Webasto Air Top 2000 S D, Air Top 2000 S B User Manual
List of Contents
Air Top 2000
Air Heater
Air Top 2000 S D (Diesel)
Air Top 2000 S B (Gasoline)
Service and Repair Manual
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
Air Top 2000 S
List of Contents
List of Contents
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
2. General Description
2.1 Combustion and Heating Air Fan ............................................................................................................201
2.2 Heat Exchanger....................................................................................................................................... 202
2.3 Burner Insert with Combustion Tube.......................................................................................................202
2.4 Control Unit / Control Circuit Board.........................................................................................................202
2.5 Flame Sensor ..........................................................................................................................................203
2.6 Glow Plug ................................................................................................................................................203
2.7 Temperature Limiter ................................................................................................................................ 203
2.8 Dosing Pump...........................................................................................................................................203
3. Functional Description
3.1 Functional Description Air Top 2000 S .......................................................................................................301
3.1.1 Control Element ..........................................................................................................................301
3.1.2 Switch-On....................................................................................................................................301
3.1.3 Stabilization.................................................................................................................................301
3.1.4 Heating Operation.......................................................................................................................302
3.1.5 Control Operation........................................................................................................................ 302
3.1.6 Control Idle..................................................................................................................................302
3.1.7 Switch-Off....................................................................................................................................302
3.1.8 Switch-Off upon Failure...............................................................................................................302
4. Technical Data ............................................................................................................................................... 401
5. Troubleshooting
5.1 General....................................................................................................................................................501
5.2 General Failure Symptoms......................................................................................................................501
5.3 Failure Symptoms during Operation........................................................................................................502
5.4 Error Code Output ......................................................................................................................................503
6. Functional Tests
6.1 General....................................................................................................................................................601
6.2 Adjustments.............................................................................................................................................601
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
Contents.................................................................................................601
2
I
List of Contents
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
Air Top 2000 S
8.7 Removal and Installation .........................................................................................................................808
8.7.1 Air Heater, Removal and Installation...........................................................................................808
8.8 Start-Up...................................................................................................................................................808
9. Repair
9.1 General....................................................................................................................................................901
9.1.1 Work on Components after Disassembly....................................................................................901
9.1.2 Incorporation of Modifications .....................................................................................................901
9.2 Disassembly and Assembly.....................................................................................................................902
9.2.1 Removal of Housing Components/Covers.................................................................................. 902
9.2.2 Replacement of Control Unit.......................................................................................................903
9.2.3 Replacement of Temperature Limiter..........................................................................................903
9.2.4 Replacement of Combustion Air Fan ..........................................................................................905
9.2.5 Replacement of Flame Sensor....................................................................................................907
9.2.6 Replacement of Glow Plug..........................................................................................................907
9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger.................................... 910
10. Packaging/Storage and Shipping
10.1 General..................................................................................................................................................1001
II
Air Top 2000 S
List of Figures
List of Figures
501 General Failure Symptoms .............................................................................................................................501
502 Failure Symptoms during Operation ...............................................................................................................502
601 Adjustment of CO
701 Terminal Pin Assignment, Air Top 2000 S.......................................................................................................701
702 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control D i a l ............................................702
703 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer ..................................703
704 Circuit Diagram Automatic Control Air Top 2000 S,
12V/24V with Control Dial and Standard Timer ..............................................................................................704
705 Connection Diagram, Air Top 2000 S with Combination Timer.....................................................................705
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 Pump, Installation Position and Attachment .......................................................................................804
807 Fuel Filter........................................................................................................................................................804
808 Exhaust Muffler, Direction of Flow..................................................................................................................805
809 Exhaust Pipe Outlet, Installation Position .......................................................................................................805
810 Weather Resistant Fuse Holder........................................................................................................................806
811 Control Di a l ...................................................................................................................................................806
812 Pulling the Plug...............................................................................................................................................806
813 Example of an Installation...............................................................................................................................807
901 Removal of Housing Components/Covers......................................................................................................902
902 Replacement of Control Unit and Temperature Limiter...................................................................................904
903 Replacement of Combustion Air Fan (Disassembly) ......................................................................................905
904 Replacement of Combustion Air Fan (Assembly............................................................................................906
905 Disassembly of Heat Exchanger (Sheet 1 of 2 ) ..........................................................................................908
906 Disassembly of Heat Exchanger (Sheet 2 of 2 ) ..........................................................................................909
Contents ..........................................................................................................................601
2
III
List of Figures
Air Top 2000 S
IV
Air Top 2000 S
1 Introduction
1. Introduction
1.1 Scope and Purpose
This repair shop manual is intended to support familiarized personnel in the repair of the Air Top 2000 S.
