Workshop Manual AT 2000 ST

Air heaters Workshop manual
Air Top 2000 ST

Type AT 2000 ST B (petrol)
Type AT 2000 ST D (diesel)
06/2005
Air Top 2000 ST Table of contents
Table of contents
1 Introduction
1.1 Contents and purpose ........................................................................................................................... 101
1.1.1 Using the air heaters ................................................................................................................... 101
1.2 Meaning of signal words ........................................................................................................................ 101

1.3 Additional documentation to be used..................................................................................................... 101
1.4 Statutory regulations and safety instructions ......................................................................................... 101
1.4.1 Regulations for installation in the vehicle .................................................................................... 101

1.4.2 General safety information .......................................................................................................... 102
1.5 Suggestions for improvements and modifications ................................................................................. 104
2 General description
2.1 Drive unit................................................................................................................................................ 201

2.2 Heat exchanger ..................................................................................................................................... 202
2.3 Burner insert with burner pipe................................................................................................................ 202
2.4 Control unit ............................................................................................................................................ 202
2.5 Flame sensor ......................................................................................................................................... 202
2.6 Glow plug............................................................................................................................................... 203
2.7 Overheating sensor ............................................................................................................................... 203
2.8 Metering pump....................................................................................................................................... 203
3 Function description
3.1 Control element ..................................................................................................................................... 301

3.2 Switch on ............................................................................................................................................... 301
3.3 Heating mode ........................................................................................................................................ 301
3.4 Control mode ......................................................................................................................................... 301
3.5 Control pause ........................................................................................................................................ 302
3.6 Switch off ............................................................................................................................................... 302
3.7 Heater functions when installed in ADR vehicles .................................................................................. 302
3.8 Fault lock-out ......................................................................................................................................... 302
3.8.1 Error monitor................................................................................................................................ 302

3.8.2 Reset a fault lock-out................................................................................................................... 303
4 Technical data ................................................................................................................................................ 401
I
Table of contents Air Top 2000 ST
5 Troubleshooting
5.1 General .................................................................................................................................................. 501

5.2 General error symptoms ........................................................................................................................ 501
5.3 Error symptoms during function ............................................................................................................. 502
5.4 Error code output in display of combination or standard timer............................................................... 503
6 Function tests
6.1 General .................................................................................................................................................. 601

6.2 Settings .................................................................................................................................................. 601
6.2.1 Setting the CO content ................................................................................................................ 601
6.3 Testing individual components............................................................................................................... 601
6.3.1 Resistance test on the glow plug ................................................................................................. 601

6.3.2 Resistance test on the flame sensor............................................................................................ 601
6.3.3 Resistance test on the overheating sensor.................................................................................. 602
7 Circuit diagrams
7.1 General .................................................................................................................................................. 701
8 Servicing work
8.1 General .................................................................................................................................................. 801

8.2 Work on the heater ................................................................................................................................ 801
8.3 Work on the vehicle ............................................................................................................................... 801
8.4 Heater trial ............................................................................................................................................. 801
8.5 Servicing work........................................................................................................................................ 801
8.6 Visual inspections and installation instructions ...................................................................................... 801
8.6.1 Hot air system.............................................................................................................................. 801

8.6.2 Fuel supply .................................................................................................................................. 802
8.6.3 Metering pump............................................................................................................................. 804
8.6.4 Fuel filter ...................................................................................................................................... 804
8.6.5 Combustion air supply ................................................................................................................. 805
8.6.6 Exhaust pipe ................................................................................................................................ 805
8.6.7 Combustion air intake and exhaust pipes.................................................................................... 805
8.6.8 Electrical connections .................................................................................................................. 806
8.7 Removal and installation ....................................................................................................................... 808
8.7.1 Heater, removal and installation .................................................................................................. 808
8.8 Start-up .................................................................................................................................................. 808
II
Air Top 2000 ST Table of contents
9 Repair
9.1 General .................................................................................................................................................. 901
9.1.1 Work on stripped-down components ........................................................................................... 901

9.1.2 Carrying out modifications ........................................................................................................... 901
9.2 Dismantling and assembling.................................................................................................................. 902
9.2.1 Remove the casing parts............................................................................................................. 902

9.2.2 Fit the casing parts ...................................................................................................................... 902
9.2.3 Change the control unit ............................................................................................................... 904
9.2.4 Change the overheating sensor .................................................................................................. 904
9.2.5 Change the combustion air fan.................................................................................................... 905
9.2.6 Change the flame sensor (only petrol heater) ............................................................................. 905
9.2.7 Change the glow plug.................................................................................................................. 907
9.2.8 Change the burner insert, combustion pipe and the heat exchanger.......................................... 909
10 Packaging/Storage/Shipping
10.1 General .................................................................................................................................................1001
III
Table of contents Air Top 2000 ST
List of illustrations
501 General error symptoms ............................................................................................................................. 501

502 Error symptoms during function .................................................................................................................. 502
503 Troubleshooting .......................................................................................................................................... 503
701 Plug assignment ......................................................................................................................................... 701

702 System circuit diagram 12V/24V with control element and vehicle blower ................................................. 702
703 System circuit diagram 12V/24V with combination timer and vehicle blower ............................................. 703
704 System circuit diagram 12V/24V with combination timer and electrical battery isolation switch ................ 704
705 System circuit diagram (diesel) 24V ADR operation with control element.................................................. 705
706 System circuit diagram (diesel) 24V ADR operation without auxiliary drive unit with control element ....... 706
707 Schematic connection of the combination timer ......................................................................................... 707
801 Fuel supply.................................................................................................................................................. 803

802 Webasto fuel extractor ................................................................................................................................ 803
803 Fuel extraction from the plastic tank (extraction through tank drain screw) ................................................ 803
804 Fuel extraction from the plastic tank (extraction through tank fittings)........................................................ 803
805 Pipe/Hose connections .............................................................................................................................. 804
806 Metering pump, installation position and attachment ................................................................................. 804
807 Fuel filter .................................................................................................................................................... 804
808 Exhaust silencer ......................................................................................................................................... 805
809 Exhaust pipe mouth, installation position ................................................................................................... 805
810 Remove the fastening plate on the fuse holder ......................................................................................... 806
811 Fuse holder, installation position ................................................................................................................ 806
812 Control element .......................................................................................................................................... 806
813 Disconnect the plug .................................................................................................................................... 806
814 Specimen installation for heater in air circulation mode ............................................................................. 807
901 Remove / Fit the casing parts .................................................................................................................... 903

902 Change the control unit, combustion air fan and overheating sensor ........................................................ 906
903 Change the glow plug, flame sensor, combustion insert and the heat exchanger...................................... 908
904 Starting air hole in burner insert ................................................................................................................. 910
IV
Air Top 2000 ST 1 Introduction
1 Introduction 1.4 Statutory regulations and safety

instructions
1.1 Contents and purpose
In principle, the general accident prevention regulations
and current works safety instructions are applicable.
This workshop manual is designed to assist trained The “General safety regulations” that go beyond the
personnel with repairing both the petrol and the diesel scope of the above regulations are stated below (see
versions of the Air Top 2000 ST air heaters. 1.4.2).
Any special safety regulations relevant to this instruction
1.1.1 Use of the air heaters manual will be highlighted in the relevant sections or text
passages of the procedures.
The Webasto Air Top 2000 ST air heaters are designed
– to heat cabins, boats, trucks, minibuses, vans, 1.4.1 Statutory regulations governing
ambulances and motorhomes. installation
– to defrost vehicle windows
They are not designed for heating cargo areas used to Air Top 2000 ST heaters have been type-tested and
carry hazardous substances. approved in accordance with EC Directives 72/245/EEC
The heaters operate independently of the engine and are (EMC) and 2001/56/EC (heater) with the following EC
connected to the fuel tank and the electrical system of the permit numbers:
vehicle. e1*72/245*95/54*1085*--
They are not designed for installation in vehicles with e1*2001/56*0022*--
water or air-cooled engines.
Installation is governed above all by the provisions in
Annex VII of Directive 2001/56/EC.
1.2 Meaning of signal words
NOTE:
Throughout this manual, the signal words WARNING, The provisions of these Directives are binding within the
CAUTION and NOTE have the following meanings: territory governed by EU Directive 70/156/EEC and
should similarly be observed in countries without specific
WARNING regulations.
This heading is used to highlight operating instructions or
procedures which, if not or not correctly followed, may (Extract from Directive 2001/56/EC Annex VII)
result in personal injury or fatal accidents.
1.7.1. A clearly visible indicator within the user's field of
CAUTION vision must show whether the heater is switched
This heading is used to highlight operating instructions or on or off.
procedures which, if not or not correctly followed, may
result in damage to the equipment or its components. 2. Regulations for installation in the vehicle
NOTE 2.1. Scope

