Escolar Documentos
Profissional Documentos
Cultura Documentos
Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
TABLE OF CONTENTS
Contents
Page
1. Introduction
1.1
1.2
1.3
1.4
1.5
2. General Description
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Burner Insert with Combustion Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flame Sensor (Gasoline Heaters Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ceramic Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overheating Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Functional Description
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4. Technical Data
13
5. Troubleshooting
15
5.1
5.2
5.3
5.4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Error Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Error Symptoms during Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Error Code Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Functional Tests
21
6.1
6.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.1 Setting the CO2 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Testing Individual Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.1 Ceramic Glow Pin Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.2 Resistance Test on Flame Sensor (gasoline heaters only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.3 Overheating Sensor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. Circuit Diagrams
7.1
23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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TABLE OF CONTENTS
8. Servicing Work
27
8.1
8.2
8.3
8.4
8.5
8.6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Work on the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Work on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Heater Trial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Servicing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Visual Inspections and Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.1 Hot Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.2 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6.2.1 Fuel Extractor (Standpipe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6.2.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3.1 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3.2 Installation and Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.4 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.5 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.6 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.7 Combustion Air Inlet and Exhaust Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.1 Heater Connection, Control Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.2 Supply Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.3 Control Element (Rheostat) Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
9. Repair
35
9.1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1 Work on Stripped-down Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.2 Remove the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.1.2.1 Installation of an External Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.2 Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1 Remove the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.1 Cover for Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.2 Grates for Hot Air Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.3 Cover for Hot Air Inlet and Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.4 Top Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.5 Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2 Fit the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.1 Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.2 Top Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.3 Cover for Hot Air Inlet and Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.4 Grates for Hot Air Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.5 Cover for Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.3 Changing the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.2.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.2.3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
II
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9.2.5
9.2.6
9.2.7
9.2.8
TABLE OF CONTENTS
10.Product Information
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45
III
INTRODUCTION
1. INTRODUCTION
1.3
1.1
1.1.1
1.4
ADDITIONAL DOCUMENTATION
1.4.1
1.2
393.77 Heaters
1.4.2
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INTRODUCTION
The Air Top 2000ST air heaters are prepared for interior
installation and sealing directly on the cabin floor or a
cabin wall. Non-release connections must be used in the
interior for combustion air and exhaust pipes with the
accessories available from Webasto.
All pipes that come into contact with fuel must have
sealed connections, they must not be damaged in
any way and the must be checked at regular intervals
(at least the same intervals as for inspection of the
vehicle as a whole).
Overheating
Keep hot air inlet and hot air outlet free of dirt and other
items. Dirty, blocked air lines can cause the heater to
shut down due to overheating.
After an overheating lock-out, check that the air system
is clear, remove any materials that may block the air flow
and have any damage to the air lines repaired by an
2
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INTRODUCTION
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.
1.5
Phone: 810.593.6000
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Fax:
810.593.6001
GENERAL DESCRIPTION
2. GENERAL DESCRIPTION
The Air Top 2000 ST air heater is based on the evaporator
principle and essentially consists of the following:
the drive unit with a combustion and hot air blower
the heat exchanger
the burner insert with combustion pipe
the control unit
Figure 2:
2.1
DRIVE UNIT
Figure 1:
The removable hot air blower transports the hot air from
the hot air inlet via the heat exchanger to the hot air
outlet.
Figure 3:
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Drive Unit
GENERAL DESCRIPTION
2.2
HEAT EXCHANGER
2.4
CONTROL UNIT
Internal
temperature sensor
Wiring
harness
Component
plug sockets
Figure 4:
Heat Exchanger
Figure 6:
2.3
Control Unit
2.5
Combustion
pipe
Burner insert
Figure 5:
Figure 7:
Flame Sensor
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GENERAL DESCRIPTION
2.7
OVERHEATING SENSOR
Figure 9:
Figure 8:
Overheating Sensor
2.8
Figure 10:
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FUNCTIONAL DESCRIPTION
3. FUNCTIONAL DESCRIPTION
3.1
Automatic Restart
If no flame is detected, the starting procedure will be
repeated. The glow plug will be switched on again
(cycled). The motor for the hot and combustion air
blower will be set to approx. 25% of its maximum speed.
