm ws 5 4 P1 12 7194 X6 TE 112 2 11 211 112 182 vilws x4 vi gel x4 ge x3lbr xo x2 bl x5 bl M EO orl Yo We a LM B1 B2 Sol B3 E JE 2 S3 x8 vig 31 Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit an e B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor E re am B3 Temperature Limiter 40mm 60mm E Glow Plug F2 Fuse 24V 10A 12V 15A Flat Fuse SAE J 1284 Wire Colours H7 LED red in item P Instant heat switch illumination i PE standy indication ge yellow operating indicator light gn green H8 Heating symbol in display in item P Operating indicator light A ads overheat indication rt red H9 Light in item P Symbol illumination s M Motor ws wh
51. iter 25mm 40mm 40 mm 6 0 mm E Glow Plug F2 Fuse 24V 10A 12V 15A Flat Fuse SAE J 1284 Wire Colours H7 LED red in item P Instant heat switch illumination bl blue standy indication br brown operating indicator light x e H8 Heating symbol in display in item P Operating indicator light gr grey overheat indication or orange H9 Light in item P Symbol illumination 2 Lat M Motor vi violet P2 Standard timer wng S1 Control Element Rated Value Setting Switch S3 Switch Instant heating remote control with plus from terminal 15 75 g to connection 10 X1 X5 Connection 2 pole of item A2 permanent operation during X6 Connection 8 pole of item A2 Mdh heating as long as f ignition on X7 Connection 4 pole of item S1 X8 Connection 2 pole without plus to connection 10 7 heating time programmable as X11 Connection 6 pole of item A2 required 10 min to 120 min X12 Connection 1 pole Diagnosis K wire default setting 120 min X13 Connection 12 pole of item P 2 Connection X11 2 and X11 3 Y1 Dosing Pump for TRS function only Fig 705 Circuit Diagram Automatic Control Air Top 2000 Diagnosis 12V 24V with Control Element and Standard Timer 705 7 Circuit Diagrams s2 1 30 07 y 15 D 61 0 5mm gr X11 vi 0 5mmz2 0 5mme gn ws k Air Top 2000 B2 A2 E B1 B3 X12 It
52. k Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit Seco ETE B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor e m ue B3 Temperature Limiter 40mm 60mm E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 Wite colours p E AE bl blue H1 LED green in item S1 Operation indication br Brawn M Motor ge yellow S1 Rated Value Setting Switch Control Element a e X1 X5 Connection 2 pole of item A2 or orange 2 rt red X6 Connection 8 pole of item A2 n rers X7 Connection 4 pole of item S vi violet X8 Connection 2 pole ws white X11 Connection 2 pole for manufacturer s installations only Y Dosing Pump Fig 711 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element 711 Circuit Diagrams Air Top 2000 30 58 15 75 B2 A2 E B1 B3 1 Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit ae poe B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor E 25 e B3 Temperature Limiter 40mm 6 0 mm E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 Mire totos H1 LED green in item S1 Operation indication Ss d H4 Light in item P Symbol illumination ge yellow M Motor m des P Timer 1529 for pre timed operation or orange S1 Rated Value Setting Switch Control Element des San X1 X5 Connection 2 pole of
53. lement for TRS combination timer for TRS TRS operation for vehicles without auxiliary drive Fig 701 shows the terminal pin assignment violet black brown yellow blue X1 Connection Combustion and Heating Air Fan X2 Connection Dosing Pump X3 Connection Flame Sensor X4 Connection Glow Plug X5 Connection Temperature Limiter Fig 701 Terminal Pin Assignment Air Top 2000 Diagnosis 701 7 Circuit Diagrams Air Top 2000 ooo ooo violet black brown yellow blue X1 Connection Combustion and Heating Air Fan X2 Connection Dosing Pump X3 Connection Flame Sensor X4 Connection Glow Plug X5 Connection Temperature Limiter Fig 702 Terminal Pin Assignment Air Top 2000 without Diagnosis 702 Air Top 2000 0 5mm bl 7 30 58 15 75 0 5mm gn ws Circuit Diagrams B2 A2 E B1 B3 Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 A2 Control Unit ae a B1 Flame Sensor 1 0mm 1 5 mm B2 Temperature Sensor ES e zu m mm B3 Temperature Limiter 40mm 60mm E Glow Plug F2 Fuse 24V 10A 12V 15A Flat Fuse SAE J 1284 Mire Colours H1 LED green in item S1 Operation indication is Es M Motor ge yellow S1 Control Element Rated Value Setting Switch a ad X1 X5 Connection 2 pole of item A2 or orange X6 Connection 8 pole of
