Webasto 2000 B, 2000S D User Manual

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List of Contents

Air Top 2000

Air Heater

Air Top 2000 D (Diesel) Air Top 2000 B (Gasoline)

Service and Repair Manual

NOTE

Technical changes in this issue of the

manual compared with its previous issue

are identified with a vertical change bar on

the lefthand side of columns.

– 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.

Air Top 2000

List of Con tents

List of Cont en ts

1. 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

1.6 Corrections and Improvements.......... ................ ................ ................ ................ ................ ................ .....103

2. General Description

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

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

2.3 Burner Insert with Com bustion Tube........................ .......... .......... ........ .......... .......... .......... .......... ........ ...202

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

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

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

2.7 Temperature Limit er. ...... ........ .......... .......... .......... .......... ........ .......... .......... .......... .......... ........ .......... .......203

2.8 Dosing Pump...........................................................................................................................................20 3

3. Functional Description

3.1 Functional Description Air Top 2000 without Diagnosis (Fig. 301)..........................................................301

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

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

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

3.1.4 Heating Operation.......................................................................................................................301

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

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

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

3.1.8 Functions of the Air Heater in TRS Vehicles............................................ .......... .......... .......... .....302

3.1.9 Switch-Off upon Failure...............................................................................................................302

3.2 Functional Description Air Top 2000 Diagnosis................................................................................ .......304

3.2.1 Control Element..........................................................................................................................304

3.2.2 Switch-On....................................................................................................................................304

3.2.3 Stabilization.................................................................................................................. .. .. .. .. .. .. .. .304

3.2.4 Heating Operation.......................................................................................................................305

3.2.5 Control Operation........................................................................................................................305

3.2.6 Control Idle..................................................................................................................................305

3.2.7 Switch-Off....................................................................................................................................305

3.2.8 Functions of the Air Heater in TRS Vehicles............................................ .......... .......... .......... .....305

3.2.9 Switch-Off upon Failure...............................................................................................................306

4. Technical Data .... ........ ........ ........ ............ ........ ............ ........ ........ ............ ........ ............ ........ ........ ............ .......401

List of Contents

5. Troubleshooting

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

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

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

5.4 Error Code Output (Air Top 2000 Diagnosis) ............................................................ ................ ..............503

6. Functional Test s

6.1 General....................................................................................................................................................601

6.2 Adjustments................................................................................................... ..........................................601

Air Top 2000

6.2.1 Adjustment of the CO

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

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

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

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

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

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

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

8.7.2 Replacement of Control Unit.......................................................................................................808

8.7.3 Replacement of Temperature Limiter..........................................................................................808

8.8 Installation of new Control Units..............................................................................................................811

8.8.1 Replacement of Control Unit Air Top 2000 (12 Volt)

with External Temperat ure Sensor............................................................ ................ ................ ..811

8.8.2 Replacement of Control Unit Air Top 2000 (24 Volt) not TRS.....................................................811

8.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) TRS......................................................... ..812

8.9 First Operation.........................................................................................................................................812

Air Top 2000

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.......................................................................................................904

9.2.3 Replacement of Temperature Limiter............................................................. ................ .............904

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

9.2.5 Replacement of Flame Sensor....................................................................................................906

9.2.6 Replacement of Glow Plug..........................................................................................................906

9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger....................................909

10. Packaging/Storage and Shipping

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

List of Con tents

III

Lis t of Figu res

Air Top 2000

Lis t of Figu res

301 Functional Diagram (Air Top 2000 without Diagnosis)....................................................................................303

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

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

601 Adjustment of CO

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

702 Terminal Pin Assignment, Air Top 2000 without Diagnosis............................................................................702

703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Control Element.........................703

704 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Combination Tim er.....................704

705 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

12V/24V with Control Elem ent and Standard Tim er........................................... ................ ................ ............705

706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Control Element................................................................ ................ ................ ......706

707 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Combination Tim er.................................................... ................ ................ ..............707

708 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Combination Tim er and 2 Auxiliary Drives..............................................................708

709 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12V with Control Element....................709

710 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis,

12V with Control Element and Timer.................................................. ................ ................ ................ ............710

711 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24V with Control Element....................711

712 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis,

24V with Control Element and Timer.................................................. ................ ................ ................ ............712

713 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis,

24V with Control Element , TRS................................................ ................ ................ ................ ................ ......713

714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Control Element in Vehicles without Auxiliary Drive................................................714

715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not TRS!).............................. ..........715

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

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

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

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

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

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

806 Dosing Pumpe, Installation Position and Attachment....................................................................... ..............804

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

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

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

810 Removal of Fuse Holder Attachment Plate.....................................................................................................806

811 Fuse Holder, Installation Position ........................................... ................ ................ ................ ................ ........806

812 Control Element..............................................................................................................................................806

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

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

815 Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis).............................809

816 Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)..........................................810

901 Removal of Housing Components/Covers......................................................................................................903

902 Replacement of Combustion Air Fan (Removal) ............................................................................................904

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

904 Disassembly of Heat Exchanger........................................................................................................... ..........907

Air Top 2000

1 Introduction

1. Introduction

1.1 Scope and Purpose

This repair shop manual is intended to support familiarized personnel in the repair of air heaters Air Top 2000 of the fuel and Diesel type as well as of Air Top 2000 Diagnosis with serial no. 30.000 and up.

1.1.1 Use of Air Heaters

The air heaters Air Top 2000 and Air Top 2000 Diagnosis are used to

- heat the cabin

- defrost the windscreens. They are not cleared for heating a transportation com-

partment 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.

1.2 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 m ay cause injuries or lethal accidents to personnel.

CAUTI ON

This heading is used to highlight that non-compliance with instruct ions or procedures m ay cause dam age 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 informat ion and procedures necessary for the repair of heaters Air Top 2000 and Air Top 2000 Diagnosis. The use of additional documentation is normally not necessary. Operating instructions/ins tallat ion instruct ions and the vehicle specific installation proposal may be used as complementary inform ation 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 highlight ed 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 Water Heater Air Top 2000 and Air Top 2000 Diagnosis with the following official marks of conformity:

-S 270 (Diesel)

-S 277 (Fuel)

The installation of the heaters is to be performed in accordance with the installation instruct ions 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

- ty pe of vehicle , and

- vehicle identif ication num ber. This validates the “Design General Approval”.

The acceptance certi ficate 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. The use of the heater in special vehicles (e.g. vehicles for the transportation of dangerous goods TRS) or vehicles not subject to the StZVO (e.g. ships) are ruled by partially regional regulations. For the installation of the the transportation of dangerous goods, in addition to the StVZO, the requirements in TRS 002 and TRS 003 (Technical Guidelines for the Transportation of Dangerous Goods on Roads) must be met.

AT 2000 D in vehicles used for

101

1 Introduction

Air Top 2000

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 station s and fuel depots the heat er mu st be switched off as there is a potenti al dan ger of exp losion.

Where flammable fumes or dust may build up (e.g. in the vicini ty of fuel, coal , wood, cereal depots, or similar installat ions) the heat er 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 telest art 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 r eplaced 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 rou ted through room s accommodating person s, these pipes shal l also be renewed after 10 years.

