List of Contents Air Top 2000 Technica changes in this issue of the manua compared with its previous issue are identified with a vertica change bar on the efthand side of coumns.
Air Top 2000 List of Contents List of Contents 1. Introduction 1.1 Scope and Purpose... 101 1.1.1 Use of Air Heaters... 101 1.2 Meaning of Warnings, Cautions, and Notes... 101 1.3 Additiona Documentation to be used... 101 1.4 Safety Information and Reguations... 101 1.4.1 Genera Safety Notes... 101 1.5 Lega Provisions for Instaation... 102 1.6 Corrections and Improvements... 103 2. Genera Description 2.1 Combustion and Heating Air Fan... 201 2.2 Heat Exchanger... 202 2.3 Burner Insert with Combustion Tube... 202 2.4 Contro Unit / Contro Circuit Board... 202 2.5 Fame Sensor... 203 2.6 Gow Pug... 203 2.7 Temperature Limiter... 203 2.8 Dosing Pump... 203 3. Functiona Description 3.1 Functiona Description Air Top 2000 without Diagnosis (Fig. 301)... 301 3.1.1 Contro Eement... 301 3.1.2 Switch-On... 301 3.1.3 Stabiization... 301 3.1.4 Heating Operation... 301 3.1.5 Contro Operation... 302 3.1.6 Contro Ide... 302 3.1.7 Switch-Off... 302 3.1.8 Functions of the Air Heater in TRS Vehices... 302 3.1.9 Switch-Off upon Faiure... 302 3.2 Functiona Description Air Top 2000 Diagnosis... 304 3.2.1 Contro Eement... 304 3.2.2 Switch-On... 304 3.2.3 Stabiization... 304 3.2.4 Heating Operation... 305 3.2.5 Contro Operation... 305 3.2.6 Contro Ide... 305 3.2.7 Switch-Off... 305 3.2.8 Functions of the Air Heater in TRS Vehices... 305 3.2.9 Switch-Off upon Faiure... 306 4. Technica Data...401 I
List of Contents Air Top 2000 5. Troubeshooting 5.1 Genera...501 5.2 Genera Faiure Symptoms...501 5.3 Faiure Symptoms during Operation...502 5.4 Error Code Output (Air Top 2000 Diagnosis)...503 6. Functiona Tests 6.1 Genera...601 6.2 Adjustments...601 6.2.1 Adjustment of the CO2 Contents...601 6.3 Components Testing...602 7. Circuit Diagrams 6.3.1 Gow Pug Resistance Test...602 6.3.2 Fame Sensor Resistance Test...602 7.1 Genera...701 8. Servicing 8.1 Genera...801 8.2 Work on the Air Heater...801 8.3 Work on the Vehice...801 8.4 Air Heater Test Run...801 8.5 Servicing...801 8.6 Visua Inspections and Instaation Reguations...801 8.6.1 Heating Air System...801 8.6.2 Fue Suppy...802 8.6.3 Dosing Pump...804 8.6.4 Fue Fiter...804 8.6.5 Combustion Air Suppy...805 8.6.6 Exhaust Line...805 8.6.7 Combustion Air Intake and Exhaust Lines...805 8.6.8 Eectrica Connections...806 8.7 Remova and Instaation...808 8.7.1 Air Heater, Remova and Instaation...808 8.7.2 Repacement of Contro Unit...808 8.7.3 Repacement of Temperature Limiter...808 8.8 Instaation of new Contro Units...811 8.8.1 Repacement of Contro Unit Air Top 2000 (12 Vot) with Externa Temperature Sensor...811 8.8.2 Repacement of Contro Unit Air Top 2000 (24 Vot) not TRS...811 8.8.3 Repacement of Contro Unit Air Top 2000 (24 Vot) TRS...812 8.9 First Operation...812 II
Air Top 2000 List of Contents 9. Repair 9.1 Genera... 901 9.1.1 Work on Components after Disassemby... 901 9.1.2 Incorporation of Modifications... 901 9.2 Disassemby and Assemby... 902 9.2.1 Remova of Housing Components/Covers... 902 9.2.2 Repacement of Contro Unit... 904 9.2.3 Repacement of Temperature Limiter... 904 9.2.4 Repacement of Combustion Air Fan... 905 9.2.5 Repacement of Fame Sensor... 906 9.2.6 Repacement of Gow Pug... 906 9.2.7 Repacement of Burner Insert, Combustion Tube, and Heat Exchanger... 909 10. Packaging/Storage and Shipping 10.1 Genera... 1001 III
List of Figures Air Top 2000 List of Figures 301 Functiona Diagram (Air Top 2000 without Diagnosis)...303 501 Genera Faiure Symptoms...501 502 Faiure Symptoms during Operation...502 601 Adjustment of CO2 Contents...601 701 Termina Pin Assignment, Air Top 2000 Diagnosis...701 702 Termina Pin Assignment, Air Top 2000 without Diagnosis...702 703 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 12V/24V with Contro Eement...703 704 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 12V/24V with Combination Timer...704 705 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 12V/24V with Contro Eement and Standard Timer...705 706 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 