This heading is used to direct your attention to a special 2.1.1. Subject to the provisions of paragraph 2.1.2,
feature deemed essential to highlight. internal combustion heaters must be installed in
accordance with the requirements contained in
this Annex.
1.3 Additional documentation 2.1.2. In the case of class O vehicles (trailers) with
heaters for liquid fuel, it is presumed that these
This workshop manual contains all the information and vehicles comply with the requirements in this
instructions required for repairing Air Top 2000 ST air Annex.
heaters. The use of additional documentation is not
normally required. If necessary the operating / installation 2.2 Position of the heater
instructions and the installation suggestion for the specific 2.2.1. Parts of the vehicle body and other components in
vehicle may also be used. the immediate vicinity of the heater must be
protected against excessive heat and the danger
of contamination by fuel or oil.
101
1 Introduction Air Top 2000 ST
2.2.2. The internal combustion heater must not pose a 2.7. Hot air outlet
fire hazard even when overheated. This 2.7.1. Hot air lines within the vehicle must be positioned
requirement is deemed to have been met if care is or protected in such a way as to exclude all risk of
taken during installation to ensure an adequate injury or damage caused by direct contact.
distance from all parts, as well as adequate 2.7.2. The air outlet must be positioned or protected so
ventilation and if fire-resistant materials or heat that it cannot be obstructed by other objects.
shields are used.
2.2.3. For class M2 and M3 vehicles the heater must not 2.8. Automatic control of the heating system
be installed in the passenger cabin. A device in a When the engine stops, the heating system must
sealed cover, which also meets the requirements cut out automatically and the fuel supply must be
set out in paragraph 2.2.2, may be used, however. stopped within 5 seconds.
2.2.4. The plate mentioned in paragraph 1.4 (model The heating system may remain in operation if a
plate) or a duplicate thereof (duplicate model manual unit has already been activated.
plate) must be fitted in such a way that it is still
clearly legible when the heater has been installed 1.4.2 General safety information
in the vehicle.
2.2.5. When positioning the heater, all due precautions The mouth of the exhaust pipe should be installed
must be taken to minimise all risk of bodily injury, upwards, to the side or, if the exhaust pipe passes under
as well as damage to items in the vehicle. the floor of the vehicle, to the side or rear limit of the
driver’s cab or the vehicle.
2.3. Fuel supply
2.3.1. The fuel filler neck must not be located in the The function of important parts of the vehicle must not be
passenger compartment and must have a tightly adversely affected. It must not be possible for condensate
fitting cap to prevent any fuel leaks. or water to collect in the exhaust pipe. Drain holes may be
2.3.2. The type of fuel and the fuel filler neck must be used.
clearly identified on heaters for liquid fuel, for
which the fuel supply is separate from the fuel The electric cables and controls for the air-conditioning
supply for the vehicle. system must be arranged in the vehicle so that their
2.3.3. A sign must be affixed to the fuel filler neck proper functioning cannot be adversely affected in normal
warning that the heater must be switched off operating conditions.
before refuelling. An identical warning must also
be included in the manufacturer's operating Compliance with §§ 45 and 46 of the Road Vehicle
instructions. Licensing Act must be ensured for the installation of fuel
lines and the installation of additional fuel tanks.
2.4. Exhaust system The main points from this law:
2.4.1. The exhaust outlet must be positioned in such a
way that exhaust fumes cannot get into the interior • Fuel pipes must be designed in such a way that
of the vehicle through ventilation devices, hot-air torsion in the vehicle, movements by the engine and
inlets or open windows. the like do not have a negative effect on their
durability. They must be protected from mechanical
2.5. Combustion air inlet damage.
2.5.1. The air for the combustion chamber of the heater • Parts that carry fuel must be protected from heat that
must not be extracted from the passenger cabin of will adversely affect their function and positioned so
the vehicle. that dripping or evaporating fuel cannot collect or
2.5.2. The air inlet must be positioned in such a way that ignite on hot parts or on electrical equipment.
it cannot be obstructed by other objects.
The air heater’s heat exchanger can be used for a
2.6. Hot air inlet maximum of 10 years and must then be replaced by the
2.6.1. The supply of heating air must consist of either manufacturer or one of its authorised workshops using a
fresh air or recirculated air and must be taken from genuine spare part. A label must then be affixed to the
a clean area which cannot be contaminated by heater showing the date of sale and the wording “Genuine
exhaust fumes from the engine, the internal spare part”.
combustion heater or any other source in the
vehicle. When you change the heat exchanger it is essential that
2.6.2. The inlet line must be protected by a grating or you also replace the overheating protection element
other suitable means. (overheating sensor) to prevent possible function faults
caused by using the old overheating sensor.
102
Air Top 2000 ST 1 Introduction
The Air Top 2000ST air heaters are prepared for interior Installation regulations for Webasto fuel tanks
installation and sealing directly on the cabin floor or a for supplying fuel to heaters in vehicles:
cabin wall. Non-release connections must be used in the
interior for combustion air and exhaust pipes with the • The tank must not be installed in the passenger or
accessories available from Webasto. driver’s cabin of buses.
• The fuel filler neck must not be inside the passenger
The seal between the heater mounting and the vehicle or driver’s cabin in any vehicle.
floor must always be installed; otherwise harmful • Fuel tanks for normal or super grades of petrol must
emissions may get into the interior of the vehicle. not be immediately behind the front trim of the vehicle.
They must be separated from the engine in such a
The hot and combustion air intake openings must be way that in the event of an accident the fuel will not be
positioned in such a way that no water can ingress into expected to ignite. This does not apply to tractor units
them if the vehicle drives through a water hazard for which with an open driver’s seat.
it has been approved.
The fuel lines (Mecanyl hose) must not be immediately
The heater must not be installed in the driver’s or next to the exhaust pipe and must be thermally insulated
passenger cabin of buses (vehicle classes M2 and M3). If if necessary, otherwise they will pose a fire risk.
the heater is nevertheless installed in such a place, the
installation box must be tightly sealed against the vehicle All pipes that come into contact with fuel must have sealed
interior. The installation box must have sufficient external connections, they must not be damaged in any way and
ventilation to ensure that a maximum temperature of the must be checked at regular intervals (at least the
40°C is not exceeded in the box. Malfunctions may occur same intervals as for inspection of the vehicle as a whole).
if the temperature exceeds this level.
NOTE
The heater must be switched off at filling stations and fuel If any damage or leaks are found on the fuel line, the
tank farms because of the risk of explosion. heater must not be used until the damage has been
rectified by an authorised Webasto workshop.
Wherever inflammable vapours or dust may form (for Put the heater out of action by removing the fuse.
example near fuel, coal, wood dust or cereal stores or the
like), the heater must be switched off because of the risk Overheating
of explosion.
Keep hot air inlet and hot air outlet free of dirt and other
The heater must not be operated in enclosed areas, such items. Dirty, blocked air lines can cause the heater to shut
as garages or workshops without an exhaust emissions down due to overheating.
extraction system, not even using the timer, because of After an overheating lock-out, check that the air system is
the risk of asphyxiation and poisoning. clear, remove any materials that may block the air flow
and have any damage to the air lines repaired by an
In the event of lengthy heavy smoke development, authorised Webasto workshop. After this the heater lock-
unusual combustion noise or a smell of fuel, the heater out can be cancelled by switching it off and then on again.
must be put out of action by removing the fuse and must If this action does not produce the required success (if the
not be started again until it has been examined by heater overheats again) take it to a Webasto-authorised
Webasto-trained personnel. Liability claims can only be workshop. Never remove the grating over the air inlet of
lodged if the claimant can prove that he has complied with the heater.
the servicing and safety instructions.
The air outlet jets or air vents with adjustable flaps must
always be opened to some extent so that the air flow
through the heater is not completely blocked. At least one
air vent must be prevented from being closed.
If the heater is installed in a storage area, you must

ensure that no inflammable substances are kept in this
area and that other material does not restrict the air supply
to the heater.
Air lines must be securely fixed to the heater (using pipe
clips, for example) and all other connection points (for
example vents).
103
1 Introduction Air Top 2000 ST
IMPORTANT
The errors described below are to be avoided at all costs:
• Do not stand on the heater or place or throw any

heavy objects on the heater.
• Do not place any items of clothing, textiles or similar
materials over the heater or in front of the hot air inlet
side and hot air outlet.
• The flow of hot air from the heater must not be
restricted or blocked by highly inflammable
substances or materials such as rags, cleaning wool,
etc.
• Inflammable or explosive substances and gases must
not be placed near or in contact with the heater, the
hot air line, the flow of hot air or the exhaust pipe.
• The heater must not be cleaned with a high pressure
cleaner.
• Do not switch the heater off at the main battery switch
or battery isolation switch since otherwise it is
possible that it may suffer long term damage if it is
switched off frequently using the battery isolation
switch and this can cause damage and negative
influences on the function of the heater.
NOTE
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
invalidates the type approval for the heater and its
homologation / EC type permit.
You must read the operating manual before starting the

heater for the first time.
1.5 Suggestions for improvements and

changes
Complaints, improvement suggestions or corrections

relating to this workshop manual should be addressed to
Webasto AG
BU: Special Products & Markets
Dept. B5.6.2
Kraillinger Str. 5
D-82131 Stockdorf
Phone: +49 (89) / 8 57 94 - 6 34

PC-Fax: +49 (89) / 8 57 94 - 3 97
104
Air Top 2000 ST 2 General description
2 General description If a fault occurs, an error code will be output in the

displayof the combination or standard timer. If the heater
has a control element , the ON control light will flash. In
The Air Top 2000 ST airheater is based on the evaporator addition, the heater can be checked using a personal
principle and essentially consists of the following computer (see PC heater diagnostic operating manual).
– the drive unit with a combustion and hot air blower

– the heat exchanger
– the burner insert with combustion pipe
– the control unit
Air Top 2000 ST air heater without casing
2.1 Drive unit

Air Top 2000 ST air heater
The drive unit consists of the drive motor, the combustion
air blower, the heat air blower and the intake casing.
To control and monitor it, the heater has The combustion air blower supplies the air required for the
combustion process from the combustion air inlet to the
– a control unit with temperature sensor burner insert.
– a flame sensor (only petrol heater) The removable hot air blower transports the hot air from
– a glow plug the hot air inlet via the heat exchanger to the hot air outlet.
– an overheating sensor
inside it.
All Air Top 2000 ST heaters can also be controlled using

an external temperature sensor.
The fuel supply is provided from an external source using

a metering pump.
Drive unit
201
2 General description Air Top 2000 ST
2.2 Heat exchanger 2.4 Control unit
The heat generated by the combustion process is The control unit is the central component for ensuring the
transferred to the air transported by the combustion and function is maintained and for monitoring the heater’s
hot air blowers in the heat exchanger. operation. A temperature sensor in the control unit is
designed to control the room temperature. An external
temperature may also be connected to all the heaters.
If a fault occurs, an error code will be output in the display

of the combination timer.
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).
Internal
Wiring
temperature sensor
harness
Component
plug
Heat exchanger
2.3 Burner insert with combustion pipe
The fuel is distributed over the burner cross-section in the

combustion pipe in the burner insert. The mixture of fuel
and air burns in the combustion pipe, thus causing the
heat exchanger to become hot.
Control unit
2.5 Flame sensor (only petrol heater)

Combustion
pipe The flame sensor is a low-ohm PTC resistor, which
changes its resistance depending on the heat emitted by
the flame.
This change in resistance is analysed by the control unit
Burner insert so that the flame status is monitored whenever the heater
is operating.
Burner insert with combustion pipe
Flame sensor
202
Air Top 2000 ST 2 General description
2.6 Glow plug 2.8 Metering pump
The mixture of fuel and air is ignited by the glow plug when The metering pump is a combined transport, metering and
the heater is started. The glow plug takes the form of an shut-off system for supplying fuel from the vehicle’s tank
electrical resistor and is positioned in the burner insert on to the heater.
the side away from the flame.
Metering pump DP 30.2/3 (with damper)
Glow plug
2.7 Overheating sensor
The overheating sensor measures the temperatures in the

rib area of the heat exchanger whenever the heater is
operating. The control unit evaluates the signal and
protects the heater from hot air outlet temperatures above
150 °C and surface temperatures above 80 °C by shutting
down the combustion process and blowing cold air over the
heater.
The heater then suffers a fault lock-out and can be
restarted by being switched off and then on again (see 3.2).
Overheating sensor
203
2 General description Air Top 2000 ST
Page for notes
204
Air Top 2000 ST 3 Function description
3 Function description Automatic restart
If no flame is detected, the starting procedure will be

