Webasto Heater Air Top 2000 Workshop Manual

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Visit www.butlertechnik.com for more technical information and downloadsAir HeatersRepair Shop ManualAir Top 2000DiagnosisAir Top 2000Type AT 2000 B (Fuel)Type AT 2000 D (Diesel)07/2000www.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 2000List of ContentsList of Contents1Introduction1.1Scope and Purpose . 1011.1.1 Use of Air Heaters . 1011.21.31.4Meaning of Warnings, Cautions and Notes . 101Additional Documentation to be used . 101Safety Information and Regulations. 1011.4.1 Legal Provisions for Installation. 1011.4.2 General Safety Notes . 1031.52General Description2.12.22.32.42.52.62.72.83Corrections and Improvements. 103Combustion and Heating Air Fan. 201Heat Exchanger . 202Burner Insert with Combustion Tube . 202Control Unit / Control Circuit Board . 202Flame Sensor . 203Glow Plug . 203Temperature Limiter . 203Dosing Pump . 203Functional Description3.1Functional Description Air Top 2000 without Diagnosis . 2Functional Description Air Top 2000 Diagnosis. ontrol Element. 301Switch-On . 301Stabilization . 301Heating Operation . 301Control Operation . 302Control Idle . 302Switch-Off . 302Functions of the Air Heater in ADR Vehicles. 302Switch-off upon Failure. 302Control Element. 304Switch-On . 304Stabilization . 304Heating Operation . 305Control Operation . 305Control Idle . 305Switch-Off . 305Functions of the Air Heater in ADR Vehicles. 305Switch-off upon Failure. 306Technical Data. 401Iwww.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 2000List of Contents5Troubleshooting5.15.25.35.46General .General Failure Symptoms .Failure Symptoms during Operation .Error Code Output (Air Top 2000 Diagnosis).501501502503Functional Tests6.16.2General . 601Adjustments . 6016.2.1 Adjustment of the CO2 Contents . 6016.3Components Testing. 6026.3.1 Glow Plug Resistance Test. 6026.3.2 Flame Sensor Resistance Test. 6027Circuit Diagrams7.18General . 701Servicing8.18.28.38.48.58.68.7General .Work on the Air Heater .Work on the Vehicle.Air Heater Test Run .Servicing . .Visual Inspections and Installation g Air System .Fuel Supply.Dosing Pump .Fuel Filter.Combustion Air Supply .Exhaust Line .Combustion Air Intake and Exhaust Lines.Electrical Connections .Removal and Installation. 8088.7.1 Air Heater, Removal and Installation . 8088.7.2 Replacement of Control Unit. 8088.7.3 Replacement of Temperature Limiter . 8088.8Installation of new Control Units . 8118.8.1 Replacement of Control Unit Air Top 2000 (12 Volt) with External Temperature Sensor. 8118.8.2 Replacement of Control Unit Air Top 2000 (24 Volt) not ADR. 8118.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) ADR. 8128.9First Operation . 812IIwww.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 20009List of ContentsRepair9.1General . 9019.1.1 Work on Components after Disassembly . 9019.1.2 Incorporation of Modifications. 9019.2Disassembly and Assembly. 9029.2.19.2.29.2.39.2.49.2.59.2.69.2.710Removal of Housing Components/Covers . 902Replacement of Control Unit . 903Replacement of Temperature Limiter . 903Replacement of Combustion Air Fan. 904Replacement of Flame Sensor . 906Replacement of Glow Plug . 906Replacement of Burner Insert, Combustion Tube, and Heat Exchanger . 909Packaging/Storage and Shipping10.1 General . 1001IIIwww.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 2000List of FiguresList of Figures301Functional Diagram (Air Top 2000 without Diagnosis). 303501502General Failure Symptoms . 501Failure Symptoms during Operation . 502601Adjustment of CO2 Contents. 601701702703708715Terminal Pin Assignment, Air Top 2000 Diagnosis.Terminal Pin Assignment, Air Top 2000 without Diagnosis .Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24Vwith Control Element.Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24Vwith Combination Timer .Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24Vwith Control Element and Standard Timer .Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operationwith Control Element.Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operationwith Combination Timer .Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operationwith Combination Timer and 2 Auxiliary Drives .Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12Vwith Control Element.Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12Vwith Control Element and Timer.Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24Vwith Control Element.Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24Vwith Control Element and Timer.Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24Vwith Control Element, ADR .Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operationwith Control Element in Vehicles without Auxiliary Drive .Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not ADR!) uel Supply .Webasto Fuel Tank Tap.Fuel Tapping from Plastic Tank (tapping via fuel drain plug).Fuel Tapping from Plastic Tank (tapping via fitting plate) .Pipe/Hose Connection .Dosing Pump, Installation Position and Attachment .Fuel Filter .Exhaust Muffler, Direction of Flow .Exhaust Pipe Outlet, Installation Position .Removal of Fuse Holder Attachment Plate.Fuse Holder, Installation Position .Control Element .Pulling the Plug .Example of an Installation.Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis) .Replacement of Control Unit and Temperature Limiter (Air Top 2000 807809810901902903904Removal of Housing Components/Covers.Replacement of Combustion Air Fan (Removal) .Replacement of Combustion Air Fan (Disassembly) .Disassembly of Heat 09710711712713714715

