Webasto Air Top 2000 STC User Manual

Luft-Heizgeräte
Air Heaters
03/2003
Workshop Manual
Air Top 2000 STC
Trade names:
Air Top 2000 STC B (petrol)
Air Top 2000 STC D (diesel)

Webasto Air Top 2000 STC Specifications

General

Heating Power Output	0.9 - 2.0 kW
Power Consumption	14 - 29 W
Weight	2.6 kg
Heater Type	Air Heater
Fuel Type	Diesel
Operating Voltage	12V
Operating Temperature Range	-40°C to +40°C

Summary

Introduction to Webasto Air Top 2000 STC

1.1 Contents and Purpose of the Manual

Manual for trained personnel on repairing petrol/diesel Air Top 2000 STC heaters.

1.1.1 Air Heater Applications and Limitations

Applications and limitations of Webasto Air Top 2000 STC air heaters.

1.2 Meaning of Signal Words in Manual

Defines signal words like CAUTION, ATTENTION, NOTE used in the manual.

1.2.1 General Safety Information and Precautions

Safety guidelines for installation and operation, including exhaust, electrical, and hazardous environments.

General Description of Air Top 2000 STC Heater

2.1 Drive Unit

Describes the drive unit, including motor, fans, and casing.

2.2 Heat Exchanger

Explains how the heat exchanger transfers heat from combustion to air.

2.3 Burner and Combustion Chamber

Details the burner's function in distributing fuel and igniting the mixture.

2.4 Control Unit

Central component for monitoring, evaluating sensors, and controlling heating operation.

2.5 Flame Monitor (Petrol Heater Only)

Explains the flame monitor's role in detecting flame status.

2.6 Glow Plug

Describes the glow plug's function in igniting the fuel/air mixture.

2.7 Overheating Sensor

Explains the sensor's role in measuring temperature and controlling shut-down.

2.8 Fuel Pump

Describes the fuel pump's function in delivering and metering fuel.

Functional Description of Air Top 2000 STC Operation

3.1 Control Element

Details the functions of the control element for operation and diagnostics.

3.2 Switching On

Explains the heater's start-up sequence and automatic restart procedure.

3.3 Heating Mode

Describes the process of heat transfer and temperature regulation during heating.

3.4 Control Mode

Explains how fan speed and fuel delivery are regulated based on heating capacity.

3.5 Control Pause

Describes the reduction in heating capacity when the set temperature is reached.

3.6 Switching Off

Details the procedure for switching the heater off and any afterrunning periods.

3.7 Heater Functions in ADR Vehicles

Specific functions and lock-out modes for ADR-equipped vehicles.

3.8 Fault Switch-off

Lists conditions that cause the heater to shut down and enter fault lock-out.

Technical Data for Air Top 2000 STC

4.1 General Technical Data

Provides technical specifications for Air Top 2000 STC B and D models.

Troubleshooting Air Top 2000 STC Heater

5.1 General Information

Guidance on identifying and remedying faults, including using fault codes.

5.2 General Fault Symptoms

Lists common fault symptoms, possible causes, and corrective measures.

5.3 Fault Symptoms During Operation

Details symptoms that occur during operation and their possible causes.

5.4 Fault Code Output (Hexadecimal / Webasto Thermo Test)

Explains fault codes and recommended actions for specific errors.

5.5 Fault Code Output (Flashing or FXX Output)

Details fault codes indicated by flashing lights or FXX codes.

Function Checks and Testing Air Top 2000 STC

6.1 General Information

Describes checks for installed and uninstalled heaters to verify working order.

6.2 Required Test and Measuring Equipment

Lists necessary equipment for testing and calibration.

6.3 Settings

Covers procedures for setting parameters like CO2 content.

6.3.1 Setting the CO2 Content

Step-by-step guide to setting exhaust gas CO2 content.

6.3.2 CO2 Setting for Reference Heater

Explains how to set CO2 for a reference heater based on altitude.

6.4 Testing Individual Components

Outlines the process for testing specific heater components.

Wiring Diagrams for Air Top 2000 STC

7.1 General Information

Overview of control element options and wiring diagram references.

7.2 System Wiring Diagrams

Presents wiring diagrams for various system configurations.

7.3 Legends to System Wiring Diagrams

Provides legends for cable cross-sections, colours, and component descriptions.

7.4 Pin Assignments Plug Connection X6, 18-pin

Details the pin assignments for the X6 plug connection.

Servicing and Maintenance of Air Top 2000 STC

8.1 General Information

Describes servicing jobs that can be performed on an installed heater.

8.2 Working on the Heater

Safety precautions and general steps for working on the heater.

8.3 Working on the Vehicle

Precautions when working on the vehicle in vicinity of the heater.

8.4 Heater Test Run

Guidelines for performing a test run of the heater.

8.5 Servicing

Recommends periodic checks and maintenance for the heater.

8.6 Visual Inspection and Installation Requirements

Outlines visual checks and requirements for installation.

8.6.1 Heating Air System

Details requirements for the heating air system, including ducting and sensors.

8.6.2 Fuel Supply

Covers fuel take-off, line lengths, and pressure requirements.

Repair Procedures for Air Top 2000 STC

9.1 General Information

General guidelines for performing repairs on the heater after removal.

9.1.1 Work on Stripped Down Components

Procedures for cleaning and visual inspection of disassembled parts.

9.1.1.1 Cleaning

Instructions for cleaning components using benzene and compressed air.

9.1.1.2 Visual Inspection

Checks for component damage, corrosion, and loose contacts.

9.1.2 Carrying Out Modifications

Information on available modifications and kits for improving performance.

9.1.2.1 Installing of an External Room Temperature Sensor

Step-by-step guide for installing an external sensor for better temperature control.

9.2 Dismantling and Assembling

Detailed instructions for dismantling and reassembling heater components.

Packaging, Storage, and Shipping of Air Top 2000 STC

10.1 General Information

Guidelines for cleaning, packing, and storing heaters for transport or repair.