3.1 Control element repeated. The glow plug will be switched on again
(cycled). The motor for the hot and combustion air blower
The control element is designed to switch the heater on will be set to approx. 25 % of its maximum speed.
and off, adjust the required room temperature (intake
temperature between 5 °C and 35 °C) and to reset the After approx. 30 seconds (petrol) or 50 seconds (diesel)
heater after a fault. the fuel metering pump will start, and the flame formation
will begin. After a further 65 seconds (petrol) or
The green LED serves as the On indicator (LED 90 seconds (diesel) the glow plug will be switched off and
permanently lit up) and as a fault signal (LED flashes). the existence of the flame established.
NOTE If the heater has again failed to ignite properly, the heater
ADR operation: will be shut down using a fault slow down procedure at
After an operating voltage has been applied by switching maximum speed after 180 seconds and will suffer a fault
the battery isolation switch and control element to “ON”, lock-out.
the control unit will be set to the “Fault lock-out” position.
Before it can be restarted the control element must be set NOTE
to “OFF”. After a restart the heater will suffer a fault lock-out. To
reset the fault switch the heater off briefly (min. 2 seconds)
and switch back on.
3.2 Switch on
Set the control element to the required temperature. 3.3 Heating mode
If the hot air temperature is lower than the nominal While the heater is operating, the combustion gases pass
temperature, the heater will start. through the heat exchanger. During this process the
combustion heat is given off to the walls of the heat
NOTE exchanger, absorbed by the hot air transported by the hot
If the temperature of the hot air intake is above the set air blower and fed into the interior of the vehicle.
nominal temperature, only the motor for the hot and The temperature of the hot air intake is measured by a
combustion air blower will start (control pause). Special temperature sensor on the intake side of the heater or an
feature: The control pause speed is 0 rpm if boat heaters external temperature sensor. If the measured
are used. temperature is lower than the value set on the control
element, the output of the heater is increased to maximum
The function of the flame sensor is checked. If the flame heat output.
sensor now reports “light”, the system will attempt to cool
the flame sensor for 60 seconds. If the flame sensor still To increase the burner service life when it is used
reports “light” the control unit will suffer a fault lock-out. If continuously the transportcapacity of the metering pump
another monitored component has suffered a fault, the is reduced for 10 seconds every 10 minutes.
fault lock-out will take effect without any slow down time. In addition, heating mode is interrupted every 8 hours in
the same way as for a control pause.
Start
3.4 Control mode
When the heater is switched on, the ON signal light will be
lit and the glow plug will be switched on (cycled). The In control mode the blower speed and the metering pump
motor for the hot and combustion air blower will be set to delivery rate are dependent on the heat output. The glow
approx. 50 % of its maximum speed. plug is switched off.
After approx. 40 seconds the fuel metering pump will start,

and the flame formation will begin. To improve the starting
quality the metering pump and combustion air blower are
started with different frequencies and speeds.
After a further 95 seconds (petrol) or 110 seconds (diesel)
the glow plug will be switched off and the existence of the
flame established.
301
3 Function description Air Top 2000 ST
3.5 Control pause If the heater is switched off using the control element, the
slow down time remains unchanged.
After the temperature set on the control element has been A brief slow down time (max. 40 seconds) is started
reached, the heat output is reduced. The speed of the automatically if
heating and combustion air blower and the delivery rate of
• the vehicle’s engine is switched off
the metering pump are reduced.
• a transport device is started.
If, at minimum heat output, the intake temperature set on
the control element is exceeded, the metering pump is
After an ADR shut down process the controlunit is in the
shut down and the combustion process ended. To burn
“Fault lock-out” position. Before it can be restarted, the
off the flame properly the blower speed falls after
control element must be set to “OFF”.
20 seconds to low-fire rate speed and then returns to the
initial speed after 15 seconds, after which it falls to the
control pause speed in 3 minutes, where it remains for the 3.8 Fault lock-out
entire control pause.
The control pause speed on boat heaters is 0. The control unit has identified errors on individual heater
If the temperature set on the control element is not components and faults during the starting procedure and
observed at the temperature sensor, the heater will in operation. The heater is switched off and goes into fault
restart. lock-out if the following conditions occur:
NOTE • No repeated or incorrect start

Changes to the setting on the control element are • Temperature sensor defective
implemented by the control unit and heater after a delay. • Overheating sensor interrupt or short circuit
• Overheating sensor installed incorrectly
3.6 Switch off • Glow plug interrupt or short circuit
• Blower motor overload or blocked or short circuit or
break
When the heater is switched off, the ON control LED on
• Flame sensor interrupt or short circuit
the control element goes out. If no fuel has been
• Error in the metering pump or overheating guard
transported or if the heater is in the control pause, the
circuit (start phase only)
heater is switched off immediately without a slow down
• Undervoltage below 10.5 V / 21 V for longer than
time.
20 seconds
If the fuel transport has been started, it is ended
• Overvoltage above 16 V / 32 V for longer than
immediately when the heater is switched off. The heater is
6 seconds
switched off using the same method as the transition from
• Control module defective
control mode to control pause. The device is then
switched off automatically. The fuel supply is stopped if the heater overheats. The
heater continues to run in the same way as if it is switched
NOTE off manually. After it stops the control unit will be set to
The heater may be switched on again during the slow fault lock-out. After the slow-down phase the control
down time. In this case the slow down time is completed module is set to fault lock-out if the overheating counter is
and the heater is then restarted. greater than the value programmed in the data record
(currently 20).
The overheating is indicated by the indicator flashing
3.7 Heater functions when installed 10 times.
in ADR vehicles
Rectify the cause of the fault.
NOTE To reset the fault, switch the heater off briefly (at least
Only for Air Top 2000 ST diesel heaters that are installed 2 seconds) and then on again.
in vehicles for transporting hazardous substances (ADR).
302
Air Top 2000 ST 3 Function description
3.8.1 Error monitor
The overheat, incorrect start and flame failure errors are

counted and cause the heater to suffer a fault lock-out
after an error has occurred the maximum number of times.
The incorrect start counter FSZ is incremented by 1 each

time the heater fails to start and decremented by 1 each
time it starts correctly, but does not fall below 0. If the
incorrect start counter reaches its maximum value of 7,
the heater will go into the heater lock-out status HGV.
The error counter SZ is incremented by 1 with each

error for which there is no separate counter. The error
counter is reset to 0 at the start of control mode. If the error
counter reaches its maximum value of 10, the heater will
go into the heater lock-out status HGV.
The overheating counter ÜHZ is incremented by 1 each

time the heater overheats. If the overheating counter
reaches its maximum value of 20, the heater will go into
the heater lock-out status HGV.
The flame failure counter FAZ is increased by 1 each time

the flame fails during heating mode. The counter is
decremented by 1 each time the heater is in control mode.
If the FAZ reaches a value of 6, the heater will go into fault

lock-out mode and the permanent flame failure counter
FAZP will be incremented by 1. In control mode the
permanent flame failure counter FAZP will be
decremented by 1. When the heater is burning properly
again, the 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 F12).
3.8.2 Reset a fault lock-out
The various fault lock-outs can be reset as follows.
Fault lock-out: Switch heater off using the

control element and then on
again after more than 2 s
Heater fault lock-out: Remove the fuse and reinsert it
303
3 Function description Air Top 2000 ST
Page for notes
304
Air Top 2000 ST 4 Technical data
4 Technical Data Fuel for Air Top 2000 ST B (petrol):

The fuel specified by the manufacturer must be used.
Except where limit values are specified, the technical data Fuel for Air Top 2000 ST D (diesel/PME):
listed in the table refer to the usual heater tolerances of The diesel fuel specified by the manufacturer must be
±10% at an ambient temperature of +20 °C and at the used. Class EL heating oil -not L heating oil- may also be
rated voltage and in rated conditions. used as long as it complies with the normal quality
available on the German market according to DIN 51603.
Electrical components: We know of no negative influences due to additives.
The control unit, combustion air blower (drive), metering If fuel is extracted from the vehicle’s tank, follow the
pump, timer*, glow plug and control element are designed additive instructions issued by the vehicle manufacturer.
for 12 V or 24 V. If you change to low-temperature fuel, the heater must be
operated for approx. 15 minutes so that the fuel system is
The components temperature sensor and flame monitor filled with the new fuel.
(only petrol heater) are not designed for a specific voltage. The Air Top 2000 ST D heater is also licensed for use with
PME (bio-diesel), which complies with DIN EN 14214.
* not for ADR
Heater Operation AT 2000 ST B AT 2000 ST D
Type test permit EMC e1*72/245*95/54*1085*--

Heater e1*2001/56*0022*--
Model Air heater with evaporator burner
Heat output Control range 1.0 -2.0 kW 0.9 -2.0 kW
Fuel Petrol Diesel/PME
Fuel consumption Control range 0.1...0.2 kg/h (0.14…0.27 l/h) 0,1...0.21 kg/h (0.12…0.24 l/h)
Rated voltage 12 V 12 V 24 V
Operating voltage range 10.5 ... 16 V 10.5 ... 16 V 21 ... 32 V
Rated power consumption Control range 14 ... 29 W
Max. ambient temperature:
Heater - operation –40 °C ... +40 °C
- warehouse –40 °C ... +85 °C
Dosing pump - operation –40 °C ... +20 °C
- warehouse –40 °C ... +85 °C
Control element - operation –40 °C ... +75 °C
- warehouse –40 °C ... +85 °C
Maximum combustion air inlet
–40 °C ... +20 °C
temperature
Adjustment range for interior
Control range +5 °C ... +35 °C
temperature
Delivery rate for hot air at fan
against 0.5 mbar Max. 93 m3/h at 4750 rpm
speed
CO2 in exhaust gas 1 kW 5.0 ... 8.0 5.0 ... 8.0
(perm. function range) 2 kW 9.0 ... 12.5 9.0 ... 12.5
Heater dimensions Length 311 ± 2 mm
Width 120 ± 1 mm
Height 121 ± 1 mm
Weight of heater 2.6 kg
401
4 Technical data Air Top 2000 ST
Page for notes
402
Air Top 2000 ST 5 Troubleshooting
5 Troubleshooting CAUTION
The troubleshooting guide is restricted to the localisation
of defective components. The following potential sources
5.1 General of malfunctions have not been included and should
always be checked so that they can then be excluded as
This section describes how to identify and remedy faults the cause of the particular fault:
on the Air Top 2000 ST air heater.
• Corrosion on plugs
If a fault occurs, an error code will be output in the • Loose plug contacts
displayof the combination timer. If the heater has a control • Poor crimp contacts on plugs
element, the ON control light will flash. In addition, the • Corroded cables and fuses
heater can be checked using a personal computer (see • Corroded battery terminals
PC heater diagnostic operating manual).
If you wish to check individual components, the electrical
CAUTION plug connectors on the control unit must be disconnected.
Troubleshooting work demands precise knowledge of the
structure and theory of operation of the various Conduct a function test in the vehicle after rectifying each
components and must be carried out by trained personnel fault.
only.
If in doubt, refer to sections 2 and 3 for a description of 5.2 General error symptoms
how the functions interact.
The following table (Fig. 501) lists the possible error
NOTE symptoms.
For ADR mode only:
After an ADR shut-down or an operating voltage has been
applied by switching the main vehicle switch and control
element to “ON”, the control unit will be set to the “Fault
lock-out” position. Before it can be restarted, the control
element must be set to “OFF” or the Immediate heat
button pressed on the combination timer.
Error symptom Possible cause Remedy
Heater cuts out automatically No combustion after start Switch heater off and then on again
and restart
ON indicator flashes
Flame extinguishes during operation Switch heater off and then on again
ON indicator flashes
Heater overheats Check that the hot air system is clear,

ON indicator flashes allow the heater to cool, switch heat off
briefly and then on again
Battery voltage too low Charge battery

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
Fig. 501 General error symptoms
501
5 Troubleshooting Air Top 2000 ST
5.3 Error symptoms during function error symptom heading, in an emergency you can contact
our technicians on our service hotline
The following table (Fig. 502) lists the possible error (see last page).
symptoms in the order in which they may occur during
operation. NOTE
Every fault is indicated by the flashing LED on the control
In the event of a fault, the error is to be located using this element after the slow down time has finished. If the other
table and rectified. It is important that the error symptom components are OK, a defective control unit may be the
is correctly identified. cause of all the faults.
If the error symptom is not included in this table or the fault There are statuses that are the same as errors.
is not found under the specific
Error symptom Occurrence Possible cause
No start and no illumination of the Immediate Incorrect cabling, defective fuse