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 A ir Line

The combustion air required must be taken from the exterior. Within rooms accommodat ing persons, the com busti on air lines must not have more than four disconnects and a splash-water protected ext erior w all 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.

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.

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 th an 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 exhaus t 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

1 Introduction

Metal lines must be used. These m ay not heat to m ore than 110 °C should there be the possibility of contact within the room interior. Protective devices against contact may be fitt ed. 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.Elec tric al 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 c omponents 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.

1.6 Corrections and Improvements

Deficiencies, improvements , or proposals for correction of this workshop manual are to be mailed to:

Webasto Thermosys tem e Gmb H Abt. Technische Dokumentation D-82131 Stockdorf

Telephone: 0 89 / 8 57 94 - 5 42 Telefax: 0 89 / 8 57 64 10

Installat ion 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 carburettor 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.

103

Air Top 2000

2 General Description

2. General Description

The air heater Air Top 2000 and Air Top 2000 Diagnosis with serial no. 30.000 and up operating to the evaporator principle basically consist of:

- combustion and heating air fan

- heat exchanger

- burner insert with combustion tube

- control unit

A malfunction in air heaters Air Top 2000 Diagnosis outputs an error code to the display of the combination or standard timer. When equipped with a control element the operating indicator flashes. In addition a heater checkout may be performed using a personal computer (refer to operating instructions PC air heater diagnosis).

Air Heater Air Top 2000 Diagnosis

(covers removed)

Air Heater Air Top 2000

For control and monitoring a

- control unit/control circuit board

- flame sensor

- glow plug

- temperature limiter

- temperature sensor are located within the unit. 12 Volt heaters (Air Top 2000 without Diagnosis) may be

controlled by means of an external temperatur e sensor. All heaters of air Top 2000 Diagnosis may be controlled by means of an 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 air outlet.

Combustion and Heating Air Fan

Air Heater Air Top 2000 without Diagnosis

(covers removed)

201

2 General Description

Air Top 2000

2.2 Heat Exchanger

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

Heat Exchanger

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 combu stion tube the combustion of the fuel/air mix ture tak es place heating up the heat exchanger.

2.4 Control Unit / Control Circuit Board

Air Top 2000 without Diagnosis

The control unit /cont rol ci rc uit boar d is the central co nt rolling unit for functional sequen cing and m on itori ng of the combustion oper ation . A tempera ture sens or locate d on the side is used for temperatur e control . 12 Volt heate rs may have the temperat ure sensor replaced agai nst an external temper at ure sensor . The com bust ion an d heat in g air fan may be set by m eans of a po te nt iom eter .

Potentiometer

Temperature Sensor

Control Unit Air Top 2000 without Diagnosis

Diesel 2 mm

Combustion Tube

Burner Insert

Air Top 2000 Diagnosis

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 against an external temperature sensor. The combustion and heating air fan may be set by means of a potentiometer.

A malfunction in air heaters Air Top 2000 Diagnosis outputs an error code to the display of the combination or standard timer. When equipped with a control element the operating indicator flashes. In addition a heater checkout may be performed using a personal computer (refe r to operating instructions PC air heater diagnosis).

Fuel 1 mm

202

Air Top 2000

2 General Description

Potentiometer

Temperature Sensor

Control Unit Air Top 2000 Diagnosis

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.

2.7 Temperature Limiter

The temperature limiter protec ts the air heater against excessive operating temperatures . Overheat protec tion is activated at temperature higher than 150 °C to interrupt the electrical circuit of the dosing pump and switch off the heater with run-dow n operation. After cooling down the electrical circuit is restored. The air heater may be switched on again (see 3.9).

Temperature Limiter

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.

Flame Sensor

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.

Glow Plug

Dosing Pump DP 2 for Fuel and Diesel operated Heaters

Dosing Pump DP 30 for Diesel operated Heaters

203

Air Top 2000

3 Functional Description

3. Functional Description

3.1 Functional Description Air Top 2000 without Diagnosis (Fig. 301)

3.1.1 Control Element

The control element is used to switch the air heater on and off, set the desired room temperat ure (air intake tem perature 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).

NOTE

After application of power upon swit ch-on of the battery switch and selecting the contr ol element “ON”, the c ontrol unit enters the “error lockout” condition. Prior to a reactivation the control element has to be placed to “OFF”.

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 mom ent) and is then under slow-dow n control.

NOTE

Should the temperature of the intake air be above the selected, rated temperature, only the mot or 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.

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 w ill 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 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 3.1.9) with a run-down of the combustion and heating air fan lasting 120 seconds at 2/3 of its max. speed.

3.1.3 Stabili zation

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. A flame-out during the speed rise control period causes a repeat start.

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. A flame-out during the speed rise control period causes a repeat start.

3.1.4 Heating Ope ra tion

During operation the combustion exhaust gasses flow through the heat exchanger charging its walls w ith com bustion 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 fitt ed to the air intake side of the air heater or in case of 12 Volt heaters also by means of an externally located temperature sensor. A temperature below the one set with the control element increases the heater performanc e 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 1.2 kW, the fuel dosing pump delivery rate is reduced every 30 minutes for 20 seconds.

A heating performance less than 1.2 kW causes the fuel delivery to the dosing pump to be interrupted every 30 minutes for 4 seconds. For both types of heaters (fuel and Diesel) heating operation is shortly interrupted every 9 hours like in control idle.

NOTE

The control unit/air heater reacts to new sett ings of the control element with a time delay.

301

3 Functional Description

Air Top 2000

3.1.5 Control Operation

During control operation fan speed and dosing pum p rate of delivery are subject to heating performance. The glow plug is deactivated.

3.1.6 Control Idle

In case the air intake temperature set with the cont rol element is exceeded and the minimum heating performance had been achieved for longer than 5 seconds, the fuel supply is cut off to terminate combustion. The motor of the combustion and heating air fan continues operation for another 155 seconds at 2/3 of maximum speed to cool down the air heater (run-dow n). In control idle the combustion and heating air fan runs at minimum speed. The operation indication remains lit. After reaching the air intake temperature set with the control element a new start procedure is launched (without break-away) .

3.1.7 Switch-Off

Switching the heater off ext inguishes the operation indication of the control element. If no fuel has been delivered (within 20 seconds for Diesel operated heaters or within 15 seconds for fuel operated heaters after swit ch-on) 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. The fan speed decreases within 35 seconds to 2/3 of maximum. Subsequently or if the flame sensor detects “no flame” the fan speed is increased to maximum for 60 seconds and run-down is initiated to last 120 seconds. Run-down is automatically halted.

NOTE

Re-activation of the heater during run-down is permitted. Run-down will be completed first with a subsequent restart.

3.1.8 Functions o f the A ir Hea ter in TRS Vehicles

NOTE

Applicable only for Air Top 2000 D Air Heaters installed in vehicles for the transportation of dangerous goods (TRS).

If the heater is deact ivated using the control element, run-down will not change.

A short run-down (max. 40 seconds) is automatically activated if:

the vehicle engine is turned off

a conveyor facility is put into operation

The short run-down time depends on the operational condition at which TRS swit ch-off occurs. A 40 second run-down with maxim um speed is initiate d (TRS switch-off) when:

air heater is s till in the start phase; stabilization not yet achieved

air heater is in normal run-down

air heater is in control idle.