54. mance less than 1 2 kW causes the fuel delivery to the dosing pump to be interrupted every 30 minutes for 4 seconds For both types of heaters fuel and Diesel heating operation is shortly interrupted every 9 hours like in control idle After reaching the temperature set with the control ele ment heating performance is controlled to decrease The speed of the combustion and heating air fan slows down and the fuel delivery rate to the pump is reduced When exceeding the air intake temperature set with the control element during minimum heating performance the dosing pump is deactivated after 5 seconds and com bustion terminates NOTE The control unit air heater reacts to new settings of the control element with a time delay 301 3 Functional Description 3 1 5 Control Operation During control operation fan speed and dosing pump rate of delivery are subject to heating performance The glow plug is deactivated 3 1 6 Control Idle In case the air intake temperature set with the control ele ment is exceeded and the minimum heating perfor mance had been achieved for longer than 5 seconds the fuel supply is cut off to terminate combustion The motor of the combustion and heating air fan con tinues operation for another 155 seconds at 2 3 of maxi mum speed to cool down the air heater run down In control idle the combustion and heating air fan runs at minimum speed The operation indication remains lit After reaching the
55. missible The drain pipe must be routed sealed through the exterior wall or the vehicle floor The heat exchanger the exhaust line connected as well as the possible drain pipe must be sealed so that with an overpressure of double the overpressure of the exhaust having the maximum per missible exhaust line length at least however at an over pressure of 0 5 bar a total leak rate of 30 I h is not exceeded The line including feedthrough disconnects material and specific type must be described in the installation instructions The line must require tools for installation and removal must be protected against damage and must be shock proof Air Top 2000 Metal lines must be used These may not heat to more than 110 C should there be the possibility of contact within the room interior Protective devices against con tact may be fitted Should exhaust pipes be routed through rooms accom modating persons these pipes shall be renewed after 10 years using genuine spare paris Combustion Air Inlet and Exhaust Outlet During installations these ports for combustion air entry and exhaust fume exit must be of such type that a ball with a diameter of 16 mm cannot be inserted Electrical lines switch gear and control gear of the heater must be located in the vehicle so that their proper function cannot be impaired under normal operating conditions For the routing of fuel lines and the installation of addi tional fuel tanks 88 45
56. ng shell according td pot Digconnect plug of cable loom from control unit Disconnect cable to dosing pump at cable disconnect Disconnect fuel inlet on air heater Disconnect connections of combustion air intake and exhaust outlet on air heater Remove four nuts and lock washers on air heater Remove air heater and discard gasket o o co DN 8 7 1 2 Installation 1 Locate air heater with new gasket in installation position and secure with four nuts and lock washers use original Webasto nuts only Tighten nuts with 6 1 Nm Secure connection for fuel inlet on air heater Secure connections for combustion air inlet and ex haust outlet on air heater 5 Route cable to dosing pump and connect to dosing pump Connect plug of cable loom to control unit Plug on cover and arrest Reconnect battery terminal leads Bleed fuel supply system Pon O ONO 8 7 2 Replacement of Control Unit 8 7 2 1 Removal NOTE During removal avoid the build up of static charge i e do not touch strip conductors 1 Withdraw cover from upper housing shell according 9211 2 Disconnect plug of cable loom from control unit 3 Withdraw covers for heating air inlet and outlet 5 and 3 according to 9 2 1 2 4 Remove upper shell according to 9 2 3 1 5 Disconnect plugged connections 1 Fig 815Jor Fig 816 of terminal 6 Remove screws 3 and remove control unit 2 808 Air Top 2000 8 7 22 Installation CAU
57. observ ing that cable of flame sensor is positioned below fuel pipe 6 Feedconnectors of glow plug and flame sensor through openings and push in cable grommets 9 and 10 CAUTION When performing the following step ensure that there is a tight fit between grommet 12 and heat exchanger 8 7 Secure burner insert 5 using screws 3 and attach spoiler 2 Torque screws 3 to 4 Nm Mount combustion air fan see 9 Install control unit see 8 7 2 2 10 Install air heater se 9 Repair Air Top 2000 Flame Sensor 2 Spoiler 4 3 Screw 4 4 Locking Tab 5 Burner Insert 6 Combustion Tube 7 Gasket 8 Heat Exchanger 9 Cable Grommet 10 Cable Grommet Glow Plug 12 Grommet 13 Screw 11 Fig 904 Disassembly of Heat Exchanger Sheet 1 of 2 907 9 Repair Air Top 2000 Detail A Detail B Twist Lock Fig 904 Disassembly of Heat Exchanger Sheet 2 of 2 908 Air Top 2000 9 2 7 Replacement of Burner Insert Combustion Tube and Heat Exchanger 9 2 7 1 Removal Remove air heater see 8 7 1 1 Remove control unit see Remove combustion air fan see Remove flame sensor see Remove glow plug see NAO CAUTION When performing the following step ensure that fuel connection is not bent 6 Remove burner insert 5 7 Withdraw combustion tube 6 from heat exchanger 8 and remove gasket 8 If the heat exchanger is to be replaced remove lock w
