Webasto Air Top 2000 ST D Service And Repair Manual
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Webasto Air Top 2000 ST D Service And Repair Manual

Webasto Air Top 2000 ST D Service And Repair Manual

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Air Heater
Air Top 2000 ST D (Diesel)
Air Top 2000 ST 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.

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Summary of Contents for Webasto Air Top 2000 ST D

  • Page 1 – 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.

  • Page 3: Table Of Contents

    7.1 General ................. . 23 www.webasto.us Webasto Product N.A., Inc.
  • Page 4 9.2.3.2 Installation ..............38 Webasto Product N.A., Inc.
  • Page 5 9.2.8.2 Installation ..............43 10.Product Information www.webasto.us Webasto Product N.A., Inc.

  • Page 6: Introduction

    1.4 S AFETY NFORMATION AND EGULATIONS The Webasto Air Top 2000 ST air heaters are designed In principle, the general accident prevention regulations – to heat cabins, boats, trucks, minibuses, vans, and current works safety instructions are applicable. ambulances and motor homes.
  • Page 7 Installation regulations for Webasto fuel tanks for of explosion. supplying fuel to heaters in vehicles: The heater must not be operated in enclosed areas, such •...

  • Page 8: Suggestions For Improvements And Changes

    If the heater is installed in a storage area, you must lead to all liability being refused by Webasto ensure that no inflammable substances are kept in this The same applies if repairs are carried out...

  • Page 9: General Description

    If the heater has a control element, the ON control light will flash. In addition, the heater can be checked using a personal computer (see PC heater diagnostic operating manual). Figure 3: Drive Unit www.webasto.us Webasto Product N.A., Inc.

  • Page 10: Heat Exchanger

    This change in resistance is analyzed by the control unit so that the flame status is monitored whenever the heater is operating. Combustion pipe Burner insert Figure 5: Burner Insert with Combustion Pipe Figure 7: Flame Sensor Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 11: Ceramic Glow Pin

    Ceramic Glow Pin 2.8 F ETERING The metering pump is a combined transport, metering and shut-off system for supplying fuel from the vehicle’s tank to the heater. Figure 10: Fuel Metering Pump DP 30.2/3 (with Damper) www.webasto.us Webasto Product N.A., Inc.

  • Page 12: Functional Description

    (diesel) the glow pin will be switched off and the existence of the flame established. In control mode the blower speed and the metering pump delivery rate are dependent on the heat output. The glow pin is switched off. www.webasto.us Webasto Product N.A., Inc.

  • Page 13: Control Pause

    In this case the To reset the fault, switch the heater off briefly (at least slow down time is completed and the heater is 2 seconds) and then on again. then restarted. Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 14: Error Monitor

    FAZP will return to 0 after a few control cycles. If the permanent flame failure counter exceeds its maximum value of 6, however, the heater will go to permanent heater lock-out status (error code F13). www.webasto.us Webasto Product N.A., Inc.

  • Page 15: Technical Data

    12 V or 24 V. The Air Top 2000 ST D heater is also licensed for use with The components temperature sensor and flame monitor PME (bio-diesel), which complies with ASTM D6751 and (only petrol heater) are not designed for a specific DIN EN 14214.

  • Page 16: Troubleshooting

    ON indicator flashes Switch heater off and then on again Heater produces black smoke Combustion air and/or exhaust system Check that the combustion air and blocked exhaust systems are clear Table 2. General Error Symptoms www.webasto.us Webasto Product N.A., Inc.

  • Page 17: Error Symptoms During Function

    No start but LED is lit Immediate The heater goes straight to control pause when it is switched on, whereby the control pause speed is 0 rpm for a boat heater. Table 3. Error Symptoms during Function Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 18: Error Code Output

    84 The voltage was less than 10.5 V or Charge battery over-voltage 21 V for longer than 20 seconds 04 The voltage was more than 16 V or 32 V for longer than 6 seconds Table 4. Troubleshooting (page 1 of 3) www.webasto.us Webasto Product N.A., Inc.
  • Page 19 Replace glow pin Break or short circuit to +Ub or short-circuit 19 Glow circuit Replace glow pin The switched cable of the element has a short circuit to earth Table 5. Troubleshooting (page 2 of 3) Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 20 (ÜHS gradient too low) F 15 Nominal sensor 9B Nominal value potentiometer circuit Check cables / replace control element break break or short circuit to +Ub Table 6. Troubleshooting (page 3 of 3) www.webasto.us Webasto Product N.A., Inc.