A 20 second run-down is switched on in normal combustion operation with the fuel delivery immediately halted maintaining the fan speed for 5 seconds. Then the speed is increased for 30 seconds within another 5 seconds.

For all heaters after July 1995 the short run-down out of all operating conditions is a max. of 20 seconds.

After a TRS switch-off the control unit is in the “error lockout” condition. Prior to resuming operation the control element has to be set to “OFF”.

3.1.9 Switch-off upon Failure

The control unit recognises 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 lockout mode under the following conditions:

flame sensor resistance out of tolerance

temperature sensor resistance out of tolerance

glow plug/glow plug trigger defective

fan speed too low , short circuit or open circuit

error in dosing pump electrical circuit or of overheat protection (in start phase only)

low voltage below 10 Volt and in excess of 20 seconds for 12 Volt heaters

low voltage below 20 Volt and in excess of 20 seconds for 24 Volt heaters

control unit defective

In case of overheating there will be no fuel supply. A rundown like after manual switch-off will be performed. After run-down the control unit is in the error lockout mode. Overheating is indicated by the operation indication flashing. For error unlock the air heater has to be switched off momentarily to be switched on again.

302

Air Top 2000

3 Functional Description

3 4

On 1 0

1 2

5 6 7 8

1 0

100% 90% 60% 30% 0

1,3 Hz 1,0 Hz 0,8 Hz 0,6 Hz 0

1 0

020

65 85 102

Fig. 301 Functional Diagram (Air Top 2000 without Diagnosis)

1 Start 2 Control Operation 3 Rated Value reached 4 Rated Value exceeded

(e.g. due to reduced heat sumption) 5 Run-down 6 Control Idle 7 Start 8 Control Operation (increased heat consumption) 9 Switch-off

(20) (60)

(120)

secondstypical

A = Control Element B = Temperature Sensor C = Glow Plug D = Combustion and Heating Air Fan E = Dosing Pump F = Flame Sensor

10 Run-down

303

3 Functional Description

Air Top 2000

3.2 Functional Description Air Top 2000 Diagnosis

3.2.1 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).

NOTE

TRS Operation:

After application of power upon switch-on of the battery switch and selecting the control element “ON” , the control unit enters the “error lockout” condition. Prior to a reactivation the control element has to be placed to “OFF”.

3.2.2 Switch-On

NOTE

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.

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 3.2.9) with a run-do w n 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-dow n) and the heater enters the error lockout condition.

3.2.3 Stabilization

Diesel Operated Heaters

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.

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 w ith the glow plug activated a nd fuel dosing pump deactivated (no fuel supply).

304

Air Top 2000

3 Functional Description

3.2.4 Heating Operation

During operation the combustion exhaust gasses flow through the heat exchanger charging its walls with com bustion 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 fit ted 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 max imum heat. In order to extend the burner idle period of Diesel operated heaters during permanent operation w ith 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.

3.2.7 Switch-Off

Switching the heater off ext inguishes 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 detect ing “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.

3.2.8 Functions o f the A ir Hea ter in TRS Vehicles

3.2.5 Control Operation

During control operation fan speed and dosing pump rate of delivery are subject to heating performance. The glow plug is deactivated.

3.2.6 Control Idle

After reaching the temperature set w ith the cont rol 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 perfor mance, 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 (wit hout break a w ay).

NOTE

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

NOTE

Applicable only for Air Top 2000 D Air Heaters installed in vehicles for the transportation of dangerous goods (TRS).

If the heater is deact ivated using the control element, run-down will not change. A short run-down (max . 20 seconds) is automatic ally activated if:

the vehicle engine is turned off

a conveyor facility is put into operation

The short run-down time depends on the operational condition at which TRS switch-off occurs. A 15 second run-down with m aximum speed is initiated (TRS switch-off) when:

air heater is still in the start phase; stabilization not yet achieved

air heater is in normal run-down

air heater is in control idle.

A 20 second run-down is switched on in normal combustion operation and in stabilization with the fuel delivery immediately halted maintaining the fan speed for 5 seconds. Then the speed is increased to maximum for 15 seconds within for a run-down.

After a TRS switch-off the contr ol unit is in the “error lockout” condition. Prior to resuming operation the control element has to be set to “OFF”.

305

3 Functional Description

3.2.9 Switch-off upon Failure

The control unit recognises 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 lockout 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 “sw itch- off” w ill 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) to be switched on

Air Top 2000

306

Air Top 2000

4 Technical Data

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.

Air Heater Operation

Mark of conformity

Heater type

Heat flow

Type of fuel

Control range

Electrical Components:

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

The components temperature limiter and flame detec tor are independent of voltage.

*not for TRS

AT 2000 B

~ S 277

Air heater with

evaporator burner

1.1 – 2.0 kW

Fuel

AT 2000 D

~ S 270

0.9 – 2.0 kW

Diesel/Fuel oil (EL)

Fuel consumption

Nominal voltage

Operation voltage

Rated power consumption

Permitted ambient temp.: Heater:

Dosing pump: Control element:

- operation

- storage

- operation

- storage

- operation

- storage

Permitted combustion air intake temperature

Setting range for indoor temperature

Volume flow of heating air against 0.5 bar

in exhaust

(perm. functional range)

Control range

Max.

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

12 Volt

10 … 15 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

9.5 … 10.5

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

12 Volt

10 … 15 Volt

9 ...22 W

70 m

9.5 … 12.0

24 Volt

20 … 30 Volt

Dimensions air heater

Weight, heater

Length 322 ± 2 mm

Width 130 ± 1 mm

Height 122 ± 1 mm

2.6 kg

401

Air Top 2000

5 Troubleshooting

5. Troubleshooting

5.1 General

This section describes troubleshooting procedures for the Air Heater Air Top 2000 and Air Top 2000 Diagnosis.

CAUTI ON

Troubleshooting requires pr ofound 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.

NOTE

Only for TRS operation

After a TRS switch-off or po w er application by vehicle main power switch operation and the control elem ent to “ON”, the control unit will be in “error lockout”. Prior to reactivation the control element m ust be set to “OFF” or the instant heat switch on the combinat ion or standard timer be operated.

CA UTI ON

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.

Failure Symptom Probable Cause Remedy

Air heater switches No combustion after start or repeat Switch off heater momentarily and off automatically start switch on

Flame extinguishes during Switch off heater momentarily an d operation switch on

Heater overheats Check heat air ducting for Operation indication flashes obstructions, allow heater to cool

down, switc h off heater mom entar ily and switch on

Vehicle electrical Charge battery system voltage too low Switch off heater momentarily and

switch on

Heater expels black fumes Combustion air and/or Check combustion and exhaust

exhaust ducting blocked ducting for obstructions

Fig. 501 General Failure Symptoms

once again

501

5 Troubleshooting

Air Top 2000

5.3 Failure Sympt oms during Opera tion

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 Sym pto m shows after

....s

No start and no illumination immediately of LED on control element

No start but LED illuminates immediately Very low speed with no start immediately

failure symptom listed, in emergenc ies assist ance by our service technicians may be requested (Tel. 089 / 8 57 94 - 512).

