Webasto AT2000STC User manual

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AirTopInstallationGuide‐AT2000STC

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WebastoAirTopInstallationGuide–AT2000STC

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2

AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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GeneralInformation

WebastoThermo&ComfortAustraliaPtyLtdispleasedtoprovidethisinstallationguidefortheAirTop2000STC

heatingsystem.Whenusedaccordingtotheguidelinesstatedinthisbooklet,youshouldexpectmanyyearsof

trouble‐free,enjoyableoperation.

Thisinstallationguiderepresentsourlatestefforttoproducethebesttechnicaldocumentationpossible.Inour

effortstowardcontinuous,ongoingproductimprovement,wealsoencourageourcustomerstoprovidefeedback

concerningthisguideandtheAirTop2000STCheatingsystem.

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Visitourwebsitefortechnicaldocuments:www.webasto.com/au

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 

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ThisWebastoDieselHeatercomeswitha2yearwarranty.

Failuretofollowtheseinstallationinstructionsandthenotescontainedthereinwillleadtoallwarrantybeingrefusedby

WebastoThermo&ComfortAustraliaLtdPty.Thesameappliesiftherepairsarecarriedoutincorrectlyorwithuseofparts

otherthangenuineWebastoserviceparts.Thiswillresultinthevoidingofallwarranty.Allserviceandrepairshavetobecarried

outbyauthorisedWebastoservicedealers.

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

PurposeoftheAirTopHeater

TheWebastoAirTop2000STCairheatersaredesignedtoheatthecabinsofboats,trucks,minibus’,vans,

motorhomes,caravansandcampertrailers.

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Theairheatersoperateindependentlyoftheengineandareconnectedtoeitherthevehicle’sownfueltankorviaa

separatefueltankandtheelectricalsystemofthevehicle.

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Theyarenotdesignedtoheathazardoussubstances.

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WebastoAirTopInstallationGuide–AT2000STC

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3AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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Pre‐InstallationConsiderations

1) Locationandorientationoftheheater.

Theheatermaybefittedtotheinteriororexteriorofthevehicle.Ifitisinstalledexternally,ensurethattheheaterisfittedin

apositionwhereitisprotectedfromwateranddustingress.

2) Lengthofhotairoutletducting–theshorter,thebetter.Ensurethatthehotairoutletisnotdirectedtowardsor

incontactwiththehumanbody,asthehotairtemperaturecanrangefrom80‐120oC.

3) Returnvent‐insomecaseswherethereisenoughaircirculationinandaroundtheheater,ductingmaynotbe

requiredtothereturnairvent.Whereitisrequired,keepductingtoaminimum.

4) Locationofthecontroller,electricalwiring,fuseandbatteryconnections.

5) Locationofthefuelpumpandfuelfilter.

6) Locationoftheexhaustsystem.Ensurethattheexhaustisnotfacingdirectionoftravel.

7) Locationofthecombustionairsystems.

8) Fuelpick‐upoptions–12LWebastofueltankorstandpipe.

9) Electrical‐ensuretousethesuppliedfusesinthekitandbatterypositiveandnegativeconnecteddirectlytothe

housebattery.

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Tips

Looselyattachtheheaterwiththemountingbracketandplaceitinyourdesiredlocationtopredeterminetheheater

orientation,ductinglayout,airflow,wiring,controllerandgeneralclearanceforeasyaccessibilityandforfuture

serviceandrepair.

SerialNumberLabelling

Ensurethattheserialnumberlabelsareattachedonthetoporthesideoftheheaterincasetheheaterismounted

againstawallandtheoriginallabelmaybeinaccessible.Additionallabelsaresuppliedinthekitandoneshouldgo

ontheinstallationmanualenvelopetohandovertothecustomeratthetimeofcommissioning.

    

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TheSerialNumberlabelontheAT2000STCwillstillstateAT2000ST.Thisistoavoidthenecessityofapplyingfora

newECtypeapproval.TheheaterwillstillbeanAT2000STCbasedonthemanufacturedateandserialnumber.

