Webasto Air Top 2000 S B Service and Repair Manual

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Webasto Air Top 2000 S B Service and Repair Manual | Manualzz

List of Contents

Air Top 2000

Air Heater

Air Top 2000 S D (Diesel)

Air Top 2000 S B (Gasoline)

Service and Repair Manual

– Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death.

– Installation and repair of Webasto heating and cooling systems requires special

Webasto training, technical information, special tools and special equipment.

– NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures.

– ALWAYS carefully follow Webasto installation and repair instructions and heed all

WARNINGS.

– Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.

4.

5.

Air Top 2000 S

1.

2.

3.

6.

List of Contents

List of Contents

Introduction

1.1

Scope and Purpose.................................................................................................................................101

1.1.1 Use of Air Heaters.......................................................................................................................101

1.2

Meaning of Warnings, Cautions, and Notes............................................................................................101

1.3 Additional Documentation to be used......................................................................................................101

1.4 Safety Information and Regulations ........................................................................................................101

1.4.1 General Safety Notes..................................................................................................................101

1.5 Legal Provisions for Installation...............................................................................................................102

General Description

2.1 Combustion and Heating Air Fan ............................................................................................................201

2.2 Heat Exchanger.......................................................................................................................................202

2.3 Burner Insert with Combustion Tube.......................................................................................................202

2.4 Control Unit / Control Circuit Board .........................................................................................................202

2.5 Flame Sensor ..........................................................................................................................................203

2.6 Glow Plug ................................................................................................................................................203

2.7 Temperature Limiter ................................................................................................................................203

2.8

Dosing Pump...........................................................................................................................................203

Functional Description

3.1

Functional Description Air Top 2000 S .......................................................................................................301

3.1.1 Control Element ..........................................................................................................................301

3.1.2 Switch-On....................................................................................................................................301

3.1.3 Stabilization.................................................................................................................................301

3.1.4 Heating Operation.......................................................................................................................302

3.1.5 Control Operation........................................................................................................................302

3.1.6 Control Idle..................................................................................................................................302

3.1.7 Switch-Off....................................................................................................................................302

3.1.8 Switch-Off upon Failure...............................................................................................................302

Technical Data

...............................................................................................................................................401

Troubleshooting

5.1 General....................................................................................................................................................501

5.2

General Failure Symptoms......................................................................................................................501

5.3 Failure Symptoms during Operation........................................................................................................502

5.4

Error Code Output ......................................................................................................................................503

Functional Tests

6.1

General....................................................................................................................................................601

6.2

Adjustments.............................................................................................................................................601

6.2.1 Adjustment of the CO

2

Contents.................................................................................................601

6.3

Components Testing ...............................................................................................................................602

6.3.1 Glow Plug Resistance Test .........................................................................................................602

6.3.2 Flame Sensor Resistance Test ...................................................................................................602

I

List of Contents

Air Top 2000 S

7.

Circuit Diagrams

7.1

General....................................................................................................................................................701

8.

Servicing

8.1

General....................................................................................................................................................801

8.2

Work on the Air Heater............................................................................................................................801

8.3

Work on the Vehicle ................................................................................................................................801

8.4 Air Heater Test Run.................................................................................................................................801

8.5

Servicing..................................................................................................................................................801

8.6

Visual Inspections and Installation Regulations ......................................................................................801

8.6.1 Heating Air System......................................................................................................................801

8.6.2 Fuel Supply .................................................................................................................................802

8.6.3 Dosing Pump...............................................................................................................................804

8.6.4 Fuel Filter ....................................................................................................................................804

8.6.5 Combustion Air Supply................................................................................................................805

8.6.6 Exhaust Line ...............................................................................................................................805

8.6.7 Combustion Air Intake and Exhaust Lines ..................................................................................805

8.6.8 Electrical Connections.................................................................................................................806

8.7

Removal and Installation .........................................................................................................................808

8.7.1 Air Heater, Removal and Installation...........................................................................................808

8.8

Start-Up...................................................................................................................................................808

9.

Repair

9.1

General....................................................................................................................................................901

9.1.1 Work on Components after Disassembly....................................................................................901

9.1.2 Incorporation of Modifications .....................................................................................................901

9.2 Disassembly and Assembly.....................................................................................................................902

9.2.1 Removal of Housing Components/Covers..................................................................................902

9.2.2 Replacement of Control Unit.......................................................................................................903

9.2.3 Replacement of Temperature Limiter..........................................................................................903

9.2.4 Replacement of Combustion Air Fan ..........................................................................................905

9.2.5 Replacement of Flame Sensor....................................................................................................907

9.2.6 Replacement of Glow Plug..........................................................................................................907

9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger....................................910

10.

Packaging/Storage and Shipping

10.1 General..................................................................................................................................................1001

II

Air Top 2000 S

List of Figures

List of Figures

501

502

601

701

702

703

704

705

801

802

803

804

805

806

807

808

809

810

811

812

813

901

902

903

904

905

906

General Failure Symptoms .............................................................................................................................501

Failure Symptoms during Operation ...............................................................................................................502

Adjustment of CO

2

Contents ..........................................................................................................................601

Terminal Pin Assignment, Air Top 2000 S.......................................................................................................701

Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control D i a l ............................................702

Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer ..................................703

Circuit Diagram Automatic Control Air Top 2000 S,

12V/24V with Control Dial and Standard Timer ..............................................................................................704

Connection Diagram, Air Top 2000 S with Combination Timer.....................................................................705

Fuel Supply.....................................................................................................................................................802

Webasto Fuel Tank Tap .................................................................................................................................803

Fuel Tapping from Plastic Tank (tapping via fuel drain plug)..........................................................................803

Fuel Tapping from Plastic Tank (tapping via fitting plate)...............................................................................803

Pipe/Hose Connection ....................................................................................................................................804

Dosing Pump, Installation Position and Attachment .......................................................................................804

Fuel Filter........................................................................................................................................................804

Exhaust Muffler, Direction of Flow ..................................................................................................................805

Exhaust Pipe Outlet, Installation Position .......................................................................................................805

Weather Resistant Fuse Holder........................................................................................................................806

Control D i a l ...................................................................................................................................................806

Pulling the Plug...............................................................................................................................................806

Example of an Installation...............................................................................................................................807

Removal of Housing Components/Covers......................................................................................................902

Replacement of Control Unit and Temperature Limiter...................................................................................904

Replacement of Combustion Air Fan (Disassembly) ......................................................................................905

Replacement of Combustion Air Fan (Assembly............................................................................................906

Disassembly of Heat Exchanger (Sheet 1 of 2)..........................................................................................908

Disassembly of Heat Exchanger (Sheet 2 of 2)..........................................................................................909

III

List of Figures

Air Top 2000 S

IV

Air Top 2000 S

1 Introduction

1.

1.1

1.2

Introduction

Scope and Purpose

This repair shop manual is intended to support familiarized personnel in the repair of the Air Top 2000 S.

1.1.1 Use of Air Heaters

The air heater Air Top 2000 S is used to

- heat the cabin

- defrost the windscreens.

They are not cleared for heating a transportation compartment for dangerous goods.

The heaters operate independent from the vehicle engine and are connected to the fuel tank and to the electrical system of the vehicle. Their use is possible in vehicles with water- or air-cooled engines.

Meaning of Warnings, Cautions and Notes

WARNINGS, CAUTIONS, and NOTES in this manual have the following meaning:

WARNING

This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents to personnel.

CAUTION

This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment.

NOTE

This heading is used to highlight and draw specific attention to information.

1.3

Additional Documentation to be used

This workshop manual contains all information and procedures necessary for the repair of the Air Top 2000 S.

The use of additional documentation is normally not necessary.

Operating instructions/installation instructions and the vehicle specific installation proposal may be used as complementary information as necessary.

1.4

Safety Information and Regulations

The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times."General Safety Regulations" beyond the scope of these regulations are detailed in the following.The specific safety regulations applicable to this manual are highlighted in the individual chapters by

Warnings, Cautions, and Notes.

1.4.1 General Safety Notes

Within the scope of the StVZO (Road Licensing Regulations of the Federal Republic of Germany) “Design

General Approvals”, laid down by the Federal Office for

Motor Traffic, exist for the Air Top 2000 S with the following official marks of conformity:

-S 324 (Diesel)

-S 325 (Gasoline)

The installation of the heater is to be performed in accordance with the installation instructions and must be checked in case of a) the vehicle type inspection in accordance with

§ 20 StVZO b) the individual inspection in accordance with

§ 21 StVZO or c) the examination in accordance with § 19 StVZO performed by an officially authorised expert or examiner for road traffic, a vehicle inspector or a public servant as per section 7.4 a of Annex VIII to the

StVZO.

