Webasto Air Top 2000 ST B User manual

Luftheizgeräte
Air Heaters
Luchtverwarmingssystemen
05/2008
9010298C
Einbauanweisung
Installation Instructions
Montagehandleiding
Air Top 2000 ST
Handelsbezeichnungen/Trade names/Handelsnamen:
Air Top 2000 ST B (Benzin/Petrol/benzine)
Air Top 2000 ST D (Diesel/PMU)

Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer
verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder
tödliche Verletzungen hervorgerufen werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines
Webastotrainings, technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
Versuchen Sie NIEMALS, Webasto Heiz- oder Kühlsysteme einzubauen oder zu reparieren, wenn Sie
das Webastotraining nicht erfolgreich abgeschlossen und dabei die notwendigen technischen
Fähigkeiten erworben haben und die für einen sachgerechten Einbau und Reparatur nötigen
technischen Dokumentationen, Werkzeuge und Ausrüstungen nicht zur Verfügung stehen.
Befolgen Sie IMMER alle Webasto Einbau- und Reparaturanleitungen, und beachten Sie alle
Warnhinweise.
Webasto übernimmt keine Haftung für Mängel und Schäden, die auf einen Einbau durch ungeschultes
Personal zurückzuführen sind.
Improper installation or repair ofWebasto heating and cooling systems can cause fire or the leakage of
deadly carbon monoxide leading to serious injury or death.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto
training course and have the appropriate technical documentation, special tools and special equipment.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto
training course, you do not have the necessary technical skills and you do not have the technical
documentation, tools and equipment available to ensure that you can complete the installation and
repair work properly.
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
I
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . 1
2 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 4
3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Fabrikschild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Einbaubeispiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Heizluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Abgasleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10 Brennluftansaug- und Abgasleitungen . . . . . . . . . . . . . . 19
11 Elektrische Anschlüsse. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12 Legende für Schaltpläne . . . . . . . . . . . . . . . . . . . . . . . . . . 29
13 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
14 Störabschaltung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
15 Technische Daten. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
16 Ausführung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Bohrschablone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table of contents
1 Statutory regulations governing installation . . . . . . . . . . 39
2 Use of the air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Factory plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10 Combustion air inlet and exhaust lines . . . . . . . . . . . . . . 57
11 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12 Legend for circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . 67
13 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
14 Fault lock-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
16 Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
17 Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Air Top 2000 ST Statutory regulations governing installation
39
1 Statutory regulations governing installation
1.1. Statutory regulations governing installation
The Air Top 2000 ST heater unit has been type- tested and approved in
accordance with Directives 72/245/EEC (EMC), 2001/56/EC (heater)
and ECE R122 with the following permit numbers:
e1*72/245*95/54*1085*00
e1*2001/56*0022*00
E1*R122 00 0216*--
Primarily the regulations of Annex VII of the Directive 2001/56/EG and
Part 2 or Annex 7 of the directive ECE R122 must be observed for the
installation.
NOTE:
The provisions of these Directives are binding within the territory
governed by EU Directive 70/156/EEC and should similarly be
observed in countries without specific regulations.
IMPORTANT
Failure to follow the installation 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 will result in the invalidation of the type
approval for the heater and therefore of its homologation / EC/ECE type
licence.
(Extract from Directive 2001/56/EC Annex VII and ECE R122 Part 2
and Annex 7)
1.7.1. / 7.1. A clearly visible tell-tale in the operator's field of view shall
inform when the combustion heater is switched on or off.
2. / 5.3. Vehicle installation requirements
2.1. / 5.3.1. Scope
2.1.1. / 5.3.1.1. Subject to paragraph 2.1.2 / 5.3.1.2 combustion heaters
shall be installed according to the requirements of this Annex/Article.
2.1.2/ 5.3.1.2. Vehicles of category O (trailers) having liquid fuel heaters
are deemed to comply with the requirements of this Annex/Article.
2.2. / 5.3.2. Positioning of heater
2.2.1. Body sections and any other components in the vicinity of the
heater must be protected from excessive heat and the possibility of fuel
or oil contamination.
2.2.2 / 5.3.2.2. The combustion heater shall not constitute a risk of fire,
even in the case of overheating. This requirement shall be deemed to
be fulfilled if the installation ensures an adequate distance to all parts
and suitable ventilation, by the use of fire resistant materials or by the
use of heat shields.
2.2.3 / 5.3.2.3. In the case of M2 and M3 vehicles, the heater must not
bepositionedinthepassengercompartment. However, an installationin
an effectively sealed envelope which also complies with the conditions
in paragraph 2.2.2 / Article 5.3.2.2 may be used.