LED on the control element
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.
Fig. 502 Error symptoms during function
502
5.4 Error code output NOTE

The error code is output if the heater is fitted with a
If the heater is fitted with a combination timer, an error controlelement after an error has occurred by the switch-
code output will appear on the display of the timer aftera on indicator/error code indicator flashing. After 5 seconds
fault occurs. of fast flashing, the error code will be output by a
sequence of long flash pulses, the number of flashes is
shown in the table below (for example F04 – 4 long flash
pulses).
Error Error (group) Additional information during PC Remedy

code diagnostic
F 00 Control unit error 01 Control unit error Replace control unit
81 EOL checksum error
11 Incorrectly coded control unit or

incorrect heater (fuel type) installed (the
heater will not work if this error occurs)
91 Neutrally coded or disabled control

unit (the heater will not work if this
error occurs)
92 Maintain command failed (the heater

will not work if this error occurs)
18 Customer bus defective
F 01 No start 02 Even after the restart, no flame has Check fuel supply
formed (tank empty, lines blocked)
Clean burner insert,
82 No start in test Petrol:
Replace flame sensor
Diesel:
Replace overheating sensor / control
unit
F 02 Flame failure 03 The flame has gone out during Check fuel supply
operation and has not reformed after a (tank empty, lines blocked)
restart attempt Clean burner insert,
83 The flame has gone out during a Petrol:
heating cycle more than FAZ times Replace flame sensor
(EEPROM) Diesel:
Replace overheating sensor / control
unit
F 03 Undervoltage or 84 The voltage was less than 10.5 V or Charge battery

overvoltage 21 V for longer than 20 seconds
04 The voltage was more than 16 V or

32 V for longer than 6 seconds
Fig. 503 Troubleshooting (page 1 of 3)
503

code diagnostic
F 04 Premature flame 05 A flame was detected before Diesel: Replace overheating sensor /
recognition combustion had started control unit
Petrol: Replace flame sensor
F 05 Flame sensor 1A Flame sensor circuit Replace flame sensor

interrupt or short The switched cable of the element has a
circuit short circuit to earth
(only petrol heater)
9A Flame sensor circuit Replace flame sensor
Break or short circuit to +Ub
F 06 External temperature 14 Temperature sensor circuit Check cables / replace temperature

sensor break or short Short circuit to earth sensor
circuit
94 Temperature sensor circuit break or Check cables and terminating resistor /
short circuit to +Ub replace temperature sensor
F 07 Metering pump 88 Break or short circuit to +Ub Check cables / replace metering pump
interrupt or short
circuit 08 Short circuit to earth Check cables / replace metering pump
F 08 Drive unit 89 Break or short circuit to +Ub Replace drive unit (combustion and hot
(combustion and hot air blower)
air blower) break or
short circuit 09 The switched drive unit cable Eliminate the cause of the blockage /
(combustion and hot air blower) has a difficulty in movement
short circuit to earth or the drive unit is Replace drive unit (combustion and hot
overloaded air blower)
15 Burner motor block guard has tripped
95 Burner motor blocking detection has

tripped
F 09 Glow plug interrupt 8A Glow plug: Replace glow plug

Break or short circuit to +Ub
or short-circuit 19 Glow circuit Replace glow plug

The switched cable of the element has a
short circuit to earth
504

code diagnostic
F 10 Overheating 06 The overheating fault lock-out has Find and remove the cause of the
tripped (heater overheated) overheating
17 Incorrect application or illegal NOTE

insulation (ÜHS gradient too high) If no other cause can be found for the
overheating, the pressure losses
caused by the hot air distribution (too
many resistance points) are too high or
a hot air filter is soiled
F 11 Overheating sensor AB Overheating sensor circuit break or Replace overheating sensor

interrupt or short short circuit to +Ub
circuit
1B Overheating sensor circuit. Replace overheating sensor
The switched cable of the element has a
short circuit to earth
F 12 Heater fault lock-out 07 The heater fault lock-out has been Remove the fuse and then refit it
activated
NOTE
The following error has occurred several
times:
Fault counter more than
3 times
Incorrect start counter more than
9 times
Overheating counter more than
3 times
F 14 Overheating sensor 97Incorrect position of overheating Position the overheating sensor

incorrect position sensor (ÜHS gradient too low) correctly
F 15 Nominal sensor 9B Nominal value potentiometer circuit Check cables / replace control element
break break or short circuit to +Ub
505
Page for notes
506
Air Top 2000 ST 6 Function tests
6 Function tests NOTE

The heater will now run in normal mode again and can be
switched off as normal using the control element.
6.1 General The heater is set at the factory to match the fitted
combustion air blower.
This section describes the tests conducted on the heater
when it is installed and not installed to verify that it is in 6.3 Testing individual components
working order.
CAUTION
WARNING For function tests always break the connection between
The heater must not be operated in enclosed areas such the control unit and the component you wish to test.
as garages and workshops without an emissions
extraction system.
6.3.1 Glow plug resistance test
NOTE
6.2 Settings The resistance test must be carried out with an ohmmeter
suitable for small resistance values.
6.2.1 Setting the CO2 content A resistance test with a simple digital multimeter is too
inaccurate to find the precise values. A new glow plug can
The CO2 content in the emissions is set using the be measured to act as a reference.
adjustment knob on the control element. At a constant
blower speed the volume of fuel is controlled by changing The glow plug should have the following values in the test:
the metering pump cycle.
Glow plug: 12 V (red) 24 V (green)
CAUTION Resistance
The CO2 measuring instruments must be calibrated. at 25 °C: 0.263 ... 0.323 Ohm 1.125 ...1.375 Ohm
The heater must be switched off. Test current: < 5 mA < 5 mA
1. Connect the CO2 line to minus.

2. Turn the adjustment knob on the control element to 6.3.2 Resistance test on flame sensor (only
the centre setting. The heater will start and go petrol heater)
automatically to low-fire rate mode.
If you conduct this test with a digital multimeter, the flame
NOTE sensor must have the following values:
If the heater can be adjusted, the operating indicator will
flash as if the control unit has suffered an error. Cold testing:
Resistance at 25 °C: 2.6 ... 3.4 Ohm
Diesel unit: Test current: < 5mA
3. Set the CO2 value by turning the adjustment knob.
Turning it anti-clockwise will reduce the CO2 value, Hot testing:
whilst turning it clockwise will increase it. The Resistance at 800 – 1000 °C: 12 ... 15 Ohm
measured CO2 content at low-fire rate (1.5 kW) must Test current: < 5 mA
be between 5.0 % and 8.0 %. In high-fire mode, the (ceramic rod at red heat over length of approx. 20 mm)
CO2 content should be 10.3 +/- 0.5 % v/v after the
setting has been made.
Petrol unit:
4. The CO2 content may only be measured when the
unit is at operating temperature. The unit must be run
for at least 8 minutes for this purpose. After this the
CO2 content is to be set to 6.1 - 6.2 % v/v in low-fire
mode (1 kW). In high-fire mode, the CO2 content
should be 9.9 +/- 0.4 % v/v after the setting has been
made.
5. If the CO2value is within this range,disconnect the
CO2 line from minus. This saves the setting.
601
6 Function tests Air Top 2000 ST
6.3.3 Overheating sensor resistance test
If you conduct this test with a digital multimeter, the

overheating sensor must have the values shown in the
following diagram:
Resistance in Ohm
Temperature in °C
Characteristic resistance values of a

PT 2000 overheating system
in a temperature range of 10 °C to 30 °C
602
Air Top 2000 ST 6 Function tests
Page for notes
603
Air Top 2000 ST 7 Circuit diagrams
7 Circuit diagrams The circuit diagrams (Fig. 702 to 706) show the possible
circuits for 12 and 24 V with
7.1 General • Control element and vehicle blower

• Combination timer and vehicle blower
The Air Top 2000 ST heater can be controlled with the • Combination timer and electrical battery isolation
control element (nominal value adjuster/switch) or a switch
combination timer. • ADR operation with control element
• ADR operation without auxiliary drive with control
element
Fig. 701 shows the plug assignment on the control unit.
Fig. 707 shows the schematic connection of the

combination timer.
X6
X2
X4
X5
X1
X3
X1 = Combustion and hot air blower connection

X2 = Glow plug connection
X3 = Overheating sensor connection
X4 = Metering pump connection
X5 = Flame sensor connection (only petrol heater)
X6 = Wiring harness connection
Fig. 701 Plug assignment
701
7 Circuit diagrams Air Top 2000 ST
30 30
15 15 X1
0,5mm² sw/rt
4 2
F1 S6 5
1 2 X11 F2
0,5mm²
X2/X3/X4/X5
0,5mm²
0,5mm²
gn/ws
br
1
rt
X6
1 14 15 7 5 6 2
S1 X9 1
3 13 A2
0,5mm² rt 4
X6
4 12 7
0,5mm² sw 3 86 87 87a
H1 16 3 K
1 10
0,5mm² bl
85 30
17
2 0,5mm² ws
11 X8
J
2 X6
B2
2
1 2 3 1 2 2 1 9 8 2 1 1 2 0 3 1
1 2 X9
0,5mm² ws/r t
brbr ge X2 ge br X5 br X6 X4 bl X3 bl
0,5mm² ws/sw
12V rt 4 1
24V gn X1 M 0,5mm²
0,5mm²
J J
sw/bl
M1 ge
E B1 B3
A1 M M3 3 2
0,5mm²
0,5mm²
sw
sw
X10
2 1 1 2
X8
X10
br
br
bl
R1
1 2
2 1
0,5mm²
X8
S4 X11
S5
6 J
Y1
B4
2 1
31
1 Diagnostic K cable
Cable cross-sections Cable colours
2 W bus
bl Blue
< 7.5 m 7.5 15 m
3 Input pin (pin 16/plug X6), cable colour on wiring harness: white/red): br Brown
“Ventilation” (fan speed depends on the position of the control element) 0.75 mm 2 1.0 mm 2
0.75 mm2 1.0 mm 2 ge Yellow
4 CO2 setting 1.0 mm 2 1.5 mm 2 gn Green
1.5 mm 2 2.5 mm 2 gr Grey
5 Fuse installed in vehicle
2.5 mm 2 4.0 mm 2 or Orange
6 If you use an external temperature sensor (B4), the resistor (R1) 4.0 mm 2 6.0 mm 2 rt Red
is replaced by the temperature sensor (B4). Standard cable sw Black
vi Violet
7 Connection for ADR vehicles only
ws White
Item Designation Comment Item Designation Comment