In the event of c) the installation must be certified on the acceptance certificate included in the copy of the

“General Operating License” giving details about

manufacturer

type of vehicle , and

vehicle identification number.

This validates the “Design General Approval”.

The acceptance certificate must be kept with the vehicle.

The year of first operation must be permanently marked on the identification label.

The heaters are cleared for heating the passenger and driver cabins but not for heating compartments intended for the transportation of dangerous goods.

101

1 Introduction

Air Top 2000 S

The heater must not be installed in the passenger or driver compartments of busses. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior.

There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 40 °C in the installation box.

At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosion.

Where flammable fumes or dust may build up (e.g.

in the vicinity of fuel, coal, wood, cereal depots, or similar installations) the heater must be switched off to prevent explosions.

Due to the danger of poisoning and suffocation the heater must not be operated in enclosed areas such as garages or workshops without exhaust venting, not even if the start-up is activated by the timer or telestart device.

When removing the heater the gasket below must be replaced.

The heat exchanger of the air heater remains serviceable for a maximum of 10 years and must then be replaced with an original spare part by the manufacturer or by one of its authorized workshops.

The heater must then be provided with a label marked with the sales date and with the words “Original Spare”.

Should exhaust pipes be routed through rooms accommodating persons, these pipes shall also be renewed after 10 years.

Installations not legally authorized will void the air heater’s “Official Marks of Conformity” and thus the vehicle’s permit of operation. The same applies for repairs performed by unskilled personnel and repairs with no original spare parts.

1.5

Legal Provisions for Installation

For testing the heater in accordance with 19, 20, or 21 of the StVZO the following regulations are to be observed in particular (§ 22 a StVZO):

Testing is performed upon presentation of the operating and installation instructions of the manufacturer.

The year of the initial operation must be durably marked on the heater identification plate by the installing person.

Heating Air System

Heating air intake openings must be arranged so that under normal operating conditions exhaust fumes of the vehicle engine or air heater are not likely to be expected.

Extracting combustion air from the vehicle interior is not permissible.

Combustion Air Line

The combustion air required must be taken from the exterior.

Within rooms accommodating persons, the combustion air lines must not have more than four disconnects and a splash-water protected exterior wall feedthrough. The disconnects must be sealed in a way not to exceed a leak rate of 200 l/h at an overpressure of 0.5 mbar.

The line including feedthrough, disconnects, material and specific type must be described in the installation instructions.

The line must require tools for installation and removal, must be protected against damage, and must be shockproof.

Exhaust Line

Heaters must be designed to discharge the exhaust to the exterior.

Exhaust pipes must be routed so that exhaust fumes are unlikely to penetrate into the vehicle’s interior.

The function of any parts of the vehicle essential for its operation must not be impaired. Condensate or water penetrated must not be able to accumulate in the exhaust line.

Drain holes are permissible; these must drain the fluid to the exterior via lines sealed against the vehicle interior.

The exhaust line outlet is to be positioned to the top, to the side, or in case of exhaust venting below the vehicle floor, to the nearest possible location of the vehicle’s or cockpit’s side or rear end. In compartments accommodating persons, exhaust lines must not have more than one disconnect and must have a splash-water protected feedthrough in the exterior wall/floor. For water, that has penetrated into the exhaust line, the connection of a drain line with a metal-sealing joint is permissible. The drain pipe must be routed sealed through the exterior wall or the vehicle floor.The heat exchanger, the exhaust line connected, as well as the possible drain pipe must be sealed so that with an overpressure of double the overpressure of the exhaust having the maximum permissible exhaust line length - at least however at an overpressure of 0.5 bar - a total leak rate of 30 l/h is not exceeded.

The line including feedthrough, disconnects, material and specific type must be described in the installation instructions.

The line must require tools for installation and removal, must be protected against damage, and must be shockproof.

102

Air Top 2000 S

Metal lines must be used. These may not heat to more than 110 °C should there be the possibility of contact within the room interior. Protective devices against contact may be fitted.

Should exhaust pipes be routed through rooms accommodating persons, these pipes shall be renewed after 10 years using genuine spare parts.

Combustion Air Inlet and Exhaust Outlet

During installations these ports for combustion air entry and exhaust fume exit must be of such type, that a ball with a diameter of 16 mm cannot be inserted. Electrical lines, switch gear and control gear of the heater must be located in the vehicle so that their proper function cannot be impaired under normal operating conditions.

For the routing of fuel lines and the installation of additional fuel tanks §§ 45 and 46 of the StVZO are to be adhered to.

The most important regulations are: Fuel lines are to be designed in such a way that they remain unaffected by torsional stresses in the vehicle, engine movement and the like. They must be protected against mechanical damage.

Fuel-carrying parts are to be protected against excessive heat and are to be arranged so that any dripping or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment.

In busses, fuel lines and fuel tanks may be located neither in the passenger area nor in the driver’s compartment. In these type of vehicles the fuel tanks must be located such that they do not pose a direct hazard to the exits in the event of a fire. Fuel supply must not be by means of gravity or pressurization of the fuel tank.

Installation Rules for Webasto Fuel Tanks for the

Fuel Supply of Heaters in Vehicles

In busses the installation is not permitted in the passenger or driver compartment.

The fuel fill neck must in no vehicle be located within any of these compartments.

Fuel containers for gasoline fuel must not be located immediately behind the front panelling of the vehicle.

They must be sparate from the engine so that even in case of an accident the inflammation of fuel is unlikely to be expected. This does not apply for towing vehicles with an open cockpit.

The operational state of the heater, i.e. an indication “on” or “off”, must be easily and clearly visible.

1 Introduction

103

2 General Description

2.

General Description

The air heater Air Top 2000 S operates under the evaporator principle and basically consists of:

- combustion and heating air fan

- heat exchanger

- burner insert with combustion tube

- control unit

Air Top 2000 S

A malfunction of the Air Top 2000 S is indicated by an error code displayed on the combination or standard timer. When equipped with the standard control dial, the operating indicator flashes. In addition a heater check out may be performed using a personal computer (refer to operating instructions PC air heater diagnosis).

Air Heater Air Top 2000 S

(covers removed)

Air Heater Air Top 2000 S

For control and monitoring a

- control unit/control circuit board

- flame sensor

- glow plug

- temperature limiter

- temperature sensor are located within the unit.

All Air Top 2000 S heaters may be controlled by means of an optional external temperature sensor.

Fuel supply is provided externally by a fuel dosing pump.

2.1

Combustion and Heating Air Fan

The combustion and heating air fan delivers the air required for combustion from the combustion air inlet to the burner insert. By means of the fan the heating air is also delivered to the hot air outlet.

Combustion and Heating Air Fan

201

Air Top 2000 S

2.2

Heat Exchanger

The heat exchanger dissipates the heat provided by combustion to the air delivered by the combustion and heating air fan.

2 General Description

2.4

Control Unit / Control Circuit Board

The control unit/control circuit board is the central controlling unit for functional sequencing and monitoring of the combustion operation. A temperature sensor located on the control unit is used for temperature control. All heaters may have the temperature sensor replaced with an external temperature sensor. The combustion and heating air fan may be set by means of a potentiometer.

A malfunction in the Air Top 2000 S is indicated by an error code displayed on the combination or standard timer. When equipped with a standard control dial the operating indicator flashes. In addition a heater check out may be performed using a personal computer (refer to operating instructions PC air heater diagnosis).

Heat Exchanger

Potentiometer

2.3

Burner Insert with Combustion Tube

Within the burner insert fuel is distributed in the combustion tube across the burner cross-section. In the combustion tube the combustion of the fuel/air mixture takes place heating up the heat exchanger.

Combustion

Tube

Temperature

Sensor

Control Unit - Air Top 2000 S

Burner

Insert

Diesel

2 mm

Fuel

1 mm

202

2 General Description

2.5

Flame Sensor

The flame sensor is a low-Ohm PTC resistor changing its resistance dependent on its heating by the flame.

The signals are routed to the control unit for processing.

The flame sensor monitors the flame operating condition over the complete duration of heater operation.

Air Top 2000 S

2.7

Temperature Limiter

The temperature limiter protects the air heater against excessive operating temperatures. Overheat protection is activated at a temperature higher than 150 °C to interrupt the electrical circuit of the dosing pump and switch off the heater with run-down operation.

After cooling down the electrical circuit is restored.

The air heater may be switched on again (see 3.1.8).

Flame Sensor

Temperature Limiter

2.6

Glow Plug

The glow plug ignites the fuel/air mixture at the start of the air heater operation. The glow plug is acting as an electrical resistor and is located in the burner insert opposed to the flame side.