24V TRS Operation with Contro Eement...706 707 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 24V TRS Operation with Combination Timer...707 708 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 24V TRS Operation with Combination Timer and 2 Auxiiary Drives...708 709 Circuit Diagram Automatic Contro Air Top 2000 without Diagnosis, 12V with Contro Eement...709 710 Circuit Diagram Automatic Contro Air Top 2000 without Diagnosis, 12V with Contro Eement and Timer...710 711 Circuit Diagram Automatic Contro Air Top 2000 without Diagnosis, 24V with Contro Eement...711 712 Circuit Diagram Automatic Contro Air Top 2000 without Diagnosis, 24V with Contro Eement and Timer...712 713 Circuit Diagram Automatic Contro Air Top 2000 without Diagnosis, 24V with Contro Eement, TRS...713 714 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 24V TRS Operation with Contro Eement in Vehices without Auxiiary Drive...714 715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not TRS!)...715 801 Fue Suppy...802 802 Webasto Fue Tank Tap...803 803 Fue Tapping from Pastic Tank (tapping via fue drain pug)...803 804 Fue Tapping from Pastic Tank (tapping via fitting pate)...803 805 Pipe/Hose Connection...804 806 Dosing Pumpe, Instaation Position and Attachment...804 807 Fue Fiter...804 808 Exhaust Muffer, Direction of Fow...805 809 Exhaust Pipe Outet, Instaation Position...805 810 Remova of Fuse Hoder Attachment Pate...806 811 Fuse Hoder, Instaation Position...806 812 Contro Eement...806 813 Puing the Pug...806 814 Exampe of an Instaation...807 815 Repacement of Contro Unit and Temperature Limiter (Air Top 2000 without Diagnosis)...809 816 Repacement of Contro Unit and Temperature Limiter (Air Top 2000 Diagnosis)...810 901 Remova of Housing Components/Covers...903 902 Repacement of Combustion Air Fan (Remova)...904 903 Repacement of Combustion Air Fan (Disassemby)...905 904 Disassemby of Heat Exchanger...907 IV
Air Top 2000 1 Introduction 1. Introduction 1.1 Scope and Purpose This repair shop manua is intended to support famiiarized personne in the repair of air heaters Air Top 2000 of the fue and Diese type as we as of Air Top 2000 Diagnosis with seria no. 30.000 and up. 1.1.1 Use of Air Heaters The air heaters Air Top 2000 and Air Top 2000 Diagnosis are used to - heat the cabin - defrost the windscreens. They are not ceared for heating a transportation compartment for dangerous goods. The heaters operate independent from the vehice engine and are connected to the fue tank and to the eectrica system of the vehice. Their use is possibe in vehices with water- or air-cooed engines. 1.2 Meaning of Warnings, Cautions and Notes WARNINGS, CAUTIONS, and S in this manua have the foowing meaning: WARNING This heading is used to highight that non-compiance with instructions or procedures may cause injuries or etha accidents to personne. CAUTION This heading is used to highight that non-compiance with instructions or procedures may cause damage to equipment. This heading is used to highight and draw specific attention to information. 1.3 Additiona Documentation to be used This workshop manua contains a information and procedures necessary for the repair of heaters Air Top 2000 and Air Top 2000 Diagnosis. The use of additiona documentation is normay not necessary. Operating instructions/instaation instructions and the vehice specific instaation proposa may be used as compementary information as necessary. 1.4 Safety Information and Reguations The genera safety reguations for the prevention of accidents and the reevant operating safety instructions have to be observed at a times."genera Safety Reguations" beyond the scope of these reguations are detaied in the foowing.the specific safety reguations appicabe to this manua are highighted in the individua chapters by Warnings, Cautions, and Notes. 