AT2000ST_Installation_Instructions.
AT2000ST_Installation_Instructions.book Page 1 Wednesday, May 29, 2013 12:54 PM Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder tödliche Verletzungen hervorgerufen werden. Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines Webastotrainings, technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
AT2000ST_Installation_Instructions.book Page I Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Inhaltsverzeichnis Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 I Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . 1 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 5 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typschild . . . . . . . . . . . . . . . . .
AT2000ST_Installation_Instructions.book Page 39 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 1 Statutory regulations governing installation Statutory regulations governing installation Type approvals according to ECE-R 10 (EMC) and ECE-R 122 (Heater) exist for the Air Top 2000 ST heater. See chapter 16, "Technical data" for the approval number. Primarily the regulations of Part I and Annex 7 of the directive ECE-R 122 must be observed for the installation.
AT2000ST_Installation_Instructions.book Page 40 Wednesday, May 29, 2013 12:54 PM Statutory regulations governing installation Requirement for basic unit: A maximum run-on period of 40 seconds is permitted when the combustion heater is switched off. Only combustion heaters with heat exchangers that are approved for this reduced run-on time of 40 seconds may be used. Air Top 2000 ST 5.3.2.
AT2000ST_Installation_Instructions.book Page 41 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Statutory regulations governing installation 5.3.6.2 The inlet duct must be protected by mesh or other suitable means. 1.3. Extract from directive ECE-R 122 Annex 9 Start of extract. 5.3.7 Heating air outlet 5.3.7.1 Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched. 5.3.7.
AT2000ST_Installation_Instructions.book Page 42 Wednesday, May 29, 2013 12:54 PM Statutory regulations governing installation 3.3 FL vehicles 3.3.1 The combustion heaters shall be put out of operation by at least the following methods: a) Intentional manual switching off from the driver’s cab; b) Stopping of the vehicle engine; in this case the heating device may be restarted manually by the driver; c) Start up of a feed pump on the motor vehicle for the dangerous goods carried.
AT2000ST_Installation_Instructions.book Page 43 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 2 Use of the air heaters Use of the air heaters The Webasto Air Top 2000 ST air heaters are designed – to heat cabins, boats, trucks, minibuses, vans and motorhomes – to defrost vehicle windows The heaters operate independently of the engine and are connected directly to the fuel tank and the electrical system of the vehicle. They may be used for vehicles with either water or air-cooled engines.
AT2000ST_Installation_Instructions.book Page 44 Wednesday, May 29, 2013 12:54 PM Installation 3 Installation IMPORTANT The statutory regulations governing installation on pages 1 and 2 must be adhered to. The requirements of the latest version of the ADR must also be observed for the installing the heater into vehicles used to transport hazardous substances. The heater must not be operated without the control unit cover (this will cause the heater to overheat). 3.1.
AT2000ST_Installation_Instructions.book Page 45 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Installation 8 1 2 7 3 5 4 6 1 2 3 4 Fig.
AT2000ST_Installation_Instructions.book Page 46 Wednesday, May 29, 2013 12:54 PM Installation Air Top 2000 ST Air Top 2000 ST - diesel: Air Top 2000 ST - petrol: horizontally Fig. 3: Seal Ensure that all moving parts can move easily! Fig. 2: Permitted installation positions for heaters Fig.
AT2000ST_Installation_Instructions.book Page 47 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 4 Type label Type label The model plate 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.
AT2000ST_Installation_Instructions.book Page 48 Wednesday, May 29, 2013 12:54 PM Installation example 5 Air Top 2000 ST Installation example 1 2 3 4 5 6 7 Control element Heater Metering pump Fuel filter (accessory) Tank connector Exhaust silencer (accessory) Fuse 1 7 2 3 4 6 Fig.
AT2000ST_Installation_Instructions.book Page 49 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 6 Hot air system Hot air system NOTE: The heater must not be integrated into the vehicle’s air system. Inside the control unit there is a temperature sensor, which operates the heater in the appropriate heat output range in conjunction with the control element depending on the intake temperatures and the position of the setpoint generator.