A1 Heater Air Top 2000 ST S4 Switch Ventilation
A2 Control unit S5 Switch Flashover sensor
B1 Flame sensor only petrol heater S6 Switch CO2 setting
B2 Temperature sensor Internal X1 Plug connector, 4-pin to item A2
B3 Overheating sensor Overheating guard X2 Plug connector, 2-pin to item A2
B4 Temperature sensor External X3 Plug connector, 2-pin to item A2
E Glow plug X4 Plug connector, 2-pin to item A2
F1 Fuse 15A (max. 20A) Flat fuse SAE J 1284 X5 Plug connector, 2-pin to item A2
F2 Fuse 20 A Flat fuse SAE J 1284 X6 Plug connector, 18-pin to item A2
K Relay with free-wheeling diode for vehicle fan X8 Plug connector, 2-pin
H1 LED, green (in item S1) Indicator X9 Plug connector, 4-pin to item S1
M1 Motor Combustion and hot air fan X10 Plug connector, 2-pin
M3 Motor Vehicle fan X11 Plug connector, 2-pin
R1 Resistor 620 Ω With internal temperature Y1 Dosing pump
sensor only
S1 Control element Setpoint generator switch
Fig. 702 System circuit diagram 12V/24V with control element and vehicle blower
702
30 30 X1
15 15
58 58
1 6 0,5mm² sw/rt
5 3 X2/X3/X4/X5
F1 S6 7
F2 1 2 X11 F3
0,5mm²
0,5mm²
0,5mm²
gn/ws
2
br
2
rt
X6 1
1 10 11
1 14 15 7 5 6
X6
A2 86 87 87a
2 0,5mm² 13 4
rt K
H4 0,5mm² 12 3 9 85 30
H5 H3 8 sw
16 4 X8
0,5mm² 10
6 bl
17
0,5mm² ws 11
P J 0 3 2
9 2 X6 1 2 1
12 7 4 B2
X10
X12 3
1 2 1 2 2 1 9 8 2 1 1 2 1 2
0,5mm² ws/r t
br br ge X2 ge br X5 br X6 X4 bl X3 bl M M3
0,5mm² ws/sw
12V rt
X1
0,5mm²
0,5mm²
24V gn J J
sw/bl
M
ge
M1 E B1 B3
A1 1 2
0,5mm²
0,5mm²
X11
sw
sw
S7 X8 2 1
X10 2 1
br
br
bl
R1 X12
2 1
0,5mm²
X8
S5 S4
8 J
Y1 3
B4 6
9
31 12
1 With positive from terminal (15/75) to connection 10:

Permanent operation for immediate heat as long as the ignition is switched on Cable cross-sections Cable colours
Without positive at connection 10:
Heating time is variably programmable (10 min to 120 min), < 7.5 m 7.5 15 m
bl Blue
default setting 120 min br Brown
0.75 mm 2 1.0 mm 2
2 Diagnostic K cable 1.0 mm 2 ge Yellow
0.75 mm2
3 W bus 1.0 mm 2 1.5 mm 2 gn Green
4 Input pin (pin 16/plug X6), cable colour on wiring harness: white/red): 1.5 mm 2 2.5 mm 2 gr Grey
“Ventilation” (fan speed depends on the position of the control element) 2.5 mm 2 4.0 mm 2 or Orange
5 CO2 setting 4.0 mm 2 6.0 mm 2 rt Red
6 NOTE Standard cable
sw Black
If the connection is made to terminal 30, permanent heating is possible with the ignition
vi Violet
switched off. In this case no connection must be made to terminal 15/75.
ws White
7 Fuse installed in vehicle
8 If you use an external temperature sensor (B4), the resistor (R1)
is replaced by the temperature sensor (B4).
Item Designation Comment Item Nomenclature Remark

A1 Heater Air Top 2000 ST M3 Motor Vehicle fan
A2 Control unit P Combination timer (1531) Timer and setpoint generator
B1 Flame sensor only petrol heater R1 Resistor 620 Ω With internal temperature sensor only
B2 Temperature sensor Internal S4 Switch Ventilation
B3 Overheating sensor Overheating guard S5 Switch Flashover sensor
B4 Temperature sensor External S6 Switch CO2 setting
E Glow plug S7 Momentary-contact switch Immediate heat button remote control
F2 Fuse max. 15A Flat fuse SAE J 1284 X2 Plug connector, 2-pin to item A2
F3 Fuse 20 A Flat fuse SAE J 1284 X3 Plug connector, 2-pin to item A2
H3 Red LED (in item P) Immediate heat button light X4 Plug connector, 2-pin to item A2
Ready indicator, X5 Plug connector, 2-pin to item A2
switch-on indicator
X6 Plug connector, 18-pin to item A2
H4 Heating symbol in the display Indicator
X8 Plug connector, 2-pin
(in item P)
H5 Light (in item P) Display and
button lights X11 Plug connector, 2-pin
K Relay with free-wheeling diode for vehicle fan X12 Plug connector, 12-pin to item P
M1 Motor Combustion and hot air fan Y1 Dosing pump
Fig. 703 System circuit diagram 12V/24V with combination timer and vehicle blower
703
30 30 X1
15 15
58 58
1 7
88 88a
S8 5 3 X2/X3/X4/X5
F1 S6
F2 86 1 2 X11
0,5mm²
0,5mm²
0,5mm²
gn/ws
rt
V1 V2 0,5mm² ge/rt 2
br
2 1
1 10 11 X6
1 15 14 7 5 6
X6
2 0,5mm² rt 13 A2
4
H4 8
H5 0,5mm² sw 12 3
H3 8
10
16 4 X8
6 0,5mm² bl
17
0,5mm² ws 11
P ϑ 2
9 2 X6 1
12 7 4 B2
X10
X12
1 2 3 1 2 2 1 9 8 2 1 1 2 1 2
0,5mm² ws/r t
br br ge X2 ge br X5 br X6 X4 bl X3 bl
0,5mm² ws/sw
12V rt
X1
0,5mm²
0,5mm²
24V gn ϑ ϑ
sw/bl
M
ge
M1 E B1 B3 1 2
A1
X11
0,5mm²
0,5mm²
sw
sw
S7 X8 2 1
X10 2 1
br
br
bl
R1 X12
X8 2 1
S5 S4
6
ϑ
Y1 3
B4 6
9
31 12
1 With positive from terminal (15/75) to connection 10:

Permanent operation for immediate heat as long as the ignition is switched on Cable cross-sections Cable colours
Without positive at connection 10:
Heating time is variably programmable (10 min to 120 min), < 7.5 m 7.5 15 m
bl Blue
default setting 120 min br Brown
0.75 mm 2 1.0 mm 2
2 Diagnostic K cable 0.75 mm2 1.0 mm 2 ge Yellow
3 W bus 1.0 mm 2 1.5 mm 2 gn Green
4 Input pin (pin 16/plug X6), cable colour on wiring harness: white/red):
“Ventilation” (fan speed depends on the position of the control element) 2.5 mm 2 4.0 mm 2 or Orange
4.0 mm 2 6.0 mm 2 rt Red
5 CO2 setting
Standard cable Black
sw
6 If you use an external temperature sensor (B4), the resistor (R1)
is replaced by the temperature sensor (B4). vi Violet
7 NOTE ws White
If the connection is made to terminal 30, permanent heating is possible with the ignition
switched off. In this case no connection must be made to terminal 15/75.

A1 Heater Air Top 2000 ST S4 Switch Ventilation
A2 Control unit S5 Switch Flashover sensor
B1 Flame sensor only petrol heater S6 Switch CO2 setting
B2 Temperature sensor Internal S7 Momentary-contact switch Immediate heat button remote control
B3 Overheating sensor Overheating guard S8 Battery isolation switch
B4 Temperature sensor External V1 Diode
E Glow plug V2 Diode
F2 Fuse max. 15A Flat fuse SAE J 1284 X2 Plug connector, 2-pin to item A2
H3 Red LED (in item P) Immediate heat button light X3 Plug connector, 2-pin to item A2
Ready indicator, X4 Plug connector, 2-pin to item A2
switch-on indicator
H4 Heating symbol in the display Indicator
(in item P)
H5 Light (in item P) Display and
button lights X10 Plug connector, 2-pin
P Combination timer (1531) Timer and setpoint generator X12 12-pin plug connection to item P
R1 Resistor 620 Ω With internal temperature sensor Y1 Dosing pump
only
Fig. 704 System circuit diagram 12V/24V with combination timer and electrical battery isolation switch
704
S2
30 30
15 15 X1
D+/61 D+/61
0,5mm² gr
4 2
F1 S6
1 2 X11
0,5mm²
S3 X2/X3/X4/X5
0,5mm²
0,5mm²
gn/ws
br
5 1
rt
X6 7
1 4 14 15 7 5 6 2
S1 X9 1
3 13 A2
0,5mm² rt
X6
4 12 3 5
0,5mm² sw 0,5mm² vi
H1 16 3
1 10
0,5mm² bl
17
2 0,5mm² ws
11 X8

2 X6
B2
2
1 2 3 1 2 2 1 9 8 2 1 1 2 1
X9
0,5mm² ws/r t
0,5mm² ws/sw
12V rt
X1
0,5mm²
0,5mm²
4 1
24V gn M sw/bl
ge
M1 E B1 B3
A1 0,5mm² 3 2
0,5mm²
sw
sw
X10
2 1 1 2
X8
X10
H6
br
br
bl
R1 Y2
1 2
X8 2 1
S4 X11
S5
S2 6
Y1
B4
2 1
31
2 W bus
< 7.5 m 7.5 15 m bl Blue
0.75 mm 2 1.0 mm 2
“Ventilation” (fan speed depends on the position of the control element) Yellow
0.75 mm2 1.0 mm 2 ge
5 NOTE 2.5 mm 2 4.0 mm 2 or Orange
Grey and violet cables required for ADR function 4.0 mm 2 6.0 mm 2 rt Red
Standard cable
6 If you use an external temperature sensor (B4), the resistor (R1) sw Black
7 Holding signal for electrical battery isolation switch ws White
The holding input (if there is one) for the isolation switch (S2) must be connected to
the control unit in PIN 15/plug X6.

A1 Heater Air Top 2000 ST S5 Switch Flashover sensor
A2 Control unit S6 Switch CO2 setting
B1 Flame sensor only petrol heater X1 Plug connector, 4-pin to item A2
H1 LED, green (in item S1) Indicator X8 Plug connector, 2-pin
H6 Light (at least 1.2 W) Switch-on indicator pumping X9 Plug connector, 4-pin to item S1
device X10 Plug connector, 2-pin
R1 Resistor 620 Ω With internal temperature Y1 Dosing pump
sensor only
Y2 Solenoid valve for pumping
S1 Control element Setpoint generator switch device
S2 1 or 2-pin disconnecting switch Emergency Stop switch
S3 Switch to or for pumping device
S4 Switch Ventilation
Fig. 705 System circuit diagram (diesel) 24V ADR mode with control element
705
S2
30 30
15 15
X1
D+/61 D+/61
0,5mm² gr
4 2
F1 S6
1 2 X11
0,5mm²
X2/X3/X4/X5
0,5mm²
0,5mm²
gn/ws
br
5 1
rt
X6 7
1 4 14 15 7 5 6 2
S1 X9 1
3 13 A2
0,5mm² rt
X6
4 12 3 5
0,5mm² sw 0,5mm² vi
H1 16 3
1 10
0,5mm² bl
17
2 0,5mm² ws
11 X8

2 X6
B2
2
1 2 3 1 2 2 1 9 8 2 1 1 2 1
X9
0,5mm² ws/r t
0,5mm² ws/sw
12V rt
X1
0,5mm²
0,5mm²
24V gn 4 1
sw/bl
M
ge
M1 E B1 B3
A1 3 2
0,5mm²
0,5mm²
sw
sw X10
2 1 1 2
X8
X10
br
br
bl
R1
1 2
X8 2 1
S4 X11
S5
S2 6
Y1
B4
2 1
31
2 W bus
< 7.5 m 7.5 15 m bl Blue
0.75 mm 2 1.0 mm 2
“Ventilation” (fan speed depends on the position of the control element) Yellow
0.75 mm2 1.0 mm 2 ge
5 NOTE 2.5 mm 2 4.0 mm 2 or Orange
Grey and violet cables required for ADR function
4.0 mm 2 6.0 mm 2 rt Red
Standard cable
6 If you use an external temperature sensor (B4), the resistor (R1) sw Black
7 Holding signal for electrical battery isolation switch ws White
The holding input (if there is one) for the isolation switch (S2) must be connected to
the control unit in PIN 15/plug X6.