Statutory regulations governing installation Air Top 2000 ST
40
2.2.4 / 5.3.2.4. The label referred to in paragraph 1.4 / annex 7 / article
1.4 (model plate), or a duplicate (duplicate model plate), must be
positioned so that itcan be easily read when the heater is installed in the
vehicle.
2.2.5 / 5.3.2.5 Every reasonable precaution should be taken in
positioning the heater to minimise the risk of injury and damage to
personal property.
2.3. / 5.3.3. Fuel supply
2.3.1 / 5.3.3.1. The fuel filler must not be situated in the passenger
compartment and must be provided with an effective cap to prevent fuel
spillage.
2.3.2/5.3.3.2.Inthe case of liquidfuelheaters,wherea supplyseparate
to that of the vehicle is provided, the type of fuel and its filler point must
be clearly labelled.
2.3.3 / 5.3.3.3. A notice, indicating that the heater must be shut down
before refuelling, must be affixed to the fuelling point. In addition a
suitable instruction must be included in the manufacturer's operating
manual.
2.4. / 5.3.4. Exhaust system
2.4.1 / 5.3.4.1. The exhaust outlet must be located so as to prevent
emissionsfrom entering the vehicle through ventilators, heated air inlets
or opening windows.
2.5. / 5.3.5. Combustion air inlet
2.5.1 / 5.3.5.1. The air for the combustion chamber of the heater must
not be drawn from the passenger compartment of the vehicle.
2.5.2 / 5.3.5.2. The air inlet must be so positioned or guarded that
blocking by rubbish or luggage is unlikely.
2.6. / 5.3.6. Heating air inlet
2.6.1 / 5.3.6.1. The heating air supply may be fresh or recirculated air
and must be drawn from a clean area not likely to be contaminated by
exhaust fumes emitted either by the propulsion engine, the combustion
heater or any other vehicle source.
2.6.2 / 5.3.6.2. The inlet duct must be protected by mesh or other
suitable means.
2.7. / 5.3.7. Heating air outlet
2.7.1 / 5.3.7.1. Any ducting used to route the hot air through the vehicle
must be so positioned or protected that no injury or damage could be
caused if it were to be touched.
2.7.2 / 5.3.7.2. The air outlet must be so positioned or guarded that
blocking by rubbish or luggage is unlikely.
2.8. / 5.3.8.1. Automatic control of the heating system
The heating system must be switched off automatically and the supply
of fuel must be stopped within five seconds when the vehicle's engine
stops running. If a manual device is already activated, the heating
system can stay in operation.
NOTE:
Contrary to point 2.2.3 / 5.3.2.3 the heater must also not be installed in
the passenger cabin of class M1 and N vehicles. However, an
installation in an effectively sealed envelope which also complies with
the conditions in paragraph 2.2.2 / section 5.3.2.2 may be used.

