Webasto Air Top 2000 ST B, Air Top 2000 ST D Installation Instructions
Luftheizgeräte
Air Heaters
Luchtverwarmingsapparaten
Einbauanweisung
Installation Instructions
Montagehandleiding
Air Top 2000 ST
Handelsbezeichnungen/Trade names/Handelsnamen:
Air Top 2000 ST B (Benzin/Petrol/benzine)
Air Top 2000 ST D (Diesel/PME)
Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer
verursachen oder zum Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder
tödliche Verletzungen hervorgerufen werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines Webastotrainings,
technischer Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
Es dürfen nur Originalteile von Webasto verwendet werden. Siehe dazu auch Zubehörkatalog Luft- und
Wasserheizgeräte von Webasto.
Versuchen Sie NIEMALS, Webasto Heiz- oder Kühlsysteme einzubauen oder zu reparieren, wenn Sie das
Webastotraining nicht erfolgreich abgeschlossen und dabei die notwendigen technischen Fähigkeiten
erworben haben und die für einen sachgerechten Einbau und Reparatur nötigen technischen
Dokumentationen, Werkzeuge und Ausrüstungen nicht zur Verfügung stehen.
Befolgen Sie IMMER alle Webasto Einbau- und Reparaturanleitungen, und beachten Sie alle Warnhinweise.
Webasto übernimmt keine Haftung für Mängel und Schäden, die auf einen Einbau durch ungeschultes
Personal zurückzuführen sind.
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.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto training
course and have the appropriate technical documentation, special tools and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto
training course, you do not have the necessary technical skills and you do not have the technical
documentation, tools and equipment available to ensure that you can complete the installation and repair
work properly.
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 ST
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau .............1
2 Verwendung der Luftheizgeräte ..................... 5
3 Einbau ...........................................6
4 Typschild.........................................9
5 Einbaubeispiel ...................................10
6 Heizluftsystem ................................... 11
7 Brennstoffversorgung ............................. 13
8 Brennluftversorgung .............................. 18
9 Abgasleitung ....................................19
10 Brennluftansaug- und Abgasleitungen ...............20
11 Elektrische Anschlüsse............................. 22
12 Anschlussschema / Schaltplan ......................25
13 Legende für Schaltpläne ..........................30
14 Erstinbetriebnahme ............................... 32
15 Störabschaltung ..................................33
16 Technische Daten .................................35
17 Ausführung...................................... 37
18 Bohrschablone ................................... 38
Table of Contents
1 Statutory regulations governing installation ...........39
2 Use of the air heaters ..............................43
3 Installation.......................................44
4 Type label .......................................47
5 Installation example ...............................48
6 Hot air system ....................................49
7 Fuel supply ......................................51
8 Combustion air supply .............................56
9 Exhaust pipe .....................................57
10 Combustion air inlet and exhaust lines................58
11 Electrical connections ..............................60
12 Connection diagram/Circuit diagram .................63
13 Legend for circuit diagrams .......................68
14 Initial start-up ....................................70
15 Fault lock-out ....................................71
16 Technical data ....................................73
17 Version..........................................75
18 Drilling template..................................76
I
Air Top 2000 ST Statutory regulations governing installation
1 Statutory regulations governing installation
Type approvals according to ECE-R 10 (EMC) and ECE-R 122 (Heater) exist
for the Air Top 2000 ST heater.
See chapter 16, "Technical data" for the approval number.
Primarily the regulations of Part I and Annex 7 of the directive ECE-R 122
must be observed for the installation.
NOTE:
The specifications of this Directive are binding in the scope of the
Basic Directive EEC/70/156 and/or EC/2007/46 (for new vehicle
models from 29/04/2009) and should also be observed in countries
in which no special regulations exist.
See chapter 1.2, "Extract of the directives 2001/56/EG Annex VII and
ECE R122 Part I and Annex 7" and chapter 1.3, "Extract of the directives 2001/56/EG Annex IX and ECE R122 Annex 9".
IMPORTANT
Failure to follow the installation instructions and the notes contained
therein will lead to all liability being refused by Webasto. The same applies
if repairs are carried out incorrectly or with the use of parts other than genuine spare parts. This will result in the invalidation of the type approval for
the heater and therefore of its homologation/ECE type licence.
1.1. Application of combustion heaters in vehicles for transporting dangerous goods
Vehicles for the purpose of transporting dangerous goods will be type tested in accordance with the standard ECE R105. The following measures are
derived for our combustion heaters:
• The electrical cable/wiring harness must be sufficiently dimensioned to
prevent overheating. The electrical cable/wiring harness must be sufficiently insulated. All power circuits must be protected with fuses or automatic circuit-breakers.