Visit www.butlertechnik.com for more technical information and downloadsAir Top 20001Introduction1.1Scope and Purpose1 Introduction1.4Safety Information and RegulationsThis repair shop manual is intended to support familiarized personnel in the repair of air heaters Air Top 2000 ofthe fuel and Diesel type as well as of Air Top 2000Diagnosis with serial no. 30.000 and up.The general safety regulations for the prevention of accidents and the relevant operating safety instructions haveto be observed at all times."General Safety Regulations"beyond the scope of these regulations are detailed in thefollowing.The specific safety regulations applicable to thismanual are highlighted in the individual chapters byWarnings, Cautions, and Notes.1.1.1 Use of Air Heaters1.4.1 Legal Provisions for InstallationThe air heaters Air Top 2000 and Air Top 2000 Diagnosisare used toWithin the scope of the StVZO (Road LicensingRegulations of the Federal Republic of Germany) "DesignGeneral Approvals", laid down by the Federal Office forMotor Traffic, exist for the Water Heater Air Top 2000 andAir Top 2000 Diagnosis with the following official marks ofconformity:– heat the cabin– defrost the windscreens.–They are not cleared for heating a transportation compartment for dangerous goods.The heaters operate independent from the vehicle engineand are connected to the fuel tank and to the electricalsystem of the vehicle. Their use is possible in vehicleswith water- or air-cooled engines.1.2Meaning of Warnings, Cautions andNotesWARNINGS, CAUTIONS, and NOTES in this manualhave the following meaning:WARNINGThis heading is used to highlight that non-compliancewith instructions or procedures may cause injuries orlethal accidents to personnel.CAUTIONThis heading is used to highlight that non-compliancewith instructions or procedures may cause damage toequipment.NOTEThis heading is used to highlight and draw specific attention to information.1.3Additional Documentation to be usedThis workshop manual contains all information and procedures necessary for the repair of heaters Air Top 2000and Air Top 2000 Diagnosis.The use of additional documentation is normally notnecessary.Operating instructions/installation instructions and thevehicle specific installation proposal may be used ascomplementary information as necessary. S 270 (Diesel) S 277 (Fuel)The installation of the heaters is to be performed inaccordance with the installation instructions and must bechecked in case ofa) the vehicle type inspection in accordance with§ 20 StVZOb) the individual inspection in accordance with§ 21 StVZO orc) the examination in accordance with § 19 StVZO performed by an officially authorised expert or examinerfor road traffic, a vehicle inspector or a public servantas per section 4 of Annex VIII b to the StVZO.In the event of c) the installation must be certified on theacceptance certificate included in the copy of the "GeneralOperating License" or on a formsheet according to thespecimen of an "approval" included in the Traffic rules1994, Page 148 giving details about– manufacturer– type of vehicle, and– vehicle identification number.This validates the "Design General Approval". Theacceptance certificate must be kept with the vehicle. Theyear of first operation must be permanently marked on theidentification label by removing the numerals of the yearsnot applicable.The heat exchanger of the air heater remainsserviceable for a maximum of 10 years and must thenbe replaced with an original spare part by the manufacturer or by one of its authorized workshops.The heater must then be provided with a label markedwith the sales date and with the words "OriginalSpare".When replacing the heat exchanger it is mandatoryto also replace the overheat protection element(temperature limiter) to avoid possible malfunctionsof old temperature limiters in use.101www.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 20001 IntroductionShould exhaust pipes be routed through roomsaccommodating persons, these pipes shall also berenewed after 10 years by original spare parts.When removing the heater the gasket below must berenewed.The heaters are cleared for heating the passenger anddriver cabins but not for heating compartments intendedfor the transportation of dangerous goods.The use of the heater in special vehicles (e.g. vehicles forthe transportation of dangerous goods ADR) or vehiclesnot subject to the StZVO (e.g. ships) are ruled by partiallyregional regulations.For the installation of the AT 2000 D in vehicles used forthe transportation of dangerous goods, in addition to theStVZO, the requirements in ADR 002 and ADR 003(Technical Guidelines for the Transportation of DangerousGoods on Roads) must be met.Heating Air SystemHeating air intake openings must be arranged so thatunder normal operating conditions exhaust fumes of thevehicle engine or air heater are not likely to be expected.Extracting combustion air from the vehicle interior is notpermissible.Combustion Air LineThe combustion air required must be taken from theexterior.Within rooms accommodating persons, the combustionair lines must not have more than four disconnectsand a splash-water protected exterior wall feedthrough.The disconnects must be sealed in a way not to exceeda leak rate of 200 l/h at an overpressure of 0.5 mbar.The line including feedthrough, disconnects, materialand specific type must be described in the installationinstructions.The line must require tools for installation and removal,must be protected against damage, and must be shockproof.Exhaust LineHeaters must be designed to discharge the exhaust tothe exterior.Exhaust pipes must be routed so that exhaust fumes areunlikely to penetrate into the vehicle's interior.The function of any parts of the vehicle essential for itsoperation must not be impaired. Condensate or waterpenetrated must not be able to accumulate in theexhaust line.Drain holes are permissible; these must drain the fluid tothe exterior via lines sealed against the vehicle interior.The exhaust line outlet is to be positioned to the top, tothe side, or in case of exhaust venting below the vehiclefloor, to the nearest possible location of the vehicle's orcockpit's side or rear end.In compartments accommodating persons, exhaust linesmust not have more than one disconnect and must havea splash-water protected feedthrough in the exteriorwall/floor. For water, that has penetrated into the exhaustline, the connection of a drain line with a metal-sealingjoint is permissible. The drain pipe must be routed sealedthrough the exterior wall or the vehicle floor.The heat exchanger, the exhaust line connected, as wellas the possible drain pipe must be sealed so that with anoverpressure of double the overpressure of the exhausthaving the maximum permissible exhaust line length – atleast however at an overpressure of 0.5 bar – a total leakrate of 30 l/h is not exceeded.The line including feedthrough, disconnects, materialand specific type must be described in the installationinstructions. The line must require tools for installation andremoval, must be protected against damage, and must beshockproof.Metal lines must be used. These may not heat to morethan 110 C should there be the possibility of contactwithin the room interior. Protective devices against contact may be fitted.Combustion Air Inlet and Exhaust OutletDuring installations these ports for combustion air entryand exhaust fume exit must be of such type, that a ballwith a diameter of 16 mm cannot be inserted.Electrical lines, switch gear and control gear of the heatermust be located in the vehicle so that their proper functioncannot be impaired under normal operating conditions.For the routing of fuel lines and the installation ofadditional fuel tanks §§ 45 and 46 of the StVZO are to beadhered to.The most important regulations are: Fuel lines are to bedesigned in such a way that they remain unaffected bytorsional stresses in the vehicle, engine movement andthe like. They must be protected against mechanicaldamage.Fuel-carrying parts are to be protected against excessiveheat and are to be arranged so that any dripping orevaporating fuel can neither accumulate nor be ignited byhot components or electrical equipment.In busses, fuel lines and fuel tanks may be located neitherin the passenger area nor in the driver's compartment.In these type of vehicles the fuel tanks must be locatedsuch that they do not pose a direct hazard to the exits inthe event of a fire. Fuel supply must not be by means ofgravity or pressurization of the fuel tank.102www.butlertechnik.com