1.1.1 Use of Air Heaters
The air heater Air Top 2000 S is used to
- heat the cabin
- defrost the windscreens.
They are not cleared for heating a transportation compartment for dangerous goods.
The heaters operate independent from the vehicle engine and are connected to the fuel tank and to the electrical system of the vehicle. Their use is possible in
vehicles with water- or air-cooled engines.
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 may cause injuries or
lethal accidents to personnel.
CAUTION
This heading is used to highlight that non-compliance
with instructions or procedures may cause damage to
equipment.
NOTE
This heading is used to highlight and draw specific attention to information.
1.4 Safety Information and Regulations
The general safety regulations for the prevention of accidents and the relevant operating safety instructions have
to be observed at all times."General Safety Regulations"
beyond the scope of these regulations are detailed in the
following.The specific safety regulations applicable to
this manual are highlighted in the individual chapters by
Warnings, Cautions, and Notes.
1.4.1 General Safety Notes
Within the scope of the StVZO (Road Licensing Regulations of the Federal Republic of Germany) “Design
General Approvals”, laid down by the Federal Office for
Motor Traffic, exist for the Air Top 2000 S with the
following official marks of conformity:
-S 324 (Diesel)
-S 325 (Gasoline)
The installation of the heater is to be performed in accordance with the installation instructions and must be
checked in case of
a) the vehicle type inspection in accordance with
§ 20 StVZO
b) the individual inspection in accordance with
§ 21 StVZO or
c) the examination in accordance with § 19 StVZO
performed by an officially authorised expert or examiner for road traffic, a vehicle inspector or a public
servant as per section 7.4 a of Annex VIII to the
StVZO.
In the event of c) the installation must be certified on the
acceptance certificate included in the copy of the
“General Operating License” giving details about
- manufacturer
- type of vehicle , and
- vehicle identification number.
This validates the “Design General Approval”.
The acceptance certificate must be kept with the
vehicle.
The year of first operation must be permanently
marked on the identification label.
1.3 Additional Documentation to be used
This workshop manual contains all information and procedures necessary for the repair of the Air Top 2000 S.
The use of additional documentation is normally not
necessary.
Operating instructions/installation instructions and the
vehicle specific installation proposal may be used as
complementary information as necessary.
The heaters are cleared for heating the passenger and
driver cabins but not for heating compartments intended
for the transportation of dangerous goods.
101
1 Introduction
Air Top 2000 S
The heater must not be installed in the passenger or
driver compartments of busses. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior.
There must be sufficient ventilation of the installation box
from the exterior in order not to exceed a maximum temperature of 40 °C in the installation box.
At filling stations and fuel depots the heater must be
switched off as there is a potential danger of explosion.
Where flammable fumes or dust may build up (e.g.
in the vicinity of fuel, coal, wood, cereal depots, or
similar installations) the heater must be switched off
to prevent explosions.
Due to the danger of poisoning and suffocation the
heater must not be operated in enclosed areas such as
garages or workshops without exhaust venting, not even
if the start-up is activated by the timer or telestart device.
When removing the heater the gasket below must be replaced.
The heat exchanger of the air heater remains serviceable for a maximum of 10 years and must then be replaced with an original spare part by the manufacturer or by one of its authorized workshops.
The heater must then be provided with a label
marked with the sales date and with the words “Original Spare”.