• The cables must be securely fastened and routed so that they are sufficiently protected against mechanical and thermal loading.
• The combustion heaters must be type-tested in accordance with the
standard ECE R122 (equivalent to EC/2001/56 in the version EC/2006/
119) and comply with the Appendix 9 – Additional regulations for vehicles for transporting dangerous goods.
• The combustion heaters and their exhaust gas routing shall be designed, located, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load.
• In the event of any leakage of the fuel line, the fuel shall drain to the
ground without coming into contact with hot parts of the vehicle or the
load;
• The exhaust system as well as the exhaust pipes shall be so directed or
protected to avoid any danger to the load through heating or ignition.
Parts of the exhaust system situated directly below the fuel tank shall
have a clearance of at least 100 mm or be protected by a thermal shield.
• The combustion heater may only be switched on manually. Programming devices shall be prohibited. The combustion heater may be
switched on again manually after the vehicle engine has been switched
off.
39
Statutory regulations governing installation Air Top 2000 ST
Requirement for basic unit:
A maximum run-on period of 40 seconds is permitted when the combustion heater is switched off. Only combustion heaters with heat exchangers
that are approved for this reduced run-on time of 40 seconds may be used.
1.2. Extract from directive ECE-R 122 Part I and Annex 7
Start of extract.
Part I
5.3 Vehicle Installation Requirements for Combustion Heaters and
for Electric Heaters
5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2, heaters shall be installed according
to the requirements of paragraph 5.3.
5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to
comply with the requirements of paragraph 5.3.
5.3.2 Positioning of heater
5.3.2.1 Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil
contamination.
5.3.2.2 The heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be met if the installation
ensures an adequate distance to all parts and suitable ventilation, by the
use of fire resistant materials or by the use of heat shields.
5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must
not be positioned in the passenger compartment. However, an installation
in an effectively sealed envelope which also complies with the conditions
in paragraph 5.3.2.2 may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 4, or a duplicate, must
be positioned so that it can be easily read when the combustion heater is
installed in the vehicle.
5.3.2.5 Every reasonable precaution should be taken in positioning the
heater to minimize the risk of injury and damage to personal property.
5.3.3 Fuel supply
5.3.3.1 The fuel filler must not be situated in the passenger compartment
and must be provided with an effective cap to prevent fuel spillage.
5.3.3.2 In the case of liquid fuel heaters, where a supply separate from that
of the vehicle is provided, the type of fuel and its filler point must be clearly
labelled.
5.3.3.3 A notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer’s operating manual.
5.3.4 Exhaust system
5.3.4.1 The exhaust outlet must be located so as to prevent emissions from
entering the vehicle through ventilators, heated air inlets or opening windows.
5.3.5 Combustion air inlet
5.3.5.1 The air for the combustion chamber of the heater must not be
drawn from the passenger compartment of the vehicle.
5.3.5.2 The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely.
5.3.6 Heating air inlet
5.3.6.1 The heating air supply may be fresh or re-circulated air and must
be drawn from a clean area not likely to be contaminated by exhaust
fumes emitted either by the propulsion engine, the combustion heater or
any other vehicle source.
40
Air Top 2000 ST Statutory regulations governing installation
5.3.6.2 The inlet duct must be protected by mesh or other suitable means.
5.3.7 Heating air outlet
5.3.7.1 Any ducting used to route the hot air through the vehicle must be
so positioned or protected that no injury or damage could be caused if it
were to be touched.
5.3.7.2 The air outlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.8 Automatic control of the heating system
5.3.8.1 The heating system must be switched off automatically and the
supply of fuel must be stopped within five seconds when the vehicle’s engine stops running. If a manual device is already activated, the heating system can stay in operation.
ANNEX 7
ADDITIONAL REQUIREMENTS FOR COMBUSTION HEATERS
7 Warning light
7.1 A clearly visible tell-tale in the operator’s field of view shall inform
when the combustion heater is switched on or off.
End of extract.
NOTE:
Contrary to point 5.3.2.3 the heater must also not be installed in the
passenger cabin of class M1 and N vehicles. However, an installation in an
effectively sealed envelope which also complies with the conditions in
paragraph 5.3.2.2 may be used.
1.3. Extract from directive ECE-R 122 Annex 9
Start of extract.
Additional provisions applicable to certain vehicles as specified in the ADR.
3. Technical Provisions
3.1 General (EX/II, EX/III, AT, FL, OX and MEMU vehicles)
3.1.1 [1] The combustion heaters and their exhaust gas routing shall be de-
signed, located, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load. This requirement shall be considered
as fulfilled if the fuel tank and the exhaust system of the appliance conform
to the following provisions:
- Any fuel tanks for supplying the appliance shall meet the following
requirements:
a) In the event of any leakage, the fuel shall drain to the ground
without coming into contact with hot parts of the vehicle or
the load;
b) Fuel tanks containing petrol shall be equipped with an effec-
tive flame trap at the filler opening or with a closure enabling
the opening to be kept hermetically sealed.
