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.

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
–
AT2000STCMainHarnessconnections
1
2
3
4
5
6
7

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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.

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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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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3.2InstallationofControlElement
  

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.



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
–
Wiringtothefuelpump

WebastoAirTopInstallationGuide–AT2000STC
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4FuelSystems

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Forcaravans,Webastocansupplya12Lplasticfueltankwithsightlevelgaugeandaquickconnectforthefuelline.
WithMotorhomes,fuelcanbesourcedoutofthevehicle’sownfueltankviaafuelpickupsuppliedwiththekit.
Note:Whensourcingfuelfromvehicle’sfueltank,donotcutintothereturnorsupplylinefortworeasons:
1. Latestmodelvehicleshavehighlypressurizedfuelsystems.
2. Ifyouperformanymodificationstothevehicle,youmayvoidthevehiclewarranty.
Ensurethattheclampsaretightonthefuelfilterandthefuelpumpandfollowthedirectionoftheflowasshownby
arrowsonthefuelfilterandthefuelpumpforcorrectoperation.Thefuellinescanbeprotectedinconduitandcable
tiestosecure;thesearenotsuppliedinthekit.
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4.1Installation–FuelPump

Ensurethatthefuelpumpisinstalledwiththeclamp,90degreeelbowandtherubbermountingbracketsuppliedin
thekit.Thiswillreduceresonationthroughthevehicle.(Fig20) 

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Fig19
–
SamplefuelsystemlayoutwithWebasto12Ltplasticfuelandvehiclefueltank.
Fig20Fuelpumpinstalled
withrubbermounting
bracket(below)

WebastoAirTopInstallationGuide–AT2000STC
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4.2InstallationofFuelStandPipe

Whenfuelissourcedoutofthevehicle’sfueltank,ensurethatthestandpipeisinstalledonaflatsurfaceandcut
thestandpipelengthsothatitis25mmfromthebottomofthetank.SeeFig21/22.

  

InstallthetankextractingdeviceasshownFig21
Shortentheimmersiontube;theendshouldbeapprox.25mmoffthebottomofthetank.Cutthetubediagonally
andensureyoudeburrthecutedges.(Fig21)
Drilla25mmholeontheflatsurfaceofthetank(Fig22).Ensureyougreasethedrillbitanddrillingsurfaceorapply
maskingtapebeforehand(tocatchsmalldrillingchipsorswarfenteringthefueltank).
Installthefuelpickupandtightenthelockingnut(thesealshouldbeslightlycompressed;applyinganylockingglue
willbeadvisable).

4.3FuelFilter
Toensureacleancombustionprocess,afuelfilterissupplied.Alwayscheckthedirectionofflowasmarkedonthe
filter(Fig23).Thefiltershouldbeinstalledbetweenthefuelsourceandthefuelpump.



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
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
DonotsubstitutetheWebastosuppliedfuelfilterwithnonWebastoreplacement.


Fig21–Installingfuelextractingdevice–(TopMounttype) Fig22–25mm‐FuelExtractingDevice
Fig23–WebastoGenuinefuelfilter

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4.4FuelLine
OnlyWebastosuppliedFuelLineshouldbeusedforthefueldeliverytotheheater.Useofanyotherfuellinewill
resultinmalfunctionoftheheaterandwillvoidwarranty.Toensurecorrectconnections,rubberhoseconnectors,
10mmhoseclampsandfuellinearesuppliedinthekit.
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
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IncaseyouarenotabletousethestandpipeshownFig21(Topmounttype),Webastocansupplyanotheroption
(Fig24bottommounttype).

Onsomemotor‐homevehiclechassis’anadditionalfactoryfuelspigotmaybeavailableatthefuelsenderunit,
Webastocansupplyaconnectionkit(Fig25)tosuitthereforeeliminatingtheneedforastand‐pipeorpick‐up.


Fig24
–
Installingfuelextractingdevice‐BottomMount
Fig25–OptionalSAEConnectorforinstallingonan
additionalfactoryfuelspigot

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5DuctingLayouts
5.1SampleOneOutletlayout


5.2SampleTwinOutletLayout


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Ensurethatthehotairandreturnairoutletsareatleast1mawayfromeachotherorlocatedindifferentdirections
toavoidanyshortcycle.Anyshortcycleinthesystemwillaffecttheperformanceoftheheater.



