Air Heater Air Top 2000 S B (Gasoline) Air Top 2000 S D (Diesel) Installation 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.
Air Top 2000 ST Table of Contents Contents Page 1. Safety and General Information 1.1 1.2 1.3 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional Documentation to be Used . . . . . . . . . . . . . . .
Table of Contents Air Top 2000 S 14. Starting the Heater for the First Time 27 14.1 Control Element Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 15. Fault Lock-out 28 15.1 Error Code Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 16. Technical Data 29 16.1 Electrical Components: . . . . .
Air Top 2000 S 1. 1.1 Safety and General Information Safety and General Information General Information Webasto Product North America, Inc. is pleased to provide this installation manual with the Air Top 2000 S heating system. When used according to the guidelines stated in this manual, you can expect to provide years of trouble-free, enjoyable operation for your customer. This manual represents our latest effort to produce the best technical documentation possible.
Regulation for Installation in the Vehicle 2. Air Top 2000 S Regulation for Installation in the Vehicle Read this installation manual in its entirety before installing this equipment. 2.1 Scope 2.1.1 Subject to the provisions of paragraph 2.1.2, internal combustion heaters must be installed in accordance with the requirements contained in this Annex. 2.1.2 In the case of class trailers with heaters for liquid fuel, it is presumed that these vehicles comply with the requirements in this Annex. 2.
Air Top 2000 S 2.6 Regulation for Installation in the Vehicle Hot Air Inlet 2.6.1 The supply of heating air must consist of either fresh air or recirculated air and must be taken from a clean area which cannot be contaminated by exhaust fumes from the engine, the internal combustion heater or any other source in the vehicle. 2.6.2 The inlet line must be protected by a grating or other suitable means. 2.7 Hot Air Outlet 2.7.
Purpose of the Air Heater 3. Air Top 2000 S Purpose of the Air Heater The Webasto Air Top 2000 S air heaters are designed – to heat cabins, boats, trucks, minibuses, vans and motor homes – to defrost vehicle windows The air heaters operate independently of the engine and are connected to the fuel tank and the electrical system of the vehicle. They may be used for vehicles with either water or air-cooled engines. They are not designed for heating hazardous substances. Webasto Product N.A., Inc. 6 www.
Air Top 2000 S 4. Installation Installation WARNING: The regulations governing installation, beginning on page 4, must be adhered to. The heater must not be operated without the control unit cover (this will cause the heater to overheat). 4.1 4.2 Recommended Installation and Service Tools • Digital Multi-Meter - Should be a good quality VAO meter. • 1/2 Heavy-Duty, low speed drill with good quality, sharp drill bits and a selection of hole saws. • Mounting/ Drilling Templates.
Installation 4.4 Air Top 2000 S To Install the Heater The M6 nuts must be tightened with a torque of 6 Nm +1 Nm for installing the Air Top 2000 S heater. The installation dimensions and space requirement for service access are shown in the installation drawing (Figure 1). The specified horizontal and axial angles must not be exceeded (Figure 2). Figure 2.
Air Top 2000 S 4.5 Installation Optional Mounting Plate 1 2 3 1. Seal - Heater to vehicle floor or optional mounting plate. 2. Mounting plate - Facilitates installation on corrugated vehicle floors. 3. Closed Cell Foam Gasket - Seals area between mounting plate and vehicle floor. WARNING: The seal or foam gasket or both must be replaced each time the heater is removed and reinstalled. A mounting plate template is provided in the installation kit for locating the heater on the floor of the vehicle.
Factory Plate 5. Air Top 2000 S Factory Plate The model/serial number plate of the heater must be positioned so that it cannot be damaged and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used). Inapplicable years must be erased from the model plate. Webasto Product N.A., Inc. 10 www.techwebasto.
Air Top 2000 S Installation Example 7 1 6 2 3 4 5 1 2 3 4 5 6 7 Control Element AT 2000 S Heater Fuel Metering Pump Fuel Filter (Optional) Fuel Satndpipe Exhaust Muffler (Optional) Fuse Block 6. Installation Example Figure 7. Installation example with heater in stalled under-bunk. (Recirculation mode) www.webasto.us 11 Webasto Product N.A., Inc.
Hot Air System 7. Air Top 2000 S Hot Air System NOTE: The heater must not be integrated into the vehicle’s air system. Both recirculation and fresh air modes are possible. For fresh air mode it must be ensured that the hot air is taken from an area protected from splashing water and spray and in such a way that no water can ingress into the heater if the vehicle travels through a water hazard for which that vehicle is licensed.
Air Top 2000 S Hot Air System NOTE: The installation must be checked for: –Air short circuit between the vehicle’s heating system and the heater air inlet. –Air short circuit between the heater’s air inlet and the heater’s air outlet (Figure 8). Figure 9. Hot air inlet with inlet grille If you use an installation box the air vent must be sealed in such a way that no hot air can get into the installation box. 7.
Fuel Supply 8. Air Top 2000 S Fuel Supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in Figure 11. Permissible fuel inflow height H At max. pressure in fuel line 0.00 m (0.00 in.) 0.2 bar (2.9 PSI) 1.00 m (39.4 in.) 0.11 bar (1.6 PSI) 2.00 m (78.7 in.) 0.03 bar (0.44 PSI) Maximum fuel intake height S At max. negative pressure in the fuel tank 0.00 m (0.00 in.) -0.10 bar (-1.45 PSI) 0.
Air Top 2000 S 8.2 Fuel Supply Vehicles with Fuel Injection Engines When installing the heater in a vehicle with fuel injection system, it is important to establish whether the fuel pump is located inside or outside the tank.