2.8

Dosing Pump

The dosing pump is a combined supply, dosing and shutoff system for the fuel supply of the heater out of the vehicle’s fuel tank.

Glow Plug

Dosing Pump DP 2 for Gasoline and Diesel operated Heaters

Dosing Pump DP 30 for Diesel operated Heaters

203

Air Top 2000 S

3 Functional Description

3.

Functional Description

3.1

Functional Description Air Top 2000 S

3.1.1 Control Element

The control element is used to switch the air heater on and off, set the desired room temperature (air intake temperature between 10 °C and 45 °C), and to unlock a failure interrupt condition.

The green LED indication is used to indicate the operating condition (LED permanently on) and an overheat condition (LED flashes).

3.1.2 Switch-On

The control element is set to the desired room temperature. When switching the air heater on, the operating indicator is illuminated and the glow plug is activated

(cycled). The motor of the combustion and heating air fan starts high-speed operation for 1 second (breakaway moment) and is then under slow-down control to approx. 30% (Diesel) or 50% (fuel) of full speed.

NOTE

Should the temperature of the intake air be above the selected, rated temperature, only the motor of the combustion and heating air fan will operate (control idle). Start operation will be initiated with a heating air temperature below the rated temperature.

The flame sensor function is checked. If the flame sensor at this time already signals “flame”, there will be a

120 second run-down and an error lockout of the control unit. A malfunction of any other component monitored causes an error lockout without run-down.

After approx. 20 seconds (for fuel operated heaters after approx. 15 seconds) the fuel dosing pump is activated.

After another 25 seconds the speed of the combustion and heating air fan is continuously increased to a higher rate and combustion begins. As soon as a flame is detected, combustion will be stabilized (see 3.1.3).

Should no normal combustion be achieved within 120 seconds (for fuel operated heaters after approx. 115 seconds), the speed of the combustion and heating air fan is increased for approx. 30 sec and there will be an automatic repeat start with the glow plug activated and fuel dosing pump deactivated (no fuel supply).

Should no proper combustion develop within 120 seconds (for fuel-operated within 115 seconds) the combustion and heating air fan speed is increased to full load for approx. 30 seconds (15 seconds for fuel-operated heaters) with the glow plug on and the dosing pump off

(no fuel delivery) with a subsequent automatic restart.

Should the no-combustion-condition persist, after another 80 seconds (for fuel operated heaters after approx.

85 seconds) there will be a switch-off by error lockout

(see 3.1.8) with a run-down of the combustion and heating air fan lasting 120 seconds at 2/3 of its max. speed.

2. Start (automatic restart)

Fan speed is again reduced to approx. 30% (for fuel operated heaters to approx. 50%) and fuel is delivered.

During the next 20 seconds fan speed is increased to approx. 60% (for fuel-operated heaters to approx. 75%) of full speed. As soon as a flame is detected within the next

55 seconds, combustion will be stabilized. Should there be no flame condition after a total fuel delivery period of

180 seconds, fuel delivery will be stopped and the glow plug deactivated. The combustion air fan continues full load operation for another 120 seconds (run-down) and the heater enters the error lockout condition.

3.1.3 Stabilization

Diesel Operated Heaters

With the glow plug activated the operating speed of the combustion and heating air fan is increased. After another 20 seconds the speed of the combustion and heating air fan is continuously increased within 17 seconds to full load for full heat.

NOTE

This operating condition is omitted if the set temperature

(control idle) has already been achieved once.

The glow plug is deactivated and heating operation commences. A flame-out during speed up control causes a restart, 5 restarts an error lockout of the heater.

Fuel Operated Heaters

With the glow plug activated the operating speed of the combustion and heating air fan is continuously increased within 4 seconds to full load for full heat. This operating condition will be omitted if the start occurs after a control idle period.

The glow plug is deactivated and heating operation commences. A flame-out during speed up control causes a restart, 5 restarts an error lockout of the heater.

301

3 Functional Description

Air Top 2000 S

3.1.4 Heating Operation

During operation the combustion exhaust gasses flow through the heat exchanger charging its walls with combustion heat, which in turn is taken up by the heating air delivered by the heating air fan to be routed to the vehicle interior.

The temperature of the heating air sucked in is measured by means of a temperature sensor fitted to the air intake side of the air heater or by means of an externally located temperature sensor.

A temperature below the one set with the control element increases the heater performance up to maximum heat. In order to extend the burner idle period of Diesel operated heaters during permanent operation with a heating performance in excess of 1.1 kW, the fuel dosing pump delivery rate is reduced every 15 minutes for

20 seconds.

A heating performance less than 1.1 kW causes the fuel delivery to the dosing pump to be interrupted every 30 minutes for 4 seconds. Additionaly heating operation is briefly suspended every 9 hours like in control idle. For

Diesel-operated heaters this is only applicable, if at this time heating performance is less than 1.1 kW.

3.1.5 Control Operation

During control operation fan speed and dosing pump rate of delivery are subject to heating performance.

The glow plug is deactivated.

3.1.6 Control Idle

After reaching the temperature set with the control element, heating performance is controlled to decrease.

The speed of the combustion and heating air fan slows down and the fuel delivery rate to the dosing pump is reduced. When exceeding the air intake temperature set with the control element during minimum heating performance, the dosing pump is deactivated after 5 seconds and combustion terminates.

Fan speed remains constant for 35 seconds and is then increased to approx. 60% of full speed for cooling the heater down. the fan then continues to operate at approx. 30% of full speed until temperature is below the temperature set with the control element. If temperature falls below the one set with the control element, the heater will restart (without break away).

NOTE

New settings on the control element are executed by the control unit/heater with a time delay.

3.1.7 Switch-Off

Switching the heater off extinguishes the operation indication of the control element.

If no fuel has been delivered or if the air heater is in control idle, the air heater is deactivated immediately without run-down.

If fuel supply has commenced it will be immediately stopped at switch-off. Fan speed remains constant and then decreases within 30 seconds to approx. 60% of full speed. After this or with the flame sensor detecting “no flame”, fan speed rises to maximum speed for 60 seconds and run down for 120 seconds is initiated. Rundown is at approx. 60% of full speed and is deactivated automatically.

NOTE

Re-activation of the heater during run-down is permitted.

Run-down will be completed first with a subsequent restart.

3.1.8 Switch-off upon Failure

The control unit recognizes failures of individual air heater components and malfunctions in the start sequence and in normal operation.

The air heater is deactivated and enters the error lock out mode under the following conditions: flame sensor open or short circuit temperature sensor open or short circuit glow plug open or short circuit fan motor open or short circuit or fan speed wrong dosing pump open or short circuit overheating low voltage below 10 Volt or high voltage above

15 Volt in excess of 20 seconds for 12 Volt heaters low voltage below 20 Volt or high voltage above

30 Volt in excess of 20 seconds for 24 Volt heaters

A switch-off like in “switch-off” will be performed.

In case of overheating there will be no fuel supply. After run-down the control unit is in the error lockout mode.

The operation indication outputs a flash code.

For error unlock the air heater has to be switched off momentarily (at least 2 seconds) before switching on.

302

Air Top 2000 S

4.

Technical Data

As long as no threshold values are given, the following technical data are understood to include tolerances of

±

10% usual for heaters at an ambient temperature of

+20 °C and at nominal voltage and conditions.

Electrical Components:

Control unit, combustion air fan, dosing pump, timer, glow plug and control dial are for 12 or 24 Volts operation.

The components temperature limiter and flame detector are independent of voltage.

4 Technical Data

Fuel for Air Top 2000 S B (gasoline):

The fuel specified by the manufacturer must be used.

Fuel for Air Top 2000 S D (diesel/PME):

The diesel fuel specified by the vehicle manufacturer must be used.

We know of no negative influences due to additives.

If fuel is extracted from the vehicle’s tank, follow the additive instructions issued by the vehicle manufacturer.

If you change to low-temperature fuel, the heater must be operated for approx. 15 minutes so that the fuel system is filled with the new fuel.

The Air Top 2000 S D heater is also licensed for use with

PME (bio-diesel), which complies with ASTM D6751 and

DIN EN 14214.

Air Heater

Mark of conformity

Heater type

Operation

Heat flow

Type of fuel

Fuel consumption

Control range

Control range

Nominal voltage

Operation voltage

Rated power consumption Control range

Permitted ambient temp.:

Heater: - operation

- storage

Dosing pump:

Control element:

- operation

- storage

- operation

- storage

Permitted combustion air intake temperature

Setting range for indoor temperature

Volume flow of heating air against 0.5 bar

CO

2

in exhaust

(perm. functional range)

Control range

Max.