58. ombustion air fan continues full load operation for another 120 seconds run down and the heater enters the error lockout condition 3 2 3 Stabilization Diesel Operated Heaters With the glow plug activated the operating speed of the combustion and heating air fan is increased After an other 20 seconds the speed of the combustion and heat ing air fan is continuously increased within 17 seconds to full load for full heat NOTE This operating condition is omitted if the set temperature control idle has already been achieved once The glow plug is deactivated and heating operation com mences A flame out during speed up control causes a restart 5 restarts an error lockout of the heater Fuel Operated Heaters With the glow plug activated the operating speed of the combustion and heating air fan is continuously increased within 4 seconds to full load for full heat This operating condition will be omitted if the start occurs after a control idle period The glow plug is deactivated and heating operation com mences A flame out during speed up control causes a restart 5 restarts an error lockout of the heater Air Top 2000 3 2 4 Heating Operation During operation the combustion exhaust gasses flow through the heat exchanger charging its walls with com bustion heat which in turn is taken up by the heating air delivered by the heating air fan to be routed to the ve hicle interior The temperature of the heating air sucked
59. ough may be from left or right 8 6 8 2 Connection of Power Supply Preferably from the vehicle s central electrics For protection of the air heater an additional flat fuse holder is to be fitted deliverable item The fuse holder may only be located in the vehicle interior F 10A 24V 15A 12V 0 309 0 309 Fig 811 Fuse Holder Installation Position 806 Air Top 2000 8 6 8 3 Connection Control Element The cable loom is prefabricated to connect to the control element rated value transmitter For plug disconnection pull on terminal plug only Fig 813 By pulling on the cable loom the terminal plug is arrested self locking Light Guide Fig 812 Control Element NOTE The light guide must be in contact with the rotating knob Fig 813 Pulling the Plug Air Top 2000 8 Servicing rp 7 4 Control Element Air Heater Dosing Pump and Anti Vibration Mount Fuel Filter Accessory Fuel Tap Exhaust Muffler Fuse NOOR WD Fig 814 Example of an Installation 807 8 Servicing 8 7 Removal and Installation CAUTION In installed condition only the following removal and dis assembly procedures are allowed the upper housing shell being accessible for removal Replacement of control unit Replacement of temperature limiter 8 7 1 Air Heater Removal and Installation 8 7 1 1 Removal Disconnect battery terminal leads Withdraw cover from upper housi
60. own will not change A short run down max 20 seconds is automatically activated if the vehicle engine is turned off aconveyor facility is put into operation The short run down time depends on the operational condition at which TRS switch off occurs A 15 second run down with maximum speed is initiated TRS switch off when airheateris still in the start phase stabilization not yet achieved air heater is in normal run down air heater is in control idle A 20 second run down is switched on in normal combus tion operation and in stabilization with the fuel delivery immediately halted maintaining the fan speed for 5 sec onds Then the speed is increased to maximum for 15 seconds within for a run down After a TRS switch off the control unit is in the error lockout condition Prior to resuming operation the control element has to be set to OFF 305 3 Functional Description Air Top 2000 3 2 9 Switch off upon Failure The control unit recognises failures of individual air heater components and malfunctions in the start se quence and in normal operation The air heater is deactivated and enters the error loc kout mode under the following conditions flame sensor open or short circuit temperature sensor open or short circuit glow plug open or short circuit fan motor open or short circuit or fan speed wrong dosing pump open or short circuit overheating low voltage below 10 Volt or high