Fuel Supply Air Top 2000 S Tank Connector Sealing ring Plastic tank Tank Fitting Sealing ring Figure 14. Fuel supply from plastic tank drain screw 8.4.1 Figure 15. Fuel supply from plastic tank fitting Connecting Two Fuel Lines with a Coupler Hose The correct procedure for connecting fuel lines with hosing is shown in Figure 16. Ensure that there are no leaks. Correct Clamp Wrong Bubble Bubble Figure 16. Fuel line / coupler hose connection 8.
Air Top 2000 S 8.5.2 Fuel Supply Installation and Attachment The metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in Figure 17 in order to ensure effective automatic bleeding. As a result of the risk of corrosion, only genuine Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness. 8.
Combustion Air Supply 9. Air Top 2000 S Combustion Air Supply Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt and road debris. NOTE: An intake silencer must be fitted if the intake hose length is greater than 0.6 m (24 in.).
Air Top 2000 S Exhaust Pipe 10. Exhaust Pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm (3/64 in.) or flexible piping of alloyed steel only must be used as exhaust line. The exhaust pipe is secured to the heater using a clamping collar, for example. See the ‘regulations for installation’ for other requirements. The exhaust muffler should ideally be installed near the heater. The heater may also be operated without a muffler. Ø 6.5 0-90° 0-90° Figure 19.
Combustion Air Inlet and Exhaust Lines Air Top 2000 S 11. Combustion Air Inlet and Exhaust Lines Both lines are to be installed falling away from the heater. If this is not possible, a condensate drain hole with a diameter of 4 mm (5/32 in.) must be made at its lowest point. Figure 20. Prevent the formation of condensate The lines must not point to the front of the vehicle. Figure 21.
Air Top 2000 S Electrical Connections 12. Electrical Connections All the cables and wires that are not required must be insulated against accidental shorting or grounding. NOTE: The electrical connection is made as shown in the system circuit diagram (Figure 31). 12.1 Heater Connection To connect the wiring harness, remove the control unit cover on the heater and connect the wiring harness plug to the control unit. Figure 24.
Electrical Connections Air Top 2000 S 12.3 Control Element (Rheostat) Connection The wiring harness is prepared for connection to the control element. Simply pull on the connector housing to unplug the connector. Shaft requires a 12 mm (15/32 in.) hole to mount. The connector housing can be locked (self-locking action) by simply pulling on the wiring harness. Locate the control element in a convenient location. The control element is not affected by temperature.
Air Top 2000 S Circuit Diagrams 13. Circuit Diagrams 13.
31 58 S1 H1 2 1 4 3 X7 0,5mm² ws 0,5mm² bl 8 5 3 7 1 X6 0,5mm² sw 0,5mm² rt br 15 A1 vi/ws M X1 1 rt 2 vi ge 2 E X4 1 F2 2 ge B1 X3 2 - 1 br B2 X9 2 - 1 6 X2 1 4 Y1 sw br 24 sw Webasto Product N.A., Inc.
31 P1 H9 12 1 1,0 mm² 58 10 1 7 4 S3 H8 H7 11 9 6 8 2 X13 1 3 X6 8 0,5mm² ws 5 0,5mm² bl 0,5mm² sw 7 0,5mm² rt 1,0 mm² br 15 A1 vi/ws M M E 1 2 2 vi ge ge X4 X1 1 rt 2 F2 B1 1 X3 br br 2 B2 X9 2 - 1 6 X2 1 4 Y1 sw br 25 sw www.webasto.
31 P2 H9 12 10 1 S3 7 H8 4 S1 H7 11 9 6 8 2 X13 0,5mm² bl 2 1 4 3 X7 1 X6 8 5 3 0,5mm² sw 7 0,5mm² rt 1,0 mm² 0,5mm² ws 1 1,0 mm² 58 br 15 A1 vi/ws M M E 1 2 2 vi ge X4 ge X1 1 rt 2 F2 B1 1 br X3 br 2 B2 X9 2 - 1 6 X2 1 4 Y1 sw br 26 sw Webasto Product N.A., Inc.
Air Top 2000 S Starting the Heater for the First Time 14. Starting the Heater for the First Time 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 and prime the system. 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. 14.
Fault Lock-out Air Top 2000 S 15. Fault Lock-out The control unit continuously monitors the heater operation. The control unit identifies errors on individual heater components and faults during operation. Should the control unit experience component errors and operational faults, the heater will be shut down.
Air Top 2000 S Technical Data 16. Technical Data Except where limit values are specified, the technical data refer to the usual heater tolerances of ±10% at an ambient temperature of +20 °C (68 °F) and at the rated voltage and in rated conditions. 16.1 Electrical Components: Control unit, motor, metering pump, lamp in the timer and ceramic glow pin are designed for either 12 V or 24 V. The timer, flame sensor and temperature limiter component are not dependent on voltage. 16.
Version Air Top 2000 S 17. Version Air Top 2000 S B (Gasoline) Air heater for gasoline (12 V) Air Top 2000 S D (Diesel) Air heater for Diesel/heating oil (12 or 24 V) Webasto Product N.A., Inc. 30 www.techwebasto.
Air Top 2000 S Drilling Template 18. Drilling Template Ø 26 Ø 26 44 Ø 7.5 12 Ø 7.5 Ø 7.5 18 55 Figure 35. Drilling Template (Dimensions in millimeters) www.webasto.us 31 Webasto Product N.A., Inc.
Technical Service Bulletins / Product Information / Updates Air Top 2000 S Technical Service Bulletin 19.
Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 432-8371 Canada: (800) 667-8900 Org. 11/2007 Rev. N/A P/N AT2S-Install www.webasto.us www.techwebasto.