Max.

Dimensions air heater

Weight, heater

AT 2000 S B

~ S 325

AT 2000 S D

~ S 324

Air heater with evaporator burner

1.1 – 2.0 kW

Gasoline

0.1 .. 0.2 kg/h (0.16..0.27 l/h)

12 Volt

10 … 15 Volt

0.9 – 2.0 kW

Diesel/Fuel oil (EL)

0.1 .. 0.21 kg/h (0.12 .. 0.24 l/h)

12 Volt

10 … 15 Volt

9 ...22 W

24 Volt

20 … 30 Volt

-40

°

… +40

°

C

-40

°

… +85

°

C

-40

°

… +20

°

C

-40

°

… +85

°

C

-40

°

… +75

°

C

-40

°

… +85

°

C

-40 ... +20

°

C

+10 ... +45

°

C

70 m

3

/h

9.5 … 10.5

9.5 … 12.0

Length 311 ± 2 mm

Width 120 ± 1 mm

Height 121 ± 1 mm

2.6 kg

401

5 Troubleshooting

Air Top 2000 S

5.

5.1

Troubleshooting

General

A malfunction of the Air Top 2000 S is indicated by an error code displayed on the combination or standard timer. When equipped with a standard control dial the operating indicator flashes. In addition a heater check out may be performed using a personal computer (refer to operating instructions PC air heater diagnosis).

CAUTION

Troubleshooting requires profound knowledge about structure and theory of operation of heater components and may only be performed by skilled personnel.

In cases of doubt refer to Sections 2 or 3 for functional interrelations.

CAUTION

Troubleshooting is normally limited to the isolation of defective components.

The following causes for trouble are not considered and should always be checked for to exclude them as cause for trouble:

corrosion on connector loose contact on connector wrong crimping on connector corrosion on electrical wiring and fuses corrosion on battery terminals

If individual components are checked, the control unit electrical connections must be disconnected.

After any correction of a failure a functional test has to be performed in the vehicle.

5.2

General Failure Symptoms

The following table (Fig. 501) lists the possible failure symptoms.

F a li u r e S y m p t o m

Air heater switches off automat i c a ll y

Heater expels black fumes

P r o b a b l e C a u s e

No combustion after start or repeat s t a tr

Flame extinguishes during o p e r a it o n

H e a t e r o v e r h e a t s

Operation indication flashes

V e h i c l e e l e c t ir c a l system voltage too low

Combustion air and/or exhaust ducting blocked

R e m e d y

Switch off heater momentarily and s w ti c h o n once again

Switch off heater momentarily and s w ti c h o n once again

C h e c k h e a t a i r d u c it n g f o r obstructions, allow heater to cool down, switch off heater momentarily and switch on once again

C h a r g e b a tt e r y

Switch off heater momentarily and switch on once again

Check combustion and exhaust ducting for obstructions

Fig. 501 General Failure Symptoms

501

Air Top 2000 S

5 Troubleshooting

5.3

Failure Symptoms during Operation

The following table (Fig. 502) lists the possible failure symptoms as they might occur during the functional sequence of operation.

In case of malfunction the failure is to be isolated and removed using this table. It is important to accurately identify the failure symptom.

Should the failure symptom not be contained in this table or the trouble not be detected under the specific failure symptom listed, in emergencies, assistance by our service technicians may be requested.

NOTE

Overheating and dosing pump failure are always indicated additionally after run-down by the flashing LED of the control dial.

In all cases of trouble also a defective control unit may be the cause should all other components turn out to be serviceable.

Failure Symptom shows after

....seconds

immediately

Possible Causes

No start and no illumination of LED on control element

No start but LED illuminates

Very low speed with no start

Motor operates momentarily and then stops

Stoppage without run-down

Run-down after

Run-down after

Run-down after and dosing pump does not cycle

Run-down after

Run-down after

R u n d o w n

Stoppage without run-down

Interruption of dosing pump cycling and max. speed for

30 sec with subsequent re-start

Wrong cabling, defective fuse

5

1

20

120 immediately immediately

1

40 to 120

230 d u ir n g c o operation m b u s it o n

Fan or control unit defective or fan blocked

Control idle operation: wrong manual control (selected temperature is below air intake temperature) or wrong integration (excessive air intake temperature)

Glow plug or flame sensor short or open circuit or control unit defective

Fan motor obstructed, binding

Flame detection erroneous

Voltage to control unit too low

Cabling to dosing pump, pump itself or overheat protection defective

Intermittent disconnect of connection to dosing pump or to overheat protection

No flame: wrong fuel supply quantity, defective or slow fan, coked burner (in particular pilot flame outlet bore), combustion air/exhaust ducting obstructed or heat exchanger coked, dosing pump seized

Overheating or voltage too low or component error (flame sensor, glow plug, overheat sensor, dosing pump, burner) or no fuel supply or obstructed combustion air/exhaust ducting

Fan motor failure or seizure during combustion operation during combustion operation

Flame-out by gas bubbles in fuel delivery or strong wind against exhaust outlet or defective no-flame detection

Fig. 502 Failure Symptoms during Operation

502

5 Troubleshooting

5.4

Error Code Output

When equipped with a combination or standard timer a malfunction will cause an error code output to the display of the timer for indication.

NOTE

When equipped with a control dial, the error code output is indicated by flashing of the operating indicator/error code indication. The number of flash pulses corresponds to the number indicated in the table below.

After a quick pulse train there will always be an error code output.

Error code output on display of combination or standard timer

F 01 No start (after 2 attempts)

F 02 Flame out (at least >5)

F 03 Voltage too low or too high

F 04 Premature flame detection

F 05 Flame sensor open or short circuit

F 06 Temperature sensor open or short circuit

F 07 Dosing pump open or short circuit

F 08 Fan motor open or short circuit or wrong speed

F 09 Glow plug open or short circuit

F 10 Overheating

Air Top 2000 S

503

Air Top 2000 S

6.

Functional Tests

6.1

General

This section describes the on-vehicle and off-vehicle testing of the air heater to check its proper operation.

WARNING

The air heater shall not be operated in enclosed areas like garages or workshops not provided with exhaust venting facilities.

6.2

Adjustments

6.2.1 Adjustment of the CO

2

Contents

6.2.1.1 General

The CO

2

contents of the exhaust is adjusted with the potentiometer on the control circuit board. The air heater is preset by the manufacturer with respect to the combustion and heating air fan fitted. After adjustment by the manufacturer the potentiometer is in center position

(Fig. 601). After an inadvertent loss of this position it is sufficient to restore its original position.

The manufacturer setting may be corrected by rotating the potentiometer. A suitable tool like a small screw driver (2.5 mm tip) is to be used.

6 Functional Tests

CAUTION

Set potentiometer slowly; observe end positions.

Adjustment may be performed at any electrical system voltage.

Clockwise rotation increases the fan speed and decreases the CO

2

contents. Counterclockwise rotation decreases the fan speed and increases the CO

2

contents.

If the setting range is not sufficient (e.g. after replacement of the combustion and heating air fan) the manufacturer’s setting may be cancelled according to the procedure described in the following.

6.2.1.2 New Basic Setting

CAUTION

The manufacturer’s setting cannot be restored.

1. Withdraw cover from upper shell according to 9.2.1.

2. Switch on air heater.

3. Rotate potentiometer two times and with no interrupt through its complete setting range (e.g. max. - min.max.).

4. Adjust desired CO

2

contents (Fig. 601).

5. Switch off air heater.

6. Install cover and secure.

+

CO

2

Fig. 601 Adjustment of CO

2

Contents

601

6 Functional Tests

6.3

Components Testing

CAUTION

During electrical testing always ensure that the control unit and the component under test are electrically disconnected from each other.

6.3.1 Glow Plug Resistance Test

During electrical testing of the glow plug using a digital multimeter, the following readings should be obtained:

Glow plug 12 Volt (red) 24 Volt (green)

Resistance at 25 °C: 0.324 ... 0.360

1.3 ... 1.44

Test current: < 5 mA < 5 mA

6.3.2 Flame Sensor Resistance Test

During electrical testing of the flame sensor using a digital multimeter, the following readings should be obtained:

Cold test:

Resistance at 25 °C:

Test current:

2.6 ... 3.4

< 5 mA

Hot test:

Resistance at 800 - 1000 °C:

(ceramic rod red hot over a length of approx. 20 mm)

Test current:

12 ... 15

< 5 mA

Air Top 2000 S

602

Air Top 2000 S

7.

Circuit Diagrams

7.1

General

The air heater Air Top 2000 S may be operated using the control dial (rated value transmitter/switch) or with the control dial and a combination or standard timer. The circuit diagrams (Figs. 702 to 704) show the possible circuits 12 or 24 Volt with control element combination timer control element and standard timer

Fig. 701 shows the terminal pin assignment.

