Webasto AT2000STC User manual

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AirTopInstallationGuide‐AT2000STC
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WebastoAirTopInstallationGuide–AT2000STC
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2
AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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GeneralInformation
WebastoThermo&ComfortAustraliaPtyLtdispleasedtoprovidethisinstallationguidefortheAirTop2000STC
heatingsystem.Whenusedaccordingtotheguidelinesstatedinthisbooklet,youshouldexpectmanyyearsof
trouble‐free,enjoyableoperation.
Thisinstallationguiderepresentsourlatestefforttoproducethebesttechnicaldocumentationpossible.Inour
effortstowardcontinuous,ongoingproductimprovement,wealsoencourageourcustomerstoprovidefeedback
concerningthisguideandtheAirTop2000STCheatingsystem.
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Visitourwebsitefortechnicaldocuments:www.webasto.com/au
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 
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ThisWebastoDieselHeatercomeswitha2yearwarranty.
Failuretofollowtheseinstallationinstructionsandthenotescontainedthereinwillleadtoallwarrantybeingrefusedby
WebastoThermo&ComfortAustraliaLtdPty.Thesameappliesiftherepairsarecarriedoutincorrectlyorwithuseofparts
otherthangenuineWebastoserviceparts.Thiswillresultinthevoidingofallwarranty.Allserviceandrepairshavetobecarried
outbyauthorisedWebastoservicedealers.
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
PurposeoftheAirTopHeater
TheWebastoAirTop2000STCairheatersaredesignedtoheatthecabinsofboats,trucks,minibus’,vans,
motorhomes,caravansandcampertrailers.
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Theairheatersoperateindependentlyoftheengineandareconnectedtoeitherthevehicle’sownfueltankorviaa
separatefueltankandtheelectricalsystemofthevehicle.
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Theyarenotdesignedtoheathazardoussubstances.
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WebastoAirTopInstallationGuide–AT2000STC
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3AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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Pre‐InstallationConsiderations
1) Locationandorientationoftheheater.
Theheatermaybefittedtotheinteriororexteriorofthevehicle.Ifitisinstalledexternally,ensurethattheheaterisfittedin
apositionwhereitisprotectedfromwateranddustingress.
2) Lengthofhotairoutletducting–theshorter,thebetter.Ensurethatthehotairoutletisnotdirectedtowardsor
incontactwiththehumanbody,asthehotairtemperaturecanrangefrom80‐120oC.
3) Returnvent‐insomecaseswherethereisenoughaircirculationinandaroundtheheater,ductingmaynotbe
requiredtothereturnairvent.Whereitisrequired,keepductingtoaminimum.
4) Locationofthecontroller,electricalwiring,fuseandbatteryconnections.
5) Locationofthefuelpumpandfuelfilter.
6) Locationoftheexhaustsystem.Ensurethattheexhaustisnotfacingdirectionoftravel.
7) Locationofthecombustionairsystems.
8) Fuelpick‐upoptions–12LWebastofueltankorstandpipe.
9) Electrical‐ensuretousethesuppliedfusesinthekitandbatterypositiveandnegativeconnecteddirectlytothe
housebattery.
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Tips
Looselyattachtheheaterwiththemountingbracketandplaceitinyourdesiredlocationtopredeterminetheheater
orientation,ductinglayout,airflow,wiring,controllerandgeneralclearanceforeasyaccessibilityandforfuture
serviceandrepair.
SerialNumberLabelling
Ensurethattheserialnumberlabelsareattachedonthetoporthesideoftheheaterincasetheheaterismounted
againstawallandtheoriginallabelmaybeinaccessible.Additionallabelsaresuppliedinthekitandoneshouldgo
ontheinstallationmanualenvelopetohandovertothecustomeratthetimeofcommissioning.
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TheSerialNumberlabelontheAT2000STCwillstillstateAT2000ST.Thisistoavoidthenecessityofapplyingfora
newECtypeapproval.TheheaterwillstillbeanAT2000STCbasedonthemanufacturedateandserialnumber.
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Note:Incaseofwarrantysituations,theserialnumberwillberequestedbyWebastooranauthoriseddealerto
validate.
Fig1–Serialnumberlabels–Heater Fig2
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SerialnumberlabelwrittenasFabrNr.

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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1Heater&FloorMountingBracketDimensions 
Note:All
dimensionsin
millimetres
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1HeatingAirInlet5FuelInlet
2HeatingAirOutlet6SpaceRequirementforHeatingAirInlet
3CombustionAirInlet7SpaceRequirementforInstallation&RemovalofHeater
4ExhaustGasOutlet8CableOutlet(OptionalRightorLeft)
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FloorMountingBracket
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Fig3
Fig4
50mm 

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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2StepbyStepInstallation
1. Aftercheckingwhatisunderthefloortoensureclearanceoftanks,chassisrailsetc.,Drillthe140mmfloor
mountbracketcutout.
2. Assemblyoftheheater
2.1 Assembletheheatertothebracketwiththerubbergasketusingthe10mmnutsandwasherssuppliedinthe
kit.
(Rubbergasketmustbeappliedtoavoidanyheatdistributionthroughthevehiclefloor)
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2.2 Placetheheatersothebracketisfacingup(Fig7),youwillnownoticeelectricalwiresbundledinthe
combustionairinlet(Fig3)(3),these2blackwiresareforthefuelpump.


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Fig6
Fig5
Fi
g
7
–
Bracket
f
acin
g
u
p
wardsandnoticethewiresinthecombustionairinlet.
Thesealgasketmustbereplacedeachtimetheheaterisremovedandreinstalled.

