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Air Top 2000 ST B

1. Error Error group Additional Information during PC Remedy Code Diagnostics F10 Overheating 06 The overheating fault lock out has Find and remove the cause of the tripped heater overheated overheating NOTE 17 Incorrect application or illegal If no other cause can be found for the insulation HS gradient too high overheating the pressure losses caused by the hot air distribution too many resistance points are too high or a hot air filter is soiled F11 Overheating sensor AB Overheating sensor circuit break or Replace overheating sensor interrupt or short short circuit to Ub circuit 1B Overheating sensor circuit Replace overheating sensor The switched cable of the element has a short circuit to earth F12 Heater fault 07 The heater fault lock out has been Remove the fuse and then refit it lock out activated NOTE The following error has occurred several times Fault counter more than 3 times Incorrect start counter more than 9 times Overheating counter more than 3 times F14 Overheating sensor 97 Incorrect position of overheating Position the overheating sensor correctly incorrect position sensor HS gradient too low F15 Nominal sensor 9B Nominal value potentiometer circuit Check cables replace control element break break or short circuit to Ub Table 6 Troubleshooting page 3 of 3 www webasto us Webasto Product N A Inc TROUBLESHOOTING AIR TOP 2000 ST This page for your notes We
2. iy Normal wear of service parts fuel nozzles filters and overheat fuses are not covered ER A 254 s TE Se Removal and replacement of heater with the exception of the Thermo Top C IS he E i it i i ier Sa eg Damage to product in transit All claims must be filed with carrier lt ETA i i THEE SO Rel Improper installation which is not in accordance with valid supplied installation instructions or E approved OEM applications ON EE Pao EN uw 3H Deterioration due to normal wear corrosion abuse damage accident improper storage or B am uae i N operation SEA Vit Sn S f AN E e Modification of product by alteration use of non genuine parts or repair by unauthorized fe zm ae E SIA ersonnel nie ETE p A 5 ds sos ST fesa Economic loss for expenses related to travel vehicle disability personal injury or other p I AS TED a AO ME incidental or consequential damages arising from any breach of this expressed warranty IS AN at Owner s Responsibilities SY ta 1 Service heater at the start of each season by an authorized Webasto dealer Service parts E DOR aid A dl 4 i mee R ae including fuel nozzles filters and overheat fuses are not covered under warranty RI ee T 2 A Warranty Registration Card is included with the sale of each heater It is the owner s TS Ne es responsibility to complete this card and return it to Webasto for
3. extraction through metal tank fitting NOTE The tank or fitting must be made of metal Webasto Product N A Inc SERVICING WORK 8 6 2 2 FUEL LINES Only steel copper and plastic lines of plasticized light and temperature stabilized PA11 or PA12 for example Mecanyl RWTL according to DIN 73378 may be used for the fuel lines Since the lines cannot normally be routed with a constant rising gradient the internal diameter must not be allowed to exceed a certain size Air or gas bubbles will accumulate in lines with an internal diameter of more than 4 mm and these will cause malfunctions if the lines sag or are routed downwards The diameters specified in Fig 15 will ensure that bubbles do not form The lines should not be routed downwards from the metering pump to the heater Unsupported fuel lines must be secured to prevent them sagging They must be installed in such a way that they cannot be damaged by flying road debris and high temperatures exhaust line The fuel lines must be secure at the connections using hose clips to prevent their slipping Connecting two pipes with a hose The correct procedure for connecting fuel lines with hosing is shown in Fig 19 Correct eH Figure 19 Pipe Hose connections 8 6 3 FUEL METERING PUMP The metering pump is a combined delivery metering and shut off system and is subject to certain installation criteria Fig 15 and
4. 5 2 GENERAL ERROR SYMPTOMS The following table lists the possible error symptoms Error Symptom Possible Cause Heater cuts out automatically and restart ON indicator flashes ON indicator flashes Heater overheats ON indicator flashes ON indicator flashes No combustion after start Flame extinguishes during operation Battery voltage too low Remedy Switch heater off and then on again Switch heater off and then on again Check that the hot air system is clear allow the heater to cool switch heat off briefly and then on again Charge battery Switch heater off and then on again Heater produces black smoke blocked Combustion air and or exhaust system Check that the combustion air and exhaust systems are clear Table 2 General Error Symptoms www webasto us Webasto Product N A Inc TROUBLESHOOTING 5 3 ERROR SYMPTOMS DURING FUNCTION The following table lists the possible error symptoms in the order in which they may occur during operation In the event of a fault the error is to be located using this table and rectified It is important that the error symptom is correctly identified If the error symptom is not included in this table or the fault is not found under the specific error symptom heading in an emergency you can contact our technicians on our service hotline see last page AIR TOP 2000 ST NOTE Every fault is indicated by the flashing LED on the
5. Jlebasto Feel the drive Air Heater Air Top 2000 ST D Diesel Air Top 2000 ST B Gasoline Service and Repair Manual Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death Installation and repair of Webasto heating and cooling systems requires special Webasto training technical information special tools and special equipment NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills technical information tools and equipment required to properly complete the necessary procedures ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel AIR TOP 2000 ST Contents 1 Introduction 1 1 Contents and Purpose else ss 1 1 1 Use of the Air Heaters 1 2 Meaning of Signal Words 1 3 Additional Documentation 1 4 Safety Information and Regulations 1 4 1 Statutory Regulations and Safety Instructions 1 4 3 General Safety Information 1 5 Suggestions for Improvements and Changes 2 General Description 2 1 Drive Unit uses i be pang ed Ba mates ede 2 2 HeatExchanger 0 2 3 Burner Insert with Combustion Pipe 2 4 Control Urt ot tai recette a es 2
6. 15 2125 mm G f this connection is made to battery positive terminal 30 permanent heating is possible with the TI 2 9r rey ignition switched off In this case no connection must be made to terminal 15 75 2 5 mm 4 0 mm or Orange 2 NOTE Typical Connection for Buses 4 0 mm 6 0 mm rt Red With positive from terminal 15 75 to connection 10 0000000 o Standard cable SW Black Permanent operation for immediate heat as long as the ignition is switched on Without positive at connection 10 VI Violet Heating time is variably programmable 10 min to 120 min default setting 120 min ws White Item Designation Comment Item Designation Comment Al Heater Air Top 2000 ST R1 Resistor 620 Q With internal temperature sensor A2 Control unit only B1 Flame sensor Gasoline heaters only S1 Control element Switch and temperature control B2 Temperature sensor Internal S4 Switch optional Ventilation B3 Overheating sensor Overheating guard S6 Switch CO setting BA Temperature sensor External X1 Plug connector 4 pin o item A2 E Ceramic glow pin X2 Plug connector 2 pin to item A2 F1 Fuse 15A max 20A Flat fuse SAE J 1284 x3 Plug connector 2 pin o item A2 F2 Fuse max 15A Flat fuse SAE J 1284 X4 Plug connector 2 pin to item A2 H1 LED green in item S1 Indicator X5 Plug connector 2 pin to item A2 H3 LED red Immediate heat button light X6 Plug connector 18 pin to item A2 Ready indicator switch on indicator X8 Plug c
7. 20 Webasto Product N A Inc AIR TOP 2000 ST 12 V and 24 V Diesel DP 30 with damper oC gt H A p 0 90 0 90 ac el N Y COR NU Fa Install in horizontal position only Figure 20 Metering pump installation position and attachment 8 6 3 1 INSTALLATION LOCATION It is advisable to install the metering pump in a cool place The maximum ambient temperature must not exceed 20 C 68 F at any time during operation The metering pump and fuel lines must not be installed within range of the radiated heat from hot vehicle parts A heat shield must be used if necessary 8 6 3 2 INSTALLATION AND ATTACHMENT The metering pump must be secured with a vibration damping mounting Its installation position is limited as shown in Fig 20 in order to ensure effective automatic bleeding As a result of the risk of corrosion only genuine Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness 8 6 4 FUEL FILTER Only a Webasto filter P N 504871714 is allowed to be used if the fuel is expected to be contaminated Install vertically if possible however at most horizontally check flow direction 0 90 Figure 21 Fuel filter www techwebasto com AIR TOP 2000 ST 8 6 5 COMBUSTION AIR SUPPLY Under no circumstances may the combustion
8. 3 with screws 2 Tighten the screws 2 to 6 x 0 6 Nm 53 x 5 Ib in Pull the cable of the flame sensor tight Install the combustion air fan see 9 2 5 2 Fit the control unit see 9 2 3 2 Position the casing parts see 9 2 2 Install the heater see 8 7 1 2 Webasto Product N A Inc AIR TOP 2000 ST REPAIR Hot air fan rotor 1 E 5 v P a nO c e ra 5 S 5 n o E ui oC a 4 o co DC Own m ou c C oa e o oct 2028 CES Q c Vu Uo x 5652 522 592 ves x O x 5 Fotos ala FumUrFUNALOSE CN s L0 00 r 00 OY Figure 30 Changing the Control Unit Combustion Air Fan and Overheating Sensor 40 www techwebasto com Webasto Product N A Inc AIR TOP 2000 ST 9 2 7 CHANGING THE CERAMIC GLOW PIN 9 2 7 1 REMOVAL Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the combustion air fan see 9 2 5 1 Ur di Sca Press the cable grommet 10 Fig 31 inwards out of the heat exchanger 9 6 Remove four screws 2 and take off the air baffle 3 NOTE Check that the burner insert 5 is n detached from the combustion pipe 13 7 Carefully remove the burner insert 5 by tilting removed with extreme care and must not be twisted under any circumstances risk of breakage After lengthy operation of the burner the glow plug may be fixed in place by fuel deposits In this case apply penetrating oil and