7 Circuit Diagrams

X 1 X 2 X3 X 4 X 5 v i o l e t b l a c k brown y e ll o w b l u e

X1

X2

X3

X4

X5

= Connection, Combustion and Heating Air Fan

= Connection, Dosing Pump

= Connection, Flame Sensor

= Connection, Glow Plug

= Connection, Temperature Limiter

Fig. 701 Terminal Pin Assignment, Air Top 2000 S

701

7 Circuit Diagrams

Air Top 2000 S

2

?

?

?

M

S 1

X 1 X 5

X 6

X 7

X8

X 9

X 1 1

X 1 2

Y1

B2

B3

E

F 2

H 1

A

tI e m

1

A2

B1

N

A i

o m

r

e n

H e a t

c

e

l

r

a t u r e

Control Unit

Flame Sensor

Temperature Sensor

Temperature Limiter

Glow Plug

F u s e 2 4 V 1 0 A / 1 2 V 1 5 A

L E D g r e e n i( n ti e m S 1 )

Motor

C o n rt o

C o n n e c

l E l e m e n t it o n 2 p o l e

C

C o o n n n n e e c c it o n 8 p o l e it o n 4 p o l e

Connection 2-pole

C o n n e c

C o n n e c it o n 2 p o l e it o n 6 p o l e

C o n n e c it o n 1 p o l e

Dosing Pump

R

A i

e

r

m

T

a

o

r k

p 2 0 0 0 S

F l a t F

O p e r a u s it o e S A n i n d

E J 1 2 8 4 i c a it o n

f

f

f o o o

R a t e d V a l u e S e t ti e m A 2 ti e m A 2 ti e m S it n g S w ti c h o o f

f ti ti e e m m

A

A

2

2

D i a g n o s i s ( K w ri e )

Wire Gauges

< 7.5 m

0.75 mm

2

1.0 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

7.5 - 15 m

1.5 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

6.0 mm

2 gr or rt sw bl br ge gn vi ws

Wire Colours

blue brown yellow green grey orange red black violet white

2 Connection X11/2 and X11/3 for TRS function only

702

Fig. 702 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control Dial

Air Top 2000 S

1

7 Circuit Diagrams

2

?

?

?

B2

B3

E

F 2

H 7

A

tI e m

1

A2

B1

N

A i

o m

r

e n

H e a t

c

e

l

r

a t u r e

Control Unit

Flame Sensor

Temperature Sensor

Temperature Limiter

Glow Plug

F u s e 2 4 V 1 0 A / 1 2 V 1 5 A

L E D r e d i( n ti e m P )

H8

H 9

M

P1

S 3

X 1 X 5

X 6

X8

X 9

X 1 1

X 1 2

X 1 3

Y1

Heating symbol in display (in item P)

L i g h t

Motor i( n ti e m P )

Combination Timer (1531)

S w ti c h

C

C o o n n n n e e c c it o n 2 p o l e it o n 8 p o l e

Connection 2-pole

C

C o o n n n n e e c c it o n 2 p o l e it o n 6 p o l e

C o n n e c

C o n n e c it it o o n n

1

1

Dosing Pump

p o l e

2 p o l e

R e m a

A i r T o

r k

p 2 0 0 0 S

F l a t F u s e S A E J 1 2 8 4

I n s t a n t h e a t s w ti c standy indication, h i ll u m operating indicator light i n a

Operating indicator light, overheat indication

S y m b o l lli u m i n a it o n it o n , o o

I n s t a n

f

f ti ti e m A 2 e m

t h e a

A 2 it n g r e m o t e c o n rt o l o o f

f ti ti e e m m

A

A

2

2

D i o f a g n o s ti e m P i s ( K w ri e )

Wire Gauges

< 7.5 m

0.75 mm

2

1.0 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

7.5 - 15 m

1.5 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

6.0 mm

2 gr or rt sw bl br ge gn vi ws

Wire Colours

blue brown yellow green grey orange red black violet white

1

2 with plus from terminal (15/75) to connection 10: permanent operation during instant heating as long as ignition on without plus to connection 10: heating time programmable as required (10 min to 120 min), default setting 120 min.

Connection X11/2 and X11/3 for TRS function only

Fig. 703 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer

703

7 Circuit Diagrams

1

Air Top 2000 S

2

?

?

?

B2

B3

E

F 2

H 7

A

tI e m

1

A2

B1

H8

H 9

M

P2

S 1

S 3

X 1 X 5

X 6

X 7

X8

X 1 1

X 1 2

X 1 3

Y1

N

A i

o m

r

e n

H e a t

c

e

l

r

a t u r e

Control Unit

Flame Sensor

Temperature Sensor

Temperature Limiter

Glow Plug

F u s e 2 4 V 1 0 A / 1 2 V 1 5 A

L E D r e d i( n ti e m P )

R e

A i r

m a

T o

r k

p 2 0 0 0 S

Heating symbol in display (in item P)

F l a t F u s e S A E J 1 2 8 4

I n s t a n t h e a t s w ti c standy indication, h i ll u m operating indicator light i n a

Operating indicator light, overheat indication

S y m b o l lli u m i n a it o n it o n ,

L i g h

Motor

t i( n ti e m P )

Standard timer

C o n rt o l E l e m e n t

S w

C o

C o n n ti c h n n e e c c it o n 2 p o l e it o n 8 p o l e

C o n n e c it o n 4 p o l e

Connection 2-pole

C o n n e c

C o n n e c it o n 6 p o l e it o n 1 p o l e

C o n n e c it o n 1

Dosing Pump

2 p o l e

f

f

f o o o

I

R a t n s t e d a n

V

t h a l u e e a it

S n g e t r e it n g S m o t e w c ti c h o n rt o l ti e m A 2 ti e m A 2 ti e m S 1 o o

f ti e m A 2

D i a g n o s i s

f ti e m P

( K w ri e )

Fig. 704 Circuit Diagram Automatic Control Air Top 2000 S,

12V/24V with Control Dial and Standard Timer

704

Wire Gauges

< 7.5 m

0.75 mm

2

1.0 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

7.5 - 15 m

1.5 mm

2

1.5 mm

2

2.5 mm

2

4.0 mm

2

6.0 mm

2 gr or rt sw bl br ge gn vi ws

Wire Colours

blue brown yellow green grey orange red black violet white

1

2 with plus from terminal (15/75) to connection 10: permanent operation during instant heating as long as ignition on without plus to connection 10: heating time programmable as required (10 min to 120 min), default setting 120 min.

Connection X11/2 and X11/3 for TRS function only

Air Top 2000 S

7 Circuit Diagrams

3

6

9

2

5

8

1

4

7

12 11 10

Combination Timer 1531

Grey

Lights (1)

(optional)

Black

Battery Positive or Ignition Signal (10)

Red

Battery Positive (11)

Brown

Battery Negative (12, 4)

Adapter Harness

P/N 9008440A

Fig. 705 Connection Diagram, Air Top 2000 S with Combination Timer

705

7 Circuit Diagrams

Air Top 2000 S

706

Air Top 2000 S

8.

Servicing

8.1

General

This section describes the servicing procedures that may be performed with the air heater installed.

8.2

Work on the Air Heater

Prior to performing any work it is mandatory to disconnect the vehicle battery main lead. As long as the air heater is in operation or in run-down, the battery main supply must not be disconnected due to the danger of overheating resulting in a response of the overheat protection.

When performing extensive repairs on the heater a complete removal is advisable. When performing repairs requiring a relocation of the installation position, the relevant installation instructions and the vehicle-specific installation proposal have to be observed.

8.3

Work on the Vehicle

CAUTION

In the vicinity of the air heater a temperature of 85 °C must not be exceeded under any circumstances (e.g. during body paint work).

8.4

Air Heater Test Run

WARNING

The air heater must not be operated, not even with timer, in enclosed areas like garages or workshops not equipped with an exhaust venting facility.

CAUTION

Operation of the heater without the control unit cover is not permitted and causes overheating.

8.5

Servicing

NOTE

In order to avoid the seizure of mechanical components, the air heater should be operated every 4 weeks for at least 20 minutes.

The air heater does not require maintenance. It should however be checked by Webasto-trained skilled personnel on regular intervals, the latest before the heating season begins (point of time, when the heater is more frequently in use due to weather conditions).

8 Servicing

For reasons of the air heater’s functional reliability perform the following servicing: check heating air inlet and outlet for foreign matter and contamination. (Contaminated or clogged heating air ducts may lead to overheating and thus response of the temperature limiter).