Should exhaust pipes be routed through rooms
accommodating persons, these pipes shall also be
renewed after 10 years.
Heating Air System
Heating air intake openings must be arranged so that
under normal operating conditions exhaust fumes of the
vehicle engine or air heater are not likely to be expected.
Extracting combustion air from the vehicle interior is not
permissible.
Combustion Air Line
The combustion air required must be taken from the
exterior.
Within rooms accommodating persons, the combustion
air lines must not have more than four disconnects and a
splash-water protected exterior wall feedthrough. The
disconnects must be sealed in a way not to exceed a
leak rate of 200 l/h at an overpressure of 0.5 mbar.
The line including feedthrough, disconnects, material
and specific type must be described in the installation
instructions.
The line must require tools for installation and removal,
must be protected against damage, and must be shockproof.
Exhaust Line
Heaters must be designed to discharge the exhaust to
the exterior.
Exhaust pipes must be routed so that exhaust fumes are
unlikely to penetrate into the vehicle’s interior.
The function of any parts of the vehicle essential for its
operation must not be impaired. Condensate or water
penetrated must not be able to accumulate in the
exhaust line.
Drain holes are permissible; these must drain the fluid to
the exterior via lines sealed against the vehicle interior.
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 than
one disconnect and must have a splash-water protected
feedthrough in the exterior wall/floor. For water, that has
penetrated into the exhaust line, the connection of a
drain line with a metal-sealing joint is permissible. The
drain pipe must be routed sealed through the exterior
wall or the vehicle floor.The heat exchanger, the exhaust
line connected, as well as the possible drain pipe must
be sealed so that with an overpressure of double the
overpressure of the exhaust having the maximum permissible exhaust line length - at least however at an overpressure of 0.5 bar - a total leak rate of 30 l/h is not
exceeded.
The line including feedthrough, disconnects, material
and specific type must be described in the installation
instructions.
The line must require tools for installation and removal,
must be protected against damage, and must be shockproof.
102
Air Top 2000 S
Metal lines must be used. These may not heat to more
than 110 °C should there be the possibility of contact
within the room interior. Protective devices against contact may be fitted.
Should exhaust pipes be routed through rooms accommodating persons, these pipes shall be renewed after 10
years using genuine spare parts.
Combustion Air Inlet and Exhaust Outlet
During installations these ports for combustion air entry
and exhaust fume exit must be of such type, that a ball
with a diameter of 16 mm cannot be inserted. Electrical
lines, switch gear and control gear of the heater must be
located in the vehicle so that their proper function cannot
be impaired under normal operating conditions.
For the routing of fuel lines and the installation of additional fuel tanks §§ 45 and 46 of the StVZO are to be
adhered to.
The most important regulations are: Fuel lines are to be
designed in such a way that they remain unaffected by
torsional stresses in the vehicle, engine movement and
the like. They must be protected against mechanical
damage.
Fuel-carrying parts are to be protected against excessive heat and are to be arranged so that any dripping
or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment.
In busses, fuel lines and fuel tanks may be located
neither in the passenger area nor in the driver’s compartment. In these type of vehicles the fuel tanks must be located such that they do not pose a direct hazard to the
exits in the event of a fire. Fuel supply must not be by
means of gravity or pressurization of the fuel tank.
1 Introduction
Installation Rules for Webasto Fuel Tanks for the
Fuel Supply of Heaters in Vehicles
In busses the installation is not permitted in the passenger or driver compartment.
The fuel fill neck must in no vehicle be located within any
of these compartments.
Fuel containers for gasoline fuel must not be located
immediately behind the front panelling of the vehicle.
They must be sparate from the engine so that even in
case of an accident the inflammation of fuel is unlikely to
be expected. This does not apply for towing vehicles
with an open cockpit.
The operational state of the heater, i.e. an indication “on”
or “off”, must be easily and clearly visible.