COMPONENTDESCRIPTION
1RETURNAIR
2Y‐JUNCTION
3HOTAIROUTLETS
Fig28
Fig27
Fig26
Return Ai
r
Return Air

WebastoAirTopInstallationGuide–AT2000STC
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6Enclosingtheheater
1) Ensurethattheareaaroundtheheaterisnotjampackedwhileusingthecompartmentasstorageasthe
heateritselfandanyductingwillgethot(70‐80oC).
2) Heatercanbeboxedbutitisrecommendedtohavesomebreathingholesorgrillsontheenclosuretoallow
airflowinandaroundtheheater.
3) Theductinghastobesecuredandensureitcannotbecrushed.
4) Ensuretheductingconnectionsareproperlysecuredbytheclampssuppliedinthekit.
5) Incaseswherenoreturnairducthasbeenapplied,ensureyouinstallthe60mmopengrilltothereturn
(heating)airsideoftheheaterassuppliedinthekit.
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Atnopointshouldahotventbelocatedordirectedtowardsapersonorareaswherepeoplearesitting.Hotair
outlettemperaturecanbebetween80o‐120oC.
TheheatSHOULDBEdirectedawayfromallbodyparts.
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7StartingtheHeaterfortheFirstTime
1) Ensureallductingisconnectedandsecured.
2) Ensureallfuelconnectionsandclampsareconnectedandsecured.
3) Ensuresufficientfuelisavailablefromyourfuelsource.
4) Ensurethatthebatteryconnectionsareconnectedandsecured.
5) Ensurethesuppliedfusehasbeeninstalled.(Checkamperage).
6) Turntheheaterto100%orMAX.
7) Ensureyoubleedthefuelsystem.(SeeFuellinebleedingtip).
8) Itwilltakeatleast5minsbeforeyouwillexperiencehotairoutofthehotairvents.
9) Leavetheheaterrunningforatleastanhour.
7.1Start‐upSequence
Theglowplugandthecombustionairfanstarttheoperationandcombustionprocess(audiblecombustionsoundof
thecombustionairfanandthetickingofthefuelpumpwillbenoticeable).Thefuelwillbedeliveredandthe
combustionairfanspeedwillaccelerateandprovidehotair.
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7.2SwitchingOff
Whenheatingisnolongerrequired,switchtheheateroffbythemeansofthecontrollerontheheater.Neverturn
theheateroffbythemainpowersupply.
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Thecombustionwillbeextinguished,followedbyashutdowncoolingcycle.
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7.3FuelLineBleedingTip
Turntheheateronwiththestart‐upsequenceandtheprocessofthefuelpumpwilloperate.Duringthisoperation
fuelwillbedeliveredtotheheater.Dependingonthelengthofthefuellinethismaytakeafewattempts.
Duringtheprocesstheheaterwilltrytostarttwiceandifthefuelhasnotbeendelivered,itwillshowafaultcodeof
F01‐Nostart(after2attemptstostart).
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Youwillneedtoresettheheaterbyfollowingtheresetprocedure–seePage16,Section9.

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8BasicLayoutofCompleteInstallation
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9ResetProcedures
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RotaryControl (formulti‐controlpleaserefertopage24,errorcode07) 
Whenthecontrollerstartstoflash,disconnectthepowersupplytotheheaterby:
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1) Whilstthecontrollerisintheonposition&codeflashing,removethefuse(15A)ordisconnectpowertothe
heater
2) Turnthedialswitchtooff
3) Waitforafewminutes
4) Re‐installthefuse
5) Restarttheheater
COMPONENTDESCRIPTIONCOMPONENTDESCRIPTION
1CONTROLLER8FUELSTANDPIPE
2INTERFACEVEHICLEHARNESS9FUELTANK
3HEATERFUSES–F1(15A)&
F2(10A){Fig.13Pg9}
10FUELLINE
4HOTAIROUTLET11EXHAUSTPIPE
5HOTAIROUTLETDUCT12COMBUSTIONAIRINTAKEPIPE
6FUELPUMP13RETURN(HEATING)AIRINTAKE
GRILL
7FUELFILTER
Fig29–BasicCompleteInstallationLayout