61. pair A EM 901 9 1 1 Work on Components after Disassembly trata rama errar ana 901 9 1 2 Incorporation of Modifications rr nennen nennen enne enne 901 9 2 Disassembly and Assembly entree ee de lec i etu ne d eder a de Cu ed aed T ee duda 902 9 2 1 Removal of Housing Components Covers sess seen eene nennen nennen 902 9 2 2 Replacement of Control Unit err enne nennen nennen tenen nen nennen 904 9 2 3 Replacement of Temperature Limiter essssssssseeseeeeeennennen eene 904 9 2 4 Replacement of Combustion Air Fan iraniana arara tenen nnn nenne 905 9 2 5 Replacement of Flame Sensor sssssssssssesessssese enne enne aa nana tnn nen nns 906 9 2 6 Replacement of Glow Plug essen nnnm et tentent nes ten en rre nenne 906 9 2 7 Replacement of Burner Insert Combustion Tube and Heat Exchanger ssssse 909 10 Packaging Storage and Shipping 10 1 Generals cent mittat a dece n eee Le c ntis boe t EE He ark erm Ed reae de due 1001 List of Figures Air Top 2000 List of Figures 301 Functional Diagram Air Top 2000 without Diagnosis sse nnn 303 501 General Failure Symbploris 2 npe i a 501 502 Failure Symptoms during Operation sse ener entr terre neri tren nnns 502 601 Adjustment ot COs Contents iie t te e e o M ea a RR e ee ltt period a bg e pd e RES 601 70
62. perating instructions PC air heater diagnosis Air Heater Air Top 2000 Diagnosis covers removed 2 1 Combustion and Heating Air Fan The combustion and heating air fan delivers the air re quired for combustion from the combustion air inlet to the burner insert By means of the fan the heating air is also delivered to the air outlet Combustion and Heating Air Fan 201 2 General Description 2 2 Heat Exchanger The heat exchanger dissipates the heat provided by combustion to the air delivered by the combustion and heating air fan Heat Exchanger 2 3 Burner Insert with Combustion Tube Within the burner insert fuel is distributed in the combus tion tube across the burner cross section In the combus tion tube the combustion of the fuel air mixture takes place heating up the heat exchanger 202 Air Top 2000 2 4 Control Unit Control Circuit Board Air Top 2000 without Diagnosis The control unit control circuit board is the central control ling unit for functional sequencing and monitoring of the combustion operation A temperature sensor located on the side is used for temperature control 12 Volt heaters may have the temperature sensor replaced against an ex ternal temperature sensor The combustion and heating air fan may be set by means of a potentiometer Potentiometer Sy Sy gt Sy gt ID g Temperature Sensor Control Unit Air Top 2000 without Diagnosis
63. pole of item A2 Minus potential applied to con X8 Connection 2 pole identification aoross Y2 and K x9 Connection 2 pole of tem A2 with plus from terminal 15 75 X11 Connection 6 pole of item A2 toconnedion 10 X12 Connection 1 pole Diagnosis K wire permanent operation during X13 Connection 12 pole of item P ano CUSTOS Y1 Dosing Pump l F s without plus to connection 10 Y2 Solenoid valve for conveyor facility heating time programmable as Y3 Solenoid valve for conveyor facility II required 10 min to 120 min Air Top 2000 7 Circuit Diagrams 30 58 15 75 F2 F a B4 Ys B2 A2 E B1 B3 NI Ts IN y inan U 0 5mm bl Item Nomenclature Remark Wire Gauges A1 Air Heater Air Top 2000 75m 75 15m 1 075mm 1 5 mm A2 Control Unit Exec CURE B1 Flame Sensor 1 5mm 25mm B2 Temperature Sensor E eom SL Di m E 40mm 6 0 mm B3 Temperature Limiter B4 Temperature Sensor Wire Colours E Glow Plug bl blue F2 Fuse 15A Flat Fuse SAE J 1284 2 Vel H1 LED green in item S1 Operation indication gn green H4 Light in item P Symbol illumination gr grey or orange M Motor rt red S1 Rated Value Setting Switch Control Element s AE X1 X5 Connection 2 pole of item A2 ws white X6 Connection 8 pole of item A2 X7 Connection 4 pole of item S X8 Connection 2 pole Y Dosing Pump Fig 709 Circuit
64. quired see 6 2 shell Before assembly always renew gasket A Fig 903 Replacement of Combustion Air Fan Disassembly 905 9 Repair 9 2 5 Replacement of Flame Sensor 9 2 5 1 Removal Remove air heater se Remove control unit see 8 7 2 1 Remove combustion air fan see Remove 2 screws 3 Fig 904 and spoiler 2 for cable protection Push out cable grommet 10 towards inside Carefully bend up locking tab 4 and withdraw flame sensor 1 from burner insert 5 Remove flame sensor Perform work on components after disassembly see 9 1 1 9 2 5 2 Installation CAUTION Route cable of flame sensor below fuel pipe 1 Po CONDO Pass flame sensor 1 Fig 904 below fuel pipe feed connector through opening and push in cable grom met 10 Feed cable with protection sleeve through locking tab and insert flame sensor 1 into burner insert 5 Squeeze locking tab 4 Secure burner insert 5 with four screws 3 and fit spoiler 2 for cable protection Pull cable of flame sensor tight Torque all 4 screws 3 to 4 Nm Mount combustion air fan see 9 2 4 2 Install control unit seg 8 7 2 2 Install air heater see 8 1 2 9 2 6 Replacement of Glow Plug 9 2 6 1 Removal Pon gt ou Remove air heater see 8 7 1 1 Remove control unit see B 7 2 1 Remove combustion air fan see Push out cable grommets 9 and 10 Fig 904 towards insid