Air Top 2000 ST Statutory regulations governing installation
41
(Extract from Directive 2001/56/EC Annex IX)
3. Technical specifications for heater units for installation in
dangerous goods transporters (Annex 9)
3.1. General (EX/II, EX/III, AT, FL and OX vehicles)
3.1.1. The combustion heaters and their exhaust gas routing shall be
designed, located, protected or covered so as to prevent any
unacceptable risk of heating or ignition of the load. This requirement
shall be considered as fulfilled if the fuel tank and the exhaust system of
the appliance conform to the provisions set out in the points 3.1.1.1 and
3.1.1.2. Compliance with those provisions shall be verified on the
completed vehicle.
3.1.1.1. Any fuel tanks for supplying the appliance shall meet the
following requirements:
a)in the event of any leakage, the fuel shall drain to the ground
without coming into contact with hot parts of the vehicle or the
load;
b)fuel tanks containing petrol shall be equipped with an
effective flame trap at the filler opening or with a closure
enabling the opening to be kept hermetically sealed.
3.1.1.2. The exhaust system as well as the exhaust pipes shall be so
directed or protected to avoid any danger to the load through heating or
ignition. Parts of the exhaustsystem situated directly below the fuel tank
(diesel) shall have a clearance of at least 100 mm or be protected by a
thermal shield.
3.1.2. The combustion heater shall be switched on manually.
Programming devices shall be prohibited.
3.2. EX/II and EX/III vehicles
Combustion heaters using gaseous fuels are not permitted.
3.3. FL vehicles
3.3.1. The combustion heaters shall be put out of operation by at least
the following methods:
a)intentional manual switching off from the driver’s cab;
b)stopping of the vehicle engine; in this case the heating device
may be restarted manually by the driver;
c) start-up of a feed pump on the motor vehicle for the
dangerous goods carried.

Use of the air heaters Air Top 2000 ST
42
2 Use of the air heaters
The Webasto Air Top 2000 ST air heaters are designed
– to heat cabins, boats, trucks, minibuses, vans and motorhomes
– to defrost vehicle windows
The heaters operate independently of the engine and are connected to
the fuel tank and the electrical system of the vehicle.
They may be used for vehicles with either water or air-cooled engines.
They are not designed for heating hazardous substances.

Air Top 2000 ST Installation
43
3 Installation
IMPORTANT
The statutory regulations governing installation on pages 1 and 2 must
be adhered to. The requirements of the latest version of the ADR must
also be observed for the installing the heater into vehicles used to
transport hazardous substances.
The heater must not be operated without the control unit cover (this will
cause the heater to overheat).
3.1. Air Top 2000 ST installation situation
NOTE:
Check the installation situation of the relevant vehicle type.
3.2. Installation location
The heater may be fitted both in the interior or on the exterior of the
vehicle.
If it is installed on the exterior ensure that the heater is fitted in a position
where it is protected from splashing water and spray.
Fig. 1: Dimensions of the heater
1 Hot air inlet
2 Hot air outlet
3 Combustion air intake
4 Exhaust fume outlet
5 Fuel intake
6 Space requirement for hot air inlet
7 Space requirement for removing the heater
8 Cable outlet (either right or left)
12
354
7
8
6

Installation Air Top 2000 ST
44
Theheatermustbeinstalled in suchawaythatnowatercaningressinto
it if the vehicle travels through a water hazard for which that vehicle is
licensed.
The openings for the combustion air inlet port, the exhaust outlet port
and the fuel pipe must be sealed if the heater is installed in the interior.
The seal designed and supplied for this purpose must be used (see
Figure 4).
We recommend that petrol heaters be installed with the exhaust port
pointing vertically downwards.
3.3. To install the heater
TheM6nutsmustbetightenedwitha torque of6Nm+1 Nm for installing
the Air Top 2000 ST heater.
The installation dimensions and space requirement for service access
are shown in the installation drawing (Figure 1). The specified horizontal
and axial angles must not be exceeded (Figure 2).
Aseal(Figure4)mustbefittedbetweentheheaterandthevehiclebody.
This seal must be replaced each time the heater is installed. The
support area for the heater foot must be flat.
A special tools can be purchased from Webasto to drill the holes and, if
necessary, smooth the support area. The seal can compensate for
unevenness of max. 1 mm.
Fig. 2: Recommended installation positions for diesel heaters
Fig. 3: Hole pattern
Fig. 4: Seal
44
ø26 ø26
12
55
18
ø7,5
ø7,5
ø7,5

Air Top 2000 ST Installation
45
IMPORTANT
After installation, check that the casing is not in contact with any parts of
thevehiclebody.A failure todo thismayresultinthehotairfanblocking.
Fig. 5: Installation
Ensure that all moving parts can move ea

Factory plate Air Top 2000 ST
46
4 Factory plate
The model plate must be positioned so that it cannot be damaged and
must be clearly legible when the heater is installed (otherwise a
duplicate model plate must be used).
Inapplicable years must be erased from the model plate.