103
2 General Description
Air Top 2000 S
2. General Description
The air heater Air Top 2000 S operates under the
evaporator principle and basically consists of:
- combustion and heating air fan
- heat exchanger
- burner insert with combustion tube
- control unit
A malfunction of the Air Top 2000 S is indicated by an
error code displayed on the combination or standard
timer. When equipped with the standard control dial,
the operating indicator flashes. In addition a heater check
out may be performed using a personal computer (refer
to operating instructions PC air heater diagnosis).
Air Heater Air Top 2000 S
(covers removed)
Air Heater Air Top 2000 S
For control and monitoring a
- control unit/control circuit board
- flame sensor
- glow plug
- temperature limiter
- temperature sensor
are located within the unit.
All Air Top 2000 S heaters may be controlled
by means of an optional external temperature sensor.
Fuel supply is provided externally by a fuel dosing pump.
2.1 Combustion and Heating Air Fan
The combustion and heating air fan delivers the air required for combustion from the combustion air inlet to
the burner insert. By means of the fan the heating air is
also delivered to the hot air outlet.
Combustion and Heating Air Fan
201
Air Top 2000 S
2 General Description
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
2.4 Control Unit / Control Circuit Board
The control unit/control circuit board is the central controlling unit for functional sequencing and monitoring of
the combustion operation. A temperature sensor located
on the control unit is used for temperature control. All
heaters may have the temperature sensor replaced
with an external temperature sensor. The combustion
and heating air fan may be set by means of a potentiometer.
A malfunction in the Air Top 2000 S is indicated by an
error code displayed on the combination or standard
timer. When equipped with a standard control dial
the operating indicator flashes. In addition a heater check
out may be performed using a personal computer (refer
to operating instructions PC air heater diagnosis).
Potentiometer
2.3 Burner Insert with Combustion Tube
Within the burner insert fuel is distributed in the combustion tube across the burner cross-section. In the combustion tube the combustion of the fuel/air mixture takes
place heating up the heat exchanger.
Combustion
Tube
Burner
Insert
Temperature
Sensor
Control Unit - Air Top 2000 S
Diesel
2 mm
Fuel
1 mm
202
2 General Description
Air Top 2000 S
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.
Flame Sensor
2.6 Glow Plug
2.7 Temperature Limiter
The temperature limiter protects the air heater against
excessive operating temperatures. Overheat protection
is activated at a temperature higher than 150 °C to interrupt the electrical circuit of the dosing pump and switch
off the heater with run-down operation.
After cooling down the electrical circuit is restored.
The air heater may be switched on again (see 3.1.8).
Temperature Limiter
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
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.
Dosing Pump DP 2 for Gasoline and Diesel
operated Heaters
203
Dosing Pump DP 30 for Diesel operated Heaters
Air Top 2000 S
3. Functional Description
3 Functional Description
3.1 Functional Description Air Top 2000 S
3.1.1 Control Element
The control element is used to switch the air heater on
and off, set the desired room temperature (air intake temperature between 10 °C and 45 °C), and to unlock a
failure interrupt condition.
The green LED indication is used to indicate the operating condition (LED permanently on) and an overheat
condition (LED flashes).
3.1.2 Switch-On
The control element is set to the desired room temperature. When switching the air heater on, the operating indicator is illuminated and the glow plug is activated
(cycled). The motor of the combustion and heating air
fan starts high-speed operation for 1 second (breakaway moment) and is then under slow-down control to
approx. 30% (Diesel) or 50% (fuel) of full speed.
NOTE
Should the temperature of the intake air be above the selected, rated temperature, only the motor of the combustion and heating air fan will operate (control idle). Start
operation will be initiated with a heating air temperature
below the rated temperature.
The flame sensor function is checked. If the flame sensor at this time already signals “flame”, there will be a
120 second run-down and an error lockout of the control
unit. A malfunction of any other component monitored
causes an error lockout without run-down.
After approx. 20 seconds (for fuel operated heaters after
approx. 15 seconds) the fuel dosing pump is activated.