Clean air heater exterior (prevent the ingress of water).

Examine electrical connections for corrosion of contacts and for security.

Check combustion air and exhaust ducts for damage and obstructions.

Check fuel lines and fuel filter for leakage.

Replace fuel filter if installed.

8.6

Visual Inspections and Installation

Regulations

8.6.1 Heating Air System

CAUTION

The integration of the air heater into the vehicle’s own air system is not permitted due to the system’s high pressure and temperature.

Fitted in the air heater on the heating air intake side is a temperature sensor, which operates the heater in the relevant range of performance in conjunction with the control dial dependent on the air intake temperature and position of the rated value transmitter. Heating performance is selected so that after quickly reaching the preselected indoor temperature it is maintained at this value. Air Top 2000 S heaters may be operated with an external temperature sensor (see 9.1.2).

Minimum inside diameter of the heating air duct is

55 mm. Standard diameter is 60 mm.

NOTE

For heating air ducting only materials may be used which are temperature-proof to at least 130 °C.

Maximum loss of pressure between suction and delivery side of the heating air duct 1.0 mbar (10 mm water column).

When exceeding this value the temperature limiter is very likely to respond. The heating air hose is to be secured at its joints.

801

8 Servicing

8.6.2 Fuel Supply

The fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for maximum pressure at the fuel extraction point are shown in Fig. 801.

Permissible fuel inflow height H

0.00 m (0.00 in.)

1.00 m (39.4 in.)

2.00 m (78.7 in.)

Maximum fuel intake height S

0.00 m (0.00 in.)

0.50 m (19.7 in.)

1.00 m (39.4 in.)

At maximum pressure in fuel line

0.20 bar (2.9 PSI)

0.11 bar (1.6 PSI)

0.03 bar (0.44 PSI)

At maximum negative pressure in fuel tank

-0.10 bar (-1.45 PSI)

-0.06 bar (-0.87 PSI)

-0.02 bar (-0.29 PSI) iØ2mm

Air Top 2000 S

I2 max. 3m (9.8 ft.) iØ2mm

8.6.2.1 Fuel Tapping

Vehicles with a Diesel Engine

The fuel must be taken from the vehicle fuel tank or from a separate tank (Figs. 802, 803 and 804). This separate fuel pickup precludes any effect of pressure.

Vehicles with an Injection Engine

When installing the heater in a vehicle with fuel injection systems, it is important to establish whether the fuel pump is located inside or outside the tank.

If the fuel pump is located inside the tank, fuel can only be extracted from the return line using a Webasto fuel tee fitting in which case it must be ensured that the return line continues almost to the bottom of the tank.

If this is not the case, a Webasto fuel standpipe

(see Figs. 802, 803 and 804) may be used.

If the fuel pump is installed outside the tank, the fuel connection may also be made between the tank and fuel pump, again using only the Webasto fuel tee fitting.

Vehicles with a Carburetor Engine

The fuel may only be extracted on cars using a special

Webasto fuel tee fitting as close to the tank as possible.

The connection may be made in either the supply or return line, in which case the return line must lead almost to the base of the tank. If this is not the case, the return line may be extended.

The fuel tee must be fitted in such a way that any air or gas bubbles are automatically discharged towards the tank.

The fuel tee should not be located near the engine, as gas bubbles may form in the lines on account of heat radiated from the engine. This may cause problems during combustion.

802

I2 iØ2mm

I 1 +

I 1

I 2

10 m (32.8 ft.)

1.2 m (3.9 ft.)

I 2

8.8 m (28.8 ft.)

I1

I1

Fig. 801 Fuel Supply

H

S

Air Top 2000 S

Hole Pattern

25 mm (1 in.)

Fuel Tank Tap

8 Servicing

Gaskets

Tank Fitting Plate

Fig. 802 Webasto Fuel Tank Tap

* Use fuel tank tap only on metal fuel tanks

Plastic Tank

Gasket

Fig. 803 Fuel Tapping from Plastic Tank

(tapping via fuel drain plug)

Fig. 804 Fuel Tapping from Plastic Tank

(tapping via fitting plate)

NOTE

The fitting plate must be made of sheet metal!

8.6.2.2 Fuel Lines

Fuel lines may only be steel, copper, or plastic lines made of unhardened, light and temperature stabilised

PA 11 or PA 12 ( e.g. Mecanyl RWTL) according to DIN

73378. As in most cases a permanently rising fuel line routing cannot be ensured, the inner diameter must not exceed a certain value. Starting from an inside diameter of 4 mm, air or gas bubbles accumulate resulting in malfunctions should the lines be descending or have sags.

The diameters specified in Fig. 801 will ensure that bubbles do not form.

A descending line routing from the dosing pump to the heater should be avoided.

Loose fuel lines must be secured in order to avoid sagging. The installation must ensure protection against stone impacts and

undue temperatures

(exhaust line).

The fuel line joints are to be secured against slipping with hose clamps.

803

8 Servicing

Connection of 2 Pipes with Hose

The proper connection of fuel lines with hoses is shown in Fig. 805.

Correct

Clamp

Wrong

Bubble

Bubble

Air Top 2000 S

8.6.3.1 Installation Location

It is advantageous to mount the dosing pump in a cool location. The ambient temperature must never exceed

+20 °C during operation.

Dosing pump and fuel lines must not be installed in locations exposed to heat radiated by hot vehicle components. A heat shield is to be provided as required.

8.6.3.2 Installation and Attachment

The dosing pump is to be attached with anti-vibration mounts. The installation location is limited according to

Fig. 806 to ensure sufficient self-venting capability. Due to the danger of corrosion the plug connection between dosing pump and dosing pump cable loom may only use

Webasto original parts.

Fig. 805 Pipe/Hose Connection

8.6.3 Dosing Pump

The dosing pump is a combined delivery, dosing, and shut-off system and is subject to certain installation criteria (see Figs. 801 and 806).

8.6.4 Fuel Filter

Only a Webasto filter, P/N 50487171A, is allowed to be used if the fuel is expected to be contaminated. Install vertically if possible, however at most horizontally (check flow direction).

0 - 90

°

A

AT 2000 S. 12 Volt and 24 Volt - Gasoline and Diesel

ø 5

Fig. 807 Fuel Filter

0-90°

0-90°

804

AT 2000 S D. 12 Volt and 24 Volt - Diesel DP 30

Installation Position only Horizontal

Fig. 806 Dosing Pump, Installation Position and Attachment

Air Top 2000 S

8 Servicing

8.6.5 Combustion Air Supply

Combustion air must under no circumstances be extracted from rooms with persons. The combustion air inlet must not point towards the forward direction of motion. It must be located so that no clogging by contamination is to be expected.

NOTE

For fuel operated heaters the combustion air tap must be located in a possibly cool and splash water proof position using a combustion air line.

If the air heater is located in a closed installation box, combustion air must be taken in from and the exhaust routed to the exterior. The feedthroughs must not allow exhaust fumes to enter the vehicle interior.

If a contamniated combustion air supply is expected, a combustion air filter (Ident No. 21963A) can be fitted

(Air Top 2000 S D only).

Both lines must be routed away from the heater in a descending attitude. If this is not possible, a condensate drain hole ø 4 mm must be provided at the lowest point.

Inner diameter of lines:

Combustion air line: 22 mm

Exhaust line: 22 mm

NOTE

When exceeding an exhaust line length of 2 m, insulated exhaust lines have to be used (below minimum dew point).

Smallest bending radius: 50 mm

In order to ensure the angle of 90° ± 10°, an attachment is required not further than 150 mm away measured from the exhaust pipe end.

8.6.6 Exhaust Line

Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only.

The exhaust pipe is secured to the air heater e.g. with a clamp.

The exhaust muffler is preferably mounted near the air heater. The direction of flow is optional.

ø 6,5

10

° 10

°

Exhaust exit direction nearly vertical 90°

±

10°

Fig. 808 Exhaust Muffler, Direction of Flow

Operation of the air heater is also permitted without muffler.

8.6.7 Combustion Air Intake and Exhaust Lines

In order to avoid damage to the dosing pump cable, no exhaust line may be used for the elongation of the combustion air intake line.

Length of the combustion air intake and exhaust line: with muffler: without muffler: max. 2.0 m max. 5.0 m

Fig. 809 Exhaust Pipe Outlet, Installation Position

WARNING

Any exhaust exit direction other than the one shown in

Fig. 809 may cause fires.

Sum of bends:

Combustion air line: max. 270°

Exhaust: max. 270°

805

8 Servicing

Air Top 2000 S

8.6.8 Electrical Connections

8.6.8.1 Connection Air Heater, Control Dial

Electrical connection is according to Circuit Diagram

Automatic Control (see Section 7).