- The exhaust system as well as the exhaust pipes shall be so directed
or protected to avoid any danger to the load through heating or ignition. Parts of the exhaust system situated directly below the fuel
tank (diesel) shall have a clearance of at least 100 mm or be protected by a thermal shield.
3.1.2 The combustion heater shall be switched on manually. Programming
devices shall be prohibited.
3.2 EX/II, EX/III and MEMU vehicles
Combustion heaters using gaseous fuels are not permitted.
41
Statutory regulations governing installation Air Top 2000 ST
3.3 FL vehicles
3.3.1 The combustion heaters shall be put out of operation by at least the
following methods:
a) Intentional manual switching off from the driver’s cab;
b) Stopping of the vehicle engine; in this case the heating device
may be restarted manually by the driver;
c) Start up of a feed pump on the motor vehicle for the danger-
ous goods carried.
[1] Compliance with this paragraph shall be verified on the completed vehicle.
End of extract.
42
Air Top 2000 ST Use of the air heaters
2 Use of the air heaters
The Webasto Air Top 2000 ST air heaters are designed
– to heat cabins, boats, trucks, minibuses, vans and motorhomes
– to defrost vehicle windows
The heaters operate independently of the engine and are connected directly to the fuel tank and the electrical system of the vehicle.
They may be used for vehicles with either water or air-cooled engines.
They are not designed for heating hazardous substances.
43
Installation Air Top 2000 ST
3 Installation
IMPORTANT
The statutory regulations governing installation on pages 1 and 2 must be
adhered to. The requirements of the latest version of the ADR must also be
observed for the installing the heater into vehicles used to transport hazardous substances.
The heater must not be operated without the control unit cover (this will
cause the heater to overheat).
3.1. Air Top 2000 ST installation situation
NOTE:
Check the installation situation of the relevant vehicle type.
3.2. Installation location
The heater may be fitted both in the interior or on the exterior of the vehicle.
When using the vehicle in normal road traffic, the heater may only be installed with contact protection if it is located within reach of the driver.
If it is installed on the exterior ensure that the heater is fitted in a position
where it is protected from splashing water and spray.
The heater must be installed in such a way that no water can ingress into
it if the vehicle travels through a water hazard for which that vehicle is licensed.
The openings for the combustion air inlet port, the exhaust outlet port and
the fuel pipe must be sealed if the heater is installed in the interior. The seal
designed and supplied for this purpose must be used (see Figure 3).
3.3. To install the heater
The M6 nuts must be tightened with a torque of 6 Nm +1 Nm for installing
the Air Top 2000 ST heater.
The installation dimensions and space requirement for service access are
shown in the installation drawing (Figure 1). The specified horizontal and
axial angles must not be exceeded (Figure 2).
A seal (Figure 3) must be fitted between the heater and the vehicle body.
This seal must be replaced each time the heater is installed. The support area for the heater foot must be flat. A special tools can be purchased from Webasto to drill the holes and, if necessary, smooth the support area. The seal can compensate for unevenness of
IMPORTANT
After installation, check that the casing is not in contact with any parts of
the vehicle body. A failure to do this may result in the hot air fan blocking.
max. 1 mm.
44
Air Top 2000 ST Installation
8
1
6
1 Hot air inlet
2 Hot air outlet
3 Combustion air intake
4 Exhaust fume outlet
Fig. 1: Dimensions of the heater
2
5
3
4
5 Fuel intake
6 Space requirement for hot air inlet
7 Space requirement for removing the heater
8 Cable outlet (either right or left)
7
45
Installation Air Top 2000 ST
Air Top 2000 ST - diesel:
Air Top 2000 ST - petrol: horizontally
Fig. 2: Permitted installation positions for heaters
46
Fig. 3: Seal
Ensure that all moving parts can move easily!
Fig. 4: Installation
Air Top 2000 ST Type label
4 Type label
The model plate must be positioned so that it cannot be damaged and
must be clearly legible when the heater is installed (otherwise a duplicate
model plate must be used).
Inapplicable years must be erased from the model plate.
47
Installation example Air Top 2000 ST
5 Installation example
1 Control element
2 Heater
3 Metering pump
4 Fuel filter (accessory)
5 Tank connector
6 Exhaust silencer (accessory)
7 Fuse
1
2
6
Fig. 5: Installation example for air heater in recirculation mode
48
7
3
4
5
Maximum
water passage height
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