Webasto Air Top 2000 ST B Manuale utente

Luftheizgeräte

Air Heaters

Luchtverwarmingssystemen

05/2008

9010298C

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/PMU)

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.

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 ofWebasto 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.

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 . . . . . . . . . . . . . . . . . . . . . 4

3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Fabrikschild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Einbaubeispiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Heizluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

9 Abgasleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10 Brennluftansaug- und Abgasleitungen . . . . . . . . . . . . . . 19

11 Elektrische Anschlüsse. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

12 Legende für Schaltpläne . . . . . . . . . . . . . . . . . . . . . . . . . . 29

13 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

14 Störabschaltung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15 Technische Daten. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

16 Ausführung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

17 Bohrschablone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Table of contents

1 Statutory regulations governing installation . . . . . . . . . . 39

2 Use of the air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Factory plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

10 Combustion air inlet and exhaust lines . . . . . . . . . . . . . . 57

11 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

12 Legend for circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . 67

13 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

14 Fault lock-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

16 Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

17 Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Air Top 2000 ST Statutory regulations governing installation

1 Statutory regulations governing installation

1.1. Statutory regulations governing installation

The Air Top 2000 ST heater unit has been type- tested and approved in

accordance with Directives 72/245/EEC (EMC), 2001/56/EC (heater)

and ECE R122 with the following permit numbers:

e1*72/245*95/54*1085*00

e1*2001/56*0022*00

E1*R122 00 0216*--

Primarily the regulations of Annex VII of the Directive 2001/56/EG and

Part 2 or Annex 7 of the directive ECE R122 must be observed for the

installation.

NOTE:

The provisions of these Directives are binding within the territory

governed by EU Directive 70/156/EEC and should similarly be

observed in countries without specific regulations.

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 / EC/ECE type

licence.

(Extract from Directive 2001/56/EC Annex VII and ECE R122 Part 2

and Annex 7)

1.7.1. / 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.

2. / 5.3. Vehicle installation requirements

2.1. / 5.3.1. Scope

2.1.1. / 5.3.1.1. Subject to paragraph 2.1.2 / 5.3.1.2 combustion heaters

shall be installed according to the requirements of this Annex/Article.

2.1.2/ 5.3.1.2. Vehicles of category O (trailers) having liquid fuel heaters

are deemed to comply with the requirements of this Annex/Article.

2.2. / 5.3.2. Positioning of heater

2.2.1. 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.

2.2.2 / 5.3.2.2. The combustion heater shall not constitute a risk of fire,

even in the case of overheating. This requirement shall be deemed to

be fulfilled 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.

2.2.3 / 5.3.2.3. In the case of M2 and M3 vehicles, the heater must not

bepositionedinthepassengercompartment. However, an installationin

an effectively sealed envelope which also complies with the conditions

in paragraph 2.2.2 / Article 5.3.2.2 may be used.

Statutory regulations governing installation Air Top 2000 ST

2.2.4 / 5.3.2.4. The label referred to in paragraph 1.4 / annex 7 / article

1.4 (model plate), or a duplicate (duplicate model plate), must be

positioned so that itcan be easily read when the heater is installed in the

vehicle.

2.2.5 / 5.3.2.5 Every reasonable precaution should be taken in

positioning the heater to minimise the risk of injury and damage to

personal property.

2.3. / 5.3.3. Fuel supply

2.3.1 / 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.

2.3.2/5.3.3.2.Inthe case of liquidfuelheaters,wherea supplyseparate

to that of the vehicle is provided, the type of fuel and its filler point must

be clearly labelled.

2.3.3 / 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.

2.4. / 5.3.4. Exhaust system

2.4.1 / 5.3.4.1. The exhaust outlet must be located so as to prevent

emissionsfrom entering the vehicle through ventilators, heated air inlets

or opening windows.

2.5. / 5.3.5. Combustion air inlet

2.5.1 / 5.3.5.1. The air for the combustion chamber of the heater must

not be drawn from the passenger compartment of the vehicle.

2.5.2 / 5.3.5.2. The air inlet must be so positioned or guarded that

blocking by rubbish or luggage is unlikely.

2.6. / 5.3.6. Heating air inlet

2.6.1 / 5.3.6.1. The heating air supply may be fresh or recirculated 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.

2.6.2 / 5.3.6.2. The inlet duct must be protected by mesh or other

suitable means.

2.7. / 5.3.7. Heating air outlet

2.7.1 / 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.

2.7.2 / 5.3.7.2. The air outlet must be so positioned or guarded that

blocking by rubbish or luggage is unlikely.

2.8. / 5.3.8.1. Automatic control of the heating system

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.

NOTE:

Contrary to point 2.2.3 / 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 2.2.2 / section 5.3.2.2 may be used.

Air Top 2000 ST Statutory regulations governing installation

(Extract from Directive 2001/56/EC Annex IX)

3. Technical specifications for heater units for installation in

dangerous goods transporters (Annex 9)

3.1. General (EX/II, EX/III, AT, FL and OX vehicles)

3.1.1. 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 provisions set out in the points 3.1.1.1 and

3.1.1.2. Compliance with those provisions shall be verified on the

completed vehicle.

3.1.1.1. 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

effective flame trap at the filler opening or with a closure

enabling the opening to be kept hermetically sealed.

3.1.1.2. 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 exhaustsystem 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 and EX/III 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

dangerous goods carried.

Use of the air heaters Air Top 2000 ST

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 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.

Air Top 2000 ST Installation

3 Installation

IMPORTANT

The statutory regulations governing installation on pages 1 and 2 must

be adhered to. The requirements of the latest version of the ADR must

also be observed for the installing the heater into vehicles used to

transport hazardous substances.

The heater must not be operated without the control unit cover (this will

cause the heater to overheat).

3.1. 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.

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.

Fig. 1: Dimensions of the heater

1 Hot air inlet

2 Hot air outlet

3 Combustion air intake

4 Exhaust fume outlet

5 Fuel intake

6 Space requirement for hot air inlet

7 Space requirement for removing the heater

8 Cable outlet (either right or left)

354

Installation Air Top 2000 ST

Theheatermustbeinstalled in suchawaythatnowatercaningressinto

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 4).

We recommend that petrol heaters be installed with the exhaust port

pointing vertically downwards.

3.3. To install the heater

TheM6nutsmustbetightenedwitha torque of6Nm+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).

Aseal(Figure4)mustbefittedbetweentheheaterandthevehiclebody.

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 max. 1 mm.

Fig. 2: Recommended installation positions for diesel heaters

Fig. 3: Hole pattern

Fig. 4: Seal

ø26 ø26

ø7,5

Air Top 2000 ST Installation

IMPORTANT

After installation, check that the casing is not in contact with any parts of

thevehiclebody.A failure todo thismayresultinthehotairfanblocking.

Fig. 5: Installation

Ensure that all moving parts can move ea

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