  • Page 21: Functional Tests

    CO content is to be set to 6.1 - 6.2% v/v in low-fire mode (1 kW). In high-fire mode, the CO content should be 9.9 +/- 0.4% v/v after the setting has been made. www.webasto.us Webasto Product N.A., Inc.

  • Page 22: Overheating Sensor Resistance Test

    Temperature in °F 28 °C = 82.4 °F 30 °C = 86 °F Characteristic resistance values of a PT 2000 overheating system in a temperature range of 10 °C to 30 °C (50 °F to 86 °F) Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 23: Circuit Diagrams

    X1 = Combustion and hot air blower connection X2 = Ceramic glow pin connection X3 = Overheating sensor connection X4 = Metering pump connection X5 = Flame sensor connection (gasoline heaters only) X6 = Wiring harness connection Figure 11: Plug Assignment www.webasto.us Webasto Product N.A., Inc.
  • Page 24 Plug connector, 2-pin Motor Combustion and hot air fan Plug connector, 12-pin to item P Combination timer Timer and temperature control Fuel metering pump (1531) Figure 12: System Circuit Diagram 12V/24V with Control Element (Rheostat Switch) Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 25 Plug connector, 2-pin Motor Combustion and hot air fan Plug connector, 12-pin to item P Combination timer Timer and temperature control Fuel metering pump (1531) Figure 13: System Circuit Diagram 12V/24V with Combination Timer Model 1531 www.webasto.us Webasto Product N.A., Inc.
  • Page 26 Combination Timer 1531 Black Battery Positive or Ignition Signal (10) Grey Lights (1) (optional) Battery Positive (11) Brown Battery Negative (12, 4) Adapter Harness P/N 9008440A Figure 14: Schematic Connection of the Combination Timer Model 1531 Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 27: Work On The Heater

    (the time after which the heater will be used due to adverse weather conditions) by Webasto- The heater can be used on the air inlet and outlet side if trained personnel.

  • Page 28: Fuel Supply

    The fuel may only be extracted on cars using a special consideration when designing the hot air system. Webasto fuel tee fitting as close to the tank as possible. The connection may be made in either the supply or 8.6.2...
  • Page 29 25 mm (1 in.) Max. depth Figure 18: Fuel standpipe for a plastic or metal tank Figure 16: Webasto fuel standpipe (extraction through metal tank fitting) NOTE: Only use this style of standpipe with NOTE: The tank or fitting must be made of metal fuel tanks.

  • Page 30: Fuel Lines

    Wrong 8.6.4 ILTER Bubble Bubble Only a Webasto filter, P/N 50487171A, is allowed to be used if the fuel is expected to be contaminated. Install vertically if possible, however at most horizontally (check flow direction). Figure 19: Pipe/Hose connections 0° - 90°...

  • Page 31: Combustion Air Supply

    If dirty combustion air is expected, a combustion air filter An attachment is required no further than 150 mm (6 in) may be fitted (only Air Top 2000 ST D). If the intake hose from the end of the exhaust pipe to ensure that the length is <...

  • Page 32: Electrical Connections

    NOTE: The connector housing can be locked (self-locking action) by simply pulling on the wiring harness. AT 2000 ST F = 15A (12V) F = 10A (24V) Figure 24: Weather Resistant Fuse holder Figure 26: Disconnecting the plug Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 33 AIR TOP 2000 ST SERVICING WORK Figure 27: Example installation for heater in an air circulation system www.webasto.us Webasto Product N.A., Inc.