NOTE

Overheating and dosing pump failure are alway s indicated additionally after run-down by the flashing LED of the control element.

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

Possible Causes

Wrong cabling, defective fuse

Fan or control unit defective or fan blocked Control idle operation: wrong manual control (selected

temperature is below air intake temperat ure) or wro ng integration (excessive air intake temperat ure)

Motor operates mom entarily 1 and then stops

Stoppage without run-dow n 5 Run-down after 1 Run-down after 20 Run-down after 120

and dosing pump does not cycle Run-down after 40 to 120

Run-down after 230

Run-down during combustion

operation

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 obst ructed or heat exchanger coked, dosing pump seized

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

Stoppage without run-dow n dur ing combust io n

operation

Interruption of dosing pump during combustion cycling and max. speed for operation 30 sec with subsequent re-start

Fig. 502 Failure Symptoms during Operati on

502

Fan motor failure or seizure

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

Air Top 2000

5.4 Error Code Output (Air Top 2000 Diagnosis)

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 element 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 comb inatio n or standard timer

F 01 No start (after 2 attempts)

5 Troubleshooting

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

503

Air Top 2000

6 Functional Tests

6. F unc tion al 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 CO2 Contents

6.2.1.1 General

The CO potentiometer on the control circuit board. The air heater is preset by the manufacturer wit h respect to the combustion and heating air fan fitted. After adjustment by the manufacturer the potenti om eter 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 correct ed by rotati ng the potentiometer. A suitable tool like a small screw driver (2.5 mm tip) is to be used.

contents of the exhaust is adjusted with the

CA UTI ON

Set potentiometer slowly; observe end positions. Adjustment may be perform ed at any electrical sys tem

voltage. Clockwise rotation increases the fan speed and de-

creases the CO creases the fan speed and increases the CO

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

The manufacturer’s setting cannot be restor ed.

1. Withdraw cover from upper shell according to 9.2.1.1.

2. Switch on air heater.

3. Rotate potentiomet er tw o tim es and with no interrupt through its complete setting range (e.g. m ax. - min.max.).

4. Adjust desired CO

5. Switch off air heater.

6. Plug on cover and secure.

contents. Counterclockwise rotation d e-

contents.

CAUTION

contents (Fig. 601).

+–

Air Top 2000 Diagnosis Air Top 2000 without Diagnosis

Fig. 601 Adjustment of CO2 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 Ω 1.3 ... 1.44 Ω 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:

Air Top 2000

Cold test:

Resistance at 25 °C: 2.6 ... 3.4 Ω Test current: < 5 mA

Hot test:

Resistance at 800 - 1000 °C: 12 ... 15 Ω (ceramic rod red hot over a length of approx. 20 mm) Test current: < 5 mA

602

Air Top 2000

7 Circuit Diagrams

7. Circuit Diagrams

7.1 General

The air heater Air Top 2000 Diagnosis may be operated using the control element (rated value transmit ter/ sw it ch) or with the control element and a combination or standard timer. The circuit diagrams (Figs. 703 to 708 and 714) show the possible circuits 12 or 24 Volt with

control element

combination timer

control element and standard timer

control element for TRS

combination timer for TRS

TRS operation for vehicles without auxiliary driv e

Fig. 701 shows the terminal pin assignment.

The air heater Air Top 2000 without Diagnosis may be operated using the control element (rated value transmit ter/switch) or w ith the control elem ent and a timer. The circuit diagrams (Figs. 709 to 713) show the possible circuits 12 or 24 Volt with

control element

control element and timer

control element for TRS

Fig. 702 shows the terminal pin assignment.

X1 X4X3X2 X5

violet yellowbrownblack blue

X1 = Connection, Combustion and Heating Air Fan X2 = Connection, Dosing Pump X3 = Connection, Flame Sensor X4 = Connection, Glow Plug X5 = Connection, Temperature Limiter

Fig. 701 Terminal Pin Assignment, Air Top 2000 Diagnosis

701

7 Circuit Diagrams

Air Top 2000

X1 X4X3X2 X5

violet yellowbrownblack blue

X1 = Connection, Combustion and Heating Air Fan X2 = Connection, Dosing Pump X3 = Connection, Flame Sensor X4 = Connection, Glow Plug X5 = Connection, Temperature Limiter

702

Fig. 702 Terminal Pin Assignment, Air Top 2000 without Diagnosis

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

Air Top 2000

7 Circuit Diagrams

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Te mperatu re Sensor B3 Temper atu re Limiter E Glow Plug F2 Fuse 24V 10A/12V 15A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indication M Motor S1 Control Element Rated Value Setting Switch X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X7 Connection 4-pole of item S X8 Connection 2-pole X9 Connection 2-pole of item A2 X11 Connection 6- pole of item A2 X12 Connection 1-pole Diagnosis (K-wire) Y1 Dosing Pump

Wire Colours

bl br ge gn gr or rt sw vi ws

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V wit h Control Element

703

112

7 Circuit Diagrams

Air Top 2000

ϑ ϑ

Item Nomencl at ure Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter E Glow Plug F2 Fuse 24V 10A/12V 15A Flat Fuse SAE J 1284 H7 LED red (in item P) Instan t heat swit ch illumination,

standy indication, operating indicator light

H8 Hea ting sy m bol in display (in item P) Operating indicator light,

overheat indication H9 Ligh t (in item P) Symbol illumin ation M Motor P1 Combination Timer (1531) S3 Switch Instant heating remo te con trol X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2 X8 Connection 2-p o le X9 Connection 2-p o le of item A2 X11 Connect ion 6-p ole of item A2 X12 Connect ion 1-p ole Diagnosis (K-wire) X13 Connection 12- pole of item P Y1 Dosing Pump

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

Wire Colours

bl br ge gn gr or rt sw vi ws

blue brown yellow green grey orange red black violet white

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

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 704 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Com bination Tim er

704

Air Top 2000

7 Circuit Diagrams

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temper atu re Limiter E Glow Plug F2 Fuse 24V 10A/12V 15A Flat Fuse SAE J 1284 H7 L ED red (in item P) Instant hea t swit ch illum ination,

standy indicatio n, operating indicator light

H8 Heating symbol in display (in item P) Operating indicator light,

overheat indication H9 L ight (in item P) Sym bol illuminat io n M M oto r P2 Standard timer S1 Control Element Rated Value Setting Switch S3 Switc h Instant heating re m ote contr ol X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X7 Connection 4-pole of item S1 X8 Connection 2-pole X11 Connection 6- pole of item A2 X12 Connection 1-pole Diagnosis (K-wire) X13 Connection 12- pole of item P Y1 Dosing Pump

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

Wire Colours

bl br ge gn gr or rt sw vi ws

blue brown yellow green grey orange red black violet white

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

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 705 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

