Webasto Air Top 2000 STC, Air Top 2000 STC B, Air Top 2000 STC D Installation Instructions
Luftheizgeräte
Air Heaters
Luchtverwarmingsapparaten
Einbauanweisung
Installation Instructions
Montagehandleiding
Air Top 2000 STC
Handelsbezeichnungen/Trade names/Handelsnamen:
Air Top 2000 STC B (Benzin/petrol/benzine)
Air Top 2000 STC D (Diesel/FAME)
9032312A_II_AT2000STC.book Page 1 Thursday, September 29, 2016 1:21 PM
Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer verursachen oder zum
Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder tödliche Verletzungen hervorgerufen
werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines Webastotrainings, technischer
Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
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.
9032312A_II_AT2000STC.book Page 1 Thursday, September 29, 2016 1:21 PM
Air Top 2000 STC
I
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . 1
2 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 5
3 Einbau. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Typschild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Einbaubeispiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Warmluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
15 Störabschaltung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
16 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
18 Bohrschablone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table of Contents
1 Statutory regulations governing installation . . . . . . . . . . .41
2 Use of air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4 Type label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
10 Combustion air intake and exhaust pipes. . . . . . . . . . . . . .60
11 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
12 Connection diagram/wiring diagram . . . . . . . . . . . . . . .65
13 Legend to wiring diagrams . . . . . . . . . . . . . . . . . . . . . .70
14 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
15 Fault switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
16 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
17 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
18 Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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Air Top 2000 STC Statutory regulations governing installation
41
1 Statutory regulations governing installation
The Air Top 2000 STC heater has been type-tested and approved in accordance with ECE-R 10 (EMC) and ECE-R 122 (heater).
For approval number see Chapter 16, "Technical data".
Primarily, the stipulations of Part I and o
f Annex 7 to the Regulation ECE-R
122 must be observed for the installation.
NOTE:
The stipulations of this regulation are binding under the framework
of t
he D
irective 70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and should also be observed in countries where
the
re ar
e no specific regulations.
See Chapter 1.2, "Excerpt from the directive ECE-R 122 Part I and Annex
7" and Chapter 1.3, "Excerpt from the directive ECE-R 122 Annex 9".
ATTENTION:
Failure to follow the installation instructions and the notes conta
ined 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 / EC type licence.
1.1. Application of combustion heaters in vehicles for the transpor-
tation of dangerous goods.
Vehicles used for the purpose of transporting dangerous goods are type
ap
pro
val tested in accordance with ECE R 105. The following measures are
derived for our combustion heaters.
• The electrical cable/wiring harness must be s
ufficiently dimensioned to pre-
vent overheating. The electrical cable/wir
ing harness must be sufficiently
insulated. All electrical circuits must be protected by fuses or automatic circuit breakers.
• The cables must be installed and firmly secured such that the wirings are
ad
equa
tely protected against mechanical and thermal stress.
• The combustion heaters must be type-tested in accordance with ECE R 122
(equi
valent to EC/2001/56 in the version EC/2006/119) and comply with
Annex 9 - Additional regulations for vehicles used for transporting dangerous goods.
• The combustion heaters and their exhaust gas piping system must be designed, arranged, protected or covered so as to prevent any unacceptable
risk
of heating or igniti
on of the load.
• In the event of a leak in the fuel line, the fuel must drain to the ground
wit
ho
ut 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
exha
ust system situated directly below the fuel tank must have a mini-
mum clearance of 100 mm or be protected b
y a heat shield.
• It must only be possible to switch the combustion heater on manually. Programming devices shall be prohibited.
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Statutory regulations governing installation Air Top 2000 STC
42
Requirements relating to the basic unit:
When switched off, it is permissible for combustion heate
rs to continue
running for max. 40 seconds. Only combustion heaters ar
e to be used with
heat exchangers that are not damaged during their standard operating
period by the reduced afterrunning time of 40 seconds.
1.2. Excerpt from the directive ECE-R 122 Part I and Annex 7
Start of excerpt.
Part I
5.3 V
ehi
cle 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.
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Air Top 2000 STC Statutory regulations governing installation
43
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 excerpt.
NOTE:
If the installation location of t
he heater is not located behind the
driver's seat
and can be reached by the driver under normal operating conditions,
supplementary to Point 5.3.2.3, the heater must only be installed in an
effectively sealed housing (that also conforms to the regulations of
Paragraph 5.3.2.2) in vehicles of Class M1 (passenger vehicles and motor
homes), M2 and M3 (coaches) as well as N (transporters and commercial
vehicles).