  • Page 34: Removal And Installation

    6. Connect the wiring harness plug to socket X6 of the control unit. 7. Fit the cover and secure it. 8. If necessary fit the hot air hose or hoses and secure them. 9. Connect the battery. 10. Bleed the fuel supply system (see 8.8). Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 35: Repair

    The following describes modifications that can be carried out without any great effort during standard repair work: • Installation of an external temperature sensor for better temperature control (see 9.1.2.1). External temperature sensor Terminating resistor Figure 28: External Temperature Sensor www.webasto.us Webasto Product N.A., Inc.

  • Page 36: Dismantling And Assembling

    • Four insulators are used as spacers between the heat exchanger and the casing parts. 1. Fit the cover (1, Fig. 29) until it audibly engages in the top cover. Webasto Product N.A., Inc. www.techwebasto.com...
  • Page 37 AIR TOP 2000 ST REPAIR Cover, electrical connection Top shell Cover, hot air outlet Bottom shell Grate Cover, hot air inlet Insulators Positioning of insulators Insulator Extension of corner rib Figure 29: Remove / Fit the Casing Parts www.webasto.us Webasto Product N.A., Inc.

  • Page 38: Changing The Control Unit

    (5, Fig. 30) and on the heat exchanger (8) are unit (3). not damaged. CAUTION: Do not pull the cables. 2. Fit a new seal (7) on the flange of the combustion air fan (5). Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 39: Changing The Flame Sensor (Gasoline Heaters Only)

    (9). 7. Carefully bend up the securing strap (4) and pull out the flame sensor (1) from the burner insert. 8. Remove flame sensor 9. Complete the work on stripped-down components (see 9.1.1). www.webasto.us Webasto Product N.A., Inc.
  • Page 40 Hot air fan rotor Torx screw (3) Electronic control unit Torx screw (5) Combustion air fan (drive unit) Seal Heat exchanger Overheating sensor Insulator (4) Figure 30: Changing the Control Unit, Combustion Air Fan and Overheating Sensor Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 41: Changing The Ceramic Glow Pin

    6 ± 0.6 Nm (53 ± .5 lb-in). 8. Install the combustion air fan (see 9.2.5.2). 9. Fit the control unit (see 9.2.3.2). 10. Position the casing parts (see 9.2.2). 11. Install the heater (see 8.7.1.2). www.webasto.us Webasto Product N.A., Inc.
  • Page 42 10 Cable grommet Air baffle 11 Cable grommet (gasoline heaters only) Burner insert 12 Seal Ceramic glow pin 13 Combustion pipe Screw Figure 31: Changing the glow plug, flame sensor, combustion insert and the heat exchanger Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 43: Removal

    7. Install the combustion air fan (see 9.2.5.2). (see 9.1.1). 8. Fit the control unit (see 9.2.3.2). 9. Fit the overheating sensor (see 9.2.4.2). 10. Fit the insulators (11). 11. Position the casing parts (see 9.2.2). 12. Install the heater (see 8.7.1.2). www.webasto.us Webasto Product N.A., Inc.
  • Page 44 REPAIR AIR TOP 2000 ST Starting air hole Figure 32: Starting air hole in burner insert Webasto Product N.A., Inc. www.techwebasto.com...

  • Page 45: Product Information

    AIR TOP 2000 ST PRODUCT INFORMATION 10. PRODUCT INFORMATION No new or updated information available at this time. www.webasto.us Webasto Product N.A., Inc.
  • Page 46 (2) years effective at the time of installationor vehicle registration date for Original Equipment installations (OE). This warranty period may not exceed three (3) years from the original date of sale by Webasto. This warranty period may be superseded by a contractual agreement.* *Warranty coverage for Marine and Off-road applications containing DBW series heaters and the CSL Cargo Heaters are limited to a maximum of 3,000 hours of usage.
  • Page 48 N.A., I EBASTO RODUCT 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.techwebasto.com Org. 06/2005 Rev. 02/2012 P/N LIT9010439B © 2012 Webasto Product N.A., Inc. www.webasto.us...

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