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Note:Incaseofwarrantysituations,theserialnumberwillberequestedbyWebastooranauthoriseddealerto

validate.

Fig1–Serialnumberlabels–Heater Fig2

–

SerialnumberlabelwrittenasFabrNr.

WebastoAirTopInstallationGuide–AT2000STC

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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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1Heater&FloorMountingBracketDimensions

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Note:All

dimensionsin

millimetres

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1HeatingAirInlet5FuelInlet

2HeatingAirOutlet6SpaceRequirementforHeatingAirInlet

3CombustionAirInlet7SpaceRequirementforInstallation&RemovalofHeater

4ExhaustGasOutlet8CableOutlet(OptionalRightorLeft)

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FloorMountingBracket

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Fig3

Fig4

50mm

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WebastoAirTopInstallationGuide–AT2000STC

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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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2StepbyStepInstallation

1. Aftercheckingwhatisunderthefloortoensureclearanceoftanks,chassisrailsetc.,Drillthe140mmfloor

mountbracketcutout.

2. Assemblyoftheheater

2.1 Assembletheheatertothebracketwiththerubbergasketusingthe10mmnutsandwasherssuppliedinthe

kit.

(Rubbergasketmustbeappliedtoavoidanyheatdistributionthroughthevehiclefloor)

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 

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2.2 Placetheheatersothebracketisfacingup(Fig7),youwillnownoticeelectricalwiresbundledinthe

combustionairinlet(Fig3)(3),these2blackwiresareforthefuelpump.





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

Fig6

Fig5

7

–

Bracket

acin

u

wardsandnoticethewiresinthecombustionairinlet.

Thesealgasketmustbereplacedeachtimetheheaterisremovedandreinstalled.

WebastoAirTopInstallationGuide–AT2000STC

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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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2.4 Thecombustionairinlet(Fig3)(3)hasaslottoaccommodatethewires,ensurethefuelpumpwiressit

neatlyinthisslot.Neverrunthewiresthroughthecombustionairinlettubeasitwillcreateairrestrictions.

 

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2.5 Attachingcombustionairtube.Amatchingslotneedstobecutinoneendofthecombustionairtubeto

accommodatethefuelpumpwires.

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  

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2.6 Usingthe25mmhoseclamp,fixthecombustionairtubetotheinlet(Fig3)(3).

Note:Ensurethatthehoseclamp&fuelpumpwiresarenotrubbing.

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Undernocircumstancemaythecombustionairbetakenfromareasoccupiedbypeople.Thecombustionairintake

openingmustnotpointinthedirectionoftravel.Itmustbelocatedsothatitcannotbecomecloggedwithdirtor

roaddebris.

Thecombustionairmustbeextractedusingacombustionairtubesuppliedinthekitandprotectedfromdustand

wateringress.

Fig8

Fig9

–

CombustionAirTube“V”cut.Fig9a–CombustionAirFilter

WebastoAirTopInstallationGuide–AT2000STC

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AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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2.7 Attachthefuellineusingthe10mmhoseclamp&rubberfuellineconnector,fixtothefuelinlet(Fig3)(5),

thenfixthefuellinetotheopenendoftherubberconnectorandsecurewithanother10mmhoseclamp.

(Ref:Fig8).

2.8 Installthestainlesssteelexhaustpipe,usingthe25mmexhaustclamptotheexhaustgasoutlet(Fig3)(5).

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Theexhaustpipetemperatureisabove250

C.Ensurethattheendcapisproperlymountedandpointingdownwards

(fig11.1).Theexhaustmustnotpointinthedirectionoftravel.Theexhaustmustbesecuredandawayfromheat

sensitivecomponents,vehiclefuellinesandharnesses.Webastocansupplyexhaustlaggingifrequired

.