A1 Heater Air Top 2000 ST S6 Switch CO2 setting
A2 Control unit X1 Plug connector, 4-pin to item A2
B1 Flame sensor only petrol heater X2 Plug connector, 2-pin to item A2
F1 Fuse 15A (max. 20A) Flat fuse SAE J 1284 X8 Plug connector, 2-pin
H1 LED, green (in item S1) Indicator X9 Plug connector, 4-pin to item S1
R1 Resistor 620 Ω With internal temperature X11 Plug connector, 2-pin
sensor only Y1 Dosing pump
S1 Control element Setpoint generator switch
S2 1 or 2-pin disconnecting switch Emergency Stop switch
S4 Switch Ventilation
S5 Switch Flashover sensor
Fig. 706 System circuit diagram (diesel) 24V ADR mode without auxiliary drive unit with control element
706
Terminal 15: black

Terminal 30: red
Terminal 58: grey
12V
Terminal 31: brown

24V
Fig. 707 Schematic connection of the combination timer
707
Page for notes
708
Air Top 2000 ST 8 Servicing work
8 Servicing work The following servicing work is to be carried out to

maintain the functional reliability of the heater:
8.1 General • Check the hot air inlet and outlet for dirt and foreign
bodies. (Dirty or blocked hot air lines may cause
This section describes the servicing work that can be overheating.)
carried out on the heater when it is installed. • Clean the exterior of the heater (avoid the ingress of
water).
• Check the electrical connections for contact corrosion
and to ensure that they are secure.
8.2 Work on the heater
• Check the exhaust and combustion air lines for signs
of damage and to ensure that they are clear.
Disconnect the main power cable from the vehicle’s • Replace the fuel filter if there is one.
battery before carrying out any work on the heater. The • Check the fuel line and filter for leaks.
main battery power must not be disconnected whilst the
heater is operating or slowing down as a result of the risk
of the heater overheating and the overheating guard thus 8.6 Visual inspections and installation
being tripped. If you wish to carry out extensive repair instructions
work on the heater, it may be a good idea to remove it
completely. 8.6.1 Hot air system
Refer to the relevant installation instructions and the CAUTION

installation proposal for the heater for the specific vehicle The integration of the heater into the vehicle’s own air
for repairs that necessitate the installation position being system is not permitted as a result of the high pressure in
changed. the vehicle’s system.
Inside the control unit there is a temperature sensor,

8.3 Work on the vehicle which operates the heater in the appropriate heat output
range in conjunction with the control element depending
CAUTION on the intake temperature and the position of the setpoint
A temperature of 85 °C must not be exceeded in the generator. The heat output is set so that after the selected
vicinity of the heater in any circumstances (for example interior temperature has been reached quickly, it is then
when completing painting work on the vehicle). kept at this selected value. Alternatively, the heaters can
be operated with an external temperature sensor
(see 9.1.2).
8.4 Heater trial NOTE
Only materials that can permanently withstand
WARNING temperatures of at least 130 °C may be used for the hot
The heater must not be operated in enclosed areas such air line.
as garages and workshops without an emissions
extraction system, even if you use the timer. Maximum pressure drop between the inlet and outlet side
of the hot air line 1.5 hPa (corresponds to 1.5 mbar /
CAUTION 15 mm WC).
The heater must not be operated without the cover for the
control unit as this will cause it to overheat. If this value is exceeded, the heat output may be reduced
as a result of the hot air outlet temperature control.
8.5 Servicing work The internal diameter of the main section of the hot air line
should be 60 mm.
NOTE When using narrower lines, the permissible pressure drop
The heater should be operated for approximately 10 is exceeded more quickly.
minutes every 4 weeks to prevent mechanical parts The hot air hose must be secured at its connection points.
seizing.
The heater can be used on the air inlet and outlet side if it
The heater requires no servicing. However, it should be is used in an air circulation system with grates. Do not
checked at regular intervals, at the latest at start of the short circuit the flow of hot air.
heating period (the time after which the heater will be used
due to adverse weather conditions) by Webasto-trained
personnel.
801
8 Servicing work Air Top 2000 ST
CAUTION Vehicles with carburettor engines

In vehicles used to transport people, the air outlet opening The fuel may only be extracted on cars using the special
is to be installed in such a way that it is at least 20 cm Webasto fuel extractor (for example ID no. 470 910), as
away from all body parts. close to the tank as possible. The connection may be
made in either the supply or return line, in which case the
The heaters check the internal temperature rise return line must lead almost to the base of the tank. If this
automatically each time they are switched on. If this is is not the case, the return line may be extended.
above the specified limits, the start is cancelled and error
messages F10 is displayed. To ensure that the heater The fuel extractor must be fitted in such a way that any air
functions stably, the flow resistance of the connected hot or gas bubbles are automatically discharged towards the
air system must be reduced. tank.
If a filter is used for the hot air, it must have the following The fuel extractor should not be located near the engine,
properties: as gas bubbles may form in the lines on account of heat
• The air flow must not carry any inflammable and/or radiated from the engine. This may cause problems
harmful fibres or particles into the heater or the interior during combustion.
of the vehicle.
• The filter material must be able to withstand Vehicles with injection engines
temperatures of at least 60 °C. When installing the heater in a vehicle with fuel injection
• The filter must be resistant to all the substances that systems, it is important to establish whether the fuel pump
may be drawn in with the hot air (for example is located inside or outside the tank.
moisture, salt, fuel vapours, etc.).
• The resistance of the filter must be taken into If the fuel pump is located inside the tank, fuel can only be
consideration when designing the hot air system. extracted from the return line using the Webasto fuel
extractor (for example ID no. 470 910), in which case it
must be ensured that the return line continues almost to
8.6.2 Fuel supply the bottom of the tank. If this is not the case, Webasto fuel
extractor (see Fig. 802, 803 or 804) may be used.
The fuel is taken from the vehicle fuel tank or from a
separate fuel tank. The values for the maximum pressure If the fuel pump is installed outside the tank, the fuel
at the fuel extraction point are shown in Fig. 801. connection may also be made between the tank and the
fuel pump, again using only the Webasto fuel extractor
(for example ID no. 470 910).
Permissible fuel inflow At max. pressure (bar) in
height H (m) fuel line
0.00 0.20
1.00 0.11
2.00 0.03
Maximum fuel intake At max. negative pres-
height S (m) sure (bar) in fuel tank
0.00 -0.10
0.50 -0.06
1.00 -0.02
8.6.2.1 Fuel extractor
Vehicles with diesel engines

The fuel must be taken from the vehicle fuel tank or from
a separate tank (Fig. 802, 803 or 804). This separate fuel
pickup precludes any effect of pressure.
802
Plastic tank
Sealing ring
l1 + l2 ≤ 10 m
l1 ≤ 1.2 m Fig. 803 Fuel extractor from the plastic tank
l2 ≤ 8.8 m (extraction through tank drain screw)
Tank connector
Fig. 801 Fuel supply
Sealing ring
Hole pattern
25
Tank fitting
> 25 mm
NOTE
Only use a tank extractor with metal fuel tanks.
Fig. 802 Webasto fuel extractor NOTE

The fitting must be made of metal.
Fig. 804 Fuel extractor from the plastic tank

(extraction through tank fitting)
803
8.6.2.2 Fuel lines
Only steel, copper and plastic lines of plasticised, light and

temperature-stabilised PA11 or PA12 (for example
Mecanyl RWTL) according to DIN 73378 may be used for
the fuel lines. Since the lines cannot normally be routed
with a constant rising gradient, the internal diameter must
not be allowed to exceed a certain size. Air or gas bubbles
will accumulate in lines with an internal diameter of more 0-90° 0-90°
than 4 mm and these will cause malfunctions if the lines 0°
sag or are routed downwards. The diameters specified in
Fig. 801 will ensure that bubbles do not form.
12 V and 24 V – diesel DP 30
The lines should not be routed downwards from the Only horizontal installation position
metering pump to the heater.
Fig. 806 Metering pump, installation position and
Unsupported fuel lines must be secured to prevent them attachment
sagging. They must be installed in such a way that they
cannot be damaged by flying road chippings and high 8.6.3.1 Installation location
temperatures (exhaust line).
The fuel lines must be secure at the connections using It is advisable to install the metering pump in a cool place.
hose clips to prevent their slipping. The maximum ambient temperature must not exceed
+20 °C at any time during operation.
Connecting two pipes with a hose
The metering pump and fuel lines must not be installed
The correct procedure for connecting fuel lines with within range of the radiated heat from hot vehicle parts.
hosing is shown in Fig. 805. A heat shield must be used if necessary.
8.6.3.2 Installation and attachment

Correct
The metering pump must be secured with a vibration-
Clip damping mounting. Its installation position is limited as
shown in Fig. 806 in order to ensure effective automatic
bleeding. As a result of the risk of corrosion, only genuine
Wrong Webasto parts may be used for the plug connections
between the metering pump and the metering pump
Bubble Bubble wiring harness.
8.6.4 Fuel filter
Only a Webasto filter, ID no. 487 171, is allowed to be

Fig. 805 Pipe/Hose connections used if the fuel is expected to be contaminated. Install
vertically if possible, however at most horizontally (check
8.6.3 Metering pump flow direction).
The metering pump is a combined delivery, metering and

shut-off system and is subject to certain installationcriteria
(Fig. 801 and 806).
0 - 90°
ø5
Fig. 807 Fuel filter
804
8.6.5 Combustion air supply Length of the combustion air inlet and exhaust lines:
With silencer: max. 2.0 m
Under no circumstances may the combustion air be taken Without silencer: max. 5.0 m
from areas occupied by people. The combustion air intake Both lines are to be installed falling away from the heater.
opening must not point in the direction of travel. It must be If this is not possible, a condensate drain hole with a
located so that it cannot become clogged with dirt. diameter of 4 mm must be made at its lowest point or a
connection element with a condensate drain used.
NOTE
The combustion air must be extracted using a combustion Internal diameter of the lines:
air line from a position that is as cool as possible and Combustion air line: 22 mm
protected from splashing water for petrol heaters. Exhaust line: 22 mm
If the heater is in a sealed installation box, the combustion NOTE

air must be drawn in from the outside and the emissions If the exhaust line is over 2 m in length, insulated lines
fed to the outside. Pipe passage holes must be made in must be used (to prevent falling below the dewpoint).
such a way as to ensure that the ingress of exhaust
fumes into the interior of the vehicle should not occur. Minimum bending radius: 50 mm
If dirty combustion air is expected, a combustion air filter An attachment is required no further than 150 mm from
may be fitted (only Air Top 2000 ST D). If the intake hose the end of the exhaust pipe to ensure that the angle of
length is < 0.6 m, an intake silencer must be used. 90° ± 10° is achieved.
8.6.6 Exhaust line
Rigid pipes of unalloyed or alloyed steel with a minimum

wall thickness of 1.0 mm or flexible piping of alloyed steel
only must be used as the exhaust line. The exhaust pipe
must be secured to the heater and exhaust silencer with a
pipe clip, ID no. 20965A.
The exhaust silencer (Fig, 808) should ideally be installed

near the heater. The flow direction is arbitrary. Discharge direction
more or less vertical
90° ± 10°
ø 6,5
10° 10°
Fig. 808 Exhaust silencer Fig. 809 Exhaust pipe mouth, installation position
The heater may also be operated without a silencer.