Air Top 2000 ST Installation example
47
5 Installation example
Fig. 6: Installation example for air heater in recirculation mode
1 Control element
2 Heater
3 Metering pump
4 Fuel filter (accessory)
5 Tank connector
6 Exhaust silencer (accessory)
7Fuse
Maximum
water passage height
1
2
3
5
4
7
6

Hot air system Air Top 2000 ST
48
6 Hot air system
NOTE:
The heater must not be integrated into the vehicle’s air system.
Both recirculation and fresh air modes are possible.
For fresh air mode it must be ensured that the hot air is taken from an
area protected from splashing water and spray and in such a way that
nowatercaningressintotheheaterifthevehicletravelsthroughawater
hazard for which that vehicle is licensed.
NOTE:
For fresh air mode an external temperature sensor must be fitted in the
appropriate zone.
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 temperatures and the position
of the setpoint generator. The heat output is controlled such that after
the selected interior temperature has been reached quickly, it is then
kept at this selected value.
The internal diameter of the main section of the hot air line should be
60 mm.
NOTE:
Only materials that can permanently withstand temperatures of at least
130 °C may be used for the hot air line. The hot air opening is to be
positioned in such a way that the air is not blown on to any parts that
cannot withstand the heat.
IMPORTANT
In vehicles used to transport people, the air outlet opening is to be
directed in such a way that it is at least 20 cm away from all body parts.
Maximum pressure drop between the inlet and outlet side of the hot air
line:
Air Top 2000 ST 1.5 hPa
1 hPa corresponds to 1 mbar corresponds to 10mm WC (water column).
The heaters check the internal temperature rise automatically each time
they are 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.
The hot air hose must be secured at its connection points.
If the heater is used in recirculation mode without a hot air guide, do not
short circuit the hot air flow.
Fig. 7: Hot air inlet and hot air outlet

Air Top 2000 ST Hot air system
49
IMPORTANT
If you use the heater without a hot air inlet hose, the inlet grille supplied
with the heater must be used at all times.
NOTE:
The installation must be checked for:
– Air short circuit between the vehicle’s heating system and the heater
air inlet
– Air short circuit between the heater’s air inlet and the heater’s air
outlet (Figure 7)
If you use an installation box the air vent must be sealed in such a way
that no hot air can get into the installation box.
6.1. External temperature sensor
The installation of an external temperature sensor is recommended if
the heater is operated in fresh air mode.
6.1.1. To install the external temperature sensor
The external temperature sensor must be installed at medium height in
the passenger cabin on vertical surfaces if possible in the area that
requires heating.
The temperature sensor must not
– be in the direct current of hot air (from the vehicle’s own heating
system or the hot air heater).
– by close to heat sources (for example the vehicle’s own heating
system).
– be placed in direct sunlight (for example on the dashboard).
– be installed behind curtains or the like.
Fig. 8: Hot air inlet with inlet grille

Fuel supply Air Top 2000 ST
50
7 Fuel supply
The fuel is taken from the vehicle fuel tank or from a separate fuel tank.
The values for the maximum pressure at the fuel extraction point are
shown in Figure 9.
Only for ADR: The statutory regulation of ADR (Accord européen relatif
au transport international des marchandises dangereuses par route)
governing fuel tanks, part 9 para. 9.2.4.7, must be adhered to.
A sign must be affixed to the fuel filler neck warning that the heater must
be switched off before refuelling. .
Permissible fuel inflow
height H (m) At max. perm. pressure (bar) in fuel line
0.00 0.2
1.00 0.11
2.00 0.03
Maximum fuel intake
height S (m) At max. perm. negative pressure (bar) in the fuel tank
0.00 -0.10
0.50 -0.06
1.00 -0.02
Fig. 9: Fuel supply
l1+ l2≤10 m
l2≤1.2 m
l2≤8.8 m

Air Top 2000 ST Fuel supply
51
7.1. Vehicles with carburettor engines
The fuel may only be extracted using the special Webasto fuel extractor
(see Figure 10) as close to the tank as possible. The connect may be
made in either the supply or return line, in which case the return line
must lead almost to the base of the tank (see Figure 11).
The fuel extractor must be fitted in such a way that any air or gas
bubbles are automatically discharged towards the tank (see Figure 10).
Thefuelextractorshould not be located near the engine, asgasbubbles
may form in the lines on account of heat radiated from the engine. This
may cause problems during combustion.
7.2. Vehicles with injection engines
When installing the heater in a vehicle with fuel injection system, it is
important to establish whether the fuel pump is located inside or outside
the tank.
Ifthefuelpumpislocatedinsidethe tank,fuelcanonly be extracted from
the return line using the Webasto fuel extractor (see Figure 10),in which
case it must be ensured that the return line continues almost to the
bottom of the tank (see Figure 11 for details of the minimum distance
fromthebottom ofthe tank).IfthisisnotthecaseWebastofuelextractor
(see Figure 11, 12 and 13) may be used.
If the fuel pump is installed outside the tank, the fuel connection may
also be made between the tank and the fuel pump, again using only the
Webasto fuel extractor (see Figure 10).
7.3. Vehicles with diesel engines
The fuel must be taken from the vehicle fuel tankor from a separate tank
(see Figs. 10,11 and 12). This separate fuel pickup precludes any effect
of pressure.
Fig. 10: Webasto fuel extractor
to metering pump
to engine
from tank
Fig. 11: Webasto tank connector
Hole pattern
Minimum distance 25 mm
Only use a tank connector if the fuel
tank is made from metal

Fuel supply Air Top 2000 ST
52
NOTE:
The tank fitting must be made from metal!
7.4. Fuel lines
Only steel, copper and plastic lines of plasticised, light and temperature-
stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378
may be used for the fuel lines.
Sincethelinesnormallycannot beroutedwitha constantrisinggradient,
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 whilst the heater is
operating if the lines sag or are routed downwards. The diameters
specified in Figure 9will 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 chippings and high temperatures (exhaust line).
The fuel lines must be secure at the connections using hose clips to
prevent their slipping.
Fig. 12: Fuel pickup from the plastic tank
(Pickup via tank drain screw)
Fig. 13: Fuel pickup from the plastic tank
(Pickup via tank fitting)
Sealing ring
Plastic tank
Sealing ring
Fuel extractor
Tank fittings

Air Top 2000 ST Fuel supply
53
7.4.1. Connecting two pipes with a hose
The correct procedure for connecting fuel lines with hosing is illustrated
in Fig. 14.
Ensure that there are no leaks.
7.5. Metering pump
Themetering pump is a combineddelivery, metering and shutoff system
and is subject to specific installation criteria (see Figs. 9and 15).
Installation location
Itisadvisabletoinstallthe metering pump in a cool place. The maximum
ambient temperature must not exceed +20 °C for petrol heaters 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.
7.5.1. Installation and attachment
The metering pump must be secured with a vibration-damping
mounting. Its installation position is limited as shown in Fig. 15 in order
to ensure effective auto-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.
Fig. 14: Pipe / hose connection
Clip
Bubble
Correct
Wrong
Bubble
Fig. 15: Metering pump DP2 / DP30.2
Installation position
Air Top 2000 ST
12 V and 24 V - petrol and diesel (with damper)

Fuel supply Air Top 2000 ST
54
7.6. Fuel filter
Only a Webasto filter, order no. 487 171, is allowed to be used if the fuel
is expected to be contaminated. Install vertically if possible, however at
least horizontally (check flow direction).
Fig. 16: Fuel filter
0° - 90°

Air Top 2000 ST Combustion air supply
55
8 Combustion air supply
Under no circumstances may the combustion air be taken from areas
occupied by people. The combustion air intake opening must not point
in the direction of travel. It must be located so that it cannot become
clogged with dirt.
NOTE:
An intake silencer must be fitted if the intake hose length is greater than
0.6 m.
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.
Do not use an exhaust line as the combustion air line since otherwise
the metering pump cable from the combustion air inlet port may be
damaged.
The combustion air opening must not be under the minimum water
drive-through level permitted for the vehicle.
See the statutory regulations for the installation for further regulations.