3.2
SWITCH ON
3.3
Start
When the heater is switched on, the ON signal light will
be lit and the glow plug will be switched on (cycled). The
motor for the hot and combustion air blower will be set
to approx. 50% of its maximum speed.
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HEATING MODE
3.4
CONTROL MODE
FUNCTIONAL DESCRIPTION
3.5
CONTROL PAUSE
3.7
FAULT LOCK-OUT
3.6
SWITCH OFF
To reset the fault, switch the heater off briefly (at least
2 seconds) and then on again.
10
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FUNCTIONAL DESCRIPTION
ERROR MONITOR
3.7.2
Fault lock-out:
Permanent heater
fault lock-out:
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11
TECHNICAL DATA
4. TECHNICAL DATA
Electrical components:
The Air Top 2000 ST D heater is also licensed for use with
PME (bio-diesel), which complies with ASTM D6751 and
DIN EN 14214.
Operation
EMC
Heater
AT 2000 ST D
e1*72/245*95/54*1085*-e1*2001/56*0022*--
Model
Heat Output
kW
Btu/h
Control Range
Fuel
Fuel Consumption
AT 2000 ST B
l/h
gal/h US
Control Range
Rated Voltage
Operating Voltage Range
1.0 - 2.0 kW
3415 - 6830
0.9 - 2.0 kW
3074 - 6830
Gasoline
0.14...0.27
0.037...0.071
0.12...0.24
0.032...0.063
12 V
V
10.5 - 16 V
Control Range
12 V
24 V
10.5 - 16 V
21 - 32 V
14 - 29 Watts
Control Range
1 kW
2 kW
5.0... 8.0
9.0... 12.5
Heater Dimensions
Length X Width X Height
5.0... 8.0
9.0... 12.5
Weight Of Heater
13
TROUBLESHOOTING
5. TROUBLESHOOTING
5.1
GENERAL
Corrosion on plugs
5.2
Error Symptom
Possible Cause
Remedy
Heater overheats
ON indicator flashes
Charge battery
Switch heater off and then on again
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15
TROUBLESHOOTING
5.3
Error Symptom
Occurrence
Remedy
Immediate
Immediate
16
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TROUBLESHOOTING
Error
Code
Error (group)
Remedy
F 00
No start
F 02
Flame failure
F 03
Under-voltage or
over-voltage
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17
TROUBLESHOOTING
Error
Code
Error (group)
F 04
Premature flame
recognition
F 05
Flame sensor
interrupt or short
circuit
(gasoline heaters
only)
F 06
F 07
F 08
External
14 Temperature sensor circuit
temperature sensor Short circuit to earth
break or short circuit
94 Temperature sensor circuit break or
short circuit to +Ub
Metering pump
interrupt or short
circuit
Remedy
8A Glow pin:
Break or short circuit to +Ub
or short-circuit
19 Glow circuit
The switched cable of the element has a
short circuit to earth
18
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Error
Code
Error (group)
F 10
Overheating
TROUBLESHOOTING
F 11
F 12
Overheating sensor
interrupt or short
circuit
Heater fault
lock-out
Remedy
Find and remove the cause of the
overheating
NOTE
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 14
Overheating sensor
incorrect position
F 15
Nominal sensor
break
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19
FUNCTIONAL TESTS
6. FUNCTIONAL TESTS
6.1
GENERAL
NOTE: The heater will now run in normal
mode again and can be switched off as normal
using the control element. The heater is set at
the factory to match the fitted combustion air
blower.