9. The unit must be run for at least 8 minutes for this purpose After this the CO content is to be set to 6 1 6 2 v v in low fire mode 1 kW In high fire mode the CO content should be 9 9 0 496 v v after the setting has been made www webasto us FUNCTIONAL TESTS 5 If the CO value is within this range disconnect the CO line from minus This saves the setting Li 6 3 TESTING INDIVIDUAL COMPONENTS NOTE The heater will now run in normal mode again and can be switched off as normal using the control element The heater is set at the factory to match the fitted combustion air blower CAUTION For function tests always break A the connection between the control unit and the component you wish to test CERAMIC GLOW PIN RESISTANCE TEST NOTE The resistance test must be carried out with an ohmmeter suitable for small resistance values A resistance test with a simple digital multimeter is too inaccurate to find the precise values A new glow plug can be measured to act as a reference The glow pin should have the following values in the test Glow plug 12 V red Resistance at 25 C 77 F 0 263 0 323 Ohm 1 125 1 375 Ohm lt 5 mA lt 5 mA 24 V green Test current 6 3 2 RESISTANCE TEST ON FLAME SENSOR GASOLINE HEATERS ONLY If you conduct this test with a digital multimeter the flame sensor must have the following values Cold Testing Resistance at 25 C 77 F 2 6 3 4 Ohm
10. Webasto Product N A Inc a 33 Example installation for heater in an air circulation system www webasto us Figure 27 SERVICING WORK 8 7 REMOVAL AND INSTALLATION CAUTION When the heater is installed it must not be dismantled 8 7 1 HEATER REMOVAL AND INSTALLATION 8 7 1 1 REMOVAL 1 Disconnect the battery 2 Pull the cover off the top shell as described in 9 2 1 1 3 Disconnect the wiring harness plug from the control unit 4 Disconnect the cable to the metering pump at the disconnection point If necessary disconnect the hot air hose or hoses Disconnect the connection for the combustion air inlet on the heater 7 Disconnect the connections for the combustion air inlet and exhaust outlet on the heater 8 Remove four nuts and locking washers from the heater 9 Remove the heater and discard the seal on the exhaust outlet 8 7 1 2 1 Place the heater with a new seal on the exhaust outlet in the installation position and secure it with 4 nuts and locking washers use only genuine Webasto nuts 2 Tighten the nuts to 6 1 Nm 63 9 Ib in 3 Secure the connection for the combustion air inlet on the heater INSTALLATION 4 Secure the connections for the combustion air inlet and exhaust outlet on the heater 5 Connect the metering pump cable to the meteri
11. and are connected to the fuel tank and the electrical system of the vehicle They are not designed for installation in vehicles with water or air cooled engines 1 2 MEANING OF SIGNAL WORDS Throughout this manual the signal words DANGER WARNING CAUTION and NOTE have the following meanings DANGER This heading and text style is used to highlight that non compliance with instructions or procedures will cause injuries or lethal accidents to personnel WARNING This heading and text style is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel CAUTION This heading and text style is used to highlight that non compliance with instructions or procedures may cause damage to equipment NOTE This heading and text style is used to highlight and draw attention to information we feel you would like to have It could have to do with procedures and tips that will help you work more efficiently DD gt gt www webasto us INTRODUCTION 1 3 ADDITIONAL DOCUMENTATION This workshop manual contains all the information and instructions required for repairing Air Top 2000 ST air heaters The use of additional documentation is not normally required If necessary the operating installation instructions and the installation suggestion for the specific vehicle may also be used 1 4 SAFETY INFORMATION AND REGULATIONS In principle the general accident preventi
12. grommets 10 into the heat exchanger CAUTION In the following procedure make sure that the grommet 8 seals off tight with the heat exchanger 9 Secure the burner insert 5 and the air baffle 3 with screws 2 Tighten the screws 2 to 6 x 0 6 Nm 53 5 Ib in Install the combustion air fan see 9 2 5 2 Fit the control unit see 9 2 3 2 Position the casing parts see 9 2 2 Install the heater see 8 7 1 2 Webasto Product N A Inc REPAIR AIR TOP 2000 ST 13 1 Flame sensor gasoline heaters only 8 Grommet 2 Torx screw 4 9 Heat exchanger 3 Securing strap 10 Cable grommet 4 Air baffle 11 Cable grommet gasoline heaters only 5 Burner insert 12 Seal 6 Ceramic glow pin 13 Combustion pipe 7 Screw Figure 31 Changing the glow plug flame sensor combustion insert and the heat exchanger Webasto Product N A Inc 42 www techwebasto com AIR TOP 2000 ST 9 2 8 CHANGING THE BURNER INSERT COMBUSTION PIPE AND THE HEAT EXCHANGER 9 2 8 1 REMOVAL Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the overheating sensor see 9 2 4 1 Remove the combustion air fan see 9 2 5 1 DU fO qm o Remove the flame sensor only petrol heater see 9 2 6 1 7 Remove the glow plug see 9 2 7 1 CAUTION In the following procedure make sure that the fuel connection is not bent 8 Remove the burner insert 5 Fig 3
13. metering pump If a fault occurs an error code will be output in the display of the combination or standard timer If the heater has a control element the ON control light will flash In addition the heater can be checked using a personal computer see PC heater diagnostic operating manual Figure 3 Drive Unit www webasto us 5 Webasto Product N A Inc GENERAL DESCRIPTION 2 2 HEAT EXCHANGER The heat generated by the combustion process is transferred to the air transported by the combustion and hot air blowers in the heat exchanger Figure 4 Heat Exchanger 2 3 BURNER INSERT WITH COMBUSTION PIPE The fuel is distributed over the burner cross section in the combustion pipe in the burner insert The mixture of fuel and air burns in the combustion pipe thus causing the heat exchanger to become hot Combustion pipe Figure 5 Burner Insert with Combustion Pipe Webasto Product N A Inc AIR TOP 2000 ST 2 4 CONTROL UNIT The control unit is the central component for ensuring the function is maintained and for monitoring the heater s operation A temperature sensor in the control unit is designed to control the room temperature An external temperature may also be connected to all the heaters If a fault occurs an error code will be output in the display of the combination timer If the heater has a control element the ON control light will flash In addition the heater can be checked using a
14. registration A proof of E AK iN Neste See i i i A E purchase is required for all heaters that are not registered CN V HANS ad ir de S x X n ii j me eg This warranty gives you specific legal rights and you may also have other rights which vary by State or Province SRO gg em EN Wu m THE WARRANTY DESCRIBED IN THIS POLICY SHALL BE IN LIEU OF ANY OTHER WARRANTY s m Ss EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF Us i MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Bw SA ue lege SN E O X M OS AIAR X s e X s e X s Pu X s Pu X s e X s seats X s oot X s e X s e X s e X E LG X s e x ae e x ae e x ae e x ae e x ae e AUF 365 A www webasto us 47 Webasto Product N A Inc l Jebasto Feel the drive WEBASTO PRODUCT N A INC 15083 North Road Fenton MI 48430 Technical Assistance Hotline USA 800 860 7866 Canada 800 667 8900 www techwebasto com Org 06 2005 Rev 03 2008 P N LIT9010439B 2008 Webasto Product N A Inc www webasto us
15. sensor interrupt or short circuit e Overheating sensor installed incorrectly e Glow pin interrupt or short circuit e Blower motor overload or blocked or short circuit or break e Flame sensor interrupt or short circuit e Error in the metering pump or overheating guard circuit start phase only e Under voltage below 10 5 V 21 V for longer than 20 seconds e Over voltage above 16 V 32 V for longer than 6 seconds e Control module defective The fuel supply is stopped if the heater overheats The heater continues to run in the same way as if it is switched off manually After it stops the control unit will be set to fault lock out After the slow down phase the control module is set to fault lock out if the overheating counter is greater than the value programmed in the data record currently 20 The overheating is indicated by the indicator flashing 10 times Rectify the cause of the fault To reset the fault switch the heater off briefly at least 2 seconds and then on again www techwebasto com AIR TOP 2000 ST 3 7 1 The overheat incorrect start and flame failure errors are counted and cause the heater to suffer a fault lock out after an error has occurred the maximum number of times ERROR MONITOR The incorrect start counter FSZ is incremented by 1 each time the heater fails to start and decremented by 1 each time it starts correctly but does not fall below O If the incorrect start counter reaches it
16. signal light will be lit and the glow plug will be switched on cycled The motor for the hot and combustion air blower will be set to approx 5096 of its maximum speed After approx 40 seconds the fuel metering pump will start and the flame formation will begin To improve the starting quality the metering pump and combustion air blower are started with different frequencies and speeds After a further 95 seconds gasoline or 110 seconds diesel the glow pin will be switched off and the existence of the flame established www webasto us FUNCTIONAL DESCRIPTION Automatic Restart If no flame is detected the starting procedure will be repeated The glow plug will be switched on again cycled The motor for the hot and combustion air blower will be set to approx 25 of its maximum speed After approx 30 seconds petrol or 50 seconds diesel the fuel metering pump will start and the flame formation will begin After a further 65 seconds petrol or 90 seconds diesel the glow plug will be switched off and the existence of the flame established If the heater has again failed to ignite properly the heater will be shut down using a fault slow down procedure at maximum speed after 180 seconds and will suffer a fault lock out il 3 3 HEATING MODE NOTE After a restart the heater will suffer a fault lock out To reset the fault switch the heater off briefly min 2 seconds and switch back on While the heater is ope
