Webasto Air Top 2000 STC Bedienungsanleitung

Air Top Installation Guide

Air Top 2000 STC

Air Top EVO 40

Air Top EVO 55

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Webasto Air Top Installation Guide

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General Information

Webasto Thermo & Comfort Australia Pty Ltd is pleased to provide this installation guide for the Air Top 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 heating system.

Visit our website for technical documents: www.webasto.com

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.

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

validate.

Purpose of the Air Top Heater

The Webasto Air Top heaters are designed to heat the cabins of boats, trucks, minibus’, vans, motorhomes, caravans

and camper trailers.

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.

They are not designed to heat hazardous substances.

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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 air 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.

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.

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

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1 Technical Details

1.1 Heater Dimensions – Air Top 2000STC

Note: All dimensions in millimetres

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)

1.2 Heater Dimensions – Air Top EVO40/55

Note: All dimensions in millimetres

1 Heating Air Inlet

A Space Requirement for Heating Air Outlet

2 Heating Air Outlet

B Space Requirement for Heating Air Inlet

3 Combustion Air Inlet

C Space Requirement for Installation & Removal of Heater

4 Exhaust Gas Outlet

6 Cable Outlet (Optional Right or Left)

5 Fuel Inlet

Fig 3

Fig 4

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1.3 Technical Data

Model Overview Air Top 2000STC Air Top EVO 40 Air Top EVO 55

Voltage (V) 12 24 12 24 12 24

Fuel Type Diesel Diesel Diesel

Heat Output (kW)

Partial Load - Full

Load/Boost

0.9 - 2.0 1.5 – 3.5 / 4.0 1.5 – 5.0 / 5.5

Fuel Consumption (L / hr)

Partial Load - Full

Load/Boost

0.12 - 0.24 0.18 – 0.43 / 0.49 0.18 – 0.61 / 0.67

Power Consumption (W)

Partial Load - Full

Load/Boost

14 - 29 15 – 40 / 55 15 – 95 / 130

Dimensions (LxWxH mm)

Weight (kg)

311 x 120 x 121

2.6

423 x 148 x 162

5.9

423 x 148 x 162

5.9

1.4 Floor Mounting Bracket

Fig 5 - Floor bracket with 140mm OD diameter flange

50mm

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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)

2.2 Place the heater so that the bracket is facing up (Fig 8), you will now notice electrical wires bundled in the

combustion air inlet, the 2 black wires are for the fuel pump.

Fig 7

Fig 6

Fig 8 – Bracket facing upwards and notice the wires in the combustion air inlet.

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

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2.3 The combustion air inlet 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.

2.4 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.

2.5 Using the hose clamp, fix the combustion air tube to the inlet.

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

Under no circumstance should the combustion air be taken from inside the cabin area. 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 9

Fig 10 – Combustion Air Tube “V”

Fig 10a – Combustion Air Filter

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2.6 Attach the fuel line using the 10mm hose clamp & rubber fuel line connector, fix to the fuel inlet, then fix the

fuel line to the open end of the rubber connector and secure with another 10mm hose clamp. (Ref: Fig 9).

2.7 Install the stainless-steel exhaust pipe, using the exhaust clamp to the exhaust gas outlet.

The exhaust pipe temperature is above 250oC. Ensure that the end cap is properly mounted and pointing downwards

(fig 12.1). 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.

Fig 12 – The exhaust or combustion pipe must be located so

that they cannot be clogged by dirt or road debris

Fig 11 an exhaust muffler is

supplied in the kit.

Fig 12.1 – Ensure that the end cap is properly mounted

and pointing downwards on the exhaust pipe.

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3Electrical System

3.1 Main Harness – Air Top 2000STC

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 13) (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 13) (3). The main positive (red) and negative (brown)

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

the heater.

Number

Function

Fuse Holder

Red Wire (Battery Positive)

Main Plug

Brown Wire (Battery Negative)

620 Ohm Resistor

Rotary Controller (Potentiometer)

Multi-control digital

Fig 13 – Air Top 2000STC Main Harness connections

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3.2 620 Ohm Resistor – Air Top 2000STC Only

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

be connected to the 620 Ωresistor 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.

NOTE: The 620ohm resistor is does not need to be exposed as it is not the temperature sensor.

3.3 Extension Harness for Controller

Where an extension harness is required for either the rotary or digital multi-control a 1.8m or 6m standard extension

is available. Due to the plug location on the EVO 40 / 55 main harness, a 1.8m extension may be supplied in the kit.

Connect 620 Ω resistor

to wires marked

‘Temperature Sensor’

620 Ω resistor supplied

loose & in a separate pack

within the kit.

Fig 15 – 1.8m or 6m extension harness for controller

Fig 14 – Air Top 2000STC 620 Ohm connection

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