6.2
6.2.1
6.3
SETTINGS
6.3.1
Glow plug:
12 V (red)
24 V (green)
Resistance at 25 C (77 F):
0.263 ... 0.323 Ohm 1.125 ...1.375 Ohm
Test current:
< 5 mA
< 5 mA
6.3.2
Diesel Unit:
Cold Testing:
Hot Testing:
Resistance at 800 1000 C:
Resistance at 1472 1832 F:
Test current:
Gasoline Unit
12 ... 15 Ohm
12 ... 15 Ohm
< 5 mA
21
FUNCTIONAL TESTS
6.3.3
Resistance in Ohm
10 C = 50 F
12 C = 53.6 F
2260
2240
2220
2200
2180
2160
2140
2120
2100
2080
2060
14 C = 57.2 F
16 C = 60.8 F
18 C = 64.4 F
20 C = 68 F
22 C = 71.6 F
10 12 14 16 18 20 22 24 26 28 30
50 53.6 57.2 60.8 64.4 68 71.6 75.2 78.8 82.4 86
24 C = 75.2 F
Temperature in C
Temperature in F
26 C = 78.8 F
28 C = 82.4 F
30 C = 86 F
22
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CIRCUIT DIAGRAMS
7. CIRCUIT DIAGRAMS
7.1
GENERAL
The circuit diagrams (Fig. 12 and Fig. 13) show the
possible circuits for 12 and 24 V with:
Control element
Combination timer
X6
X2
X4
X5
X1
X3
Figure 11:
Plug Assignment
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23
CIRCUIT DIAGRAMS
S6
14
0,5mm2
br
15
2 X11
0,5mm2
gn/ws
0,5mm2
rt
X6
F1
1
6
X9
1
2
3
16
10
0,5mm2 bl
11
0,5mm2 ws
17
X6
B2
X1
br
1 2
2
1
ge X2 ge br X5 br
M1
B1
X8
X8
X6
X4
0,5mm2
sw/bl
0,5mm2
ge
br
1 2
bl X3 bl
B3
X10
br
br
A1
1
12V rt
24V gn
H1
12
0,5mm2 sw
0,5mm2
sw
13
0,5mm2 rt
bl
A2
0,5mm2
sw
S1
R1
1
S3
*To use vent mode, connect to ground through a switch (S3) for proper operation.
If ventilation mode is not desired, leave pink wire disconnected and protect from grounding.
No heating operation with pink wire grounded!
BATTERY
X1
X2/X3/X4/X5
2
1
X6
X8
2
1
X9
X10
1 2
X11
Y1
B4
2
GROUND
1
2
3
4
5
Diagnostic K cable
W bus
CO2 setting
Input pin (pin 16/plug X6), cable color on wiring harness: pink):
Ventilation (fan speed depends on the position of the control element)
If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4).
Item
Designation
Comment
A1
A2
B1
B2
B3
B4
E
F1
F2
H1
H3
Heater
Control unit
Flame sensor
Temperature sensor
Overheating sensor
Temperature sensor
Ceramic glow pin
Fuse 15A (max. 20A)
Fuse max. 15 A
LED, green (in item S1)
LED, red
H4
H5
M1
P
Figure 12:
< 7.5 m
0.75 mm 2
7.5 15 m
1.0 mm 2
2
0.75 mm 2 1.0 mm
1.0 mm 2 1.5 mm 2
1.5 mm 2 2.5 mm 2
2.5 mm 2 4.0 mm 2
4.0 mm 2 6.0 mm 2
Standard cable
Item
Designation
R1
Resistor 620
S1
S4
S6
X1
X2
X3
X4
X5
X6
X8
X9
X10
X11
X12
Y1
Cable Cross-sections
Cable Colors
bl
br
ge
gn
gr
or
rt
sw
vi
ws
Blue
Brown
Yellow
Green
Grey
Orange
Red
Black
Violet
White
Comment
24
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CIRCUIT DIAGRAMS
30
15
58
H5
H3
15
1
6
A2
0,5mm 13
2
rt
0,5mm 12
8
sw
0,5mm 10
6
bl
3
16
X6
B2
X12
1
12V rt
24V gn
A1
3
2
1 2
2
1
ge X2 ge br X5 br
br br
X1
M1
B1
X6
X4
2
bl X3 bl
B3
X10
br
br
X8
0,5mm
sw
bl
0,5mm
sw
0,5mm
sw/bl
0,5mm
ge
12
17
0,5mm ws 11
R1
2
X8
S3
H4
14
2 X11
0,5mm
gn/ws
X6
11
0,5mm
br
10
S6
rt
F1
F2
0,5mm
OPTIONAL
6 7
Y1
3
4
5
Item
Designation
Comment
A1
A2
B1
B2
B3
B4
E
F1
F2
H1
H3
Heater
Control unit
Flame sensor
Temperature sensor
Overheating sensor
Temperature sensor
Ceramic glow pin
Fuse 15A (max. 20A)
Fuse max. 15 A
LED, green (in item S1)
LED, red
H4
H5
M1
P
Figure 13:
Cable Cross-sections
< 7.5 m
0.75 mm 2
7.5 15 m
1.0 mm 2
2
0.75 mm 2 1.0 mm
1.0 mm 2 1.5 mm 2
1.5 mm 2 2.5 mm 2
2.5 mm 2 4.0 mm 2
4.0 mm 2 6.0 mm 2
Standard cable
Item
Designation
R1
Resistor 620
S1
S4
S6
X1
X2
X3
X4
X5
X6
X8
X9
X10
X11
X12
Y1
X6
X8
2
1
X10
1 2
X11
X12
Diagnostic K cable
W bus
CO2 setting
Input pin (pin 16/plug X6), cable color on wiring harness: pink):
Ventilation (fan speed depends on the position of the control element)
If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4).