WARNING
8.6.7 Combustion air inlet and exhaust lines If the exhaust pipe mouth is positioned other than as
shown in Fig. 809, it will pose a fire risk.
To prevent damaging the metering pump cable, exhaust
line must not be used to extend the combustion air supply Total bends:
line. Combustion air line: max. 270°
Exhaust line: max. 270°
805
8.6.8 Electrical connections 8.6.8.3 Control element connection
8.6.8.1 Heater connection, control element The wiring harness is prepared for connection to the
control element (adjuster).
The electrical connection is to be made as shown in the Simply pull on connector housing to disconnect the
appropriate circuit diagram (see section 7). connector (Fig. 813).
To connect the wiring harness, remove the cover (see

9.2.1.1) on the heater and connect the wiring harness plug
to the control unit.
Before using the heater for the first time fit the cover to
prevent the illegal escape of hot air (heater overheating).
The wiring harness can be fed out of the left or right side Fibre optic cable
of the heater.
8.6.8.2 Supply voltage connection
Ideally from the vehicle’s central electrical system.

Fig. 812 Control element
An additional blade terminal fuse holder is to be fitted to
NOTE
protect the heater (supplied with the heater). The fuse
The fibre optic cable must be in contact with the rotary knob.
holder may only be installed in theinterior of the vehicle.
NOTE
The connector housingcan be locked (self-locking action)
by simply pulling on the wiring harness.
Fig. 810 Remove the fastening plate

on the fuse holder
F = 10A 24V
F = 15A 12V
Fig. 811 Fuse holder, installation position
Fig. 813 Disconnect the plug
806
1 Control element
2 Heater
3 Metering pump and damper
4 Fuel filter (accessory)
5 Tank connector
6 Exhaust silencer
7 Fuse
Fig. 814 Specimen installation for heater in an air circulation system
807
8.7 Removal and installation 8.8 Start-up
CAUTION After you have installed the heater, bleed the fuel supply
When the heater is installed it must not be dismantled. system carefully.
8.7.1 Heater, removal and installation NOTE

As a result of the low fuel consumption the heater must be
8.7.1.1 Removal switched on several times to fill the fuel line.
1. Disconnect the battery. Conduct a trial of the heater to check all the connections
2. Pull the cover off the top shell as described in 9.2.1.1. for leaks and to ensure that they are secure. If the heater
3. Disconnect the wiring harness plug from the control suffers a fault during operation, the fault must be located
unit. and remedied.
4. Disconnect the cable to the metering pump at the
disconnection point.
5. If necessary disconnect the hot air hose or hoses.
6. Disconnect the connection for the combustion air inlet
on the heater.
7. Disconnect the connections for the combustion air
inlet and exhaust outlet on the heater.
8. Remove four nuts and locking washers from the
heater.
9. Remove the heater and discard the seal on the
exhaust outlet.
8.7.1.2 Installation
1. Place the heater with a new seal on the exhaust outlet

in the installation position and secure it with 4 nuts and
locking washers (use only genuine Webasto nuts).
2. Tighten the nuts to 6 + 1 Nm.
3. Secure the connection for the combustion air inlet on
the heater.
4. Secure the connections for the combustion air inlet
and exhaust outlet on the heater.
5. Connect the metering pump cable to the metering
pump wiring harness.
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).
808
Air Top 2000 ST 9 Repair
9 Repair 9.1.2.1 Installation of an external temperature sensor
General
9.1 General The heater can control the required temperature perfectly
if its temperature sensor is exposed to the airtemperature
This section describes the repair work that may be carried of the main area of the vehicle. In certain circumstances,
out on the Air Top 2000 ST heater after it has been this is not always possible using the temperature sensor
removed from the vehicle. Any further dismantling will integrated in the control unit due to the installation
invalidate the warranty. Only use the spare parts from the circumstances (addition of fresh air). In this case perfect
appropriate spare parts kits for assembling the heater. temperature control can be ensured using an external
temperature sensor fitted in the appropriate area.
9.1.1 Work on stripped-down components
Method
CAUTION 1. Select a suitable position for an external temperature
All sealing elements between the stripped-down sensor.
components and the seal on the exhaust outlet must
always be discarded and replaced. NOTE
• The temperature sensor should not be in the direct
9.1.1.1 Cleaning line of hot air and not close to heat sources (for
example the vehicle’s own heating system).
• Clean all stripped-down components with benzene • The sensor is to be installed at medium height in the
and then dry them with compressed air. vehicle cabin on surfaces that are as vertical as
• Remove all seal residue on the components carefully possible.
using a suitable tool. • The installation site should not be exposed to direct
sunlight.
9.1.1.2 Visual inspection • Do not install the temperature sensor behind curtains
or the like.
• Check all components for damage (cracks,
deformation, wear, etc.) and fit new ones if necessary. 2. Install the external temperature sensor and route the
• Inspect the plugs and cables for corrosion, loose cable to the control element.
contacts, crimping faults, etc. and repair them if 3. Cut off the terminating resistor connection at the
necessary. wiring harness.
• Check plug strips for signs of corrosion and contacts 4. Crimp on the plug X8 for the external temperature
to ensure they are secure. Repair them if necessary. sensor at the end of the cable.
5. Connect the plug of the external temperature sensor
at plug X8 of the wiring harness.
9.1.2 Carrying out modifications 6. Conduct a trial and check the control properties.
NOTE
The constant development of our heaters is aimed Plug X8 for external
at optimising them so as to prevent failures and temperature sensor
malfunctions.
Generally it is possible to modify heaters that are already
in use. We can supply the appropriate modification kits for
this purpose.
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
901
9 Repair Air Top 2000 ST
9.2 Dismantling and assembling CAUTION

When you fit the bottom shell (4, Fig. 901), spread it
9.2.1 Remove the casing parts slightly so that the spacers on the overheating sensor
(8, Fig. 902) are not damaged.
9.2.1.1 Cover for electrical connection
1. Expand the bottom shell (4, Fig. 901) slightly at the
side and fit it to the heater from underneath until the
The cover (1, Fig. 901) can be levered off using a blunt
securing pins on the heater engage in the holes in the
blade in the areas X .
shell.
2. Fit a new seal on the exhaust outlet.
9.2.1.2 Grates for hot air inlet and outlet
9.2.2.2 Top shell
The grates (5) can be released from the mounting by
twisting and pulling off forwards.
1. Place the top shell (2, Fig. 901) on the heater and
secure it in the grooves in the bottom shell.
9.2.1.3 Cover for hot air inlet and outlet
9.2.2.3 Cover for hot air inlet and outlet
Both covers (3 and 6, Fig. 901) can be released from their
mountings and removed by pressing the four detents at
NOTE
the top and bottom using a suitable tool.
The covers for the hot air inlet and outlet are different. Fit
the cover with the smaller opening at the front on the hot
9.2.1.4 Top shell
air blower.
NOTE
1. Push on the covers (3 and 6, Fig. 901) until the four
The covers for the hot air inlet and outlet must have been
securing holes engage properly in the detents on the
removed.
bottom and top covers.
The shell (2, Fig. 901) can be raised by pulling up.
9.2.2.4 Grates for hot air inlet and outlet
9.2.1.5 Bottom shell
1. Fit the grates (5, Fig. 901) on the covers for the hot air
inlet and outlet and twist them to secure them.
By gently pulling the bottom shell (4, Fig. 901) on both
sides in the areas Y , you can release the fixing and the
9.2.2.5 Cover for electrical connection
shell can be taken off the motor casing.
NOTE
9.2.2 Fit the casing parts The wiring harness is to be taken out of the left or rightof
the heater to suit the installation situation.
9.2.2.1 Bottom shell
1. Fit the cover (1, Fig. 901) until it audibly engages in
IMPORTANT the top cover.
To ensure that the heater and the overheating sensor
work perfectly, please note the following when fitting the
casing:
• Four insulators are used as spacers between the

heat exchanger and the casing parts.
• Slide the four insulators (8, Fig. 901) onto the four
corner ribs of the heat exchanger and position
exactly next to the rib extension.
• Check that all four insulators (8, Fig. 901) are
securely positioned.
902
.
1
1 Cover, electrical connection

2 Top shell
3 Cover, hot air outlet
4 Bottom shell
5 Grate
6 Cover, hot air inlet
7 Insulators
7
Positioning of insulators
Insulator
Extension
of corner rib
Fig. 901 Remove / Fit the casing parts
903
9.2.3 Change the control unit 9.2.4 Change the overheating sensor
9.2.3.1 Removal 9.2.4.1 Removal
1. Remove the heater (see 8.7.1.1). 1. Remove the heater (see 8.7.1.1).
2. Remove the casing parts (see 9.2.1). 2. Remove the casing parts (see 9.2.1).
3. Open the catches on the hot air blower. 3. Remove the insulators (9, Fig. 902).
4. Pull the hot air blower (1, Fig. 902) off the motor shaft 4. Disconnect the plug connector X5 on the control unit (3).
by hand.
5. Disconnect the plug connectors on the control unit (3). CAUTION
6. Remove screws (2) and the control unit (3). Do not pull the cables.
7. Complete the work on stripped-down components
(see 9.1.1). 5. Lever the overheating sensor (8) out of the ribs of the
heat exchanger (7) using a suitable tool (see detail A).
NOTE 6. Remove the overheating sensor (8).
Do not carry out any repair work to the control unit.
1. Measure the resistance of the overheating sensor
1. Place the control unit (3, Fig. 902) in the installation (8, Fig. 902) (see 6.3.3).
position and attach with screws (2). 2. Position the overheating sensor (8, Fig. 902) on the
2. Tighten the screws to 0.7 ±0.07 Nm. heat exchanger (7) and press it into place by hand.
3. Slide the hot air blower (1) onto the motor shaft until
the detent on both sides is heard to engage in the IMPORTANT
shaft groove at the stop. There must not be an electrical connection between
4. Connect the plug connectors at the sockets of the the sensor cables and the sheet metal holder.
control unit (3) as shown in Fig. 701.
5. Position the casing parts (see 9.2.2). 3. Ensure that the overheating sensor is correctly
6. Install the heater (see 8.7.1.2). positioned in the heat exchanger (7).
7. Check the CO2 setting and adjust it if necessary 4. Connect the plug connector X5 at the control unit (3).
(see 6.2). Check that the cables are routed in parallel between
8. Check that the hot air blower moves easily with your the ribs on the heat exchanger.
hand. Check for any noise when you switch it on later. 5. Push the insulators (9) on to the heat exchanger.
The sensor magnets on the hot air blower must be 6. Position the casing parts (see 9.2.2).
clear of ferrous chips, etc. 7. Install the heater (see 8.7.1.2).
904
9.2.5 Change the combustion air fan 9.2.6 Change the flame sensor
(only petrol heater)
9.2.5.1 Removal
9.2.6.1 Removal
1. Remove the heater (see 8.7.1.1).
2. Remove the casing parts (see 9.2.1). 1. Remove the heater (see 8.7.1.1).
3. Remove the control unit (see 9.2.3.1). 2. Remove the casing parts (see 9.2.1).
3. Remove the control unit (see 9.2.3.1).
NOTE 4. Remove the combustion air fan (see 9.2.5.1).
A total of 9 screw heads are visible on the combustion air 5. Remove two screws (2, Fig. 903) and take off the air
fan (5, Fig. 902). Of these the 5 outer screws are used to baffle (3).
attach the combustion air fan to the heat exchanger (7). 6. Press the cable grommet (11) on the flame sensor
Only these screws should be removed. connecting cable inwards out of the heat exchanger (9).
7. Carefully bend up the securing strap (4) and pull out
4. Remove the screws (4). the flame sensor (1) from the burner insert.
5. Remove the combustion air fan (5) from the heat 8. Remove flame sensor
exchanger (7), remove the seal (6) and dispose of it 9. Complete the work on stripped-down components
separately. (see 9.1.1).
6. Complete the work on stripped-down components
(see 9.1.1). 9.2.6.2 Installation
9.2.5.2 Installation CAUTION