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10Multi‐ControlSet‐Up&OperationsGuide
10.1Set‐Up
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InitialStart‐Up
WhentheControlunitisconnectedforthefirsttime,amessageabouttheSetting/Configurationoftheheateris
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1MenuName
2MenuSymbols
3TimeSettingActivated
4Time
5  On/OffButton
6  ControlKnob
TimerHeatingVentilationSettings
PressthecontrolknobandtheOn/OffButtonsimultaneouslyfor3seconds
SelectyourHeater(Note:AirTopEvo40/55isdisplayedasAT40/55)
PresstheControlKnob
SelectthecurrentDay
PresstheControlKnob
SelectthecurrentTime‐turntheControlKnobclockwisetoselectHour,presstheControlKnobto
confirm,thenturntheControlKnobclockwiseagaintoselecttheMinutes,presstheControlKnobto
set.
PresstheControlKnob

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Selectthesymbol“Settings”
PresstheControlKnob
The“QuickStart”menuisdisplayed
TurntheControlKnobclockwise10timesuntil“Reset”isdisplayed
Select“Reset”bypressingtheControlKnob
PresstheControlKnobtoconfirm.
TheControlKnobisnowrestarted
DuringtherestartoftheControlKnob,anHourglasswillquicklyappear
PresstheControlKnobandtheOn/OffButtonsimultaneouslyfor3seconds
TheControlisnowreadyforuse.
SelectyourHeater(Note:AirTopEvo40/55isdisplayedasAT40/55)
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PresstheControlKnob
IfyourheaterwasnotselectedcorrectlyatInitialStart‐UpaManualResetisrequired.
PresstheOn/OffButtontogototheMainMenuScreenandfollowthefollowingsteps.

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10.2TimerSet‐Up
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ItispossibletoprogramtheTimerSetting7daysinadvance.Theheaterswitchesonautomaticallyatthe
programmedtime.Upto3timesettingsperdaycanbeset,withatotalof21timesettingsfortheweek.
Beforethetimercanbeactivated,makesurethatthe:
∙Timeandcurrentdayoftheweekareset,
∙Heaterisswitchedoff
∙“Timer”symbolhasbeenselectedinthemainmenu
PresstheControlKnob
“AddTimer”screenisdisplayed
PresstheControlKnobinordertoaddanewtimer
TurntheControlKnobtoselectchosen“Day”
PresstheControlKnobtoconfirmselection
TurntheControlKnobtochoosethedesiredSwitchOntime(Hour)
PresstheControlKnobtoconfirm
TurntheControlKnobagaintochoosetheMinutes
PresstheControlKnobtoconfirm
TurntheControlKnobtochoosethedesiredSwitchOFFtime(Hour)
PresstheControlKnobtoconfirm
TurntheControlKnobagaintochoosetheMinutes
PresstheControlKnobtoconfirm
Selectthe“Heating”operationmodefromtheMainMenuscreen

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10.3AltitudeFunctionActivation
Altitudefunctioncanbeswitchedonwhenoperatingtheheaterathigheraltitudes(>1,500mto2,200m).

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Whenaltitudefunctionisactive,thealtitudesymbol isshownatthetopleftinthemainmenu.
Note:Thealtitudefunctionmustbeswitchedoffmanuallywhenitisnolongerrequired.
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TurntheControlKnobtochoosethedesiredheatingmode
Optionsavailable:Eco(PowerSavingMode);Normal(ComfortHeating);Boost(RapidHeat)
PresstheControlKnobtoconfirmselection
NOTE:EcoandBoostmodesarenotavailablefortheAT2000STC
TurntheControlKnobinordertochoosethedesiredtemperature
(Temperaturerange:5‐35⁰C)
PresstheControlKnobtoconfirmselection
Theprogrammedtimerissavedandshownonthedisplay
PresstheControlKnobtoactivatetheprogrammedtime
“Activate”messagewillappearonthedisplay
Repeattheprocesstoaddtimers(3timersettingsperday,21perweek)
Themenuelement"Settings"hasbeenchosen.
Pressthecontrolknobtoselectthealtitudefunction.
‘Off’ispreset
Pressthecontrolknobtoselectthealtitudefunction.