12V/24V with Contr ol Element and Standard Timer

705

7 Circuit Diagrams

Air Top 2000

ϑ ϑ

Item Nomencl at ure Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indicati on H6 Ligh t (at least 1.2 W) Operation indicatio n

conveyor facility M Motor S1 Rated Value Setting Sw itch Control Element S2 Disconnect Switch 1 or 2-pole Emergency-off Switch;

electr. or pneum. S4 Switch Conveyor facility I X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2 X7 Connection 4-p o le of item S1 X8 Connection 2-p o le X9 Connection 2-p o le of item A2 X11 Connect ion 6-p ole of item A2 X12 Connect ion 1-p ole Diagnosis (K-wire) Y1 Dosing Pump Y2 Solenoid valve for conveyor facility II

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

706

Fig. 706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Control Elem ent

Air Top 2000

7 Circuit Diagrams

CAUTION: Pin 4 no ground connection

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temper atu re Limiter E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H6 L ight (at least 1.2 W) Operation indication

conveyor facility

H7 L ED red (in item P) Instant hea t swit ch illum ination,

standy indicatio n, operating indicator light

H8 Heating symbol in display (in item P) operating indicator light,

overheat indication H9 L ight (in item P) Sym bol illuminat io n M M oto r P1 Combination Timer (1531) S2 Disconnect Switch 1 or 2-pole Emergency-off Switch;

electr. or pneum. S3 Switc h Instant heating re m ote contr ol S4 Switch Conveyor facility I X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X8 Connection 2-pole X9 Connection 2-pole of item A2 X11 Connection 6- pole of item A2 X12 Connection 1-pole Diagnosis (K-wire) X13 Connection 12- pole of item P Y1 Dosing Pump Y2 Solenoid valve for conveyor facility II

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

Wire Colours

bl br ge gn gr or rt sw vi ws

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.

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 707 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Combination Timer

707

7 Circuit Diagrams

Air Top 2000

CAUTION: Pin 4 no ground connection

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H7 LED red (in item P) Instant heat switch illumination,

standy indication, operating indicator light

H8 Hea ting sy m bol in display (in item P) operating indicato r ligh t,

overheat indication H9 Ligh t (in item P) Symbol illumin ation M Motor P1 Combination Timer (1531) S2 Disconnect Switch 1 or 2-pole Emergency-off Switch;

electr. or pneum. S3 Switch Instant heating remo te con trol S4 Switch Conveyor facility I S5 Switch Conveyor facility II X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2 X8 Connection 2-p o le X9 Connection 2-p o le of item A2 X11 Connect ion 6-p ole of item A2 X12 Connect ion 1-p ole Diagnosis (K-wire) X13 Connection 12- pole of item P Y1 Dosing Pump Y2 Solenoid valve for conveyor facility I Y3 Solenoid valve for conveyor facility II

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

Wire Colours

bl br ge gn gr or rt sw vi ws

NOTE:

Minus potential applied to control unit input X11/2 (TRS identification) across Y2 and K

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),

1.5 mm

2.5 mm

4.0 mm

6.0 mm

blue brown yellow green grey orange red black violet white

2 2 2 2

Fig. 708 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Combination Timer and 2 Auxiliary Drives

708

Air Top 2000

7 Circuit Diagrams

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temper atu re Limiter B4 Temperature Sensor E Glow Plug F2 Fuse 15A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indication H4 L ight (in item P) Sym bol illuminat io n M M oto r S1 Rated Value Setting Switch Control Element X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X7 Connection 4-pole of item S X8 Connection 2-pole Y Dosing Pump

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 709 Circuit Diagram Automatic Control Air Top 2000 wit hout Diagnosis, 12V with Contr ol Element

709

7 Circuit Diagrams

Air Top 2000

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter B4 Temperature Sensor E Glow Plug F2 Fuse 15A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indicati on H4 Ligh t (in item P) Symbol illumin ation M Motor P Timer 1529 for pre-timed operation S1 Rated Value Setting Sw itch Control Element X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2 X7 Connection 4-p o le of item S X8 Connection 2-p o le X10 Connect ion 8-p ole Y Dosing Pump

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

710

Fig. 710 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis,

12V with Control Element and Tim er

Air Top 2000

7 Circuit Diagrams

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temper atu re Limiter E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indication M Motor S1 Rated Value Setting Switch Control Element X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X7 Connection 4-pole of item S X8 Connection 2-pole X11 Connection 2- pole for manufacturer’s installat ions

only

Y Dosing Pump

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 711 Circuit Diagram Automatic Control Air Top 2000 wit hout Diagnosis, 24V with Contr ol Element

711

7 Circuit Diagrams

Air Top 2000

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter

Wire Gauges

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

1.5 mm

2.5 mm

4.0 mm

6.0 mm

E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indicati on H4 Ligh t (in item P) Symbol illumin ation M Motor P Timer 1529 for pre-timed operation S1 Rated Value Setting Sw itch Control Element X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2

Wire Colours

bl br ge gn gr or rt sw vi ws

blue brown yellow green grey orange red black violet white

X7 Connection 4-p o le of item S X8 Connection 2-p o le X10 Connect ion 8-p ole X11 Connection 2-p o le for manufacturer ’s installation s

only Y Dosing Pump

Fig. 712 Circuit Diagram Automatic Control Air Top 2000 wit hout Diagnosis, 24V with Control Element and Timer

2 2 2 2

712

Air Top 2000

7 Circuit Diagrams

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temper atu re Limiter E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indication M Motor S1 Rated Value Setting Switch Control Element S2 Disconnect Switch 1 or 2-pole Emergency-off Switch;

electr. or pneum. X1-X5 Connection 2-pole of item A2 X6 Connection 8-pole of item A2 X7 Connection 4-pole of item S X8 Connection 2-pole X11 Connection 2- pole for manufacturer’s installat ions

only Y Dosing Pump

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

Fig. 713 Circuit Diagram Automatic Control Air Top 2000 wit hout Diagnosis, 24V with Control Element , TRS

713

7 Circuit Diagrams

Air Top 2000

ϑ ϑ

Item Nomenclature Remark

A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Tempera ture Limiter E Glow Plug F2 Fuse 10A Flat Fuse SAE J 1284 H1 LED green (in item S1) Operation indicati on M Motor S1 Rated Value Setting Sw itch Control Element S2 Disconnect Switch 1 or 2-pole Emergency-off Switch;

electr. or pneum. X1-X5 Connection 2-p ole of item A2 X6 Connection 8-p o le of item A2 X7 Connection 4-p o le of item S1 X8 Connection 2-p o le X9 Connection 2-p o le of item A2 X11 Connect ion 2-p ole of item A2 X12 Connect ion 1-p ole Diagnosis (K-wire) Y1 Dosing Pump

Fig. 714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis,

24V TRS Operation with Control Element in Vehicles wit hout Aux iliary Drive

Wire Gauges

Wire Colours

bl br ge gn gr or rt sw vi ws

< 7.5 m 7.5 - 15 m

0.75 mm

1.0 mm

1.5 mm

2.5 mm

4.0 mm

blue brown yellow green grey orange red black violet white

1.5 mm

2.5 mm

4.0 mm

6.0 mm

2 2 2 2

714

Terminal 30

Terminal 31

Air Top 2000

7 Circuit Diagrams

Jumper

Terminal 15

Terminal 58

Fig. 715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not TRS!)