65. re will be no fuel supply A run down like after manual switch off will be performed After run down the control unit is in the error lockout mode Overheating is indicated by the operation indica tion flashing For error unlock the air heater has to be switched off momentarily to be switched on again Air Top 2000 3 Functional Description i A 0 B i C 0 100 90 am D 1 3Hz 1 0 Hz He Eo y F 0 45 65 85 102 gt typical seconds Fig 301 Functional Diagram Air Top 2000 without Diagnosis Start Control Operation Rated Value reached Rated Value exceeded e g due to reduced heat sumption Run down Control Idle Start Control Operation increased heat consumption Switch off amp Qe CcGo AONO Run down A Control Element B Temperature Sensor C Glow Plug D Combustion and Heating Air Fan E Dosing Pump F Flame Sensor 303 3 Functional Description 3 2 Functional Description Air Top 2000 Diagnosis 3 2 1 Control Element The control element is used to switch the air heater on and off set the desired room temperature air intake tem perature between 10 C and 45 C and to unlock a failure interrupt condition The green LED indication is used to indicate the opera ting condition LED permanently on and an overheat condition LED flashes NOTE TRS Operation After application of power
66. rsons the combustion air lines must not have more than four disconnects anda splash water protected exterior wall feedthrough The disconnects must be sealed in a way not to exceed a leak rate of 200 l h at an overpressure of 0 5 mbar The line including feedthrough disconnects material and specific type must be described in the installation instructions The line must require tools for installation and removal must be protected against damage and must be shock proof Exhaust Line Heaters must be designed to discharge the exhaust to the exterior Exhaust pipes must be routed so that exhaust fumes are unlikely to penetrate into the vehicle s interior The function of any parts of the vehicle essential for its operation must not be impaired Condensate or water penetrated must not be able to accumulate in the exhaust line Drain holes are permissible these must drain the fluid to the exterior via lines sealed against the vehicle interior The exhaust line outlet is to be positioned to the top to the side or in case of exhaust venting below the vehicle floor to the nearest possible location of the vehicle s or cockpit s side or rear end In compartments accommo dating persons exhaust lines must not have more than one disconnect and must have a splash water protected feedthrough in the exterior wall floor For water that has penetrated into the exhaust line the connection of a drain line with a metal sealing joint is per
67. s play of the timer for indication NOTE When equipped with a control element the error code output is indicated by flashing of the operating indica tor error code indication The number of flash pulses corresponds to the number indicated in the table below After a quick pulse train there will always be an error code output Error code output on display of combination or standard timer F 01 No start after 2 attempts F 02 Flame out at least gt 5 F 03 Voltage too low or too high F 04 Premature flame detection F 05 Flame sensor open or short circuit F 06 Temperature sensor open or short circuit F 07 Dosing pump open or short circuit F 08 Fan motor open or short circuit or wrong speed F 09 Glow plug open or short circuit F 10 Overheating 5 Troubleshooting 503 Air Top 2000 6 Functional Tests 6 1 General This section describes the on vehicle and off vehicle testing of the air heater to check its proper operation WARNING The air heater shall not be operated in enclosed areas like garages or workshops not provided with exhaust venting facilities 6 2 Adjustments 6 2 1 Adjustment of the CO2 Contents 6 2 1 1 General The CO2 contents of the exhaust is adjusted with the potentiometer on the control circuit board The air heater is preset by the manufacturer with respect to the com bustion and heating air fan fitted After adjustment by the rer the potentiometer is in center position Fig 601 After an