AT2000ST_Installation_Instructions.book Page 50 Wednesday, May 29, 2013 12:54 PM Hot air system IMPORTANT If you use the heater without a hot air inlet hose, the inlet grille supplied with the heater must be used at all times. 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 6) Fig.
AT2000ST_Installation_Instructions.book Page 51 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 7 Fuel supply 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 8. Permissible fuel inflow height H (m) At max. perm. pressure (bar) in fuel line 0,00 0,2 1,00 0,11 2,00 0,03 Maximum fuel intake height S (m) At max. perm.
AT2000ST_Installation_Instructions.book Page 52 Wednesday, May 29, 2013 12:54 PM Fuel supply Air Top 2000 ST 7.1. Vehicles with carburettor engines The fuel may only be extracted using the special Webasto fuel extractor (see Figure 9) as close to the tank as possible. The connect 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 (see Figure 10).
AT2000ST_Installation_Instructions.book Page 53 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Fuel supply NOTE: The tank fitting must be made from metal! Plastic tank 7.4. Fuel lines Only steel, copper and plastic lines of plasticised, light and temperaturestabilised PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines. Since the lines normally cannot be routed with a constant rising gradient, the internal diameter must not be allowed to exceed a certain size.
AT2000ST_Installation_Instructions.book Page 54 Wednesday, May 29, 2013 12:54 PM Fuel supply Air Top 2000 ST 7.4.1. Connecting two pipes with a hose The correct procedure for connecting fuel lines with hosing is shown in Figure 13. Ensure that there are no leaks. Air Top 2000 ST 12 V - petrol Correct Preferably 15° - 90° Clip Metering pump Wrong Bubble Bubble Installation position of damper Fig. 14: Metering pump DP 2 with damper Installation position Air Top 2000 ST 12 V and 24 V - diesel Fig.
AT2000ST_Installation_Instructions.book Page 55 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Fuel supply 7.5.2. Installation and attachment The metering pump must be secured with a vibration-damping mounting (for example a rubberised clip). Its installation position is limited as shown in Figures 14 and 15 in order to ensure effective automatic bleeding.
AT2000ST_Installation_Instructions.book Page 56 Wednesday, May 29, 2013 12:54 PM Combustion air supply 8 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. NOTE: An intake silencer must be fitted if the intake hose length is shorter than 0.6 m.
AT2000ST_Installation_Instructions.book Page 57 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 9 Exhaust pipe Exhaust pipe Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm 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 statutory regulations for other requirements. The exhaust silencer should ideally be installed near the heater.
AT2000ST_Installation_Instructions.book Page 58 Wednesday, May 29, 2013 12:54 PM Combustion air inlet and exhaust lines 10 Air Top 2000 ST 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 must be made at its lowest point. Fig. 21: Avoid the lines becoming clogged with dirt Fig. 19: Prevent the formation of condensate The lines must not point to the front of the vehicle.
AT2000ST_Installation_Instructions.book Page 59 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Combustion air inlet and exhaust lines An attachment is required no further than 150 mm from the end of the exhaust pipe to ensure that the angle of 90° r 10° is achieved Discharge direction almost vertical 90° r 10° Fig.
AT2000ST_Installation_Instructions.book Page 60 Wednesday, May 29, 2013 12:54 PM Electrical connections 11 Air Top 2000 ST Electrical connections All the cables that are not required must be insulated. NOTE: If the combination timer is used, a touch-sensitive switch may be installed in the sleeping section to act as a remote control and improved convenience. The connections must be made as shown in the circuit diagrams in Figure 32.
AT2000ST_Installation_Instructions.book Page 61 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST The cable passage can be placed at either the left or right side. To ensure that the cable passage in the control unit cover seals perfectly, the cable grommet is to be adjusted appropriately on the wiring harness. Electrical connections F = 15 A (12 and 24V) 11.3. Supply voltage connection Ideally from the vehicle’s central electrical system.