   

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

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

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Fig11–Theexhaustorcombustionpipemustbelocatedsothatthey

cannotbecloggedbydirtorroaddebris

Fig10anexhaustmuffleris

suppliedinthekit.

Fig11.1–Ensurethattheendcapisproperlymounted

andpointingdownwardsontheexhaustpipe.

WebastoAirTopInstallationGuide–AT2000STC

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8

AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.

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3ElectricalSystem

3.1MainHarness

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Donotcutorextendthecontrollerwiringharness.Thiswillvoidthewarranty.Ifanextensionisrequiredforthe

controlelementplug(Fig12)(X9),anextensionharnessisavailablefromWebasto.

Weonlyrecommendextendingthebatterypositive(red)andnegative(brown)wires.Correctwiresizeof6mmtobe

usedtoavoidanycurrentorvoltagedropinthecircuit.

Ensurethatthemainplugisproperly“home”intheECU(Fig12)(3).Themainpositive(red)andnegative(brown)

hastobedirectlyconnectedtothehousebatteryandNOTviaamasterswitchtoensurecorrectshutdowncycleof

theheater.



NumberFunction

1FuseHolder

2RedWire(BatteryPositive)

3MainPlug

4BrownWire(BatteryNegative)

5620OhmResistor

6RotaryController(Potentiometer)

7 Multi‐controldigital

Fig12

–

AT2000STCMainHarnessconnections

WebastoAirTopInstallationGuide–AT2000STC



9

AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.



Pleasenote–Theblackwirewithbluestripes,withtheminispadeterminals‐labelledas‘temperaturesensor’,must

beconnectedtothe620Ωresistorwhichissuppliedinthekit.Polaritydoesnotmatter.Iftheresistorisnot

connectedwhenusingthemulti‐controllertheerrorcodeF94willappear.Otherwise,ifusingthedialcontrollerand

theresistorisnotconnectedtheerrorcodeF06willoccur.







TheAirTop2000STCrequires72‐85watts,6‐7ampsduringstart‐up.Themainpowerconnectionhastobemadeatacircuit

designedtosustainthisloadwithoutanyvoltageorcurrentdraw.Cigarlightersocketsorauxiliaryoutputsforanyother

electronicaccessoriesarenotconsideredadequateforthepowersupplyfortheheater.

Ifanybatterymanagementsystemisused,pleasecontactaWebastoauthoriseddealertoensurecorrectshutdowncycleis

maintainedandpreventcarbonbuildup.

Fig13–Fuseholderandfusessuppliedinthe

kit.



F1=20AforHeater‐12VHeater

F1=15AforHeater‐24VHeater

F2=1AforMulti‐Controller

3.1A620OhmResistor

Connect620Ωresistor

towiresmarked

‘TemperatureSensor’

620Ωresistorsupplied

loose&inaseparatepack

withinthekit.

WebastoAirTopInstallationGuide–AT2000STC



10

AirTop2000STCInstallationGuide2020|WebastoThermo&ComfortAustraliaPtyLtd.



3.1FuelpumpWiring

A7mfuelpumpharness(Fig14)issuppliedinthekittoconnecttothefuelpump.Blueandbrown,twincore

harnessconnectstothetwoblackwiresoutofthecombustionairinlet(Fig3)(3).PolaritydoesNOTmatter.

Plugkitsaresupplied;spadeterminalsorstandardautomotiveelectricalconnectionscanbeused.

Note:Neverrunthewiresthroughthecombustionairinlettube,asitwillcreateairrestrictions.Ref:Section

2–(2.4&2.5)



  



3.2InstallationofControlElement

  



Installthecontrolelementinaconvenientlocation.Thecontrolelementdoesnotmeasuretemperature.The

monitoringoftemperatureisregisteredviaareturnairtemperaturesensorlocatedinsidetheheater.







Fig14–Fuelpumpwiringharness

Fig17–RotaryController‐connectsto

plug(Fig10)(X9)

Fig16–MultiController–

completewithmountingkit

Fig15

–

Wiringtothefuelpump

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