For connection of the cable loom the cover (see 9.2.1.1) of the air heater has to be removed for connecting the cable loom plug(s) to the control unit. Avoid touching the control unit strip conductors.

Prior to first operation of the air heater the cover must be fitted to avoid the loss of heated air (air heater overheating).

The cable feedthrough may be from left or right.

8.6.8.2 Connection of Power Supply

Ideally from the vehicle’s central electrical system.

An additional blade terminal fuse holder is to be fitted to protect the heater and harness (supplied with the heater). The fuse holder should be installed as close as is practical to the power source e.g. in the vehicle battery enclosure.

The fuse holder is constructed of weather resistant components.

8.6.8.3 Connection Control Dial

The cable loom is prefabricated to connect to the control dial (rated value transmitter).

For plug disconnection pull on terminal plug only

(Fig. 812).

By pulling on the cable loom the terminal plug is secured (self-locking).

Fiber optic lens

(operation indicator)

Fig. 811 Control Dial

NOTE

The fiber optic lens must be in contact with the rotary knob.

AT 2000 S

F = 15A (12V)

F = 10A (24V)

Fig. 810 Weather Resistant Fuse Holder

Fig. 812 Pulling the Plug

806

Air Top 2000 S

8 Servicing

Fig. 813 Example of an Installation

807

8 Servicing

Air Top 2000 S

8.7

Removal and Installation 8.8

Start-Up

CAUTION

When the heater is installed it must not be dismantled.

8.7.1 Air Heater, Removal and Installation

8.7.1.1 Removal

1. Disconnect battery terminal leads.

2. Withdraw cover from upper housing shell according to 9.2.1.

3. Disconnect the wire harness plug from control unit.

4. Disconnect interior air ducts if present.

5. Disconnect cable to dosing pump at cable disconnect.

6. Disconnect fuel inlet on air heater.

7. Disconnect connections of combustion air intake and exhaust outlet on air heater.

8. Remove four nuts and lock washers on air heater.

9. Remove air heater and discard gasket.

After you have installed the heater, bleed the fuel supply system carefully.

NOTE

As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line.

Conduct a trial of the heater to check all the connections for leaks and to ensure that they are secure. If the heater suffers a fault during operation, the fault must be located and remedied.

8.7.1.2 Installation

1. Locate air heater with

new

gasket in installation position and secure with four nuts and lock washers

(use original Webasto nuts only).

2. Tighten nuts with 6 + 1 Nm.

3. Secure connection for fuel inlet on air heater.

4. Secure connections for combustion air inlet and exhaust outlet on air heater.

5. Route cable to dosing pump and connect to dosing pump.

6. Connect wire harness to control unit.

7. Install cover and secure.

8. Reconnect battery terminal leads.

9. Install interior ducting if present.

10. Bleed fuel supply system (see 8.8).

808

Air Top 2000 S

9 Repair

9.

Repair

9.1

General

This section describes the repairs that may be performed on the air heater Air Top 2000 S after it has been removed from the vehicle.

Any further disassembly will void the warranty.

For reassembly, only components of the proper spare parts and kits are to be used.

9.1.1 Work on Components after Disassembly

CAUTION

All gaskets located between disassembled components as well as the exhaust outlet seal must always be replaced and discarded.

9.1.1.1 Cleaning

All components disassembled must be cleaned with cleaning spirit and subsequently dried with pressurized air.

All sealing compound must be carefully removed from components using a suitable tool.

9.1.1.2 Visual Inspection

Examine all components for damages (cracks, deformation, wear, etc.) and replace as necessary.

Examine connectors and wiring for corrosion, loose contacts, wrong crimping, etc. and repair as necessary.

Check terminals for corrosion and contacts for security. Repair as required.

9.1.2.1 Installation of an External Temperature

Sensor

General

The heater can control the required temperature perfectly if its temperature sensor is exposed to the air of the main area of the vehicle. In certain circumstances, this is not always possible using the temperature sensor integrated in the control unit due to the installation circumstances (addition of fresh air). In this case proper temperature control can be ensured using an external temperature sensor fitted in the appropriate area.

Procedure

1. Select adequate installation location for external temperature sensor.

IMPORTANT

Temperature sensor should not be in the direct line of heated air flow or located in the vicinity of heating sources (e.g. vehicle’s own heater).

The sensor is to be installed at medium height in the vehicle interior on surfaces that are as vertical as possible.

The installation location should not be exposed to direct sun light.

Do not mount temperature sensor behind curtains or the like.

2. Mount external temperature sensor and route cable to control unit.

3. Connect connector X9 and install cover.

4. Perform test run and check control behaviour.

9.1.2 Incorporation of Modifications

NOTE

The continous design improvement of the heaters is intended to optimise their serviceability avoiding failures or malfunctions.

In general equipment in service may be retrofitted with available modification kits. In the following that modification which may be incorporated easily during maintenace: installation of an external temperature sensor for optimising temperature control of the Air Top 2000 S

(see 9.1.2.1).

X9

Control Unit

Cover

External

Temperature Sensor

Connector X9

901

9 Repair

Air Top 2000 S

9.2

Disassembly and Assembly

9.2.1 Removal of Housing Components/Covers

9.2.1.1 Cover for Electrical Connection

Dependent on the type of installation the cable loom exits the air heater either on the left or right.

The cover (1, Fig. 901) may be levered off using a blunt blade in the areas marked

X

.

9.2.1.2 Grates for Heating Air Inlet and Outlet

The grates (5, Fig. 901) can be released from the covers by twisting and pulling off forwards.

9.2.1.3 Covers for Heating Air Inlet and Outlet

Both covers (3 and 6, Fig. 901) can be released and removed by pressing the four detents on top and bottom using a suitable tool.

9.2.1.4 Upper Housing Shell

NOTE

The covers for the heating air inlet and outlet must be removed.

The upper shell (2, Fig. 901) can be raised by pulling up.

9.2.1.5 Lower Housing Shell

By gently pulling the lower shell (4, Fig. 901) on both

Y

the shell can be taken off the motor casing.

1

2

3

5

X

X

1 Cover, Electrical Connection

2 Upper Housing Shell

3 Cover, Heating Air Outlet

4 Lower Housing Shell

5 Grates

6 Cover, Heating Air Inlet

6

4

Y

5

Y

Fig. 901 Removal of Housing Components/Covers

902

Air Top 2000 S

9 Repair

9.2.2 Replacement of Control Unit

9.2.2.1 Removal

During removal avoid the build-up of static charge (i.e.

do not touch strip conductors).

1. Remove heater from vehicle (see 8.7.1.1).

2. Remove covers for heating air inlet and outlet

(6 and 3, Fig. 901) according to 9.2.1.3.

3. Remove upper housing shell according to 9.2.1.4.

4. Disconnect terminal connections (1, Fig. 902).

5. Remove screws (3) and remove control unit (2) with bracket (6).

6. Remove screw (7) to separate control unit (2) from bracket (6) if necessary.

7. Perform work on components after disassembly

(see 9.1.1).

9.2.2.2 Installation

NOTE

During installation avoid the build-up of static charge (i.e.

do not touch strip conductors).

1. Place control unit (2, Fig. 902) in position on bracket (6) and secure with screw (7).

2. Place control unit (2) with bracket (6) in installation position and secure with screws (3).

Torque screws to 0.7 ± 0.07 Nm.

3. Connect plug connections to terminal (Fig. 701).

4. Install upper housing shell and fix in position.

5. Slide on covers for heating air inlet and outlet and fix in position.

6. Install heater (see 8.7.1.2).

7. Check CO

2

setting and if necessary, adjust (see 6.2)

9.2.3 Replacement of Temperature Limiter

9.2.3.1 Removal

1. Remove heater from vehicle (see 8.7.1.1).

2. Remove covers for heating air inlet and outlet

(6 and 3, Fig. 901) according to 9.2.1.3.

3. Remove upper housing shell according to 9.2.1.4.

4. Disconnect plug connection (blue) from terminal.

5. Remove screws (4, Fig. 902).

6. Remove temperature limiter (5).

7. Perform work on components after disassembly

(see 9.1.1).

9.2.3.2 Installation

1. Place temperature limiter (5, Fig. 902) into installation position and secure with screws (4).

Ensure limiter is properly seated.