1.4.1 Genera Safety Notes Within the scope of the StVZO (Road Licensing Reguations of the Federa Repubic of Germany) Design Genera Approvas, aid down by the Federa Office for Motor Traffic, exist for the Water Heater Air Top 2000 and Air Top 2000 Diagnosis with the foowing officia marks of conformity: -S 270 (Diese) -S 277 (Fue) The instaation of the heaters is to be performed in accordance with the instaation instructions and must be checked in case of a) the vehice type inspection in accordance with 20 StVZO b) the individua inspection in accordance with 21 StVZO or c) the examination in accordance with 19 StVZO performed by an officiay authorised expert or examiner for road traffic, a vehice inspector or a pubic servant as per section 7.4 a of Annex VIII to the StVZO. In the event of c) the instaation must be certified on the acceptance certificate incuded in the copy of the Genera Operating License giving detais about - manufacturer - type of vehice, and - vehice identification number. This vaidates the Design Genera Approva. The acceptance certificate must be kept with the vehice. The year of first operation must be permanenty marked on the identification abe. The heaters are ceared for heating the passenger and driver cabins but not for heating compartments intended for the transportation of dangerous goods. The use of the heater in specia vehices (e.g. vehices for the transportation of dangerous goods TRS) or vehices not subject to the StZVO (e.g. ships) are rued by partiay regiona reguations. For the instaation of the AT 2000 D in vehices used for the transportation of dangerous goods, in addition to the StVZO, the requirements in TRS 002 and TRS 003 (Technica Guideines for the Transportation of Dangerous Goods on Roads) must be met. 101
1 Introduction Air Top 2000 The heater must not be instaed in the passenger or driver compartments of busses. Shoud the heater nevertheess be instaed in such a compartment, the instaation box must be seaed tight against the vehice interior. There must be sufficient ventiation of the instaation box from the exterior in order not to exceed a maximum temperature of 40 C in the instaation box. At fiing stations and fue depots the heater must be switched off as there is a potentia danger of exposion. Where fammabe fumes or dust may buid up (e.g. in the vicinity of fue, coa, wood, cerea depots, or simiar instaations) the heater must be switched off to prevent exposions. Due to the danger of poisoning and suffocation the heater must not be operated in encosed areas such as garages or workshops without exhaust venting, not even if the start-up is activated by the timer or teestart device. When removing the heater the gasket beow must be repaced. The heat exchanger of the air heater remains serviceabe for a maximum of 10 years and must then be repaced with an origina spare part by the manufacturer or by one of its authorized workshops. The heater must then be provided with a abe marked with the saes date and with the words Origina Spare. Shoud exhaust pipes be routed through rooms accommodating persons, these pipes sha aso be renewed after 10 years. Instaations not egay authorized wi void the air heater s Officia Marks of Conformity and thus the vehice s permit of operation. The same appies for repairs performed by unskied personne and repairs with no origina spare parts. 1.5 Lega Provisions for Instaation For testing the heater in accordance with 19, 20, or 21 of the StVZO the foowing reguations are to be observed in particuar ( 22 a StVZO): Testing is performed upon presentation of the operating and instaation instructions of the manufacturer. The year of the initia operation must be duraby marked on the heater identification pate by the instaing person. Heating Air System Heating air intake openings must be arranged so that under norma operating conditions exhaust fumes of the vehice engine or air heater are not ikey to be expected. Extracting combustion air from the vehice interior is not permissibe. Combustion Air Line The combustion air required must be taken from the exterior. Within rooms accommodating persons, the combustion air ines must not have more than four disconnects and a spash-water protected exterior wa feedthrough. The disconnects must be seaed in a way not to exceed a eak rate of 200 /h at an overpressure of 0.5 mbar. The ine incuding feedthrough, disconnects, materia and specific type must be described in the instaation instructions. The ine must require toos for instaation and