715

Air Top 2000

8 Servicing

8. Servicing

8.1 General

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

8.2 Work on the Air Heater

Prior to performing any work it is mandat ory to disconnect the vehicle battery main lead. As long as the air heater is in operation or in run-down, the battery mai n supply must not be disconnected due to the danger of overheating resulting in a response of the over heat 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-spec ific installation proposal have to be observed.

8.3 Work on the Vehicle

For reasons of the air heater’s functional reliability perform the following servicing:

check heating air inlet and outlet for foreign matter and contamination. (Contaminat ed 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 A ir Sys te m

CA UTI ON

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

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 .

CAUTI ON

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 10 minutes.

The air heater can only be operated in the ventilation mode of operation.

Fitted in the air heater on the heating air intake side is a temperature sensor, wh ic h operates the heater in the relevant range of performance in conjunction with the control element 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. 12 Volt heaters (Air Top 2000 without Diagnosis) may be operated with an external tem perat ure sensor (see 9.1.2). Air heaters Air Top 2000 Diagnosis 12 Volt and 24 Volt may also be operated with an external temperat ure se nsor (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 temperatur e-proof to at least 130 °C.

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

Maximum loss of pressure betw een 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

The air heater, when used in the ventilation mode of operation, may also be employed for heating air ducting without any furt her accessor ies. A short circuit of the heating air flow is to be avoided.

8.6.2 Fuel Supply

Air Top 2000

Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel container. The rated pressure at the fuel tapping location is shown in Fig. 801.

Permissible fuel feed At max. permissible

height H (m) overpressure (bar) in fuel

line

0.00 0.2

1.00 0.11

2.00 0.03

Permissible fuel suction At max. permissible low

height S (m) pressure (bar) in fuel tank

0.00 -0.10

0.50 -0.06

1.00 -0.02

8.6.2.1 Fuel Tapping

Vehicles with Diesel Engine

Fuel tapping must be from the fuel reservoir or from a separate tank (Figs. 802, 803 and 804). This separate fuel tapping avoids an influence on the pressure.

Vehicles with Carburettor Engine

Fuel tapping in motorcars may only be performed using the special Webasto fuel tap (e.g. Ident No. 470 910) possibly in the vicinity of the fuel tank. Connection to the supply or return line is optional, the return line must be routed almost to the tank floor, otherwise the return line may be extended.

The fuel tap is to be mounted so that air or gas bubbles can escape towards the fuel tank.

The fuel tap should be located in the engine compartment because the radiation of engine heat may cause gas bubbles to build up in the fuel lines causing malfunctions in the combustion operation.

max. 3 m

i ø 2 mm

+ l2 ≤ 10 m

≤ 1.2 m

≤ 8.8 m

i ø 2 mm

Fig. 801 Fuel Supply

the case, the Webasto fuel tap (see Fig. 802, 803 and

804) may be used. In case of a fuel pump mounted externally to the tank

the fuel tap between fuel tank and fuel pump may also only be fitted using the Webasto fuel tap (e.g. Ident No. 470 910).

Vehicles with Fuel Injection Engines

When installing the heat er in vehicles with fuel injection system the fuel pump’s location wit hin or outside the fuel tank must be investigated first.

If the fuel pump is fitted inside the fuel tank, the fuel may be tapped only from the return line using the Webasto fuel tap only (e.g. Ident No. 470 910) ensuring that the return line is routed almost to the tank floor. If this is not

802

Air Top 2000

Hole Pattern

> 25 mm

Fig. 802 Webasto Fuel Tank Tap

* Use fuel tank tap only on metal fuel tanks

Fuel Tank Tap

Tank Fitting Plate

8 Servicing

Gasket

Plastic Tank

Gasket

Fig. 803 Fuel T apping 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 ensure no disturbing formation of bubbles.

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 prot ection against stone impacts and undue temperatures (exhaust line). The fuel line joints are to be secured against slipping with hos e clamps.

803

8 Servicing

Air Top 2000

Connection of 2 Pipes with Hose

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

correct

clamp

wrong

bubble

Fig. 805 Pipe/Hose Connection

bubble

8.6.3 Dosing Pump

The dosing pump is a combined delivery, dosing, and shut-off system and is subject to cert ain installat ion criteria (see Figs. 801 and 806).

8.6.3.1 Installation Locatio n

It is advantageous to mount the dosing pump in a cool location. The ambient temperature must never exc eed +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 A tt achmen t

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.

8.6.4 Fuel Filter

If there is the probability of contaminated fuel only the Webasto filter, Order No. 487 171, may be used. Installation possibly vertical up to horizontal at the most (observe direction of fl ow).

AT 2000. 12 Volt and 24 Volt - Fuel and Diesel

0-90°

0°

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

Installatio n Positi on only Horiz ontal

Fig. 806 Dosing Pump, Installation Position

and Attachment

0-90°

0 - 90°

ø 5

Fig. 807 Fuel Filter

804

Air Top 2000

8 Servicing

8.6.5 Combustion Air Supply

Combustion air must under no circum stanc es be extracted from rooms w ith persons. The combustion air inlet must not point towards the forward direct ion 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 mus t 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 D only).

8.6.6 Exhaust Line

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.

Rigid pipes made of unalloyed or alloyed steel with a minimum w all 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

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

Exhaust exit direction nearly vertical 90° ± 10°

10°

Fig. 809 Exhaust Pipe Outlet, Installation Positio n

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°

10°

WARNING

In order to avoid dam age 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 : max. 2.0 m without muf fler: max. 5.0 m

805

Light Guide

8 Servicing

Air Top 2000

8.6.8 Electrica l Connec tions

8.6.8.1 Connection Ai r Heater, Contro l Element

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

Preferably from the vehicle’s central electrics. For protection of the air heater an additional flat fuse

holder is to be fitted (deliverable item). The fuse holder may only be located in the vehicle interior.

8.6.8.3 Connection Control Element

The cable loom is prefabricated to connect to the control element (rated value transmitter ). For plug disconnection pull on terminal plug only (Fig. 813). By pulling on the cable loom the terminal plug is arrested (self-locking).

Fig. 812 Control Element

NOTE

The light guide must be in contact with the rotating knob.

Fig. 810 Removal of Fuse Holder Attachment Plate

F = 10A 24V 15A 12V

Fig. 811 Fuse Holder, Installation Position

806

Fig. 813 Pulling t he Plug

Air Top 2000

8 Servicing

1 Control Element 2 Air Heater 3 Dosing Pump and Anti-Vibration Mount 4 Fuel Filter (Accessory) 5 Fuel Tap 6 Exhaust Muffler 7 Fuse

Fig. 814 Example of an Installation

807

8 Servicing

Air Top 2000

8.7 Removal and Installation

CAUTION

In installed condition only the following removal and disassembly procedures are allowed, the upper housin g shell being accessible for removal:

Replacement of control unit

Replacement of temperature limiter

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 9.2.1.1.

3. Disconnect plug of cable loom from control unit.

4. Disconnect cable to dosing pump at cable disconnect.

5. Disconnect fuel inlet on air heater.

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

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

8. Remove air heater and discard gask et.

8.7.2.2 Installation

CAUTION

When installing a new control unit in heaters Air Top 2000 without diagnosis, it is mandatory to observe the remarks in 8.8.