The installation of the heater in a place that is inaccessible
whi
le driving or
in a suitable enclosure conforming to Paragraphs 5.3.2.2 and 5.3.2.5 is
recommended in order to avoid unintentional contact with the heater
surface and possible injuries.
1.3. Excerpt from the directive ECE-R 122 Annex 9
Start of excerpt.
Additional provisions applicable to certain vehic
les as specif
ied 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 designed, 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.
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Statutory regulations governing installation Air Top 2000 STC
44
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.
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 excerpt.
9032312A_II_AT2000STC.book Page 44 Thursday, September 29, 2016 1:21 PM
Air Top 2000 STC Use of air heaters
45
2 Use of air heaters
The Webasto Air Top 2000 STC air heaters are designed
– to heat cabins, boats, commercial vehicles, minibusses, vans/t
ransporters
and motor homes
– to defrost vehicle windows.
The heaters operate independently of the engine and are connected directly
to th
e fuel tank and the electrical system of the vehicle.
They are not approved for heating dangerous goods/hazar
dous substances.
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Installation Air Top 2000 STC
46
3 Installation
ATTENTION:
Comply with the legal requirements for installation on Page 41 and 42. The
requirements stipulated in the latest version of the ADR must b
e additionally
observed for the installation of the heater in vehicles used to transport
dangerous goods/hazardous substances.
The heater must not be operated without the control unit cover (this will
cau
se t
he heater to overheat).
3.1. Air Top 2000 STC installation situation
NOTE:
Check the given conditions for installation
in the respective type of vehicle.
3.2. Installation location
The heater may be installed 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
a contact guard to prevent contact if it is located within the
reach of the driver.
If installed on the exterior, ensure that the heater is fitted in a position where
it
is
protected from splash water and spray.
The heater must be installed in such a way that no wate
r can enter the
heater when the vehicle is driven through water conforming to the
permissible fording level.
The openings for the combustion air inlet, the ex
haust gas outlet and the
fuel pipe must be sealed. The seal designed and supplied for this purpose
must be used.
(See Fig. 3).
3.3. Heater installation
When installing the Air Top 2000 STC heater, tighten the M6 nuts to a torque
of
6 Nm +
1.
The installation dimensions and space r
equirement
s for service access are
shown in the installation drawing (Fig. 1). The specified horizontal and axial
angles of inclination must not be exceeded (Fig. 2).
A seal (Fig. 3) must be fitted between the heater and the vehicle body. The
se
al must be replaced each time the heater is reinstalled. The suppo
rt
surface for the heater base must be flat. The seal can compensate for
unevenness of
max. 1 mm.
ATTENTION:
After installation check that the casing is not in contact with any part of the
b
ody
. Failure to do this may result in the heating air fan blocking.
9032312A_II_AT2000STC.book Page 46 Thursday, September 29, 2016 1:21 PM
Air Top 2000 STC Installation
47
Fig. 1: Heater dimensions
A
B
C
120
121
>155
29
>30
120
310
2
>20
>20
>20
Ø22 Ø22
1
2
3
456
Cold air inlet
Cable outlet (optionally on right or left)
Hot air outlet
Exhaust gas outlet
Fuel inlet
Combustion air inlet
A Space requirements for hot air outlet
B Space requirements for cold air inlet
C Space requirements for removing heater
9032312A_II_AT2000STC.book Page 47 Thursday, September 29, 2016 1:21 PM
Installation Air Top 2000 STC
48
Fig. 2: Permissible heater installation positions
Diesel:
Petrol: horizontal
Fig. 3: Seal
Fig. 4: Installation
Ensure ease of movement of
all moving parts!
9032312A_II_AT2000STC.book Page 48 Thursday, September 29, 2016 1:21 PM
Air Top 2000 STC Type label
49
4Type label
If the type label is not visible with the heater in installed position, a duplicate
of the type plate must be displayed in a position where it is clearly visible and
protected from damage.
Year figures that do not apply must be removed from the type label.
9032312A_II_AT2000STC.book Page 49 Thursday, September 29, 2016 1:21 PM
Installation example Air Top 2000 STC
50
5 Installation example
Fig. 5: Installation example of air heater in recirculated air mode
12 3
4
567
10
9 8
Control element
Heater
Fuse
Tank extracting device
Fuel filter (accessory)
Fuel pump
Exhaust silencer (accessory)
Combustion air intake line
Combustion air intake silencer (accessory)
Maximum permissible fording level
9032312A_II_AT2000STC.book Page 50 Thursday, September 29, 2016 1:21 PM
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