Visit www.butlertechnik.com for more technical information and downloadsAir Top 20001 Introduction1.4.2 General Safety NotesThe heater must not be installed in the passenger ordriver compartments of busses. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior.There must be sufficient ventilation of the installation boxfrom the exterior in order not to exceed a maximumtemperature of 40 C in the installation box. Excessivetemperatures may cause malfunctions.Installation Instructions for Webasto Fuel Tanks forFuel Supply of Heaters in VehiclesIn busses the installation is not permitted in the passengers or driver's compartment.The fuel filler neck must not be located in the passengersor driver's compartment of any type of vehicle. Fuel reservoirs for carburettor fuel must not be located immediatelybehind the vehicle front fairing. They must be away fromthe engine to prevent fuel fires in case of accidents.The same applies to towing vehicles with open cockpit.It is mandatory to install the seal between the heatermounting and the vehicle floor to prevent poisonousexhaust fumes from entering the vehicle interior.All fuel line connections must be tight, must show nodamage and have to be inspected in regular intervals(at least in the same frequency as vehicle inspections).When detecting damages or leaks the heater must not beoperated until repair will have been performed by anauthorised Webasto repair shop.NOTEMake heater inoperative by removing fuse. The fuel lines(Mecanyl hoses) must not be in direct contact with theexhaust pipe and be provided with a heat insulation asrequired to prevent fires.Keep air intakes and exit ports for warm and heating airclean and free from foreign objects. Contaminated andclogged air ducts may cause overheating and response ofthe temperature limiter. After an overheat condition with

This repair shop manual is intended to support familiar-ized personnel in the repair of air heaters Air Top 2000 of the fuel and Diesel type as well as of Air Top 2000 Diagnosis with serial no. 30.000 and up. 1.1.1 Use of Air Heaters The air heaters Air Top 2000 and Air Top 2000 Diagnosis are used to

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