GROUND
X2/X3/X4/X5
B4
X1
*To use vent mode, connect to ground through a switch (S3) for proper operation.
If ventilation mode is not desired, leave pink wire disconnected and protect from grounding.
No heating operation with pink wire grounded!
BATTERY
IGNITION
LIGHTS
12
Cable Colors
bl
br
ge
gn
gr
or
rt
sw
vi
ws
Blue
Brown
Yellow
Green
Grey
Orange
Red
Black
Violet
White
Comment
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25
CIRCUIT DIAGRAMS
Black
Battery Positive
or Ignition Signal (10)
Red
Battery Positive (11)
12V
24V
Brown
Battery Negative (12, 4)
1
2
3
4
5
7
6
8
0
9
11
1
12
Figure 14:
Adapter Harness
P/N 9008440A
26
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SERVICING WORK
8. SERVICING WORK
8.1
Check the hot air inlet and outlet for dirt and foreign
bodies. (Dirty or blocked hot air lines may cause
overheating.)
8.2
GENERAL
8.6
8.3
8.6.1
HEATER TRIAL
WARNING: The heater must not be
operated in enclosed areas such as garages
and workshops without an emissions
extraction system, even if the heater is
equipped with a timer.
8.5
SERVICING WORK
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8.4
SERVICING WORK
If a filter is used for the hot air, it must have the following
properties:
8.6.2
If the fuel pump is located inside the tank, fuel can only
be extracted from the return line using a Webasto fuel
tee fitting in which case it must be ensured that the
return line continues almost to the bottom of the tank. If
this is not the case, a Webasto fuel standpipe
(see Fig. 16, 17 or 18) may be used.
If the fuel pump is installed outside the tank, the fuel
connection may also be made between the tank and the
fuel pump, again using only the Webasto fuel tee fitting.
Vehicles with Carburetor Engines
The fuel may only be extracted on cars using a special
Webasto fuel tee fitting as close to the tank as possible.
The connection may be made in either the supply or
return line, in which case the return line must lead almost
to the base of the tank. If this is not the case, the return
line may be extended.
FUEL SUPPLY
The fuel tee must be fitted in such a way that any air or
gas bubbles are automatically discharged towards the
tank.
The fuel tee should not be located near the engine, as
gas bubbles may form in the lines on account of heat
radiated from the engine. This may cause problems
during combustion.
28
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SERVICING WORK
Plastic tank
I1
i2mm
I 1 + I 2 10 m (32.8 ft.)
I 1 1.2 m (3.9 ft.)
I 2 8.8 m (28.8 ft.)
Figure 15:
Sealing ring
i2mm
I2
S
I1
Figure 17:
Fuel supply
Sealing ring
Hole pattern
Max. depth
25 mm (1 in.)