remova, must be protected against damage, and must be shockproof. Exhaust Line Heaters must be designed to discharge the exhaust to the exterior. Exhaust pipes must be routed so that exhaust fumes are unikey to penetrate into the vehice s interior. The function of any parts of the vehice essentia for its operation must not be impaired. Condensate or water penetrated must not be abe to accumuate in the exhaust ine. Drain hoes are permissibe; these must drain the fuid to the exterior via ines seaed against the vehice interior. The exhaust ine outet is to be positioned to the top, to the side, or in case of exhaust venting beow the vehice foor, to the nearest possibe ocation of the vehice s or cockpit s side or rear end. In compartments accommodating persons, exhaust ines must not have more than one disconnect and must have a spash-water protected feedthrough in the exterior wa/foor. For water, that has penetrated into the exhaust ine, the connection of a drain ine with a meta-seaing joint is permissibe. The drain pipe must be routed seaed through the exterior wa or the vehice foor.the heat exchanger, the exhaust ine connected, as we as the possibe drain pipe must be seaed so that with an overpressure of doube the overpressure of the exhaust having the maximum permissibe exhaust ine ength - at east however at an overpressure of 0.5 bar - a tota eak rate of 30 /h is not exceeded. The ine incuding feedthrough, disconnects, materia and specific type must be described in the instaation instructions. The ine must require toos for instaation and remova, must be protected against damage, and must be shockproof. 102
Air Top 2000 1 Introduction Meta ines must be used. These may not heat to more than 110 C shoud there be the possibiity of contact within the room interior. Protective devices against contact may be fitted. Shoud exhaust pipes be routed through rooms accommodating persons, these pipes sha be renewed after 10 years using genuine spare parts. Combustion Air Inet and Exhaust Outet During instaations these ports for combustion air entry and exhaust fume exit must be of such type, that a ba with a diameter of 16 mm cannot be inserted.eectrica ines, switch gear and contro gear of the heater must be ocated in the vehice so that their proper function cannot be impaired under norma operating conditions. 1.6 Corrections and Improvements Deficiencies, improvements, or proposas for correction of this workshop manua are to be maied to: Webasto Thermosysteme GmbH Abt. Technische Dokumentation D-82131 Stockdorf Teephone: 0 89 / 8 57 94-5 42 Teefax: 0 89 / 8 57 64 10 For the routing of fue ines and the instaation of additiona fue tanks 45 and 46 of the StVZO are to be adhered to. The most important reguations are: Fue ines are to be designed in such a way that they remain unaffected by torsiona stresses in the vehice, engine movement and the ike. They must be protected against mechanica damage. Fue-carrying parts are to be protected against excessive heat and are to be arranged so that any dripping or evaporating fue can neither accumuate nor be ignited by hot components or eectrica equipment. In busses, fue ines and fue tanks may be ocated neither in the passenger area nor in the driver s compartment. In these type of vehices the fue tanks must be ocated such that they do not pose a direct hazard to the exits in the event of a fire. Fue suppy must not be by means of gravity or pressurization of the fue tank. Instaation Rues for Webasto Fue Tanks for the Fue Suppy of Heaters in Vehices In busses the instaation is not permitted in the passenger or driver compartment. The fue fi neck must in no vehice be ocated within any of these compartments. Fue containers for carburettor fue must not be ocated immediatey behind the front paneing of the vehice. They must be sparate from the engine so that even in case of an accident the infammation of fue is unikey to be expected. This does not appy for towing vehices with an open cockpit. The operationa state of the heater, i.e. an indication on or off, must be easiy and ceary visibe. 103