2. Torque screws to 1.5 ± 0.15 Nm.

3. Connect plug connections (blue) to terminal.

4. Install on upper housing shell and fix in position.

5. Slide on covers for heating air inlet and outlet and fix in position.

6. Install heater (see 8.7.1.2).

903

9 Repair

3

X6

1

7

2

6

Air Top 2000 S

5

4

904

1 Plug Connections

2 Control Unit

3 Screw (2)

4 Screw (2)

5 Temperature Limiter

6 Bracket

7 Screw

Fig. 902 Replacement of Control Unit and Temperature Limiter

Air Top 2000 S

9 Repair

1

!

MAX.

2

1 Insulation

2 Seal

Fig. 903 Replacement of Combustion Air Fan (Disassembly)

9.2.4 Replacement of Combustion Air Fan

9.2.4.1 Removal

1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 9.2.2.1).

3. Remove seal (2 Fig. 903) from lower housing shell and discard.

4. Remove air heater from lower housing shell.

5. Remove insulation (1, Fig. 903)

6. Remove screws (1, Fig. 904).

7. Withdraw combustion air fan (3) and remove gasket

(2).

8. Perform work on components after disassembly (see

9.1.1).

905

1 Screw (5)

2 Gasket

3 Combustion Air Fan

9 Repair

Air Top 2000 S

9.2.4.2 Installation

1. Ensure that sealing surfaces on combustion air fan and on heat exchanger are not damaged.

2. Place new gasket (2, Fig. 904) onto flange of combustion air fan (3).

3. Place combustion air fan into assembly position and mount using screws (1). Torque screws (1) to 6 Nm.

CAUTION

To ensure the proper function of the heater and to prevent malfunctions of the temperature sensor, the following must be observed when installing the wire insulating mesh:

• The wire insulating mesh must be installed as shown in Fig. 903 to prevent unwanted contact with the temperature sensor terminals.

• Loose wire strands of the mesh must be cut off to prevent contact with the temperature sensor.

• Ensure a secure fit between the heat exchanger,

insulating mesh, and the upper housing.

• An overly worn, damaged or flattened insulating mesh must be replaced with a new mesh.

4. Place wire insulating mesh into position on the heat exchanger (1, Fig. 903).

5. While slightly spreading the lower housing shell, place over heat exchanger until guide slots engage with pins on fan housing.

6. Fit new seal (2, Fig. 903) on heater mount base.

7. Install control unit (see 9.2.2.2).

8. Install upper housing shell, air inlet and air outlet.

9. Install air heater (see 8.7.1.2).

10. Check CO

2

setting and adjust as required (see 6.2).

1 Screw (5)

2 Gasket

3 Combustion Air Fan

1

906

2

Before assembly always renew gasket.

Combustion air fan must not be disassembled any further

3

Fig. 904 Replacement of Combustion Air Fan (Assembly)

Air Top 2000 S

9 Repair

9.2.5 Replacement of Flame Sensor

9.2.5.1 Removal

1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 9.2.2.1).

3. Remove combustion air fan (see 9.2.4.1).

4. Remove screws (3, Fig. 905) and spoiler (2) for cable protection.

5. Push out cable grommet (10) towards inside.

6. Carefully bend up locking tab (4) and withdraw flame sensor (1) from burner insert (5).

7. Remove flame sensor.

8. Perform work on components after disassembly

(see 9.1.1).

9.2.5.2 Installation

CAUTION

Route cable of flame sensor below fuel pipe.

1. Pass flame sensor (1, Fig. 905) below fuel pipe, feed connector through opening and push in cable grommet (10).

2. Feed cable with protection sleeve through locking tab and insert flame sensor (1) into burner insert (5).

3. Squeeze locking tab (4).

4. Secure burner insert (5) with four screws (3) and fit spoiler (2) for cable protection.

5. Pull cable of flame sensor tight.

6. Torque all 4 screws (3) to 6 ± 0.6 Nm.

7. Mount combustion air fan (see 9.2.4.2).

8. Install control unit (see 9.2.2.2).

9. Install air heater (see 8.7.1.2).

9.2.6 Replacement of Glow Plug

9.2.6.1 Removal

1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 9.2.2.1).

3. Remove combustion air fan (see 9.2.4.1).

4. Push out cable grommets (9 and 10, Fig. 905) towards inside.

5. Remove four screws (3) and spoiler (2).

6. Tilt and withdraw burner insert (5) carefully.

NOTE

Ensure that burner insert (5) has separated from burner tube (6).

CAUTION

The glow plug has to be pulled out with utmost care and must under no circumstances be twisted (danger of breaking). After a long period of combustion operation the glow plug may be caked by fuel deposits. In this case allow penetrating oil to react long enough to free glow plug for removal.

7. Loosen screw (13) and remove glow plug (11) from burner insert.

8. Perform work on components after disassembly (see

9.1.1).

9.2.6.2 Installation

1. Insert new gasket (7, Fig. 905) into heat exchanger and place combustion tube (6) in assembly position.

2. Ensure that starting air bore is not clogged. If required clean with wire (approx. 1 mm ø) (see Detail A).

CAUTION

During glow plug installation observe twist lock (see Detail B). That means that the glow has to be inserted so that the contacts point towards the heat exchanger.

Otherwise there will be the danger of a short circuit.

3. Feed glow plug (11) into burner insert (5) and arrange cable protective sleeve in slot of burner insert.

CAUTION

When performing the following step ensure that glow plug is inserted in burner insert fully against stop.

4. Secure glow plug (11) with screw (13). Torque screw

(13) to 0.5 Nm.

5. Locate burner insert (5) in heat exchanger (8) observing that cable of flame sensor is positioned below fuel pipe.

6. Feed connectors of glow plug and flame sensor through openings and push in cable grommets (9 and 10).

CAUTION

When performing the following step ensure that there is a tight fit between grommet (12) and heat exchanger (8).

7. Secure burner insert (5) using screws (3) and attach spoiler (2). Torque screws (3) to 4 Nm.

8. Mount combustion air fan (see 9.2.4.2).

9. Install control unit (see 9.2.2.2).

10. Install air heater (see 8.7.1.2).

907

9 Repair

8

7

6

4

5

11

3

1 Flame Sensor

2 Spoiler

3 Screw (4)

4 Locking Tab

5 Burner Insert

6 Combustion Tube

7 Gasket

8 Heat Exchanger

9 Cable Grommet

10 Cable Grommet

11 Glow Plug

12 Grommet

13 Screw

1

2

Fig. 905 Disassembly of Heat Exchanger (Sheet 1 of 2)

13

12

908

Air Top 2000 S

9

10

Air Top 2000 S

Detail A

Starting Air Bore

9 Repair

Detail B

Fig. 906 Disassembly of Heat Exchanger (Sheet 2 of 2)

Twist Lock

909

9 Repair

9.2.7 Replacement of Burner Insert,

Combustion Tube, and Heat Exchanger

CAUTION

If the heat exchanger is going to be replaced, the temperature limiter must also be replaced.

9.2.7.1 Removal

1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 9.2.2.1).

3. Remove combustion air fan (see 9.2.4.1).

4. Remove flame sensor (see 9.2.5.1).

5. Remove glow plug (see 9.2.6.1).

CAUTION

When performing the following step ensure that fuel connection is not bent.

6. Remove burner insert (5, Fig. 905).

7. Withdraw combustion tube (6) from heat exchanger

(8) and remove gasket.

8. Perform work on components after disassembly (see

9.1.1).

9.2.7.2 Installation

1. In case a new heat exchanger is fitted, secure temperature limiter (5, Fig. 902) with screws (4).

Torque screws to 1.5 ± 0.15 Nm.

2. Fit new gasket (7, Fig. 905).

3. Bring combustion tube (6) in assembly position.

NOTE

The burner insert will be secured when installing flame sensor and glow plug.

CAUTION

When performing the following step ensure that the fuel connection is not bent.

4. Install glow plug (see 9.2.6.2).

5. Install flame sensor (see 9.2.5.2).

6. Mount combustion air fan (see 9.2.4.2).

7. Install control unit (see 9.2.2.2).

8. Install air heater (see 8.7.1.2).

Air Top 2000 S

910

Air Top 2000 S

10. Packaging/Storage and Shipping

10.1 General

When it is necessary to ship the heater and its components to a Webasto repair center for inspection or repair, they are to be cleaned and packaged so that they are protected against damage during handling, transportation, and storage.

In storage an ambient temperature of +85 °C and -40 °C must not be exceeded.

10 Packaging/Storage and Shipping

06/2008 1001

Notes

Air Top 2000 S

Org. 06/2008 Rev. N/A P/N LIT9000557A © 2008 Webasto Product N.A., Inc.

W

EBASTO

P

RODUCT

N.A., I

NC

.

15083 North Road

Fenton, MI 48430

Technical Assistance Hotline

USA: (800) 860-7866

Canada: (800) 667-8900 www.techwebasto.com

www.webasto.us

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