After another 25 seconds the speed of the combustion
and heating air fan is continuously increased to a higher
rate and combustion begins. As soon as a flame is
detected, combustion will be stabilized (see 3.1.3).
Should no normal combustion be achieved within 120
seconds (for fuel operated heaters after approx. 115
seconds), the speed of the combustion and heating air
fan is increased for approx. 30 sec and there will be an
automatic repeat start with the glow plug activated and
fuel dosing pump deactivated (no fuel supply).
Should no proper combustion develop within 120 seconds (for fuel-operated within 115 seconds) the combustion and heating air fan speed is increased to full load for
approx. 30 seconds (15 seconds for fuel-operated
heaters) with the glow plug on and the dosing pump off
(no fuel delivery) with a subsequent automatic restart.
Should the no-combustion-condition persist, after another 80 seconds (for fuel operated heaters after approx.
85 seconds) there will be a switch-off by error lockout
(see 3.1.8) with a run-down of the combustion and heating air fan lasting 120 seconds at 2/3 of its max. speed.
2. Start (automatic restart)
Fan speed is again reduced to approx. 30% (for fuel
operated heaters to approx. 50%) and fuel is delivered.
During the next 20 seconds fan speed is increased to approx. 60% (for fuel-operated heaters to approx. 75%) of
full speed. As soon as a flame is detected within the next
55 seconds, combustion will be stabilized. Should there
be no flame condition after a total fuel delivery period of
180 seconds, fuel delivery will be stopped and the glow
plug deactivated. The combustion air fan continues full
load operation for another 120 seconds (run-down) and
the heater enters the error lockout condition.
3.1.3 Stabilization
Diesel Operated Heaters
With the glow plug activated the operating speed of the
combustion and heating air fan is increased. After another 20 seconds the speed of the combustion and heating air fan is continuously increased within 17 seconds
to full load for full heat.
NOTE
This operating condition is omitted if the set temperature
(control idle) has already been achieved once.
The glow plug is deactivated and heating operation commences. A flame-out during speed up control causes a
restart, 5 restarts an error lockout of the heater.
Fuel Operated Heaters
With the glow plug activated the operating speed of the
combustion and heating air fan is continuously increased
within 4 seconds to full load for full heat. This operating
condition will be omitted if the start occurs after a control
idle period.
The glow plug is deactivated and heating operation commences. A flame-out during speed up control causes a
restart, 5 restarts an error lockout of the heater.
301
3 Functional Description
Air Top 2000 S
3.1.4 Heating Operation
During operation the combustion exhaust gasses flow
through the heat exchanger charging its walls with combustion heat, which in turn is taken up by the heating air
delivered by the heating air fan to be routed to the vehicle interior.
The temperature of the heating air sucked in is
measured by means of a temperature sensor fitted to
the air intake side of the air heater or by means of an externally located temperature sensor.
A temperature below the one set with the control element increases the heater performance up to maximum
heat. In order to extend the burner idle period of Diesel
operated heaters during permanent operation with a
heating performance in excess of 1.1 kW, the fuel dosing pump delivery rate is reduced every 15 minutes for
20 seconds.
A heating performance less than 1.1 kW causes the fuel
delivery to the dosing pump to be interrupted every 30
minutes for 4 seconds. Additionaly heating operation is
briefly suspended every 9 hours like in control idle. For
Diesel-operated heaters this is only applicable, if at this
time heating performance is less than 1.1 kW.
3.1.5 Control Operation
3.1.7 Switch-Off
Switching the heater off extinguishes the operation indication of the control element.
If no fuel has been delivered or if the air heater is in control idle, the air heater is deactivated immediately
without run-down.
If fuel supply has commenced it will be immediately
stopped at switch-off. Fan speed remains constant and
then decreases within 30 seconds to approx. 60% of full
speed. After this or with the flame sensor detecting “no
flame”, fan speed rises to maximum speed for 60 seconds and run down for 120 seconds is initiated. Rundown is at approx. 60% of full speed and is deactivated
automatically.
NOTE
Re-activation of the heater during run-down is permitted.