68. s service able for a maximum of 10 years and must then be re placed with an original spare part by the manu facturer or by one of its authorized workshops The heater must then be provided with a label marked with the sales date and with the words Orig inal Spare Should exhaust pipes be routed through rooms accommodating persons these pipes shall also be renewed after 10 years Installations not legally authorized will void the air heater s Official Marks of Conformity and thus the vehicle s permit of operation The same applies for repairs performed by unskilled personnel and repairs with no original spare parts 1 5 Legal Provisions for Installation For testing the heater in accordance with 19 20 or 21 of the StVZO the following regulations are to be ob served in particular 22 a StVZO Testing is performed upon presentation of the operating and installation instructions of the manufacturer The year of the initial operation must be durably marked on the heater identification plate by the installing person 102 Air Top 2000 Heating Air System Heating air intake openings must be arranged so that under normal operating conditions exhaust fumes of the vehicle engine or air heater are not likely to be expected Extracting combustion air from the vehicle interior is not permissible Combustion Air Line The combustion air required must be taken from the exterior Within rooms accommodating pe
69. s then increased to approx 6096 of full speed for cooling the heater down the fan then continues to operate at ap prox 3096 of full speed until temperature is below the temperature set with the control element If temperature falls below the one set with the control element the heater will restart without break away NOTE New settings on the control element are executed by the control unit heater with a time delay 3 Functional Description 3 2 7 Switch Off Switching the heater off extinguishes the operation indi cation of the control element If no fuel has been delivered or if the air heater is in con trol idle the air heater is deactivated immediately without run down If fuel supply has commenced it will be immediately stopped at switch off Fan speed remains constant and then decreases within 30 seconds to approx 60 of full speed After this or with the flame sensor detecting no flame fan speed rises to maximum speed for 60 sec onds and run down for 120 seconds is initiated Run down is at approx 60 of full speed and is deactivated automatically NOTE Re activation of the heater during run down is permitted Run down will be completed first with a subsequent re start 3 2 8 Functions of the Air Heater in TRS Vehicles NOTE Applicable only for Air Top 2000 D Air Heaters installed in vehicles for the transportation of dangerous goods TRS If the heater is deactivated using the control element run d
70. ter expels black fumes Combustion air and or exhaust ducting blocked Check combustion and exhaust ducting for obstructions Fig 501 General Failure Symptoms 501 5 Troubleshooting 5 3 Failure Symptoms during Operation The following table Fig 502 lists the possible failure symptoms as they might occur during the functional sequence of operation In case of malfunction the failure is to be isolated and removed using this table It is important to accurately identify the failure symptom Should the failure symptom not be contained in this table or the trouble not be detected under the specific Air Top 2000 failure symptom listed in emergencies assistance by our service technicians may be requested Tel 089 8 57 94 512 NOTE Overheating and dosing pump failure are always indi cated additionally after run down by the flashing LED of the control element In all cases of trouble also a defective control unit may be the cause should all other components turn out to be serviceable Failure Symptom shows after Possible Causes zS No start and no illumination immediately Wrong cabling defective fuse of LED on control element No start but LED illuminates immediately Fan or control unit defective or fan blocked Very low speed with no start immediately Control idle operation wrong manual control selected temperature is below air intake temperature or wrong integration excessive air intake temper
71. tes 1 4 4 General Safety Notes Within the scope of the StVZO Road Licensing Regula tions of the Federal Republic of Germany Design General Approvals laid down by the Federal Office for Motor Traffic exist for the Water Heater Air Top 2000 and Air Top 2000 Diagnosis with the following official marks of conformity S 270 Diesel S 277 Fuel The installation of the heaters is to be performed in ac cordance with the installation instructions and must be checked in case of a the vehicle type inspection in accordance with 20 StVZO b the individual inspection in accordance with 21 StVZO or c the examination in accordance with 8 19 StVZO performed by an officially authorised expert or exam iner for road traffic a vehicle inspector or a public servant as per section 7 4 a of Annex VIII to the StVZO In the event of c the installation must be certified on the acceptance certificate included in the copy of the General Operating License giving details about manufacturer type of vehicle and vehicle identification number This validates the Design General Approval The acceptance certificate must be kept with the vehicle The year of first operation must be permanently marked on the identification label The heaters are cleared for heating the passenger and driver cabins but not for heating compartments intended for the transportation of dangerous goods The use of the heater in special v
72. tween fuel tank and fuel pump may also only be fitted using the Webasto fuel tap e g Ident No 470 910 Air Top 2000 Hole Pattern gt 25 mm gt Fig 802 Webasto Fuel Tank Tap Use fuel tank tap only on metal fuel tanks Plastic Tank Mu Gasket Fig 803 Fuel Tapping from Plastic Tank tapping via fuel drain plug 8 Servicing Fuel Tank Tap F Basket Tank Fitting Plate TX Fig 804 Fuel Tapping from Plastic Tank tapping via fitting plate NOTE The fitting plate must be made of sheet metal 8 6 2 2 Fuel Lines Fuel lines may only be steel copper or plastic lines made of unhardened light and temperature stabilised PA 11 or PA 12 e g Mecanyl RWTL according to DIN 73378 As in most cases a permanently rising fuel line routing cannot be ensured the inner diameter must not exceed a certain value Starting from an inside diameter of 4 mm air or gas bubbles accumulate resulting in mal functions should the lines be descending or have sags The diameters specified in Fig 801 ensure no disturbing formation of bubbles A descending line routing from the dosing pump to the heater should be avoided Loose fuel lines must be secured in order to avoid sagg ing The installation must ensure protection against stone impacts and undue temperatures exhaust line The fuel line joints are to be secured against slipping with hose clamps 803 8 Servicing Connection of
73. x in position Connect plug of cable loom to control unit Fit cover and fix in position AON oo Air Top 2000 8 Servicing Plug Connections Control Unit Screw 2 Lock Washer 2 Temperature Limiter Arrester Groove Fig 815 Replacement of Control Unit and Temperature Limiter Air Top 2000 without Diagnosis 809 8 Servicing Air Top 2000 Plug Connections Control Unit Screw 2 Lock Washer 2 Temperature Limiter Arrester Groove ociA25cnm Fig 816 Replacement of Control Unit and Temperature Limiter Air Top 2000 Diagnosis 810 Air Top 2000 8 8 Installation of new Control Units CAUTION When replacing the control unit the following must be ob served e When replacing the control unit Air Top 2000 12 Volt without external temperature sensor with a new control unit Air Top 2000 Diagnosis 12 Volt without external temperature sensor no further in structions for replacement as detailed dl applicable e When replacing the control unit Air Top 2000 12 Volt with external temperature sensor with the control unit Air Top 2000 Diagnosis 12 Volt with external temperature sensor the modifications per must be performed Control Unit Air Top 2000 Diagnosis NOTE If a new temperature sensor is to be used place an order for no 883 84A including new cover e When replacing the control unit Air Top 2000 24 Volt not TRS with a control unit Air Top 20
74. ys be possible due to the installation conditions with the temperature sensor being integrated in the heater In such case the best temperature control may be achieved by installation of an external tempera ture sensor in the relevant room area Procedure 1 Select adequate installation location for external temperature sensor NOTE Temperature sensor should not directly be exposed to heated air flow or located in the vicinity of heating Sources e g vehicle own heater Forinstallation of the sensor in the motorcar we recommend to locate the sensor in mid height in possibly vertical location The installation location should not be exposed to direct sun light Do not mount temperature sensor behind curtains or similar 2 Mountexternal temperature sensor and route cable to control unit 3 Connect connector X9 and place cover 4 Perform test run and check control behaviour Cover co O g Som External Temperature Sensor Connector X9 901 9 Repair 9 1 2 2 Removal of External Temperature Sensor Air Top 2000 without Diagnosis General The heater Air Top 2000 regulates the desired tempera ture the best when its temperature sensor is exposed to the air temperature of the most probable surrounding in use This might not always be possible due to the instal lation conditions with the temperature sensor being inte grated in the heater In such case the best temperature control

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