Air Top 2000 2 Genera Description 2. Genera Description The air heater Air Top 2000 and Air Top 2000 Diagnosis with seria no. 30.000 and up operating to the evaporator principe basicay consist of: A mafunction in air heaters Air Top 2000 Diagnosis outputs an error code to the dispay of the combination or standard timer. When equipped with a contro eement the operating indicator fashes. In addition a heater checkout may be performed using a persona computer (refer to operating instructions PC air heater diagnosis). - combustion and heating air fan - heat exchanger - burner insert with combustion tube - contro unit Air Heater Air Top 2000 Diagnosis (covers removed) For contro and monitoring a Air Heater Air Top 2000 - contro unit/contro circuit board - fame sensor - gow pug - temperature imiter - temperature sensor 2.1 Combustion and Heating Air Fan The combustion and heating air fan deivers the air required for combustion from the combustion air inet to the burner insert. By means of the fan the heating air is aso deivered to the air outet. are ocated within the unit. 12 Vot heaters (Air Top 2000 without Diagnosis) may be controed by means of an externa temperature sensor. A heaters of air Top 2000 Diagnosis may be controed by means of an externa temperature sensor. Fue suppy is provided externay by a fue dosing pump. Combustion and Heating Air Fan Air Heater Air Top 2000 without Diagnosis (covers removed) 201
2 Genera Description Air Top 2000 2.2 Heat Exchanger The heat exchanger dissipates the heat provided by combustion to the air deivered by the combustion and heating air fan. 2.4 Contro Unit / Contro Circuit Board Air Top 2000 without Diagnosis The contro unit/contro circuit board is the centra controing unit for functiona sequencing and monitoring of the combustion operation. A temperature sensor ocated on the side is used for temperature contro. 12 Vot heaters may have the temperature sensor repaced against an externa temperature sensor. The combustion and heating air fan may be set by means of a potentiometer. Potentiometer Heat Exchanger 2.3 Burner Insert with Combustion Tube Within the burner insert fue is distributed in the combustion tube across the burner cross-section. In the combustion tube the combustion of the fue/air mixture takes pace heating up the heat exchanger. Temperature Sensor Contro Unit Air Top 2000 without Diagnosis Burner Insert Combustion Tube Air Top 2000 Diagnosis The contro unit/contro circuit board is the centra controing unit for functiona sequencing and monitoring of the combustion operation. A temperature sensor ocated on the contro unit is used for temperature contro. A heaters may have the temperature sensor repaced against an externa temperature sensor. The combustion and heating air fan may be set by means of a potentiometer. A mafunction in air heaters Air Top 2000 Diagnosis outputs an error code to the dispay of the combination or standard timer. When equipped with a contro eement the operating indicator fashes. In addition a heater checkout may be performed using a persona computer (refer to operating instructions PC air heater diagnosis). Diese 2 mm Fue 1 mm 202
Air Top 2000 2 Genera Description Potentiometer 2.7 Temperature Limiter Temperature Sensor The temperature imiter protects the air heater against excessive operating temperatures. Overheat protection is activated at temperature higher than 150 C to interrupt the eectrica circuit of the dosing pump and switch off the heater with run-down operation. After cooing down the eectrica circuit is restored. The air heater may be switched on again (see 3.9). Contro Unit Air Top 2000 Diagnosis 2.5 Fame Sensor The fame sensor is a ow-ohm PTC resistor changing its resistance dependent on its heating by the fame. The signas are routed to the contro unit for processing. The fame sensor monitors the fame operating condition over the compete duration of heater operation. 2.8 Dosing Pump Temperature Limiter The dosing pump is a combined suppy, dosing and shutoff system for the fue suppy of the heater out of the vehice s fue tank. Fame Sensor Dosing Pump DP 2 for Fue and Diese operated Heaters 2.6 Gow Pug The gow pug ignites the fue/air mixture at the start of the air heater operation. The gow pug is acting as an eectrica resistor and is ocated in the burner insert opposed to the fame side. Dosing Pump DP 30 for Diese operated Heaters Gow Pug 203