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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2.4 Thecombustionairinlet(Fig3)(3)hasaslottoaccommodatethewires,ensurethefuelpumpwiressit
neatlyinthisslot.Neverrunthewiresthroughthecombustionairinlettubeasitwillcreateairrestrictions.
 
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2.5 Attachingcombustionairtube.Amatchingslotneedstobecutinoneendofthecombustionairtubeto
accommodatethefuelpumpwires.
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  
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2.6 Usingthe25mmhoseclamp,fixthecombustionairtubetotheinlet(Fig3)(3).
Note:Ensurethatthehoseclamp&fuelpumpwiresarenotrubbing.
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Undernocircumstance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or
roaddebris.
Thecombustionairmustbeextractedusingacombustionairtubesuppliedinthekitandprotectedfromdustand
wateringress.
Fig8
Fig9
–
CombustionAirTube“V”cut.Fig9a–CombustionAirFilter

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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2.7 Attachthefuellineusingthe10mmhoseclamp&rubberfuellineconnector,fixtothefuelinlet(Fig3)(5),
thenfixthefuellinetotheopenendoftherubberconnectorandsecurewithanother10mmhoseclamp.
(Ref:Fig8).
2.8 Installthestainlesssteelexhaustpipe,usingthe25mmexhaustclamptotheexhaustgasoutlet(Fig3)(5).
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Theexhaustpipetemperatureisabove250
o
C.Ensurethattheendcapisproperlymountedandpointingdownwards
(fig11.1).Theexhaustmustnotpointinthedirectionoftravel.Theexhaustmustbesecuredandawayfromheat
sensitivecomponents,vehiclefuellinesandharnesses.Webastocansupplyexhaustlaggingifrequired
.
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
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
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Fig11–Theexhaustorcombustionpipemustbelocatedsothatthey
cannotbecloggedbydirtorroaddebris
Fig10anexhaustmuffleris
suppliedinthekit.
Fig11.1–Ensurethattheendcapisproperlymounted
andpointingdownwardsontheexhaustpipe.

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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3ElectricalSystem
3.1MainHarness
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Donotcutorextendthecontrollerwiringharness.Thiswillvoidthewarranty.Ifanextensionisrequiredforthe
controlelementplug(Fig12)(X9),anextensionharnessisavailablefromWebasto.
Weonlyrecommendextendingthebatterypositive(red)andnegative(brown)wires.Correctwiresizeof6mmtobe
usedtoavoidanycurrentorvoltagedropinthecircuit.
Ensurethatthemainplugisproperly“home”intheECU(Fig12)(3).Themainpositive(red)andnegative(brown)
hastobedirectlyconnectedtothehousebatteryandNOTviaamasterswitchtoensurecorrectshutdowncycleof
theheater.
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NumberFunction
1FuseHolder
2RedWire(BatteryPositive)
3MainPlug
4BrownWire(BatteryNegative)
5620OhmResistor
6RotaryController(Potentiometer)
7 Multi‐controldigital
Fig12
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AT2000STCMainHarnessconnections
1
2
3
4
5
6
7

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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Pleasenote–Theblackwirewithbluestripes,withtheminispadeterminals‐labelledas‘temperaturesensor’,must
beconnectedtothe620Ωresistorwhichissuppliedinthekit.Polaritydoesnotmatter.Iftheresistorisnot
connectedwhenusingthemulti‐controllertheerrorcodeF94willappear.Otherwise,ifusingthedialcontrollerand
theresistorisnotconnectedtheerrorcodeF06willoccur.
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 
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TheAirTop2000STCrequires72‐85watts,6‐7ampsduringstart‐up.Themainpowerconnectionhastobemadeatacircuit
designedtosustainthisloadwithoutanyvoltageorcurrentdraw.Cigarlightersocketsorauxiliaryoutputsforanyother
electronicaccessoriesarenotconsideredadequateforthepowersupplyfortheheater.
Ifanybatterymanagementsystemisused,pleasecontactaWebastoauthoriseddealertoensurecorrectshutdowncycleis
maintainedandpreventcarbonbuildup.
Fig13–Fuseholderandfusessuppliedinthe
kit.
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F1=20AforHeater‐12VHeater
F1=15AforHeater‐24VHeater
F2=1AforMulti‐Controller
3.1A620OhmResistor
Connect620Ωresistor
towiresmarked
‘TemperatureSensor’
620Ωresistorsupplied
loose&inaseparatepack
withinthekit.

WebastoAirTopInstallationGuide–AT2000STC
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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.
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3.1FuelpumpWiring
A7mfuelpumpharness(Fig14)issuppliedinthekittoconnecttothefuelpump.Blueandbrown,twincore
harnessconnectstothetwoblackwiresoutofthecombustionairinlet(Fig3)(3).PolaritydoesNOTmatter.
Plugkitsaresupplied;spadeterminalsorstandardautomotiveelectricalconnectionscanbeused.
Note:Neverrunthewiresthroughthecombustionairinlettube,asitwillcreateairrestrictions.Ref:Section
2–(2.4&2.5)
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  
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3.2InstallationofControlElement
  
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Installthecontrolelementinaconvenientlocation.Thecontrolelementdoesnotmeasuretemperature.The
monitoringoftemperatureisregisteredviaareturnairtemperaturesensorlocatedinsidetheheater.

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Fig14–Fuelpumpwiringharness
Fig17–RotaryController‐connectsto
plug(Fig10)(X9)
Fig16–MultiController–
completewithmountingkit
Fig15
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Wiringtothefuelpump