17. the heater will not work if this error occurs 91 Neutrally coded or disabled control unit the heater will not work if this error occurs 92 Maintain command failed the heater will not work if this error occurs 18 Customer bus defective F 01 No start 02 Even after the restart no flame has Check fuel supply formed tank empty lines blocked Clean burner insert 82 No start in test Gasoline Replace flame sensor Diesel Replace overheating sensor control unit F 02 Flame failure 03 The flame has gone out during Check fuel supply operation and has not reformed after a tank empty lines blocked restart attempt Clean burner insert Gasoline 83 The flame has gone out during a Replace flame sensor heating cycle more than FAZ times Diesel EEPROM Replace overheating sensor control unit F 03 Under voltage or 84 The voltage was less than 10 5 V or Charge battery over voltage 21 V for longer than 20 seconds 04 The voltage was more than 16 V or 32 V for longer than 6 seconds Table 4 Troubleshooting page 1 of 3 www webasto us Webasto Product N A Inc TROUBLESHOOTING AIR TOP 2000 ST Error Error group Additional Information during PC Renied Code group Diagnostics y F 04 Premature flame 05 A flame was detected before Diesel Replace overheating sensor recognition combustion had started control unit Gasoline Replace flame sensor F 05 Flame sensor 1A Flame sensor circuit Replace flame s
18. www webasto us 13 Webasto Product N A Inc TECHNICAL DATA AIR TOP 2000 ST This page for your notes Webasto Product N A Inc 14 www techwebasto com AIR TOP 2000 ST 5 TROUBLESHOOTING 5 1 GENERAL This section describes how to identify and remedy faults on the Air Top 2000 ST air heater If a fault occurs an error code will be output in the display of the combination timer If the heater has a control element the ON control light will flash In addition the heater can be checked using a personal computer see PC heater diagnostic operating manual demands precise knowledge of the structure and theory of operation of the various components and must be carried out by trained personnel only A CAUTION Troubleshooting work If in doubt refer to sections 2 and 3 for a description of how the functions interact TROUBLESHOOTING restricted to the localization of defective components The following potential sources of malfunctions have not been included and should always be checked so that they can then be excluded as the cause of the particular fault A CAUTION The troubleshooting guide is e Corrosion on plugs e Loose plug contacts e Poor crimp contacts on plugs e Corroded cables and fuses e Corroded battery terminals If you wish to check individual components the electrical plug connectors on the control unit must be disconnected Conduct a function test in the vehicle after rectifying each fault
19. 1 9 Remove the combustion pipe 13 and seal 12 from the heat exchanger 9 and dispose of the seal 12 separately 10 Complete the work on stripped down components see 9 1 1 www webasto us 43 REPAIR 9 2 8 2 1 Fit a new seal 12 Fig 31 into the heat exchanger 9 and bring the combustion pipe 13 into the assembly position Li 2 Fit the glow plug see 9 2 7 2 3 Fit the flame sensor gasoline heaters only see 9 2 6 2 INSTALLATION NOTE The burner insert 5 is only fixed in place when installing the flame sensor and glow plug CAUTION In the following procedure make sure that the fuel connection is not bent 4 Introduce the burner insert 5 in the heat exchanger 9 Make sure that the cable of the flame sensor is positioned under the fuel line 5 Secure the burner insert 5 and the air baffle 3 with screws 2 6 Tighten the screws 2 to 6 0 6 Nm 53 5 Ib in 7 Install the combustion air fan see 9 2 5 2 8 Fit the control unit see 9 2 3 2 9 Fit the overheating sensor see 9 2 4 2 10 Fit the insulators 11 11 Position the casing parts see 9 2 2 12 Install the heater see 8 7 1 2 Webasto Product N A Inc REPAIR AIR TOP 2000 ST Starting air hole Figure 32 Starting air hole in burner insert Webasto Product N A Inc 44 www techwebasto com AIR TOP 2000 ST PRODUCT INFORMATION 10 PRODUCT INFORMATION No new or updated infor
20. 130 C may be used for the hot air line The internal diameter of the main section of the hot air line should be 60 mm When using narrower lines the permissible pressure drop is exceeded more quickly The hot air hose must be secured at its connection points The heater can be used on the air inlet and outlet side if it is used in an air circulation system with grates Do not short circuit the flow of hot air Webasto Product N A Inc SERVICING WORK A The heater checks the internal temperature rise automatically each time it is switched on If this is above the specified limits the start is cancelled and error messages F10 is displayed To ensure that the heater functions stably the flow resistance of the connected hot air system must be reduced CAUTION In vehicles used to transport people the air outlet opening is to be installed in such a way that it is at least 20 cm away from all body parts If a filter is used for the hot air it must have the following properties e The air flow must not carry any inflammable and or harmful fibers or particles into the heater or the interior of the vehicle e The filter material must be able to withstand temperatures of at least 60 C e The filter must be resistant to all the substances that may be drawn in with the hot air for example moisture salt fuel vapors etc e The resistance of the filter must be taken into consideration when designing the hot air sy
21. 14 shows the schematic connection of the combination timer X1 Combustion and hot air blower connection X2 Ceramic glow pin connection X3 Overheating sensor connection X4 Metering pump connection X5 Flame sensor connection gasoline heaters only X6 Wiring harness connection Figure 11 Plug Assignment www webasto us Webasto Product N A Inc CIRCUIT DIAGRAMS BATTERY 0 5mm bl par Ea 5 v o o E E S amp 5 E I gt d 5 2 x E a UO o n To use vent mode connect to ground through a switch S3 for proper operation AIR TOP 2000 ST 30 X2 X3 X4 X5 If ventilation mode is not desired leave pink wire disconnected and protect from grounding No heating operation with pink wire grounded e ES K cable Cable Cross sections Cable Colors us CO setting 75m 75 15m bl Blue 4 Input pin pin 16 plug X6 cable color on wiring harness pink 045 mm 1 0 mm br Brown Ventilation fan speed depends on the position of the control element 075 mm 1 0 mm ge Yellow f you use an external temperature sensor B4 the resistor R1 is replaced by the temperature sensor B4 pum 2 2 j i 1 0 mm 1 5 mm gn Green 6 NOTE Typical Connection for Trucks
22. 5 Flame Sensor Gasoline Heaters Only 2 6 Ceramic Glow Pin 2 0 0 0 lesse sse 2 7 Overheating Sensor 2 8 Fuel Metering Pump 00 3 Functional Description 3 1 Control Element Rheostat 32 Switch One zelo ELE ee ee ea le 3 3 Heating Mode 00 0 0 eee eee 3 4 Control Mode cio ic cd i 3 5 Control Pause 2 iii cde ce mn 3 6 Switch Off xo oidiuu oe be aoe PED eee 3 7 Fault Lock out 0 3 7 1 Error Monitor LL 3 7 2 Reset a Fault Lock out 4 Technical Data 5 Troubleshooting 5 1 General us it bee i e m Ee 5 2 General Error Symptoms 5 3 Error Symptoms during Function 5 4 Error Code Output 6 Functional Tests 6 1 General aia aree 6 2 Settings orar EA a 6 2 1 Setting the CO2 Content 6 3 Testing Individual Components 6 3 1 Ceramic Glow Pin Resistance Test 6 3 2 Resistance Test on Flame Sensor gasoline heaters only 6 3 3 Overheating Sensor Resistance Test 7 Circuit Diagrams del General scssenzerew Oe ach wba a XR Aba www webasto us TABLE OF CONTENTS Webasto Product N A Inc TABLE OF CONTENTS AIR TOP 2000 ST 8 Servicing Work 27 Si Generali sme aida anita a 27 82 Workon thedHeater e om dx Eee Ro Rer dU ed bera doe RR dani d nash ae aD anal Ph e 27 8 3 Workon the Vehicles uos ua smt me iure Y aa e e Opodo lille le No dc d 27 AAA 27 8 5 Servicing WOFK sita a ja EORR a i 27 8 6 Visual Inspections and Installation Instructions LL 27 36 1 HotAir System ira a ai p
23. ANT e The temperature sensor should not be in the direct line of hot air and not close to heat sources for example the vehicle s own heating system e The sensor is to be installed at medium height in the vehicle cabin on surfaces that are as vertical as possible e The installation site should not be exposed to direct sunlight e Do not install the temperature sensor behind curtains or the like 2 Install the external temperature sensor and route the cable to the control element 3 Remove the terminating resistor at plug X8 of the wiring harness see Fig 28 4 Connect the external temperature sensor at plug X8 of the wiring harness 5 Conduct a trial and check the control properties NANA Plug X8 for external temperature sensor External temperature sensor Terminating resistor Figure 28 External Temperature Sensor Webasto Product N A Inc REPAIR 9 2 DISMANTLING AND ASSEMBLING 9 2 1 REMOVE THE CASING PARTS 9 2 1 1 COVER FOR ELECTRICAL CONNECTION The cover 1 Fig 29 can be levered off using a blunt blade in the areas 9 9 2 1 2 GRATES FOR HOT AIR INLET AND OUTLET The grates 5 can be released from the mounting by twisting and pulling off forwards 9 2 1 3 COVER FOR HOT AIR INLET AND OUTLET Both covers 3 and 6 Fig 29 can be released from their mountings and removed by pressing the four detents at the top and bottom using a suitable tool 9 2 1 4 ToP SHELL NOTE The covers fo
24. L INSPECTION e Check all components for damage cracks deformation wear etc and fit new ones if necessary e Inspect the plugs and cables for corrosion loose contacts crimping faults etc and repair them if necessary e Check plug strips for signs of corrosion and contacts to ensure they are secure Repair them if necessary 9 1 2 CARRYING OUT MODIFICATIONS The constant development of our heaters is aimed at optimizing them so as to prevent failures and malfunctions Generally it is possible to modify heaters that are already in use We can supply the appropriate modification kits for this purpose The following describes modifications that can be carried out without any great effort during standard repair work e Installation of an external temperature sensor for better temperature control see 9 1 2 1 www webasto us REPAIR 9 1 2 1 INSTALLATION OF AN EXTERNAL TEMPERATURE SENSOR General The heater can control the required temperature perfectly if its temperature sensor is exposed to the air of the main area of the vehicle In certain circumstances this is not always possible using the temperature sensor integrated in the control unit due to the installation circumstances addition of fresh air In this case proper temperature control can be ensured using an external temperature sensor fitted in the appropriate area Method 1 Selecta suitable position for an external temperature sensor IMPORT