Air Top 2000 3 Functiona Description 3. Functiona Description 3.1 Functiona Description Air Top 2000 without Diagnosis (Fig. 301) 3.1.1 Contro Eement The contro eement is used to switch the air heater on and off, set the desired room temperature (air intake temperature between 10 C and 45 C), and to unock a faiure interrupt condition. The green LED indication is used to indicate the operating condition (LED permanenty on) and an overheat condition (LED fashes). After appication of power upon switch-on of the battery switch and seecting the contro eement ON, the contro unit enters the error ockout condition. Prior to a reactivation the contro eement has to be paced to OFF. 3.1.2 Switch-On The contro eement is set to the desired room temperature. When switching the air heater on, the operating indicator is iuminated and the gow pug is activated (cyced). The motor of the combustion and heating air fan starts high-speed operation for 1 second (breakaway moment) and is then under sow-down contro. Shoud the temperature of the intake air be above the seected, rated temperature, ony the motor of the combustion and heating air fan wi operate (contro ide). Start operation wi be initiated with a heating air temperature beow the rated temperature. After approx. 20 seconds (for fue operated heaters after approx. 15 seconds) the fue dosing pump is activated. After another 25 seconds the speed of the combustion and heating air fan is continuousy increased to a higher rate and combustion begins. As soon as a fame is detected, combustion wi be stabiized (see 3.1.3). Shoud no norma combustion be achieved within 120 seconds (for fue operated heaters after approx. 115 seconds), the speed of the combustion and heating air fan is increased for approx. 30 sec and there wi be an automatic repeat start with the gow pug activated and fue dosing pump deactivated (no fue suppy). Shoud the no-combustion-condition persist, after another 80 seconds (for fue operated heaters after approx. 85 seconds) there wi be a switch-off by error ockout (see 3.1.9) with a run-down of the combustion and heating air fan asting 120 seconds at 2/3 of its max. speed. 3.1.3 Stabiization Diese Operated Heaters With the gow pug activated the operating speed of the combustion and heating air fan is increased. After another 20 seconds the speed of the combustion and heating air fan is continuousy increased within 17 seconds to fu oad for fu heat. A fame-out during the speed rise contro period causes a repeat start. Fue Operated Heaters With the gow pug activated the operating speed of the combustion and heating air fan is continuousy increased within 4 seconds to fu oad for fu heat. A fame-out during the speed rise contro period causes a repeat start. 3.1.4 Heating Operation During operation the combustion exhaust gasses fow through the heat exchanger charging its was with combustion heat, which in turn is taken up by the heating air deivered by the heating air fan to be routed to the vehice interior. The temperature of the heating air sucked in is measured by means of a temperature sensor fitted to the air intake side of the air heater or in case of 12 Vot heaters aso by means of an externay ocated temperature sensor. A temperature beow the one set with the contro eement increases the heater performance up to maximum heat. In order to extend the burner ide period of Diese operated heaters during permanent operation with a heating performance in excess of 1.2 kw, the fue dosing pump deivery rate is reduced every 30 minutes for 20 seconds. A heating performance ess than 1.2 kw causes the fue deivery to the dosing pump to be interrupted every 30 minutes for 4 seconds. For both types of heaters (fue and Diese) heating operation is shorty interrupted every 9 hours ike in contro ide. After reaching the temperature set with the contro eement, heating performance is controed to decrease. The speed of the combustion and heating air fan sows down and the fue deivery rate to the pump is reduced. When exceeding the air intake temperature set with the contro eement during minimum heating performance, the dosing pump is deactivated after 5 seconds and combustion terminates. The contro unit/air heater reacts to new settings of the contro eement with a time deay. 301
3 Functiona Description Air Top 2000 3.1.5 Contro Operation During contro operation fan speed and dosing pump rate of deivery are subject to heating performance. The gow pug is deactivated. 3.1.6 Contro Ide In case the air intake temperature set with the contro eement is exceeded and the minimum heating performance had been achieved for onger than 5 seconds, the fue suppy is cut off to terminate combustion. The motor of the combustion and heating air fan continues operation for another 155 seconds at 2/3 of maximum speed to coo down the air heater (run-down). In contro ide the combustion and heating air fan runs at minimum speed. The operation indication remains it. After reaching the air intake temperature set with the contro eement a new start procedure is aunched (without break-away). 3.1.7 Switch-Off Switching the heater off extinguishes the operation indication of the contro eement. If no fue has been deivered (within 20 seconds for Diese operated heaters or within 15 seconds for fue operated heaters after switch-on) or if the air heater is in contro ide, the air heater is deactivated immediatey without run-down. If fue suppy has commenced it wi be immediatey stopped at switch-off. The fan speed decreases within 35 seconds to 2/3 of maximum. Subsequenty or if the fame sensor detects no fame the fan speed is increased to maximum for 60 seconds and run-down is initiated to ast 120 seconds. Run-down is automaticay hated. Re-activation of the heater during run-down is permitted. Run-down wi be competed first with a subsequent restart. 3.1.8 Functions of the Air Heater in TRS Vehices Appicabe ony for Air Top 2000 D Air Heaters instaed in vehices for the transportation of dangerous goods (TRS). If the heater is deactivated using the contro eement, run-down wi not change. A short run-down (max. 40 seconds) is automaticay activated if: the vehice engine is turned off a conveyor faciity is put into operation The short run-down time depends on the operationa condition at which TRS switch-off occurs. A 40 second run-down with maximum speed is initiated (TRS switch-off) when: air heater is sti in the start phase; stabiization not yet achieved air heater is in norma run-down air heater is in contro ide. A 20 second run-down is switched on in norma combustion operation with the fue deivery immediatey hated maintaining the fan speed for 5 seconds. Then the speed is increased for 30 seconds within another 5 seconds. For a heaters after Juy 1995 the short run-down out of a operating conditions is a max. of 20 seconds. After a TRS switch-off the contro unit is in the error ockout condition. Prior to resuming operation the contro eement has to be set to OFF. 3.1.9 Switch-off upon Faiure The contro unit recognises faiures of individua air heater components and mafunctions in the start sequence and in norma operation. The air heater is deactivated and enters the error ockout mode under the foowing conditions: fame sensor resistance out of toerance gow pug/gow pug trigger defective fan speed too ow, short circuit or open circuit error in dosing pump eectrica circuit or of overheat protection (in start phase ony) ow votage beow 10 Vot and in excess of 20 seconds for 12 Vot heaters ow votage beow 20 Vot and in excess of 20 temperature sensor resistance out of toerance seconds for 24 Vot heaters contro unit defective In case of overheating there wi be no fue suppy. A rundown ike after manua switch-off wi be performed. After run-down the contro unit is in the error ockout mode. Overheating is indicated by the operation indication fashing. For error unock the air heater has to be switched off momentariy to be switched on again. 302