Run-down will be completed first with a subsequent restart.
3.1.8 Switch-off upon Failure
The control unit recognizes failures of individual air
heater components and malfunctions in the start sequence and in normal operation.
During control operation fan speed and dosing pump
rate of delivery are subject to heating performance.
The glow plug is deactivated.
3.1.6 Control Idle
After reaching the temperature set with the control element, heating performance is controlled to decrease.
The speed of the combustion and heating air fan slows
down and the fuel delivery rate to the dosing pump is reduced. When exceeding the air intake temperature set
with the control element during minimum heating performance, the dosing pump is deactivated after 5 seconds
and combustion terminates.
Fan speed remains constant for 35 seconds and is then
increased to approx. 60% of full speed for cooling the
heater down. the fan then continues to operate at approx. 30% of full speed until temperature is below the
temperature set with the control element. If temperature
falls below the one set with the control element, the
heater will restart (without break away).
NOTE
New settings on the control element are executed by the
control unit/heater with a time delay.
The air heater is deactivated and enters the error lock
out mode under the following conditions:
flame sensor open or short circuit
temperature sensor open or short circuit
glow plug open or short circuit
fan motor open or short circuit or fan speed wrong
dosing pump open or short circuit
overheating
low voltage below 10 Volt or high voltage above
15 Volt in excess of 20 seconds for 12 Volt heaters
low voltage below 20 Volt or high voltage above
30 Volt in excess of 20 seconds for 24 Volt heaters
A switch-off like in “switch-off” will be performed.
In case of overheating there will be no fuel supply. After
run-down the control unit is in the error lockout mode.
The operation indication outputs a flash code.
For error unlock the air heater has to be switched off
momentarily (at least 2 seconds) before switching on.
302
Air Top 2000 S
4 Technical Data
4. Technical Data
As long as no threshold values are given, the following
technical data are understood to include tolerances of
±10% usual for heaters at an ambient temperature of
+20 °C and at nominal voltage and conditions.
Electrical Components:
Control unit, combustion air fan, dosing pump, timer,
glow plug and control dial are for 12 or 24 Volts
operation.
The components temperature limiter and flame detector
are independent of voltage.
Air Heater Operation
Mark of conformity
Heater type
Fuel for Air Top 2000 S B (gasoline):
The fuel specified by the manufacturer must be used.
Fuel for Air Top 2000 S D (diesel/PME):
The diesel fuel specified by the vehicle manufacturer
must be used.
We know of no negative influences due to additives.
If fuel is extracted from the vehicle’s tank, follow the
additive instructions issued by the vehicle manufacturer.
If you change to low-temperature fuel, the heater must
be operated for approx. 15 minutes so that the fuel
system is filled with the new fuel.
The Air Top 2000 S D heater is also licensed for use with
PME (bio-diesel), which complies with ASTM D6751 and
DIN EN 14214.
AT 2000 S B
~ S 325
Air heater with evaporator burner
AT 2000 S D
~ S 324
Heat flow
Type of fuel
Fuel consumption
Nominal voltage
Operation voltage
Rated power consumption
Permitted ambient temp.:
Heater:
Dosing pump:
Control element:
Permitted combustion air
intake temperature
Setting range for
indoor temperature
- operation
- storage
- operation
- storage
- operation
- storage
Control range
Control range
Control range
Control range
1.1 – 2.0 kW
Gasoline
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
0.9 – 2.0 kW
Diesel/Fuel oil (EL)
0.1 .. 0.21 kg/h (0.12 .. 0.24 l/h)
12 Volt
10 … 15 Volt
9 ...22 W
24 Volt
20 … 30 Volt
Volume flow of heating air
against 0.5 bar
CO
in exhaust
2
(perm. functional range)
Dimensions air heater
Weight, heater
Max.
Max.
9.5 … 10.5
3
70 m
/h
Length 311 ± 2 mm
Width 120 ± 1 mm
Height 121 ± 1 mm
2.6 kg
9.5 … 12.0
401
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