25. LED red Immediate heat button light X6 Plug connector 18 pin to item A2 Ready indicator switch on indicator X8 Plug connector 2 pin H4 Heating symbol in the Indicator X9 Plug connector 4 pin to item S1 display in item P X10 Plug connector 2 pin to item Y1 H5 Light in item P Display and button lights X11 Plug connector 2 pin M1 Motor Combustion and hot air fan X12 Plug connector 12 pin to item P P Combination timer Timer and temperature control Y1 Fuel metering pump 1531 Figure 13 System Circuit Diagram 12V 24V with Combination Timer Model 1531 www webasto us 25 Webasto Product N A Inc CIRCUIT DIAGRAMS AIR TOP 2000 ST Combination Timer 1531 Black Battery Positive or Ignition Signal 10 Grey Lights 1 Red T P ovi Positive 11 Brown Battery Negative 12 4 Adapter Harness P N 9008440A Figure 14 Schematic Connection of the Combination Timer Model 1531 Webasto Product N A Inc 26 www techwebasto com AIR TOP 2000 ST 8 SERVICING WORK 8 1 GENERAL This section describes the servicing work that can be carried out on the heater when it is installed 8 2 WORK ON THE HEATER Disconnect the main power cable from the vehicle s battery before carrying out any work on the heater The main battery power must not be disconnected whilst the heater is operating or slowing down as a result of
26. Test current bmA Hot Testing Resistance at 800 1000 C 12 15 Ohm Resistance at 1472 1832 F 12 15 Ohm Test current lt 5mA ceramic rod at red heat over length of approx 20 mm Webasto Product N A Inc FUNCTIONAL TESTS 6 3 3 OVERHEATING SENSOR RESISTANCE TEST If you conduct this test with a digital multimeter the overheating sensor must have the values shown in the following diagram 2260 2240 2220 2200 2180 2160 2140 2120 2100 2080 2060 Resistance in Ohm 10 12 14 16 18 20 22 24 26 28 30 Temperature in C Characteristic resistance values of a PT 2000 overheating system in a temperature range of 10 C to 30 C Conversion chart C to F 10 C 50 F 12 C 53 6 F 14 C 57 2 F 16 C 60 8 F 18 C 64 4 F 20 C 68 F 22 C 71 6 F 24 C 75 2 F 26 C 78 8 F 28 C 82 4 F 30 C 86 F Webasto Product N A Inc 22 AIR TOP 2000 ST www techwebasto com AIR TOP 2000 ST 7 CIRCUIT DIAGRAMS 7 1 GENERAL The Air Top 2000 ST heater can be controlled with the control element nominal value adjuster switch or a combination timer E DA CIRCUIT DIAGRAMS The circuit diagrams Fig 12 and Fig 13 show the possible circuits for 12 and 24 V with e Control element e Combination timer Fig 11 shows the plug assignment on the control unit Fig
27. air be taken from areas occupied by people The combustion air intake opening must not point in the direction of travel It must be located so that it cannot become clogged with dirt Li If the heater is in a sealed installation box the combustion air must be drawn in from the outside and the emissions fed to the outside Pipe passage holes must be made in such a way as to ensure that the ingress of exhaust fumes into the interior of the vehicle should not occur NOTE The combustion air must be extracted using a combustion air line from a position that is as cool as possible and protected from splashing water for petrol heaters If dirty combustion air is expected a combustion air filter may be fitted only Air Top 2000 ST D If the intake hose length is lt 0 6 m 2 ft an intake silencer must be used 8 6 6 EXHAUST LINE Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1 0 mm 3 64 in or flexible piping of alloyed steel only must be used as the exhaust line The exhaust pipe must be secured to the heater and exhaust muffler with a pipe clip P N 20965A The exhaust muffler Fig 22 should ideally be installed near the heater The flow direction is arbitrary Exhaust muffler Figure 22 The heater may also be operated without a muffler 8 6 7 COMBUSTION AIR INLET AND EXHAUST LINES To prevent damaging the metering pump cable exhaust line must not be used to extend the combustion air su
28. al should be addressed to Webasto Product North America Inc Technical Documentation Group 15083 North Road Fenton MI 48430 Phone 810 593 6000 PC Fax 810 593 6135 Webasto Product N A Inc INTRODUCTION AIR TOP 2000 ST This page for your notes Webasto Product N A Inc 4 www techwebasto com AIR TOP 2000 ST GENERAL DESCRIPTION 2 GENERAL DESCRIPTION The Air Top 2000 ST air heater is based on the evaporator principle and essentially consists of the following the drive unit with a combustion and hot air blower the heat exchanger the burner insert with combustion pipe the control unit Figure 2 Air Top 2000 ST Air Heater without Casing 2 1 DRIVE UNIT The drive unit consists of the drive motor the combustion air blower the heat air blower and the intake casing The combustion air blower supplies the air required for the combustion process from the combustion air inlet to the burner insert Figure 1 Air Top 2000 ST Air Heater The removable hot air blower transports the hot air from the hot air inlet via the heat exchanger to the hot air outlet To control and monitor it the heater has acontrol unit with temperature sensor a flame sensor gasoline heaters only a ceramic glow pin an overheating sensor inside it All Air Top 2000 ST heaters can also be controlled using an external temperature sensor The fuel supply is provided from an external source using a
29. ali DAA a A PL e 27 86 2 T el Supply aiii utt eto Rb eade AO ai 28 8 6 2 1 Fuel Extractor Standpipe LL 28 8 622 FUEL MES edita prio edile alare i a ie i na 30 8 6 3 FuelMeteting PU ca ca ria la ERR dala a aaa ne dee ed 30 8 6 3 1 Installation Location cesse ciiis ie a a ia i E ae i E a a a a E A EA 30 8 6 3 2 Installation and Attachment 30 84 PuelRiltet s scesa e a ii da da ha 30 8 65 Combustion All Supply di rg Rx Ro X er oA red S P qur dare y due Stare dum abend 31 3 6 6 Exhaust LNE sd de Xe Alpe hd eet ee ol oa SO dss ba A A A hohe 31 8 6 7 Combustion Air Inlet and Exhaust LINES 31 8 6 8 Electrical Connections 32 8 6 8 1 Heater Connection Control Element i 32 8 6 8 2 Supply Voltage Connection i 32 8 6 8 3 Control Element Rheostat Connection iii 32 8 7 Removal and Installation le 34 8 7 1 Heater Removal and Installation 0 o oooo ee 34 SI Removal sas erea EROR TTE 34 32712 installationi sartoria PASSI a ein eta 34 8 8 Start up e esL Redi dA ew gid ERI RL ALLEA an lee 34 9 Repair 35 9 11 Gerieral sa ies em St sete fasc tonto Sess e S EE Rueda Tarde A de a eo ae te 35 9 1 1 Work on Stripped down COMponents o 35 Spi Cleaning a E EE E E a E D AA a ES 35 9 1 1 2 Visual IMSpECHON ieis xiu d eom dic es c cn spl e ee a AE d 35 9 1 2 Remove the Casing Parts sues ta raen Rea rege desee db Ru E Rh AUR e s Py Rue a dn ede s 36 9 1 2 1 Installation of an Externa
30. allow to work until the glow plug can be removed A CAUTION The glow plug should be 8 Release the screw 7 pull out the glow plug 6 from the burner insert and remove 9 Remove the combustion pipe 13 and seal 12 from the heat exchanger 9 and dispose of the seal separately 10 Complete the work on stripped down components see 9 1 1 www webasto us 41 REPAIR 9 2 7 2 INSTALLATION 1 3 Fit a new seal 12 Fig 31 into the heat exchanger 9 and bring the combustion pipe 13 into the assembly position Check that the starting air hole in the burner insert 5 is free If necessary clean with a wire approximately 4 mm 5 32 in Y see Fig 32 CAUTION When installing the glow plug make sure that the contacts point to the heat exchanger Otherwise there is a risk of a short circuit Introduce the glow plug 6 in the burner insert 5 and position the protective sheath in the slit of the burner insert CAUTION In the following procedure make sure that the glow plug is placed in the burner insert up to the stop 4 Secure the glow plug 6 with the screw 7 Tighten 7 10 11 the screw 7 to 0 5 Nm 4 4 Ib in Introduce the burner insert 5 in the heat exchanger 9 Make sure that the cable of the flame sensor 1 only present with petrol heater is positioned under the fuel line Guide the plug of the glow plug and the flame sensor through the holes and press the cable
31. basto Product N A Inc 20 www techwebasto com AIR TOP 2000 ST 6 FUNCTIONAL TESTS 6 1 GENERAL This section describes the tests conducted on the heater when it is installed and not installed to verify that it is in working order WARNING The heater must not be A operated in enclosed areas such as garages and workshops without an emissions extraction system 6 2 SETTINGS 6 2 1 SETTING THE CO CONTENT The CO content in the emissions is set using the adjustment knob on the control element At a constant blower speed the volume of fuel is controlled by changing the metering pump cycle CAUTION The CO measuring instruments must be calibrated The heater must be switched off 1 Connect the CO line to minus 2 Turn the adjustment knob on the control element to the centre setting The heater will start and go automatically to low fire rate mode Li Diesel Unit NOTE f the heater can be adjusted the operating indicator will flash as if the control unit has suffered an error 3 Set the CO value by turning the adjustment knob Turning it anti clockwise will reduce the CO value whilst turning it clockwise will increase it The measured CO content at low fire rate 1 5 kW must be between 5 096 and 8 096 In high fire mode the CO content should be 10 3 0 5 v v after the setting has been made Gasoline Unit 4 The CO content may only be measured when the unit is at operating temperature
32. be used Webasto Product N A Inc INTRODUCTION The electric cables and controls for the air conditioning system must be arranged in the vehicle so that their proper functioning cannot be adversely affected in normal operating conditions The following points for the installation of fuel lines and the installation of additional fuel tanks must be observed e Fuel pipes must be designed in such a way that torsion in the vehicle movements by the engine and the like do not have a negative effect on their durability They must be protected from mechanical damage e Parts that carry fuel must be protected from heat that will adversely affect their function and positioned so that dripping or evaporating fuel cannot collect or ignite on hot parts or on electrical equipment e The fuel lines Mecanyl hose must not be immediately next to the exhaust pipe and must be thermally insulated if necessary otherwise they will pose a fire risk e All pipes that come into contact with fuel must have sealed connections they must not be damaged in any way and the must be checked at regular intervals at least the same intervals as for inspection of the vehicle as a whole NOTE If any damage or leaks are found on n the fuel line the heater must not be used until the damage has been rectified by an authorized Webasto workshop Put the heater out of action by removing the fuse Installation regulations for Webasto fuel tanks for su
33. control element after the slow down time has finished If the other components are OK a defective control unit may be the cause of all the faults il There are statuses that are the same as errors Error Symptom Occurrence Remedy No start and no illumination of the Immediate Incorrect cabling defective fuse LED on the control element No start but LED is lit Immediate The heater goes straight to control pause when it is switched on whereby the control pause speed is 0 rpm for a boat heater Table 3 Error Symptoms during Function Webasto Product N A Inc www techwebasto com AIR TOP 2000 ST 5 4 ERROR CODE OUTPUT If the heater is fitted with a combination timer an error code output will appear on the display of the timer after a fault occurs il TROUBLESHOOTING NOTE The error code is output if the heater is fitted with a control element after an error has occurred by the switch on indicator error code indicator flashing After 5 seconds of fast flashing the error code will be output by a sequence of long flash pulses the number of flashes is shown in the table below for example F04 4 long flash pulses Error Error group Additional Information during PC Remed Code group Diagnostics y F 00 Control unit error 041 Control unit error Replace control unit 81 EOL checksum error 11 Incorrectly coded control unit or incorrect heater fuel type installed
34. e a 38 9 2 5 Changing the Combustion Air Fan Li 38 925 REMOVA ru A Ra 38 92 52 Install it ctv A A A A A A AR A Pde Hh 38 9 2 6 Changing the Flame Sensor gasoline heaters only LL 39 9 2 6 1 REMOVAL aux du a a Re a POLE Ae Soe eS ea 39 9 2 6 2 installation zu ouais ees tes a derit a ds ale i ee Pawling alt 39 9 2 7 Changing the Ceramic Glow Pin 41 9 2 7 1 Removal step ase e a Gh der o ge e Gi dr o m i edd 41 92 72 Installation ss is ae e ER a UR REG PIXXG PYGGesupAR OPE ees 41 9 2 8 Changing the Burner Insert Combustion Pipe and the Heat Exchanger 0 43 DP Or REMOVA decae td beri dis sexa Pe toe set tee ed e ales Ee Soe dine ra a Ae cara 43 92 8 2 Installation cst seek ha eee WR ee ae dee el E aes 43 10 Product Information 45 www webasto us Ill Webasto Product N A Inc TABLE OF CONTENTS AIR TOP 2000 ST Webasto Product N A Inc IV www techwebasto com AIR TOP 2000 ST 1 INTRODUCTION 1 1 CONTENTS AND PURPOSE This repair shop manual is intended to assist trained personnel with repairing both the gasoline and the diesel versions of the Air Top 2000 ST air heaters 1 1 1 The Webasto Air Top 2000 ST air heaters are designed to heat cabins boats trucks minibuses vans ambulances and motor homes USE OF THE AIR HEATERS to defrost vehicle windows They are not designed for heating cargo areas used to carry hazardous substances The heaters operate independently of the engine
35. e fuel connection may also be made between the tank and the fuel pump again using only the Webasto fuel tee fitting Vehicles with Carburetor Engines The fuel may only be extracted on cars using a special Webasto fuel tee fitting as close to the tank as possible The connection may be made in either the supply or return line in which case the return line must lead almost to the base of the tank If this is not the case the return line may be extended The fuel tee must be fitted in such a way that any air or gas bubbles are automatically discharged towards the tank The fuel tee should not be located near the engine as gas bubbles may form in the lines on account of heat radiated from the engine This may cause problems during combustion www techwebasto com AIR TOP 2000 ST max 3m 9 8 ft 12 S l4 12 lt 10m 228 ft HW I1 lt 12m 3 9 ft 1 88m 28 8 ft P Figure 15 Fuel supply Hole pattern 25 mm 1 in gt 25 mm gt 1 in Max depth Figure 16 Webasto fuel standpipe Li www webasto us NOTE Only use this style of standpipe with metal fuel tanks SERVICING WORK Plastic tank Sealing ring Figure 17 Fuel extractor from a plastic or metal tank extraction through tank drain screw Sealing ring 32 Metal tank fitting or sender plate Figure 18 Fuel standpipe for a plastic or metal tank
36. ed and then returns to the initial speed after 15 seconds after which it falls to the control pause speed in 3 minutes where it remains for the entire control pause The control pause speed on boat heaters is 0 If the temperature set on the control element is not observed at the temperature sensor the heater will restart NOTE Changes to the setting on the control n element are implemented by the control unit and heater after a delay 3 6 SWITCH OFF When the heater is switched off the ON control LED on the control element goes out If no fuel has been transported or if the heater is in the control pause the heater is switched off immediately without a slow down time If the fuel transport has been started it is ended immediately when the heater is switched off The heater is switched off using the same method as the transition from control mode to control pause The device is then switched off automatically NOTE The heater may be switched on again n during the slow down time In this case the slow down time is completed and the heater is then restarted Webasto Product N A Inc AIR TOP 2000 ST 3 7 FAULT LOCK OUT The control unit has identified errors on individual heater components and faults during the starting procedure and in operation The heater is switched off and goes into fault lock out if the following conditions occur e No repeated or incorrect start e Temperature sensor defective e Overheating
37. ensor interrupt or short The switched cable of the element has a circuit short circuit to earth gasoline heaters only 9A Flame sensor circuit Replace flame sensor Break or short circuit to Ub F 06 External 14 Temperature sensor circuit Check cables replace temperature sensor temperature sensor Short circuit to earth break or short circuit 94 Temperature sensor circuit break or Check cables and terminating resistor short circuit to Ub replace temperature sensor F 07 Metering pump 88 Break or short circuit to Ub Check cables replace metering pump interrupt or short circuit 08 Short circuit to earth Check cables replace metering pump F 08 Drive unit 89 Break or short circuit to Ub Replace drive unit combustion and hot air combustion and blower hot air blower break or short 09 The switched drive unit cable Eliminate the cause of the blockage circuit combustion and hot air blower has a difficulty in movement short circuit to earth or the drive unit is Replace drive unit combustion and hot air overloaded blower 15 Burner motor block guard has tripped 95 Burner motor blocking detection has tripped F 09 Glow pin interrupt 8A Glow pin Replace glow pin Break or short circuit to Ub or short circuit 19 Glow circuit Replace glow pin The switched cable of the element has a short circuit to earth Table 5 Troubleshooting page 2 of 3 Webasto Product N A Inc www techwebasto com AIR TOP 2000 ST TROUBLESHOOTING
38. et for dirt and foreign bodies Dirty or blocked hot air lines may cause overheating e Clean the exterior of the heater avoid the ingress of water e Check the electrical connections for contact corrosion and to ensure that they are secure e Check the exhaust and combustion air lines for signs of damage and to ensure that they are clear e Replace the fuel filter if there is one e Check the fuel line and filter for leaks 8 6 VISUAL INSPECTIONS AND INSTALLATION INSTRUCTIONS 8 6 1 Hor AIR SYSTEM CAUTION The integration of the heater A into the vehicle s own air system is not permitted as a result of the high pressure in the vehicle s system Inside the control unit there is a temperature sensor which operates the heater in the appropriate heat output range in conjunction with the control element depending on the intake temperature and the position of the control element s dial The heat output is set so that after the selected interior temperature has been reached quickly it is then kept at this selected value Alternatively the heaters can be operated with an external temperature sensor see 9 1 2 Li Maximum pressure drop between the inlet and outlet side of the hot air line 1 5 hPa corresponds to 1 5 mbar 15 mm WC If this value is exceeded the heat output may be reduced as a result of the hot air outlet temperature control NOTE Only materials that can permanently withstand temperatures of at least
39. he wiring harness to the motor at the same time Tighten the screws 4 to 6 0 6 Nm 53 5 Ib in Fit the control unit see 9 2 3 2 Position the casing parts see 9 2 2 Install the heater see 8 7 1 2 Check the CO setting and adjust it if necessary see 6 2 9 2 6 CHANGING THE FLAME SENSOR GASOLINE HEATERS ONLY 9 2 6 1 REMOVAL Ux de We cJ s Remove the heater see 8 7 1 1 Remove the casing parts see 9 2 1 Remove the control unit see 9 2 3 1 Remove the combustion air fan see 9 2 5 1 Remove two screws 2 Fig 31 and take off the air baffle 3 Press the cable grommet 11 on the flame sensor connecting cable inwards out of the heat exchanger 9 Carefully bend up the securing strap 4 and pull out the flame sensor 1 from the burner insert Remove flame sensor 9 Complete the work on stripped down components see 9 1 1 www webasto us 39 9 2 6 2 A 1 CO o 9 m OY Ur E ow REPAIR INSTALLATION CAUTION Install the flame sensor cable under the fuel line Slide the flame sensor 1 Fig 31 through under the fuel line insert the plug through the hole in the heat exchanger 9 and press the cable grommet 11 into the heat exchanger 9 from inside Insert the cable with the protective sheath through the securing strap 4 and insert the flame monitor 1 into the burner insert 5 Press the securing strap 4 back together Secure the air baffle
40. hrow any heavy objects on the heater e Do not place any items of clothing textiles or similar materials over the heater or in front of the hot air inlet side and hot air outlet e The flow of hot air from the heater must not be restricted or blocked by highly inflammable substances or materials such as rags cleaning wool etc e Inflammable or explosive substances and gases must not be placed near or in contact with the heater the hot air line the flow of hot air or the exhaust pipe www webasto us INTRODUCTION e The heater must not be cleaned with a high pressure cleaner e Do not switch the heater off at the main battery switch or battery isolation switch since otherwise it is possible that it may suffer long term damage if it is switched off frequently using the battery isolation switch and this can cause damage and negative influences on the function of the heater NOTE Failure to follow the installation Hn instructions and the notes contained therein will lead to all liability being refused by Webasto The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts This invalidates the type approval for the heater and its homologation EC type permit You must read the operating manual before starting the heater for the first time 1 5 SUGGESTIONS FOR IMPROVEMENTS AND CHANGES Complaints improvement suggestions or corrections relating to this workshop manu
41. it EMC e1 72 245 95 54 1085 Heater e1 2001 56 0022 Model Air heater with evaporator burner Heat Output kW Control Range 1 0 2 0 kw 0 9 2 0 kW Btu h 3415 6830 3074 6830 Fuel Gasoline Diesel 41 42 Arctic PME and Kerosene Fuel Consumption Vh Control Range 0 14 0 27 0 12 0 24 gal h US 0 037 0 071 0 032 0 063 Rated Voltage 12V 12V 24V Operating Voltage Range V 10 5 16V 10 5 16V 21 32V Rated Power Consumption Control Range 14 29 Watts Maximum Ambient Temperature Heater operation 40 C 40 C 40 F 104 F warehouse 40 C 85 C 40 F 185 F Dosing Pump operation 40 C 20 C 40 F 68 F warehouse 40 C 85 C 40 F 185 F Control Element operation 40 C 75 C 40 F 167 F warehouse 40 C 85 C 40 F 185 F Max Combustion Air Inlet Temperature 40 C 20 C 40 F 68 F Adjustment Range For Interior Temperature Control Range 5 C 35 C 41 F 95 F Delivery Rate For Hot Air At Fan Speed against 0 5 bar against 7 25 PSI Max 93 m h at 4750 rpm Max 55 cfm at 4750 rom Co In Exhaust Gas 1 kw 5 0 8 0 5 0 8 0 permanent function range 2 kW 9 0 12 5 9 0 12 5 Heater Dimensions 311 mm L X 120 mm W X 121 mm H Length X Width X Height 12 25 in L X 4 72 in W X 4 76 in H Weight Of Heater 2 6 kg 5 73 Ib Table 1 Technical data
42. l Temperature Sensor LL 35 9 2 Dismantling a a Asserblirig z ria Peace pet Sakae cance X VEA E Ra pe qp Red ere aed usa ob EE 36 9 2 1 Remove the Casing Parts daa da ia da e ERU RR ed are Roe iod da ide ea 36 9 2 1 1 Cover for Electrical Connection 0000 36 9 2 1 2 Grates for Hot Air Inletxand Outlet o ELE Leech oer edu en aruda 36 9 2 1 3 Cover for Hot Air Inlet and Outlet 36 92 14 Tlop Shiell e bee de edge tte RALE en ete RR Reb dote PR a des 36 92 1 5 Bottomishell z ssaa ERE A AAA deo au UE TE exea EA 36 9 2 2 Hitthe Casing Parts priora ivo hae eek ada E ide feta Peste en ub Far a I eager a 36 922 JBottom Shell sssr sss se e lr a m RR RS UR Un Dm cer ay dew ease ace cid 36 92 22 TOD SHEN rs eso dde lie job De ERI Ed a mex uot sedent soU SERERE UP TU deco quic RU da Gd 36 9 2 2 3 Cover for Hot Air Inlet and Outlet 36 9 2 2 4 Grates for Hot Air Inlet and Outlet iilii 36 9 2 2 5 Cover for Electrical Connection o 36 9 2 3 Changing the Control UNI esscr nr oed Pip i DER G Pu Rag be RR ER E ERU 38 9 2 3 1 REMOVAL niys caidas pai dalia qaos n dies etat te dak add s dd B RR Dette 38 9 2 3 2 ilnistallationi second A a il 38 Webasto Product N A Inc Il www techwebasto com AIR TOP 2000 ST TABLE OF CONTENTS 9 2 4 Changing the Overheating Sensor 38 9 24 1 Removals os real Lie Ds Eas ple aid AE ed ao bd nat ald eed d 38 92 4 2 Installation 5 ec Lee de tke Ba oe na ee ead edd Pd Re ae e e de
43. mation available at this time www webasto us 45 Webasto Product N A Inc PRODUCT INFORMATION AIR TOP 2000 ST This page for your notes Webasto Product N A Inc 46 www techwebasto com AIR TOP 2000 ST WARRANTY ES E ES EE SIE CS Sla li ZE RN aaa rg A RESO este MAUS ER ESSI N AS O O GO SUI SER SO ROSIN SK ESSI OR EUN MAN e IS AN On St AN EO IS AN e AS AN eO AN AN MEO AN AN e AN AN e AN AN e AN A SN Beau fas Fase Fs Y s Y s T uus Yr Yu t s Fas T aen T ana s Trust Ye Tua TN eae s dd n es EI es WARRANTY COVERAGE AND LIMITATIONS tei o Webasto Product North America Inc herein after referred to Web heir h TS NS e on ebasto Product North America Inc herein after referred to Webasto warrants their heaters Bw SH ast tai f i if and heater kits against defects in material and workmanship for two 2 years effective at the time Re E de i e gt 1 of installationor vehicle registration date for Original Equipment installations OE This warranty e period may not exceed three 3 years from the original date of sale by Webasto This wa
44. mn NOTE The covers for the hot air inlet and 1 Push on the covers 3 and 6 Fig 29 until the four securing holes engage properly in the detents on the bottom and top covers 9 2 2 4 GRATES FOR HOT AIR INLET AND OUTLET Fit the grates 5 Fig 29 on the covers for the hot air inlet and outlet and twist them to secure them 9 2 2 5 COVER FOR ELECTRICAL CONNECTION the left or right of the heater to suit the Hn NOTE The wiring harness is to be taken out of installation situation 1 Fit the cover 1 Fig 29 until it audibly engages in the top cover www techwebasto com AIR TOP 2000 ST REPAIR Cover electrical connection Top shell Cover hot air outlet Bottom shell Grate Cover hot air inlet Insulators N dl Un aUuUN Positioning of insulators sas NTC Extension of corner rib Figure 29 Remove Fit the Casing Parts www webasto us 37 Webasto Product N A Inc REPAIR 9 2 3 CHANGING THE CONTROL UNIT 9 2 3 1 REMOVAL 1 Remove the heater see 8 7 1 1 2 Remove the casing parts see 9 2 1 3 Open the catches on the hot air blower 4 Pull the hot air blower 1 Fig 30 off the motor shaft by hand 5 Disconnect the plug connectors on the control unit 3 6 Remove screws 2 and the control unit 3 7 Complete the work on stripped down components see 9 1 1 Li 9 2 3 2 1 Place the control unit 3 Fig 30 in the installation position and attach with
45. ng pump wiring harness 6 Connect the wiring harness plug to socket X6 of the control unit 7 Fit the cover and secure it 8 If necessary fit the hot air hose or hoses and secure them 9 Connect the battery Bleed the fuel supply system see 8 8 Webasto Product N A Inc 34 AIR TOP 2000 ST 8 8 START UP After you have installed the heater bleed the fuel supply system carefully il Conduct a trial of the heater to check all the connections for leaks and to ensure that they are secure If the heater suffers a fault during operation the fault must be located and remedied NOTE As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line www techwebasto com AIR TOP 2000 ST 9 REPAIR 9 1 GENERAL This section describes the repair work that may be carried out on the Air Top 2000 ST heater after it has been removed from the vehicle Any further dismantling will invalidate the warranty Only use the spare parts from the appropriate spare parts kits for assembling the heater 9 1 1 WORK ON STRIPPED DOWN COMPONENTS CAUTION All sealing elements between A the stripped down components and the seal on the exhaust outlet must always be discarded and replaced 9 1 1 1 CLEANING e Clean all stripped down components with benzene and then dry them with compressed air e Remove all seal residue on the components carefully using a suitable tool 9 1 1 2 VISUA
46. nnel Liability claims can only be lodged if the claimant can prove that he has complied with the servicing and safety instructions Overheating Keep hot air inlet and hot air outlet free of dirt and other items Dirty blocked air lines can cause the heater to shut down due to overheating After an overheating lock out check that the air system is clear remove any materials that may block the air flow and have any damage to the air lines repaired by an www techwebasto com AIR TOP 2000 ST authorized Webasto workshop After this the heater lock out can be cancelled by switching it off and then on again If this action does not produce the required success if the heater overheats again take it to a Webasto authorized workshop Never remove the grating over the air inlet of the heater The air outlet jets or air vents with adjustable flaps must always be opened to some extent so that the air flow through the heater is not completely blocked At least one air vent must be prevented from being closed If the heater is installed in a storage area you must ensure that no inflammable substances are kept in this area and that other material does not restrict the air supply to the heater Air lines must be securely fixed to the heater using pipe clips for example and all other connection points for example vents IMPORTANT The errors described below are to be avoided at all costs e Do not stand on the heater or place or t
47. on regulations and current works safety instructions are applicable The General safety regulations that go beyond the scope of the above regulations are stated below see 1 4 2 Any special safety regulations relevant to this instruction manual will be highlighted in the relevant sections or text passages of the procedures 1 4 1 il Extract from the Federal Motor Carrier Safety Administration STATUTORY REGULATIONS AND SAFETY INSTRUCTIONS NOTE The provisions of these Directives are binding within the United States of America by FMCSA Directive 393 77 and should similarly be observed in countries without specific regulations Part 393 Parts and Accessories Necessary for Safe Operation 8393 77 Heaters b 15 Certification required Every combustion type heater shall be marked plainly to indicate the type of service for which such heater is designed and with a certification by the manufacturer that the heater meets the applicable requirements for such use For example Meets FMCSA Bus Heater Requirements 1 4 2 GENERAL SAFETY INFORMATION The mouth of the exhaust pipe should be installed upwards to the side or if the exhaust pipe passes under the floor of the vehicle to the side or rear limit of the driver s cab or the vehicle The function of important parts of the vehicle must not be adversely affected It must not be possible for condensate or water to collect in the exhaust pipe Drain holes may
48. onnector 2 pin H4 Heating symbol in the Indicator x9 Plug connector 4 pin to item S1 display in item P X10 Plug connector 2 pin to item Y1 H5 Light in item P Display and button lights X11 Plug connector 2 pin M1 Motor Combustion and hot air fan X12 Plug connector 12 pin to item P P Combination timer Timer and temperature control Y1 Fuel metering pump 1531 Figure 12 System Circuit Diagram 12V 24V with Control Element Rheostat Switch Webasto Product N A Inc 24 www techwebasto com AIR TOP 2000 ST BATTERY IGNITION LIGHTS OPTIONAL Tl N RI 20 Ga Pink for ventilation mode only CIRCUIT DIAGRAMS X2 X3 X4 X5 If ventilation mode is not desired leave pink wire disconnected and protect from grounding To use vent mode connect to ground through a switch 53 for proper operation No heating operation with pink wire grounded xi Tal m N E OW e i 154 GROUND 2 ME K cable Cable Cross sections Cable Colors us CO setting 75m 75 15m bl Blue 4 Input pin pin 16 plug X6 cable color on wiring harness pink 0 75 mm 10 mm br Brown Ventilation fan speed depends on the position of the control element 075 mm 1 0 mm ge Yellow f you use an external temperature sensor B4 the resistor R1 is replaced by
49. personal computer see PC heater diagnostic operating manual iri Internal Wiring harness temperature sensor Component plug sockets Control Unit Figure 6 2 5 FLAME SENSOR GASOLINE HEATERS ONLY The flame sensor is a low ohm PTC resistor which changes its resistance depending on the heat emitted by the flame This change in resistance is analyzed by the control unit so that the flame status is monitored whenever the heater is operating Flame Sensor Figure 7 www techwebasto com AIR TOP 2000 ST 2 6 CERAMIC GLOW PIN The mixture of fuel and air is ignited by the glow plug when the heater is started The glow pin takes the form of an electrical resistor and is positioned in the burner insert on the side away from the flame Ceramic Glow Pin Figure 8 www webasto us GENERAL DESCRIPTION 2 7 OVERHEATING SENSOR The overheating sensor measures the temperatures in the rib area of the heat exchanger whenever the heater is operating The control unit evaluates the signal and protects the heater from hot air outlet temperatures above 150 C and surface temperatures above 80 C by shutting down the combustion process and blowing cold air over the heater The heater then suffers a fault lock out and can be restarted by being switched off and then on again see 3 2 Figure 9 Overheating Sensor 2 8 FUEL METERING PUMP The metering pump is a combined transport metering and shut off sy
50. pply line www webasto us SERVICING WORK Length of the combustion air inlet and exhaust lines With muffler max 2 0 m 6 5 ft Without muffler max 5 0 m 16 4 ft Both lines are to be installed falling away from the heater If this is not possible a condensate drain hole with a diameter of 4 mm must be made at its lowest point or a connection element with a condensate drain used Internal diameter of the lines 22 mm 7 8 in 22 mm 7 8 in Combustion air line Exhaust line Li Minimum bending radius NOTE If the exhaust line is over 2 m in length insulated lines must be used to prevent falling below the dew point 50 mm 2 in An attachment is required no further than 150 mm 6 in from the end of the exhaust pipe to ensure that the angle of 90 10 is achieved Discharge direction more or less vertical 90 10 Figure 23 Exhaust pipe mouth installation position WARNING If the exhaust pipe mouth is N positioned other than as shown in Fig 23 it will pose a fire risk Total bends Combustion air line max 270 Exhaust line max 270 Webasto Product N A Inc SERVICING WORK 8 6 8 ELECTRICAL CONNECTIONS 8 6 8 1 HEATER CONNECTION CONTROL ELEMENT The electrical connection is to be made as shown in the appropriate circuit diagram see section 7 To connect the wiring harness remove the cover see 9 2 1 1 on the heater and connect the wiring harness plug to the cont
51. pplying fuel to heaters in vehicles e The tank must not be installed in the passenger or driver s cabin of buses e The fuel filler neck must not be inside the passenger or driver s cabin in any vehicle e Fuel tanks for normal or super grades of petrol must not be immediately behind the front trim of the vehicle They must be separated from the engine in such a way that in the event of an accident the fuel will not be expected to ignite This does not apply to tractor units with an open driver s seat The air heater s heat exchanger can be used for a maximum of 10 years and must then be replaced by the manufacturer or one of its authorized workshops using a genuine spare part A label must then be affixed to the heater showing the date of sale and the wording Genuine spare part Webasto Product N A Inc AIR TOP 2000 ST When you change the heat exchanger it is essential that you also replace the overheating protection element overheating sensor to prevent possible function faults caused by using the old overheating sensor The Air Top 2000ST air heaters are prepared for interior installation and sealing directly on the cabin floor or a cabin wall Non release connections must be used in the interior for combustion air and exhaust pipes with the accessories available from Webasto The seal between the heater mounting and the vehicle floor must always be installed otherwise harmful emissions may get into the interior of
52. r the hot air inlet and n outlet must have been removed The shell 2 Fig 29 can be raised by pulling up 9 2 1 5 BOTTOM SHELL By gently pulling the bottom shell 4 Fig 29 on both sides in the areas O you can release the fixing and the shell can be taken off the motor casing 9 2 2 FIT THE CASING PARTS 9 2 2 1 BOTTOM SHELL IMPORTANT To ensure that the heater and the overheating sensor work perfectly please note the following when fitting the casing e Four insulators are used as spacers between the heat exchanger and the casing parts Webasto Product N A Inc AIR TOP 2000 ST e Slide the four insulators 8 Fig 29 onto the four corner ribs of the heat exchanger and position exactly next to the rib extension e Check that all four insulators 8 Fig 29 are securely positioned 4 Fig 29 spread it slightly so that the spacers on the overheating sensor 8 Fig 30 are not damaged A CAUTION When you fit the bottom shell 1 Expand the bottom shell 4 Fig 29 slightly at the side and fit it to the heater from underneath until the securing pins on the heater engage in the holes in the shell 2 Fit a new seal on the exhaust outlet 9 2 2 2 TOP SHELL 1 Place the top shell 2 Fig 29 on the heater and secure it in the grooves in the bottom shell 9 2 2 3 COVER FOR HOT AIR INLET AND OUTLET outlet are different Fit the cover with the smaller opening at the front on the hot air blower
53. rating the combustion gases pass through the heat exchanger During this process the combustion heat is given off to the walls of the heat exchanger absorbed by the hot air transported by the hot air blower and fed into the interior of the vehicle The temperature of the hot air intake is measured by a temperature sensor on the intake side of the heater or an external temperature sensor If the measured temperature is lower than the value set on the control element the output of the heater is increased to maximum heat output To increase the burner service life when it is used continuously the transport capacity of the metering pump is reduced for 10 seconds every 10 minutes In addition heating mode is interrupted every 8 hours in the same way as for a control pause 3 4 CONTROL MODE In control mode the blower speed and the metering pump delivery rate are dependent on the heat output The glow pin is switched off Webasto Product N A Inc FUNCTIONAL DESCRIPTION 3 5 CONTROL PAUSE After the temperature set on the control element has been reached the heat output is reduced The speed of the heating and combustion air blower and the delivery rate of the metering pump are reduced If at minimum heat output the intake temperature set on the control element is exceeded the metering pump is shut down and the combustion process ended To burn off the flame properly the blower speed falls after 20 seconds to low fire rate spe
54. rol unit Before using the heater for the first time fit the cover to prevent the illegal escape of hot air heater overheating The wiring harness can be fed out of the left or right side of the heater 8 6 8 2 SUPPLY VOLTAGE CONNECTION Ideally from the vehicle s central electrical system An additional blade terminal fuse holder is to be fitted to protect the heater and harness supplied with the heater The fuse holder should be installed as close as is practical to the power source e g in the vehicle battery enclosure The fuse holder is constructed of weather resistant components AT 2000 ST F 15A 12V F 10A 24V Figure 24 Weather Resistant Fuse holder Webasto Product N A Inc AIR TOP 2000 ST 8 6 8 3 CONTROL ELEMENT RHEOSTAT CONNECTION The wiring harness is prepared for connection to the control element rheostat switch Simply pull on connector housing to disconnect the connector Fig 26 Fiber optic lens operation indicator Figure 25 Control element rheostat switch Li il NOTE The fiber optic lens must be in contact with the rotary knob NOTE The connector housing can be locked self locking action by simply pulling on the wiring harness Figure 26 Disconnecting the plug www techwebasto com SERVICING WORK AIR TOP 2000 ST 10ss9238 131 14 N v asnj Z Jadwep pue duind Bunaea Ny Jejjnuijsneuxj 9 JH Z Jopauuod jue S juauaja j0 u0D
55. rranty c eg F period may be superseded by a contractual agreement cet Warranty coverage for Marine and Off road applications containing DBW series heaters and the EE Gi rr ET A x 3 kk hti OY e CSL Cargo Heaters are limited to a maximum of 3 000 hours of usage All other models are Oia limited to 2 000 maximum hours E EN es Replacement parts are covered for six 6 months or the remainder of the original warranty period A an n E ee Wee which ever is longer Replacement heaters are considered a Replacement Part QU fs The intent of the Webasto warranty is to protect the end user heater from such defects and provide BE ei eterea a A E i SZ e free repair and replacement of defective parts in the manner provided herein During the warranty te A Y A S ie period the exclusive remedy will be for Webasto at their discretion to repair or replace those parts Tie y E lt E 3 NU which are demonstrated to be defective in material or workmanship Eu den ce ci E CON WS um sui I wes While warranty is provided to the end user it is to be administered and serviced through an SSN ES S s gt SP e e j authorized Webasto dealer in accordance with the Webasto warranty policy or contractual Tir Sem MANT m ON esse agreement between Webasto and a second party E RIC EA ll A E Spi A E Er PS ss Limitations Webasto specifically excludes and limits from warranty the following
56. s maximum value of 7 the heater will go into the heater lock out status HGV The error counter SZ is incremented by 1 with each error for which there is no separate counter The error counter is reset to 0 at the start of control mode If the error counter reaches its maximum value of 10 the heater will go into the heater lock out status HGV The overheating counter HZ is incremented by 1 each time the heater overheats If the overheating counter reaches its maximum value of 20 the heater will go into the heater lock out status HGV The flame failure counter FAZ is increased by 1 each time the flame fails during heating mode The counter is decremented by 1 each time the heater is in control mode If the FAZ reaches a value of 6 the heater will go into fault lock out mode and the permanent flame failure counter FAZP will be incremented by 1 In control mode the permanent flame failure counter FAZP will be decremented by 1 When the heater is burning properly again the FAZP will return to O after a few control cycles If the permanent flame failure counter exceeds its maximum value of 6 however the heater will go to permanent heater lock out status error code F12 www webasto us FUNCTIONAL DESCRIPTION 3 7 2 RESET A FAULT LOCK OUT The various fault lock outs can be reset as follows Fault lock out Switch heater off using the control element and then on again after more than 2 sec Heater fault lock out Remove the f
57. screws 2 2 Tighten the screws to 0 7 0 07 Nm 6 6 Ib in 3 Slide the hot air blower 1 onto the motor shaft until the detente on both sides is heard to engage in the shaft groove at the stop NOTE Do not carry out any repair work to the control unit INSTALLATION 4 Connect the plug connectors at the sockets of the control unit 3 as shown in Fig 11 5 Position the casing parts see 9 2 2 6 Install the heater see 8 7 1 2 7 Check the CO setting and adjust it if necessary see 6 2 8 Check that the hot air blower moves easily with your hand Check for any noise when you switch it on later The sensor magnets on the hot air blower must be clear of ferrous chips etc 9 2 4 CHANGING THE OVERHEATING SENSOR 9 2 4 1 REMOVAL 9 2 4 1 Removal 1 Remove the heater see 8 7 1 1 2 Remove the casing parts see 9 2 1 3 Remove the insulators 9 Fig 30 4 Disconnect the plug connector X5 on the control unit 3 A CAUTION Do not pull the cables Webasto Product N A Inc AIR TOP 2000 ST 5 Lever the overheating sensor 8 out of the ribs of the heat exchanger 7 using a Suitable tool see detail A Fig 30 6 Remove the overheating sensor 8 9 2 4 2 1 Measure the resistance of the overheating sensor 8 Fig 30 see 6 3 3 2 Position the overheating sensor 8 Fig 30 on the heat exchanger 7 and press it into place by hand INSTALLATION IMPORTANT There must no
58. stem 8 6 2 FUEL SUPPLY The fuel is taken from the vehicle fuel tank or from a separate fuel tank The values for the maximum pressure at the fuel extraction point are shown in Fig 15 Permissible fuel inflow height H m At max pressure bar in fuel line 0 00 m 0 00 in 0 20 bar 2 9 PSI 1 00 m 39 4 in 0 11 bar 1 6 PSI 2 00 m 78 7 in 0 03 bar 0 44 PSI Maximum fuel intake height S m At max negative pressure bar in fuel tank 0 00 m 0 00 in 0 10 bar 1 45 PSI 0 50 m 19 7 in 0 06 bar 0 87 PSI 1 00 m 39 4 in 0 02 bar 0 29 PSI Webasto Product N A Inc 28 AIR TOP 2000 ST 8 6 2 1 FUEL EXTRACTOR STANDPIPE Vehicles with Diesel Engines The fuel must be taken from the vehicle fuel tank or from a separate tank Fig 16 17 or 18 This separate fuel pickup precludes any effect of pressure Vehicles with injection Engines When installing the heater in a vehicle with fuel injection systems it is important to establish whether the fuel pump is located inside or outside the tank If the fuel pump is located inside the tank fuel can only be extracted from the return line using a Webasto fuel tee fitting in which case it must be ensured that the return line continues almost to the bottom of the tank If this is not the case a Webasto fuel standpipe see Fig 16 17 or 18 may be used If the fuel pump is installed outside the tank th
59. stem for supplying fuel from the vehicle s tank to the heater Figure 10 Fuel Metering Pump DP 30 2 3 with Damper Webasto Product N A Inc GENERAL DESCRIPTION AIR TOP 2000 ST This page for your notes Webasto Product N A Inc 8 www techwebasto com AIR TOP 2000 ST 3 FUNCTIONAL DESCRIPTION 3 1 CONTROL ELEMENT RHEOSTAT The control element is designed to switch the heater on and off adjust the required room temperature intake temperature between 5 C and 35 C and to reset the heater after a fault The green LED serves as the On indicator LED permanently lit up and as a fault signal LED flashes 3 2 SWITCH ON Set the control element to the required temperature If the hot air temperature is lower than the nominal temperature the heater will start NOTE f the temperature of the hot air intake n is above the set nominal temperature only the motor for the hot and combustion air blower will start control pause Special feature The control pause speed is 0 rpm if boat heaters are used The function of the flame sensor is checked If the flame sensor now reports light the system will attempt to cool the flame sensor for 60 seconds If the flame sensor still reports light the control unit will suffer a fault lock out If another monitored component has suffered a fault the fault lock out will take effect without any slow down time Start When the heater is switched on the ON
60. t be an electrical connection between the sensor cables and the sheet metal holder 3 Ensure that the overheating sensor is correctly positioned in the heat exchanger 7 4 Connect the plug connector X5 at the control unit 3 Check that the cables are routed in parallel between the ribs on the heat exchanger 5 Push the insulators 9 on to the heat exchanger Position the casing parts see 9 2 2 7 Install the heater see 8 7 1 2 9 2 5 CHANGING THE COMBUSTION AIR FAN 9 2 5 1 REMOVAL 1 Remove the heater see 8 7 1 1 2 Remove the casing parts see 9 2 1 3 Remove the control unit see 9 2 3 1 Li 4 Remove the screws 4 NOTE A total of 9 screw heads are visible on the combustion air fan 5 Fig 30 Of these the 5 outer screws are used to attach the combustion air fan to the heat exchanger 7 Only these screws should be removed 5 Remove the combustion air fan 5 from the heat exchanger 7 remove the seal 6 and dispose of it separately 6 Complete the work on stripped down components see 9 1 1 9 2 5 2 1 Ensure that the sealing surfaces on the combustion fan 5 Fig 30 and on the heat exchanger 8 are not damaged INSTALLATION 2 Fit a new seal 7 on the flange of the combustion air fan 5 www techwebasto com AIR TOP 2000 ST 0o ouv A Bring the combustion air fan 5 into the assembly position and secure with screws 4 attaching the electrical bonding of t
61. the risk of the heater overheating and the overheating guard thus being tripped If you wish to carry out extensive repair work on the heater it may be a good idea to remove it completely Refer to the relevant installation instructions and the installation proposal for the heater for the specific vehicle for repairs that necessitate the installation position being changed 8 3 WORK ON THE VEHICLE CAUTION A temperature of 85 C 185 F A must not be exceeded in the vicinity of the heater in any circumstances for example when completing painting work on the vehicle 8 4 HEATER TRIAL WARNING The heater must not be A operated in enclosed areas such as garages and workshops without an emissions extraction system even if the heater is equipped with a timer CAUTION The heater must not be operated without the cover for the control unit as this will cause it to overheat 8 5 SERVICING WORK NOTE The heater should be operated for n approximately 20 minutes every 4 weeks to prevent mechanical parts seizing The heater requires no servicing However it should be checked at regular intervals at the latest at start of the heating period the time after which the heater will be used due to adverse weather conditions by Webasto trained personnel www webasto us SERVICING WORK The following servicing work is to be carried out to maintain the functional reliability of the heater e Check the hot air inlet and outl
62. the temperature sensor B4 2 2 i i 1 0 mm 1 5 mm gn Green 6 NOTE Typical Connection for Trucks 15 2 25 mm G f this connection is made to battery positive terminal 30 permanent heating is possible with the TI 2 9r rey ignition switched off In this case no connection must be made to terminal 15 75 2 5 mm 4 0 mm or Orange 2 NOTE Typical Connection for Buses 4 0 mm 6 0 mm rt Red With positive from terminal 15 75 to connection 10 000000000 o Standard cable SW Black Permanent operation for immediate heat as long as the ignition is switched on Without positive at connection 10 VI Violet Heating time is variably programmable 10 min to 120 min default setting 120 min WS White Item Designation Comment Item Designation Comment Al Heater Air Top 2000 ST R1 Resistor 620 Q With internal temperature sensor A2 Control unit only B1 Flame sensor Gasoline heaters only S1 Control element Switch and temperature control B2 Temperature sensor Internal S4 Switch optional Ventilation B3 Overheating sensor Overheating guard S6 Switch CO setting BA Temperature sensor External x1 Plug connector 4 pin to item A2 E Ceramic glow pin x2 Plug connector 2 pin to item A2 F1 Fuse 15A max 20A Flat fuse SAE J 1284 x3 Plug connector 2 pin to item A2 F2 Fuse max 15 A Flat fuse SAE J 1284 X4 Plug connector 2 pin o item A2 H1 LED green in item S1 Indicator X5 Plug connector 2 pin to item A2 H3
63. the vehicle The hot and combustion air intake openings must be positioned in such a way that no water can ingress into them if the vehicle drives through a water hazard for which it has been approved For passenger carrying vehicles such as shuttle busses transit busses and coaches where the heater is to be installed in the passenger cabin a protective cover or installation box should be installed over the heater to prevent contact with hot surfaces by passengers and heat sensitive objects The protective cover or installation box must have sufficient external ventilation to ensure that a maximum temperature of 40 C 104 F is not exceeded in the box Malfunctions may occur if the temperature exceeds this evel The heater must be switched off at filling stations and fuel tank farms because of the risk of explosion Wherever inflammable vapors or dust may form for example near fuel coal wood dust or cereal stores or the ike the heater must be switched off because of the risk of explosion The heater must not be operated in enclosed areas such as garages or workshops without an exhaust emissions extraction system not even using the timer because of the risk of asphyxiation and poisoning In the event of lengthy heavy smoke development unusual combustion noise or a smell of fuel the heater must be put out of action by removing the fuse and must not be started again until it has been examined by Webasto trained perso
64. use and reinsert it Webasto Product N A Inc FUNCTIONAL DESCRIPTION AIR TOP 2000 ST This page for your notes Webasto Product N A Inc 12 www techwebasto com AIR TOP 2000 ST 4 TECHNICAL DATA Except where limit values are specified the technical data listed in the table refer to the usual heater tolerances of 10 at an ambient temperature of 20 C 68 F and at the rated voltage and in rated conditions Electrical components The control unit combustion air blower drive metering pump timer glow plug and control element are designed for 12 V or 24 V The components temperature sensor and flame monitor only petrol heater are not designed for a specific voltage Fuel for Air Top 2000 ST B gasoline The fuel specified by the manufacturer must be used TECHNICAL DATA Fuel for Air Top 2000 ST D diesel PME The diesel fuel specified by the vehicle manufacturer must be used We know of no negative influences due to additives If fuel is extracted from the vehicle s tank follow the additive instructions issued by the vehicle manufacturer If you change to low temperature fuel the heater must be operated for approx 15 minutes so that the fuel system is filled with the new fuel The Air Top 2000 ST D heater is also licensed for use with PME bio diesel which complies with ASTM D6751 and DIN EN 14214 HEATER Operation AT 2000 ST B AT 2000 ST D Type Test Perm

Air Top 2000 ST B

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