NOTE

During installation avoid the build-up of static charge (i.e. do not touch strip conductors).

1. Locate control unit (2, Fig. 815) in installation position and secure with screw s (3). Ensure control unit engages in arrester groove (6). Torque screws to

0.5 Nm.

2. Connect plug connections to terminal (Fig. 701 or Fig. 702).

3. Plug on upper housing shell and fix in position.

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

5. Connect plug of cable loom to control unit.

6. Fit cover and fix in position.

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 plug of cable loom to control unit.

7. Plug on cover and arrest.

8. Reconnect battery terminal leads.

9. Bleed fuel supply system.

8.7.2 Replacement of Control Unit

8.7.2.1 Removal

NOTE

During removal avoid the build-up of static charge (i.e. do not touch strip conductors).

1. Withdraw cover from upper housing shell according to 9.2.1.1.

2. Disconnect plug of cable loom from control unit.

3. Withdraw covers for heating air inlet and outlet (5 and 3) according to 9.2.1.2.

4. Remove upper shell according to 9.2.3.1.

5. Disconnect plugged connections (1, Fig. 815 or Fig.

816) of terminal.

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

8.7.3 Replacement of Temperature Limiter

8.7.3.1 Removal

1. Withdraw cover from upper housing shell according to 9.2.1.1.

2. Disconnect plug of cable loom from control unit.

3. Withdraw covers for heating air inlet and outlet according to 9.2.1.2.

4. Remove upper housing shell according to 9.2.1.3.

5. Disconnect plugged connection (blue) from terminal.

6. Rem ove lock was hers (4, Fig. 815 or Fig. 816).

7. Remove temperature limiter (5).

8.7.3.2 Installation

1. Locate temperature limiter (5, Fig. 815 or Fig. 816) in installation position and secure with lock w ashers (4). Ensure that temperature limit er rests properly on heat exchanger.

2. Connect plug connections (blue) to terminal.

3. Plug on upper housing shell and fix in position.

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

5. Connect plug of cable loom to control unit.

6. Fit cover and fix in position.

808

Air Top 2000

8 Servicing

1 Plug Connections 2 Control Unit 3 Screw (2) 4 Lock Washer (2) 5 Temperature Limiter 6 Arrester Groove

Fig. 815 Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis)

809

8 Servicing

Air Top 2000

X11

1 Plug Connections 2 Control Unit 3 Screw (2) 4 Lock Washer (2) 5 Temperature Limiter 6 Arrester Groove

810

Fig. 816 Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)

Air Top 2000

8.8 Installation of new Control Units

CAUTION

When replacing the control unit the following must be observed:

When replacing the control unit Air Top 2000 (12 Volt) without exter nal temper ature sensor with a new control unit Air Top 2000 Diagnosis (12 Volt) without ext ernal tem perat ure sensor no further instructions for replacement as detailed in 8.7.2 are applicable.

When replacing the control unit Air Top 2000 (12 Volt) with external tem perat ure sensor w ith the control unit Air Top 2000 Diagnosis (12 Volt) with external temperature sensor the modifications per

8.8.1 must be per form ed.

8 Servicing

When replacing the control unit Air Top 2000 TRS (24 Volt) with a control unit Air Top 2000 Diagnosis TRS (24 Volt) perform modifications per 8.8.3.

WARNING

Failure to perform modifications will result in a potential safety risk.

In all cases there will be no possibility for diagnosis after replacement as the wiring harness installed in the vehicle is not provided with a diagnosis connector.

8.8.1 Replacement of Control Unit Air Top 2000

(12 Volt) with External Tem pera ture Sensor

1. Remove control unit according to 8.7.2.1.

2. Remove leaf spring contacts 4 and 6 from connector

X6.

X11

Control Unit Air Top 2000 Diagnosis

NOTE

If a new temperature sensor is to be used place an order for no. 883 84A (including new cover).

When replacing the control unit Air Top 2000 (24 Volt) not TRS with a control unit Air Top 2000 Diagnosis (24 Volt) not TRS the modifications per

8.8.2 must be incorporated.

CA UTI ON

Not performing the modification may result in a short circuit.

NOTE

The following step is not applicable when installing a new temperat ure s ensor.

3. Position leaf spring contacts order no. 880 39A (must

be ordered) and arrest in connector X9 order no. 881 97A (must also be ordered). Polarity is irrelevant.

4. Install new control unit according to 8.7.2.2.

5. Connect connectors X6 and X9.

8.8.2 Replacement of Control Unit Air Top 2000

(24 Volt) not TRS

1. Remove control unit according to 8.7.2.1.

2. Remove leaf spring contacts of grey and violet wi re

from connector X6, contacts 4 and 6.

3. Install new control unit according to 8.7.2.2.

4. Connect connector X6.

811

8 Servicing

Air Top 2000

8.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) TRS

1. Remove control unit according to 8.7.2.1.

2. Remove leaf spring contacts of grey and violet wi re

from connector X6, contacts 4 and 6.

3. Arrest leaf spring contacts in connector X11 as

follows: grey wire in contact 3, violet w ire in contact 2.

4. Install new control unit according to 8.7.2.2.

5. Connect connector X6 and X 11.

6. Perform functional check. Test TRS switch-off as

required stopping engine and starting auxiliary drive.

grey

violet

X11

8.9 First Operation

After installation of the air heater the fuel supply system must be bled thoroughly.

NOTE

Due to low fuel consumption several switch-ons are required to prime the fuel supply line to the air heater.

During the test run of the air heater all connections are to be checked for no leakage and tight fit. Should the air heater during operation assume an error lockout condition, perform troubleshooting.

812

Air Top 2000

9 Repair

9. Repair

9.1 General

This section describes the repairs that may be performed on the air heater Air Top 2000 and Air Top 2000 Diagnosis serial no. 30.000 and up when removed. Any further disassem bly will void the war ranty . For reassembly only components of the proper spare kits are to be used.

9.1.1 Work on Components after Disasse mbly

CAUTI ON

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

9.1.1.1 Cleaning

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

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

9.1.1.2 Visual Inspection

Examine all components for dam ages (crack s, deformation, w ear, 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 Temp eratu re Sensor (Air Top 2000 Diagnosis)

General

The heater Air Top 2000 regulates the desired temperature best when its temperature sensor is exposed to the air temperature of the most probable surrounding in use. This might not alway s be possible due to the installation conditions with the temperature sensor being integrated in the heater. I n such case the best t emperature control may be achieved by installation of an external temperature sensor in the relevant room area.

Procedure

1. Select adequate installation location for external

temperature sensor.

NOTE

Temperature sensor should not directly be exposed to heated air flow or located in the vicinity of heating sources (e.g. vehicle own heater)

For installation of the sensor in the motorcar we recommend to locate the sensor in mid height in possibly vertical location.

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

Do not mount temperature sensor behind curtains or similar.

2. Mount external temperature sensor and route cable

to control unit.

3. Connect connector X9 and place 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 w ith available modification kits. In the following that modification which m ay be incorporated easily during maintenace:

installation of an external temperature sensor for optimising temperature contr ol Air Top 2000 Diagnosis (see 9.1.2. 1).

installation of an external temperature sensor for optimising temperature (see 9.1. 2.2) (only for 12 Volt heaters Air Top 2000 without Diagnosis).