AT2000ST_Installation_Instructions.book Page 62 Wednesday, May 29, 2013 12:54 PM Electrical connections Air Top 2000 ST 11.4. Control element connection The wiring harness is prepared for connection to the control element. Simply pull on connector housing to unplug the connector. The connector housing can be locked (self-locking action) by simply pulling on the wiring harness. NOTE: The fibre optic cable must be in contact with the rotary knob Fig.
AT2000ST_Installation_Instructions.book Page 63 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 12 Connection diagram/Circuit diagram Connection diagram/Circuit diagram Combination timer 1531 black: Terminal 15 red: Terminal 30 grey: Terminal 58 brown: Terminal 31 Adapter wiring harness Fig.
AT2000ST_Installation_Instructions.book Page 64 Wednesday, May 29, 2013 12:54 PM Connection diagram/Circuit diagram Air Top 2000 ST Fig.
AT2000ST_Installation_Instructions.book Page 65 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Connection diagram/Circuit diagram Fig.
AT2000ST_Installation_Instructions.book Page 66 Wednesday, May 29, 2013 12:54 PM Connection diagram/Circuit diagram Air Top 2000 ST Fig.
AT2000ST_Installation_Instructions.book Page 67 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Connection diagram/Circuit diagram Fig.
AT2000ST_Installation_Instructions.book Page 68 Wednesday, May 29, 2013 12:54 PM Legend for circuit diagrams 13 Legend for circuit diagrams Cable cross-sections < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.0 mm2 1.5 mm2 1.5 mm2 2.5 mm2 2.5 mm2 4.0 mm2 4.0 mm2 6.
AT2000ST_Installation_Instructions.book Page 69 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST Item A1 A2 B1 B2 B3 B4 E F1 F2 Description Heater Control module Flame sensor Temperature sensor Overheating sensor Temperature sensor Glow plug Fuse 15 A 12 V/24 V (max.
AT2000ST_Installation_Instructions.book Page 70 Wednesday, May 29, 2013 12:54 PM Initial start-up 14 Initial start-up 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. Until the fuel lines have been filled the heater may switch into a fault lockout for safety reasons - see chapter 15, "Fault lock-out".
AT2000ST_Installation_Instructions.book Page 71 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 15 Fault lock-out Fault lock-out The control unit has identified errors on individual heater components and faults during the operation.
AT2000ST_Installation_Instructions.book Page 72 Wednesday, May 29, 2013 12:54 PM Fault lock-out 15.1. Error code output NOTE: The error code is output if the heater is fitted with a control element after an error has occurred by the switch-on indicator/error code indicator flashing. After 5 seconds of fast flashing, the error code will be output by a sequence of long flash pulses, the number of flashes is shown in the table below.
AT2000ST_Installation_Instructions.book Page 73 Wednesday, May 29, 2013 12:54 PM Air Top 2000 ST 16 Technical data Technical data Except where limit values are specified, the technical data refer to the usual heater tolerances of r 10 % at an ambient temperature of + 20 °C and at the rated voltage and in rated conditions. 16.1. Electrical components: Control unit, motor, metering pump, lamp in the timer and glow plug / flame monitor are designed for either 12 V or 24 V.
AT2000ST_Installation_Instructions.book Page 74 Wednesday, May 29, 2013 12:54 PM Technical data Heater Type test permit Model Heat output Fuel Fuel consumption Rated voltage Operating voltage range Rated power consumption Max.
AT2000ST_Installation_Instructions.
AT2000ST_Installation_Instructions.book Page 76 Wednesday, May 29, 2013 12:54 PM Drilling template 18 Air Top 2000 ST Drilling template Seal NOTE: Max. base unevenness around the seal: 1 mm Fig.
AT2000ST_Installation_Instructions.
Die Betriebsanweisung vor Inbetriebnahme des Heizgerätes unbedingt lesen. Im Fall einer mehrsprachigen Version ist Deutsch verbindlich. Die Telefonnummer des jeweiligen Landes entnehmen Sie bitte dem Webasto Servicestellenfaltblatt oder der Webseite Ihrer jeweiligen Webasto-Landesvertretung. The Operating Instructions must be read before attempting to start up the heater. In multilingual versions the German language is binding.