Install the flame sensor cable under the fuel line.
1. Ensure that the sealing surfaces on the combustion
fan (5, Fig. 902) and on the heat exchanger (8) are not 1. Slide the flame sensor (1, Fig. 903) through under the
damaged. fuel line, insert the plug through the hole in the heat
2. Fit a new seal (7) on the flange of the combustion air exchanger (9) and press the cable grommet (11) into
fan (5). the heat exchanger (9) from inside.
3. Bring the combustion air fan (5) into the assembly 2. Insert the cable with the protective sheath through the
position and secure with screws (4), attaching the securing strap (4) and insert the flame monitor (1)
electrical bonding of the wiring harness to the motor at into the burner insert (5).
the same time. 3. Press the securing strap (4) back together.
4. Tighten the screws (4) to 6 ± 0.6 Nm. 4. Secure the air baffle (3) with screws (2).
5. Fit the control unit (see 9.2.3.2). 5. Tighten the screws (2) to 6 ± 0.6 Nm.
6. Position the casing parts (see 9.2.2). 6. Pull the cable of the flame sensor tight.
7. Install the heater (see 8.7.1.2). 7. Install the combustion air fan (see 9.2.5.2).
8. Check the CO2 setting and adjust it if necessary. 8. Fit the control unit (see 9.2.3.2).
(see 6.2). 9. Position the casing parts (see 9.2.2).
10. Install the heater (see 8.7.1.2).
905
9
Detail A
4
3
8
2
1
1 Hot air blower

2 Torx screw (3)
3 Control unit
4 Torx screw (5)
5 Combustion air fan (drive unit)
6 Seal
7 Heat exchanger
8 Overheating sensor
9 Insulator (4)
Fig. 902 Change the control unit, combustion air fan and overheating sensor
906
9.2.7 Change the glow plug 9.2.7.2 Installation
9.2.7.1 Removal 1. Fit a new seal (12, Fig. 903) into the heat exchanger
(9) and bring the combustion pipe (13) into the
1. Remove the heater (see 8.7.1.1). assembly position.
2. Remove the casing parts (see 9.2.1). 2. Check that the starting air hole in the burner insert (5)
3. Remove the control unit (see 9.2.3.1). is free.
4. Remove the combustion air fan (see 9.2.5.1). If necessary, clean with a wire, approx. 4 mm Ø
5. Press the cable grommet (10, Fig. 903) inwards out of (see Fig. 904).
the heat exchanger (9).
6. Remove four screws (2) and take off the air baffle (3). CAUTION
When installing the glow plug, make sure that the contacts
NOTE point to the heat exchanger. Otherwise there is a risk of
Check that the burner insert (5) is detached from the short-circuiting.
combustion pipe (13).
3. Introduce the glow plug (6) in the burner insert (5) and
7. Carefully remove the burner insert (5) by tilting. position the protective sheath in the slit of the burner
insert.
CAUTION
The glow plug should be removed with extreme care and CAUTION
must not be twisted under any circumstances (risk of In the following procedure make sure that the glow plug is
breakage). After lengthy operation of the burner the glow placed in the burner insert up to the stop.
plug may be fixed in place by fuel deposits. In this case
apply penetrating oil and allow to work until the glow plug 4. Secure the glow plug (6) with the screw (7). Tighten
can be removed. the screw (7) to 0.5 Nm.
5. Introduce the burner insert (5) in the heat exchanger
8. Release the screw(7), pull out the glow plug (6) from (9) . Make sure that the cable of the flame sensor (1)
the burner insert and remove. (only present with petrol heater) is positioned under
9. Remove the combustion pipe (13) and seal (12) from the fuel line.
the heat exchanger (9) and dispose of the seal 6. Guide the plug of the glow plug and the flame sensor
separately. through the holes and press the cable grommets (10)
10. Complete the work on stripped-down components into the heat exchanger.
(see 9.1.1).
CAUTION
In the following procedure make sure that the grommet (8)
seals off tight with the heat exchanger (9).
7. Secure the burner insert (5) and the air baffle (3) with
screws (2). Tighten the screws (2) to 6 ± 0.6 Nm .
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).
907
3
7
2 9
8
10
11
12
13
1 Flame sensor (only petrol heater) 8 Grommet

2 Torx screw (4) 9 Heat exchanger
3 Air baffle 10 Cable grommet
4 Securing strap 11 Cable grommet
5 Burner insert (only petrol heater)
6 Glow plug 12 Seal
7 Screw 13 Combustion pipe
Fig. 903 Change the glow plug, flame sensor, combustion insert and the heat exchanger
908
9.2.8 Change the burner insert, combustion 9.2.8.2 Installation

pipe and the heat exchanger
1. Fit a new seal (12, Fig. 903) into the heat exchanger
9.2.8.1 Removal (9) and bring the combustion pipe (13) into the
assembly position.
1. Remove the heater (see 8.7.1.1).
2. Remove the casing parts (see 9.2.1). NOTE
3. Remove the control unit (see 9.2.3.1). The burner insert (5) is only fixed in place when installing
4. Remove the overheating sensor (see 9.2.4.1). the flame sensor and glow plug.
5. Remove the combustion air fan (see 9.2.5.1).
6. Remove the flame sensor (only petrol heater) 2. Fit the glow plug (see 9.2.7.2).
(see 9.2.6.1). 3. Fit the flame sensor (only petrol heater)
7. Remove the glow plug (see 9.2.7.1). (see 9.2.6.2).
CAUTION CAUTION
In the following procedure make sure that the fuel In the following procedure make sure that the fuel
connection is not bent. connection is not bent.
8. Remove the burner insert (5, Fig. 903). 4. Introduce the burner insert (5) in the heat exchanger
9. Remove the combustion pipe (13) and seal (12) from (9). Make sure that the cable of the flame sensor is
the heat exchanger (9) and dispose of the seal (12) positioned under the fuel line.
separately. 5. Secure the burner insert (5) and the air baffle (3) with
10. Complete the work on stripped-down components screws (2).
(see 9.1.1). 6. Tighten the screws (2) to 6 ± 0.6 Nm .
7. Install the combustion air fan (see 9.2.5.2).
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).
909
Starting air hole
Fig. 904 Starting air hole in burner insert
910
Air Top 2000 ST 10 Packing / Storage / Shipment
10 Packaging/Storage/Shipping
10.1 General
If the heater or its components are sent to Webasto

Thermosysteme GmbH for testing or repair, it must be
cleaned and packed in such a way that it is protected
against damage during handling, transport and storage.
An ambient temperature of +85 °C or -40 °C must not be

exceeded for storage.
Shipment address:
Webasto AG
Abt. QGN
Speicherstraße 3/4
D-17033 Neubrandenburg
1001
10 Packing / Storage / Shipment Air Top 2000 ST
Page for notes
1002

Workshop Manual AT 2000 ST

Uploaded by

Copyright:

Available Formats

Workshop Manual AT 2000 ST

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop Manual AT 2000 ST

Uploaded by

Copyright:

Available Formats

Air heaters Workshop manual

Air Top 2000 ST

1.1 Contents and purpose ........................................................................................................................... 101

1.1.1 Using the air heaters ................................................................................................................... 101

1.2 Meaning of signal words ........................................................................................................................ 101

1.4.1 Regulations for installation in the vehicle .................................................................................... 101

1.5 Suggestions for improvements and modifications ................................................................................. 104

2.1 Drive unit................................................................................................................................................ 201

3.1 Control element ..................................................................................................................................... 301

3.8.1 Error monitor................................................................................................................................ 302

4 Technical data ................................................................................................................................................ 401

5.1 General .................................................................................................................................................. 501

6.1 General .................................................................................................................................................. 601

6.2.1 Setting the CO content ................................................................................................................ 601

6.3 Testing individual components............................................................................................................... 601

6.3.1 Resistance test on the glow plug ................................................................................................. 601

7.1 General .................................................................................................................................................. 701

8.1 General .................................................................................................................................................. 801

8.6.1 Hot air system.............................................................................................................................. 801

8.7 Removal and installation ....................................................................................................................... 808

8.7.1 Heater, removal and installation .................................................................................................. 808

8.8 Start-up .................................................................................................................................................. 808

9.1 General .................................................................................................................................................. 901

9.1.1 Work on stripped-down components ........................................................................................... 901

9.2 Dismantling and assembling.................................................................................................................. 902

9.2.1 Remove the casing parts............................................................................................................. 902

10.1 General .................................................................................................................................................1001

501 General error symptoms ............................................................................................................................. 501

701 Plug assignment ......................................................................................................................................... 701

801 Fuel supply.................................................................................................................................................. 803

901 Remove / Fit the casing parts .................................................................................................................... 903

1 Introduction 1.4 Statutory regulations and safety

NOTE 2.1. Scope

If the heater is installed in a storage area, you must

• Do not stand on the heater or place or throw any

You must read the operating manual before starting the

1.5 Suggestions for improvements and

Complaints, improvement suggestions or corrections

Phone: +49 (89) / 8 57 94 - 6 34

2 General description If a fault occurs, an error code will be output in the

– the drive unit with a combustion and hot air blower

Air Top 2000 ST air heater without casing

2.1 Drive unit

All Air Top 2000 ST heaters can also be controlled using

The fuel supply is provided from an external source using

2.2 Heat exchanger 2.4 Control unit

If a fault occurs, an error code will be output in the display

2.3 Burner insert with combustion pipe

The fuel is distributed over the burner cross-section in the

2.5 Flame sensor (only petrol heater)

Burner insert with combustion pipe

2.6 Glow plug 2.8 Metering pump

Metering pump DP 30.2/3 (with damper)

2.7 Overheating sensor

The overheating sensor measures the temperatures in the

Page for notes

3 Function description Automatic restart

If no flame is detected, the starting procedure will be

Type test permit EMC e172/24595/541085--