External Temperature Sensor

Control Unit

Cover

Connector X9

901

Cover

9 Repair

Air Top 2000

9.1.2.2 Removal of External Temperature Senso r (Air Top 2000 without Diagnosis)

General

The heater Air Top 2000 regulates the desired temperature the best when its temperature sensor is exposed to the air temperature of the most probable surrounding in use. This might not always be possible due to the installation conditions with the temperature sensor being integrated in the heater. In such case the best temperature control may be achieved by installation of an external temperature sensor (Order No. 85049A) in the relevant living area.

Procedure

1. Remove control unit (see 8.7.2.1).

2. Using a suitable tool (e.g. cutting pliers or similar)

remove temperature sensor from contr ol unit.

Control unit

6. Arrest leaf spring contacts in empty com partm ent s of connector X6 (contacts 4 and 6). Polarity is irrel evant.

7. Connect connector X6 and fit cover.

8. Perform test run and check control behaviour.

External Temperature Sensor

Connector X6

12 Volt type only

Remove temperature sensor

3. Select adequate installation location for external temperature sensor.

NOTE

Temperature sensor should not directly be exposed to heated air flow.

For installation of the sensor in the motorcar we recommend to locate the sensor on the window spar of the windshield or in the vicinity of the air intake in the air flow for air circulation operation.

For installation of the sensor in the lorry we recommend to locate the sensor on the window spar of the windshield or on the underside of the roof console.

4. Mount external temperature sensor and route cable to heater.

5. Install control unit.

9.2 Disassembly and Assembly

9.2.1 Removal of Housing Components/Covers

9.2.1.1 Cover for Electrical Con necti on

Dependent on the type of installation the cable loom exits the air heat er either on the left or right. The cover may be levered off using a blunt blade in the areas marked X .

9.2.1.2 Covers for Heating Air Inlet and Outlet

Both covers (3 and 5, Fig. 901) may be removed by a slight side lift and a slide to left or right out of the locked position.

9.2.1.3 Upper Housing Shel l

NOTE

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

By simultaneously exerting press ure on the catches of the upper housing shell (2, Fig. 901) in the areas Y , the shell disengages an can be lifted off.

9.2.1.4 Lower Housing Shell

By simultaneously exerting a light pull to the lower housing shell (4, Fig. 901) in the areas Z , the catch is released and the shell may be separated from the motor housing.

902

Air Top 2000

9 Repair

1 Cover, Electrical Connection 2 Upper Housing Shell 3 Cover, Heating Air Outlet 4 Lower Housing Shell 5 Cover, Heating Air Inlet

Fig. 901 Removal of Housing Components/Covers

903

9 Repair

Air Top 2000

9.2.2 Replacement of Control Unit

NOTE

The procedure for replacement of the control unit is identical for the air heater in installed or removed condition.

Replacement is to be performed in accordance with

NOTE

Air heater Air Top 2000 without Diagnosis shown. Figure is also applicable for replacement of combustion air fan or Air Top 2000 Diagnosis.

9.2.3 Replacement of Temperature Limiter

NOTE

The procedure for replacement of the temperature limiter is identical for the air heater in installed or removed condition.

Replacement is to be performed in accordance with

8.7.3.

1 Heating Air Intake 2 Insulation 3 Seal

904

Fig. 902 Replacement of Combustion Air Fan (Removal)

Before assembly alway s renew gasket.

Air Top 2000

9 Repair

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 8.7.2.1).

3. Remove seal (3 Fig. 902) from lower housing shell

and discard.

4. Remove air heater from lower housing shell.

5. Remove heating air intake (1, Fig. 902) and remove

insulation (2).

6. Remove screw s (1, Fig. 903).

7. Withdra w combust ion air fan (3) and remove gasket

(2).

8. Perform work on components after disassembly (see

9.1.1).

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. 903) onto flange of

combustion air fan (3).

NOTE

Apply Loctite to screws (1).

3. Bring combustion air fan into assembly position and mount using screws (1).

4. Torque screw s (1) to 4 Nm.

5. Place air heater with heating air intake (1, Fig. 902) and insulation (2) into lower housing shell and on side lock in position in housing.

6. Fit new seal (3) to lower housing shell.

7. Install control unit (see 8.7.2.2).

8. Install air heater (see 8.7.1.2).

9. Check CO

setting and adjust as required (s ee 6.2).

1 Screw (5) 2 Gasket 3 Combustion Air Fan

Combustion air fan must not be disassembled any further

Fig. 903 Replacement of Combustion Air Fan (Disassembly)

905

9 Repair

Air Top 2000

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 8.7. 2.1) .

3. Remove combustion air fan (see 9.2.4.1).

4. Remove 2 scre ws (3, Fig. 904) 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. 904) 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 scr e w s (3) and fit spoiler (2) for cable protection.

5. Pull cable of flame sensor tight.

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

7. Mount combustion air fan (see 9.2.4.2).

8. Install control unit (see 8.7.2.2).

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 8.7.2.1).

3. Remove combustion air fan (see 9.2.4.1).

4. Push out cable grommets (9 and 10, Fig. 904) 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 burne r tube (6).

CAUTIO N

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 creep oil to react long enough to free glow plug for withdrawal.

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

8. Perform work on component s after disassem bly (see

9.1.1).

9.2.6.2 Installation

1. Insert new gasket (7, Fig. 904) into heat exchanger and bring combustion tube (6) in ass embly position.

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

CAUTIO N

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

CAUTIO N

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) with 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 gromm et (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 8.7.2.2).

10. Install air heater (see 8.7.1.2).

906

Air Top 2000

9 Repair

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

Fig. 904 Disassembly of Heat Exchanger (Sheet 1 of 2)

907

Twist Lock

9 Repair

Air Top 2000

Detail A

Starting Air Bore

908

Detail B

Fig. 904 Disassembly of Heat Exchanger (Sheet 2 of 2)

Air Top 2000

9.2.7 Replacem e nt of Burner Ins er t, Combustion Tube, and Heat Exchange r

9.2.7.1 Removal

1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 8.7.2.1).

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).

CAUTI ON

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

6. Remove burner insert (5, Fig. 904).

7. Withdraw combustion tube (6) from heat exchanger

(8) and remove gasket.

8. If the heat exchanger is to be replaced remove lock-

washers (4, Fig. 815) and pull off temperature limiter (5).

9. Perform work on components after disassembly (see

9.1.1).

9 Repair

9.2.7.2 Installation

1. In case a new heat exchanger is fitted, secure tem-

perature lim iter (5, Fig. 815) w ith lock w ashers (4) .

2. Fit new gasket (7, Fig. 904).

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 st ep 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 8.7.2.2).

8. Install air heater (see 8.7.1.2).

909

Air Top 2000

10. Packaging/Storage and Shipping

10.1General

The air heater and its components shipped to Webasto Thermosysteme GmbH for inspection or repair 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/ Sto rage and Ship p in g

1001 02/2002

Webasto 2000 B, 2000S D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual