Webasto Air Top 2000 ST B User manual

Luftheizgeräte
Air Heaters
Luchtverwarmingsapparaten
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/PME)
AT2000ST_Installation_Instructions.book Page 1 Wednesday, May 29, 2013 12:54 PM

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.
Es dürfen nur Originalteile von Webasto verwendet werden. Siehe dazu auch Zubehörkatalog Luft- und
Wasserheizgeräte von Webasto.
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 of Webasto 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.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
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.
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Air Top 2000 ST
I
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau .............1
2 Verwendung der Luftheizgeräte .....................5
3 Einbau ...........................................6
4 Typschild.........................................9
5 Einbaubeispiel ...................................10
6 Heizluftsystem ...................................11
7 Brennstoffversorgung .............................13
8 Brennluftversorgung ..............................18
9 Abgasleitung ....................................19
10 Brennluftansaug- und Abgasleitungen ...............20
11 Elektrische Anschlüsse.............................22
12 Anschlussschema / Schaltplan ......................25
13 Legende für Schaltpläne ..........................30
14 Erstinbetriebnahme ...............................32
15 Störabschaltung ..................................33
16 Technische Daten .................................35
17 Ausführung...................................... 37
18 Bohrschablone ...................................38
Table of Contents
1 Statutory regulations governing installation ...........39
2 Use of the air heaters ..............................43
3 Installation.......................................44
4 Type label .......................................47
5 Installation example ...............................48
6 Hot air system ....................................49
7 Fuel supply ......................................51
8 Combustion air supply .............................56
9 Exhaust pipe .....................................57
10 Combustion air inlet and exhaust lines................58
11 Electrical connections ..............................60
12 Connection diagram/Circuit diagram .................63
13 Legend for circuit diagrams .......................68
14 Initial start-up ....................................70
15 Fault lock-out ....................................71
16 Technical data ....................................73
17 Version..........................................75
18 Drilling template..................................76
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Air Top 2000 ST Statutory regulations governing installation
39
1 Statutory regulations governing installation
Type approvals according to ECE-R 10 (EMC) and ECE-R 122 (Heater) exist
for the Air Top 2000 ST heater.
See chapter 16, "Technical data" for the approval number.
Primarily the regulations of Part I and Annex 7 of the directive ECE-R 122
must be observed for the installation.
NOTE:
The specifications of this Directive are binding in the scope of the
Basic Directive EEC/70/156 and/or EC/2007/46 (for new vehicle
models from 29/04/2009) and should also be observed in countries
in which no special regulations exist.
See chapter 1.2, "Extract of the directives 2001/56/EG Annex VII and
ECE R122 Part I and Annex 7" and chapter 1.3, "Extract of the direc-
tives 2001/56/EG Annex IX and ECE R122 Annex 9".
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 gen-
uine spare parts. This will result in the invalidation of the type approval for
the heater and therefore of its homologation/ECE type licence.
1.1. Application of combustion heaters in vehicles for transport-
ing dangerous goods
Vehicles for the purpose of transporting dangerous goods will be type test-
ed in accordance with the standard ECE R105. The following measures are
derived for our combustion heaters:
• The electrical cable/wiring harness must be sufficiently dimensioned to
prevent overheating. The electrical cable/wiring harness must be suffi-
ciently insulated. All power circuits must be protected with fuses or au-
tomatic circuit-breakers.
• The cables must be securely fastened and routed so that they are suffi-
ciently protected against mechanical and thermal loading.
• The combustion heaters must be type-tested in accordance with the
standard ECE R122 (equivalent to EC/2001/56 in the version EC/2006/
119) and comply with the Appendix 9 – Additional regulations for ve-
hicles for transporting dangerous goods.
• The combustion heaters and their exhaust gas routing shall be de-
signed, located, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load.
• In the event of any leakage of the fuel line, the fuel shall drain to the
ground without coming into contact with hot parts of the vehicle or the
load;
• 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 exhaust system situated directly below the fuel tank shall
have a clearance of at least 100 mm or be protected by a thermal shield.
• The combustion heater may only be switched on manually. Program-
ming devices shall be prohibited. The combustion heater may be
switched on again manually after the vehicle engine has been switched
off.
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Statutory regulations governing installation Air Top 2000 ST
40
Requirement for basic unit:
A maximum run-on period of 40 seconds is permitted when the combus-
tion heater is switched off. Only combustion heaters with heat exchangers
that are approved for this reduced run-on time of 40 seconds may be used.
1.2. Extract from directive ECE-R 122 Part I and Annex 7
Start of extract.
Part I
5.3 Vehicle Installation Requirements for Combustion Heaters and
for Electric Heaters
5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2, heaters shall be installed according
to the requirements of paragraph 5.3.
5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to
comply with the requirements of paragraph 5.3.
5.3.2 Positioning of heater
5.3.2.1 Body sections and any other components in the vicinity of the heat-
er must be protected from excessive heat and the possibility of fuel or oil
contamination.
5.3.2.2 The heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be met 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.
5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must
not be positioned in the passenger compartment. However, an installation
in an effectively sealed envelope which also complies with the conditions
in paragraph 5.3.2.2 may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 4, or a duplicate, must
be positioned so that it can be easily read when the combustion heater is
installed in the vehicle.
5.3.2.5 Every reasonable precaution should be taken in positioning the
heater to minimize the risk of injury and damage to personal property.
5.3.3 Fuel supply
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.
5.3.3.2 In the case of liquid fuel heaters, where a supply separate from that
of the vehicle is provided, the type of fuel and its filler point must be clearly
labelled.
5.3.3.3 A notice, indicating that the heater must be shut down before re-
fuelling, must be affixed to the fuelling point. In addition a suitable instruc-
tion must be included in the manufacturer’s operating manual.
5.3.4 Exhaust system
5.3.4.1 The exhaust outlet must be located so as to prevent emissions from
entering the vehicle through ventilators, heated air inlets or opening win-
dows.
5.3.5 Combustion air inlet
5.3.5.1 The air for the combustion chamber of the heater must not be
drawn from the passenger compartment of the vehicle.
5.3.5.2 The air inlet must be so positioned or guarded that blocking by rub-
bish or luggage is unlikely.
5.3.6 Heating air inlet
5.3.6.1 The heating air supply may be fresh or re-circulated 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.
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Air Top 2000 ST Statutory regulations governing installation
41
5.3.6.2 The inlet duct must be protected by mesh or other suitable means.
5.3.7 Heating air outlet
5.3.7.1 Any ducting used to route the hot air through the vehicle must be
so positioned or protected that no injury or damage could be caused if it
were to be touched.
5.3.7.2 The air outlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.8 Automatic control of the heating system
5.3.8.1 The heating system must be switched off automatically and the
supply of fuel must be stopped within five seconds when the vehicle’s en-
gine stops running. If a manual device is already activated, the heating sys-
tem can stay in operation.
ANNEX 7
ADDITIONAL REQUIREMENTS FOR COMBUSTION HEATERS
7 Warning light
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.
End of extract.
NOTE:
Contrary to point 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 5.3.2.2 may be used.
1.3. Extract from directive ECE-R 122 Annex 9
Start of extract.
Additional provisions applicable to certain vehicles as specified in the ADR.
3. Technical Provisions
3.1 General (EX/II, EX/III, AT, FL, OX and MEMU vehicles)
3.1.1 [1] The combustion heaters and their exhaust gas routing shall be de-
signed, 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 following provisions:
- 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 effec-
tive flame trap at the filler opening or with a closure enabling
the opening to be kept hermetically sealed.
- 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 ig-
nition. Parts of the exhaust system situated directly below the fuel
tank (diesel) shall have a clearance of at least 100 mm or be protect-
ed by a thermal shield.
3.1.2 The combustion heater shall be switched on manually. Programming
devices shall be prohibited.
3.2 EX/II, EX/III and MEMU vehicles
Combustion heaters using gaseous fuels are not permitted.
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Statutory regulations governing installation Air Top 2000 ST
42
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 danger-
ous goods carried.
[1] Compliance with this paragraph shall be verified on the completed ve-
hicle.
End of extract.
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Air Top 2000 ST Use of the air heaters
43
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 direct-
ly 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.
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Installation Air Top 2000 ST
44
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 haz-
ardous 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 vehi-
cle.
When using the vehicle in normal road traffic, the heater may only be in-
stalled with contact protection if it is located within reach of the driver.
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.
The heater must be installed in such a way that no water can ingress into
it if the vehicle travels through a water hazard for which that vehicle is li-
censed.
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 3).
3.3. To install the heater
The M6 nuts must be tightened with a torque of 6 Nm +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).
A seal (Figure 3) must be fitted between the heater and the vehicle body.
This seal must be replaced each time the heater is installed. The sup-
port area for the heater foot must be flat. A special tools can be pur-
chased from Webasto to drill the holes and, if necessary, smooth the sup-
port area. The seal can compensate for unevenness of max. 1 mm.
IMPORTANT
After installation, check that the casing is not in contact with any parts of
the vehicle body. A failure to do this may result in the hot air fan blocking.
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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
Air Top 2000 ST Installation
45
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Fig. 2: Permitted installation positions for heaters
Air Top 2000 ST - diesel:
Air Top 2000 ST - petrol: horizontally Fig. 3: Seal
Fig. 4: Installation
Ensure that all moving parts can move easily!
Installation Air Top 2000 ST
46
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Air Top 2000 ST Type label
47
4 Type label
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.
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Installation example Air Top 2000 ST
48
5 Installation example
Fig. 5: Installation example for air heater in recirculation mode
1 Control element
2 Heater
3 Metering pump
4 Fuel filter (accessory)
5 Tank connector
6 Exhaust silencer (accessory)
7 Fuse
Maximum
water passage height
1
2
3
5
4
7
6
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Air Top 2000 ST Hot air system
49
6 Hot air system
NOTE:
The heater must not be integrated into the vehicle’s air 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 temperatures and the position of the set-
point generator. The heat output is controlled such that after the selected
interior temperature has been reached quickly, it is then kept at this select-
ed value.
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 no water
can ingress into the heater if the vehicle travels through a water hazard for
which that vehicle is licensed.
NOTE:
For fresh air mode an external temperature sensor must be fitted in the ap-
propriate zone.
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 posi-
tioned 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 can-
celled and error messages F10 is displayed. To ensure that the heater func-
tions stably, the flow resistance of the connected hot air system must be
reduced.
The points table for air guide parts in the Webasto catalogue may be used
to design the hot air system.
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. 6: Hot air inlet and hot air outlet
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Hot air system Air Top 2000 ST
50
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 6)
Fig. 7: Hot air inlet with inlet grille
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
For fresh air mode an external temperature sensor must be fitted in the ap-
propriate zone.
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.
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Air Top 2000 ST Fuel supply
51
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 8.
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 pres-
sure (bar) in the fuel tank
0,00 -0,10
0,50 -0,06
1,00 -0,02
Only for ADR: The statutory regulation of ADR (Accord européen relatif au
transport international des marchandises dangereuses par route) govern-
ing fuel tanks, part 9 paragraph 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.
Fig. 8: Fuel supply
l1+l
2d10 m
l1d1.2 m
l2d8.8 m
.
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Fuel supply Air Top 2000 ST
52
7.1. Vehicles with carburettor engines
The fuel may only be extracted using the special Webasto fuel extractor
(see Figure 9) 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 10).
The fuel extractor must be fitted in such a way that any air or gas bubbles
are automatically discharged towards the tank (see Figure 9).
Fig. 9: Webasto fuel extractor
to metering pump
to engine
from tank
The fuel extractor 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.
7.2. Vehicles with injection engines
When installing the heater in a vehicle with fuel injection system, it is im-
portant to establish whether the vehicles 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 the Webasto fuel extractor (see Figure 9), in which
case it must be checked to ensure that the fuel return pipe in the tank ter-
minates near the bottom of the fuel tank (see Figure 10 for details of the
minimum distance from the bottom of the tank). If this is not the case We-
basto fuel extractor (see Figure 10, 11 and 12) 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 We-
basto fuel extractor (see Figure 9).
7.3. Vehicles with diesel engines
The fuel must be taken from the vehicle fuel tank or from a separate tank
(see Figs. 9, 10 and 11). This separate fuel pick-up precludes any effect of
pressure.
Fig. 10: Webasto tank connector
Hole pattern
Minimum distance 25 mm
Only use a tank connector if the fuel
tank is made from metal
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Fig. 11: Fuel pick-up from the plastic tank
(Pick-up via tank drain screw)
Sealing ring
Plastic tank
Fig. 12: Fuel pick-up from the plastic tank
(Pick-up via tank fitting)
Sealing ring
Tank connector
Tank fitting
Air Top 2000 ST Fuel supply
53
NOTE:
The tank fitting must be made from metal!
7.4. Fuel lines
Only steel, copper and plastic lines of plasticised, light and temperature-
stabilised PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may
be used for the fuel lines.
Since the lines normally cannot 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 whilst the heater is operating if
the lines sag or are routed downwards. The diameters specified in Figure 8
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
chippings and high temperatures (exhaust line).
The fuel lines must be secure at the connections using hose clips to prevent
their slipping.
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Fuel supply Air Top 2000 ST
54
7.4.1. Connecting two pipes with a hose
The correct procedure for connecting fuel lines with hosing is shown in Fig-
ure 13.
Ensure that there are no leaks.
Fig. 13: Pipe / hose connection
Clip
Bubble
Correct
Wrong
Bubble
7.5. Metering pump
The metering pump is a combined delivery, metering and shut-off system
and is subject to certain installation criteria (see Figures 8, 14 and 15).
Fig. 14: Metering pump DP 2 with damper
Installation position
Air Top 2000 ST 12 V - petrol
Preferably
15° - 90°
Installation posi-
tion of damper
Metering
pump
Fig. 15: Metering pump DP 30.2
Installation position
Air Top 2000 ST
12 V and 24 V - diesel
Installation
position of
damper
Horizontal installation
7.5.1. Installation location
The metering pump must be installed in a cool place as close as possible to
the tank (see Figure 8). The maximum ambient temperature must not ex-
ceed +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 neces-
sary.
AT2000ST_Installation_Instructions.book Page 54 Wednesday, May 29, 2013 12:54 PM