Air Heaters Installation Instructions Air Top 2000 S Type AT 2000 S-B (Petrol) Type AT 2000 S-D (Diesel) Modèle AT 2000 S-B (Essence) Modèle AT 2000 S-D (Diesel) 5/2000
Air Top 2000 S Table of Contents Page Installation Instructions Legal Provisions for Installation Installation Heating Air System Installation diagram Installation Example Fuel Supply Combustion Air Supply Exhaust Pipe Electrical Connections Connection diagram Circuit Diagrams Legende for Circuit diagrams Initial Operation Shut-Down on Faults Technical Data Version Drilling Template II 1 3 5 6 7 8 11 11 12 14 15 22 23 23 24 25 26
Air Top 2000 S Installation Instructions Legal Provisions for Installation For testing the heater in accordance with §§ 19, 20 or 21 StVZO (German Road Licensing Regulations) the following regulations are primarily to be observed (§ 22 a StVZO): NOTE: These provisions are binding within the scope of the StVZO and should also be observed in countries where no special regulations are in effect! Within the scope of the StVZO (German Road Licensing Regulations) “General Design Certifications” have been granted
Air Top 2000 S hicle through a sealed bush. The heat exchanger, the connected exhaust pipe as well as any drain pipe that may be connected must be so sealed that in the event of an overpressure equivalent to the twofold overpressure of the exhaust gas at maximum permissible exhaust pipe length – however, at a minimum overpressure of 0.5 mbar – a leakage rate of a total of 30 l/h is not exceeded.
Air Top 2000 S Scope of Application of the Air Heaters 8 The Webasto Air Top 2000 S air heaters are designed to provide the following features: - heating the vehicle’s saloon, - defrosting the vehicle’s windows. 2 1 The heaters operate independently of the vehicle engine and are connected to the fuel tank and the electrical system of the vehicle. They can be used in vehicles with water-cooled or aircooled engines.
Air Top 2000 S CAUTION: After the installation has been performed, a check must be carried out to verify that no part of the housing is in contact with any surrounding parts. Non-compliance could result in a blockage of the heater fan. Unobstructed installation to be ensured! Fig. 3: Hole Pattern Fig. 5: A gasket (Fig. 4) must be fitted between heater and car body. The gasket must be renewed prior to each reinstallation. The support surface for the heater mounting foot must be level.
Air Top 2000 S Heating Air System Mounting of External Temperature Sensor NOTE: It is not permissible to integrate the heater into the vehicle’s air ducting system. The external temperature sensor must be mounted in the vehicle cab at mid-height on surfaces as vertical as possible. The air heater can be operated in the recirculating air mode only. - The temperature sensor must not - be located directly in the hot air stream (vehicle’s or heater’s heating air).
Air Top 2000 S Digital timer: comfort accessory ❉ Fuel filter: option ❉ Petrol-operated heater without damper Fig.
Air Top 2000 S 1 2 3 4 5 6 7 Heater control dial Heater Metering pump and damping device Fuel filter (accessory) Tank extracting device Exhaust silencer (accessory) Fuse Petrol-operated heater without damper ❉ 1 2 7 ❉ 3 4 5 6 Fig.
Air Top 2000 S Fuel Supply Fuel is extracted from the vehicle’s fuel tank or a separate fuel tank. The values relating to the permissible pressure at the fuel extraction point are shown in Fig. 10. permissible fuel feed height H (m) at max. permissible overpressure (bar) in fuel line 0.00 0.2 1.00 0.11 2.00 0.03 permissible fuel suction height S (m) at max. permissible underpressure (bar) in fuel tank 0.00 -0.10 0.50 -0.06 1.00 -0.
Air Top 2000 S Vehicles with Carburetor Engines Vehicles with Fuel Injection Engines In passenger cars, fuel may only be extracted with the special Webasto fuel pickup (see Fig. 11) and as close to the tank as possible. The connection can be made either in the flow or the return pipe whereby it must be ensured that the return pipe reaches almost to the bottom of the tank. Failing this, the return pipe can be extended.
Air Top 2000 S fuel extracting device sealing ring the inside diameter must not exceed a given dimension. If the inside diameter is equal to or larger than 4 mm, air or gas bubbles accumulate which result in malfunctions if the lines sag or are routed in a downward pitch. When the diameters shown in Fig. 10 are used, you can be sure that no unwanted bubbles will be formed. The lines leading from the metering pump to the heater should not be routed in a downward pitch.
Air Top 2000 S Installation Location Combustion Air Supply It is recommended that the metering pump be installed in a cool location. The permissible ambient temperature must not exceed a temperature of + 20°C at any given operating state. Metering pump and fuel lines must not be mounted within the radiation range of hot vehicle parts. If necessary, a radiation protection is to be provided. On no account may the combustion air be extracted from areas where persons are present.
Air Top 2000 S The lines must be so arranged that any clogging due to contamination is not to be expected. To ensure an angle of discharge of 90° ± 10°, it is required that the pipe clamp be attached no more than 150 mm, from the exhaust pipe end Electrical Connections NOTE: When using the combination or standard digital timer a remote-control pushbutton may be provided near the bunk for added convenience. The connection is to be performed in accordance with wiring diagram 32, 33, 35 or 36.
Air Top 2000 S heaters may only be switched on by means of a special switch installed in the driver’s cabin and are to be actuated manually. If the heater is equipped with a combination or standard digital timer, it must ensured that pin 4 on the combination or standard digital timer remains unassigned. The heater can therefore only be started up by means of the instant heating button. No other digital timers are allowed to be used in ADR vehicles.
Air Top 2000 S Jumper Terminal 15 Terminal 58 Terminal 30 Terminal 31 Fig.
Air Top 2000 S ➁ ϑ ϑ ϑ Fig.
Air Top 2000 S 30 30 15 15 58 58 F2 rt 2 6 4 A2 X11 0,5mm² gr 3 8 6 P1 9 7 4 6 0,5mm² ws 5 4 8 1 X6 X6 X1,2,3,4,5 1 2 1 2 vi/ws X1 vi ge X4 ge M 1 2 X3 br 2 X9 ϑ br E B1 1 1 X2 2 13 5 2 1 2 bl X5 bl ϑ B2 ϑ sw A1 S3 B3 4 6 7 8 X9 X8 2 1 X11 bl X8 br 1 2 M 1,0 mm² ➁ X12 5 3 0,5mm² bl 0,5mm² vi 2 0,5mm² gn/ws br 12 0,5mm² sw 7 sw H7 X5 X4 X3 X2 X1 X9 1 0,5mm² rt H8 B1 B3 A2 X11 11 2 E X6 X13 10 H9 A2 1,0 mm² ➀ 1 B2 6 X12
Air Top 2000 S B2 30 30 15 15 58 58 F2 rt 6 2 0,5mm² rt 4 A2 1 X11 0,5mm² gr 3 0,5mm² sw 7 H7 8 6 7 4 0,5mm² ws 0,5mm² bl 5 9 8 X6 1 1 2 1 2 vi/ws X1 vi ge X4 ge M 3 M 1 2 X3 br 2 X9 ϑ br E B1 1 1 X2 S3 2 1 2 bl X5 bl ϑ B2 ϑ sw S1 A1 B3 1 13 5 2 2 X7 1 4 4 6 7 8 X9 2 3 X8 2 1 X11 X8 bl 4 br 1,0 mm² X7 X6 X1,2,3,4,5 4 br 12 ➁X12 5 3 6 P2 0,5mm² vi 2 0,5mm² gn/ws sw H8 H9 X5 X4 X3 X2 X1 X9 11 2 B1 B3 X6 X13 10 E A2
Air Top 2000 S ϑ ϑ ϑ Fig.
Air Top 2000 S S2 30 15 15 58 58 D+/61 B2 A2 E B1 B3 D+/61 F2 0,5mm² gr rt ➀ X13 1 10 2 6 4 11 A2 1 0,5mm² rt 3 H8 H7 8 6 P1 9 7 4 4 8 1 X6 X1,2,3,4,5 1 2 1 2 vi/ws X1 vi ge X4 ge M 1 2 X3 br 2 X9 ϑ br E B1 1 1 X2 2 13 5 2 2 1 2 bl X5 bl ϑ 4 6 7 8 X9 ϑ B2 sw A1 S3 X8 B3 2 1 X11 X8 br 1 X11 M 1,0 mm² X12 X6 6 0,5mm² ws 5 6 X12 bl 12 vi 0,5mm² 5 3 0,5mm² bl X9 2 0,5mm² gn/ws br H9 0,5mm² sw 7 X5 X4 X3 X2 X1 X6 sw 2 A2 X11
Air Top 2000 S S2 30 15 15 58 58 D+/61 B2 A2 S4 F2 S5 A2 X11 0,5mm² gr rt X13 1 10 2 6 4 11 A2 1 0,5mm² rt X9 3 H7 8 6 P1 9 4 4 8 1 X6 1 2 1 2 vi/ws X1 vi ge X4 ge M 1 2 X3 br 2 X9 ϑ br E B1 1 1 X2 1 2 13 5 2 2 1 2 bl X5 bl B3 4 6 7 8 X9 ϑ B2 sw A1 S3 X8 2 ϑ 1 X11 X8 br 1,0 mm² M 86 87 87a 6 X12 K 85 S2 X1,2,3,4,5 X11 bl 7 X6 6 0,5mm² ws 5 br 12 gn/ws 0,5mm² 5 3 0,5mm² bl X12 2 0,5mm² vi H8 H9 0,5mm² sw 7 sw 2 X5 X
Air Top 2000 S ϑ ϑ ϑ Fig.
Air Top 2000 S Legende for circuit diagrams: Pos. A1 A2 B1 B2 B3 E F2 H1 H6 H7 H8 H9 M P1 P2 S1 S2 S3 S4 S5 X1-X5 X6 X7 X8 X9 X11 X12 X13 Y1 Y2 Y3 22 Designation Heater Electronic control unit Flame detector Temperature sensor Overheating protection Pencil-type glow plug Fuse 24V 10A/12V 15A LED Lamp (min. 1.2W) LED Heating symbol in display (in pos. P) Lamps (in pos. P) Motor Combination timer (1531) Standard digital timer (1531) Control element Disconnecting switch 1 or 2 poles.
Air Top 2000 S Initial Operation Shut-Down on Faults Fault Code Display After the heater has been installed, the fuel supply system is to be bled thoroughly. Faults related to individual heater components and malfunctions during the start-up sequence are detected in the control unit.
Air Top 2000 S Technical Data Heater Unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient temperature of +20°C and at the rated voltage and conditions. Type Electrical Components: Control unit, motor, fuel metering pump, light bulb in the digital timer* and pencil-type glow plug are designed either for 12-volt or 24-volt operation. Fuel consumption The digital timer*, temperature limiter and flame detector are voltage-independent components.
Air Top 2000 S Version AT 2000 S-B (Petrol) Air heaters for petrol fuel (12 volts) AT 2000 S-D (Diesel) Air heaters for “Diesel/EL Fuel Oil EL” (12 or 24 volts) 25
Air Top 2000 S Gasket NOTE: Max. floor unevenness in the vicinity of the gasket: 1mm Fig.
Service Phone Line In case you encounter technical problems with your auxiliary heater - Webasto's world-wide Service Network will be glad to assist you! Simply dial the Service Phone Number for your country as indicated below.