Figure 18:
Figure 16:
SERVICING WORK
0-90
0
Figure 20:
Correct
Clamp
Wrong
Figure 19:
8.6.3
8.6.4
Bubble
0-90
Bubble
FUEL FILTER
Pipe/Hose connections
0 - 90
5
Figure 21:
30
Fuel filter
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SERVICING WORK
22 mm (7/8 in)
22 mm (7/8 in)
8.6.6
EXHAUST LINE
6.5
10
Figure 22:
10
Exhaust muffler
8.6.7
Total bends:
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31
max. 270
Exhaust line:
max. 270
SERVICING WORK
8.6.8
ELECTRICAL CONNECTIONS
Figure 25:
AT 2000 ST
F = 15A (12V)
F = 10A (24V)
Figure 24:
Figure 26:
32
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SERVICING WORK
Control element
Heater
Metering pump and damper
Fuel filter (accessory)
1
2
3
4
5
6
7
3 4
Tank connector
Exhaust muffler
Fuse
Figure 27:
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33
SERVICING WORK
8.7
8.8
8.7.1
START-UP
After you have installed the heater, bleed the fuel supply
system carefully.
NOTE: As a result of the low fuel consumption
the heater must be switched on several times to
fill the fuel line.
8.7.1.1 REMOVAL
1. Disconnect the battery.
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 (63 + 9 lb-in).
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).
34
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REPAIR
9. REPAIR
9.1
GENERAL
General
The heater can control the required temperature
perfectly if its temperature sensor is exposed to the air of
the main area of the vehicle. In certain circumstances,
this is not always possible using the temperature sensor
integrated in the control unit due to the installation
circumstances (addition of fresh air). In this case proper
temperature control can be ensured using an external
temperature sensor fitted in the appropriate area.
9.1.1
Method
9.1.1.1 CLEANING
9.1.2
Figure 28:
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35
REPAIR
9.2
9.2.1
Slide the four insulators (8, Fig. 29) onto the four
corner ribs of the heat exchanger and position
exactly next to the rib extension.
sides in the areas Y , you can release the fixing and the
shell can be taken off the motor casing.
Fit the grates (5, Fig. 29) on the covers for the hot air
inlet and outlet and twist them to secure them.
36
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REPAIR
1
2
3
5
6
4
5
1
2
3
4
5
6
7
7
Positioning of insulators
Insulator
Extension of
corner rib
Figure 29:
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37
REPAIR
9.2.3
9.2.3.1 REMOVAL
9.2.4.2 INSTALLATION
4. Pull the hot air blower (1, Fig. 30) off the motor
shaft by hand.
9.2.3.2 INSTALLATION
1. Place the control unit (3, Fig. 30) in the installation
position and attach with screws (2).
3. Slide the hot air blower (1) onto the motor shaft
until the detente on both sides is heard to engage in
the shaft groove at the stop.
9.2.5
9.2.5.1 REMOVAL
9.2.4
9.2.4.1 REMOVAL
9.2.4.1 Removal
9.2.5.2 INSTALLATION
38
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REPAIR
9.2.6.2 INSTALLATION
1. Slide the flame sensor (1, Fig. 31) through under the
fuel line, insert the plug through the hole in the
heat exchanger (9) and press the cable grommet
(11) into the heat exchanger (9) from inside.
9.2.6
9.2.6.1 REMOVAL
5. Remove two screws (2, Fig. 31) and take off the air
baffle (3).
6. Press the cable grommet (11) on the flame sensor
connecting cable inwards out of the heat exchanger
(9).
7. Carefully bend up the securing strap (4) and pull out
the flame sensor (1) from the burner insert.
8. Remove flame sensor
9. Complete the work on stripped-down components
(see 9.1.1).
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39
REPAIR
Detail A
7
6
5
4
3
2
1
2
3
4
5
6
7
8
9
Figure 30:
Changing the Control Unit, Combustion Air Fan and Overheating Sensor
40
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REPAIR
9.2.7.2 INSTALLATION
1. Fit a new seal (12, Fig. 31) into the heat exchanger
(9) and bring the combustion pipe (13) into the
assembly position.
9.2.7.1 REMOVAL
1. Remove the heater (see 8.7.1.1).
4. Secure the glow plug (6) with the screw (7). Tighten
the screw (7) to 0.5 Nm (4.4 lb-in).
5. Introduce the burner insert (5) in the heat
exchanger (9). Make sure that the cable of the
flame sensor (1) (only present with petrol heater) is
positioned under the fuel line.
8. Release the screw (7), pull out the glow plug (6)
from the burner insert and remove.
7. Secure the burner insert (5) and the air baffle (3)
with screws (2). Tighten the screws (2) to
6 0.6 Nm (53 .5 lb-in).
8. Install the combustion air fan (see 9.2.5.2).
9. Fit the control unit (see 9.2.3.2).
10. Position the casing parts (see 9.2.2).
11. Install the heater (see 8.7.1.2).
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41
REPAIR
6
5
4
3
7
2
8
1
10
11
12
13
1
2
3
4
5
6
7
Figure 31:
8
9
10
11
12
13
Grommet
Heat exchanger
Cable grommet
Cable grommet (gasoline heaters only)
Seal
Combustion pipe
Changing the glow plug, flame sensor, combustion insert and the heat exchanger
42
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REPAIR
9.2.8.2 INSTALLATION
1. Fit a new seal (12, Fig. 31) into the heat exchanger
(9) and bring the combustion pipe (13) into the
assembly position.
9.2.8.1 REMOVAL
1. Remove the heater (see 8.7.1.1).
5. Secure the burner insert (5) and the air baffle (3)
with screws (2).
6. Tighten the screws (2) to 6 0.6 Nm (53 .5 lb-in).
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43
REPAIR
Figure 32:
44
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PRODUCT INFORMATION
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45
WARRANTY COVERAGE
WARRANTY
AND
LIMITATIONS
Webasto Product North America, Inc. (herein after referred to Webasto) warrants their heaters
and heater kits against defects in material and workmanship for two (2) years effective at the time
of installationor vehicle registration date for Original Equipment installations (OE). This warranty
period may not exceed three (3) years from the original date of sale by Webasto. This warranty
period may be superseded by a contractual agreement.*
*Warranty coverage for Marine and Off-road applications containing DBW series heaters and the
CSL Cargo Heaters are limited to a maximum of 3,000 hours of usage. All other models are
limited to 2,000 maximum hours.
Replacement parts are covered for six (6) months or the remainder of the original warranty period,
which ever is longer. Replacement heaters are considered a Replacement Part.
The intent of the Webasto warranty is to protect the end-user heater from such defects and provide
free repair and replacement of defective parts in the manner provided herein. During the warranty
period the exclusive remedy will be for Webasto, at their discretion, to repair or replace those parts
which are demonstrated to be defective in material or workmanship.
While warranty is provided to the "end-user", it is to be administered and serviced through an
authorized Webasto dealer in accordance with the Webasto warranty policy or contractual
agreement between Webasto and a second party.
Limitations: Webasto specifically excludes and limits from warranty the following:
Normal wear of service parts: (fuel nozzles, filters and overheat fuses are not covered).
Removal and replacement of heater (with the exception of the Thermo Top C).
Damage to product in transit. All claims must be filed with carrier.
Improper installation, which is not in accordance with valid, supplied installation instructions or
approved OEM applications.
Deterioration due to normal wear, corrosion, abuse, damage, accident, improper storage or
operation.
Modification of product by alteration, use of non-genuine parts or repair by unauthorized
personnel.
Economic loss for expenses related to travel, vehicle disability, personal injury or other
incidental or consequential damages arising from any breach of this expressed warranty.
Owner's Responsibilities:
1) Service heater at the start of each season by an authorized Webasto dealer (Service parts
including; fuel nozzles, filters and overheat fuses are not covered under warranty).
2) A Warranty Registration Card is included with the sale of each heater. It is the owner's
responsibility to complete this card and return it to Webasto for registration. A proof of
purchase is required for all heaters that are not registered.
This warranty gives you specific legal rights and you may also have other rights which vary by State or Province
THE WARRANTY DESCRIBED IN THIS POLICY SHALL BE IN LIEU OF ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
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47
Rev. 02/2012
P/N LIT9010439B
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