Air Top 2000 3 Functiona Description 1 2 On A 0 1 3 4 5 6 7 8 9 10 B C 0 1 D 100% 90% 60% 30% 0 E 1,3 Hz 1,0 Hz 0,8 Hz 0,6 Hz 0 F 0 1 0 20 45 65 85 102 typica seconds (20) (60) (120) Fig. 301 Functiona Diagram (Air Top 2000 without Diagnosis) 1 Start 2 Contro Operation 3 Rated Vaue reached 4 Rated Vaue exceeded (e.g. due to reduced heat sumption) 5 Run-down 6 Contro Ide A = Contro Eement B = Temperature Sensor C = Gow Pug D = Combustion and Heating Air Fan E = Dosing Pump F = Fame Sensor 7 Start 8 Contro Operation (increased heat consumption) 9 Switch-off 10 Run-down 303
3 Functiona Description Air Top 2000 3.2 Functiona Description Air Top 2000 Diagnosis 3.2.1 Contro Eement The contro eement is used to switch the air heater on and off, set the desired room temperature (air intake temperature between 10 C and 45 C), and to unock a faiure interrupt condition. The green LED indication is used to indicate the operating condition (LED permanenty on) and an overheat condition (LED fashes). TRS Operation: After appication of power upon switch-on of the battery switch and seecting the contro eement ON, the contro unit enters the error ockout condition. Prior to a reactivation the contro eement has to be paced to OFF. 3.2.2 Switch-On The contro eement is set to the desired room temperature. When switching the air heater on, the operating indicator is iuminated and the gow pug is activated (cyced). The motor of the combustion and heating air fan starts high-speed operation for 1 second (breakaway moment) and is then under sow-down contro to approx. 30% (Diese) or 50% (fue) of fu speed. Shoud the temperature of the intake air be above the seected, rated temperature, ony the motor of the combustion and heating air fan wi operate (contro ide). Start operation wi be initiated with a heating air temperature beow the rated temperature. The fame sensor function is checked. If the fame sensor at this time aready signas fame, there wi be a 120 second run-down and an error ockout of the contro unit. A mafunction of any other component monitored causes an error ockout without run-down. After approx. 20 seconds (for fue operated heaters after approx. 15 seconds) the fue dosing pump is activated. After another 25 seconds the speed of the combustion and heating air fan is continuousy increased to a higher rate and combustion begins. As soon as a fame is detected, combustion wi be stabiized (see 3.2.3). Shoud no proper combustion deveop within 120 seconds (for fue-operated within 115 seconds) the combustion and heating air fan speed is increased to fu oad for approx. 30 seconds (15 seconds for fue-operated heaters) with the gow pug on and the dosing pump off (no fue deivery) with a subsequent automatic restart. Shoud the no-combustion-condition persist, after another 80 seconds (for fue operated heaters after approx. 85 seconds) there wi be a switch-off by error ockout (see 3.2.9) with a run-down of the combustion and heating air fan asting 120 seconds at 2/3 of its max. speed. 2. Start (automatic restart) Fan speed is again reduced to approx. 30% (for fue operated heaters to approx. 50%) and fue is deivered. During the next 20 seconds fan speed is increased to approx. 60% (for fue-operated heaters to approx. 75%) of fu speed. As soon as a fame is detected within the next 55 seconds, combustion wi be stabiized. Shoud there be no fame condition after a tota fue deivery period of 180 seconds, fue deivery wi be stopped and the gow pug deactivated. The combustion air fan continues fu oad operation for another 120 seconds (run-down) and the heater enters the error ockout condition. 3.2.3 Stabiization Diese Operated Heaters With the gow pug activated the operating speed of the combustion and heating air fan is increased. After another 20 seconds the speed of the combustion and heating air fan is continuousy increased within 17 seconds to fu oad for fu heat. This operating condition is omitted if the set temperature (contro ide) has aready been achieved once. The gow pug is deactivated and heating operation commences. A fame-out during speed up contro causes a restart, 5 restarts an error ockout of the heater. Fue Operated Heaters With the gow pug activated the operating speed of the combustion and heating air fan is continuousy increased within 4 seconds to fu oad for fu heat. This operating condition wi be omitted if the start occurs after a contro ide period. The gow pug is deactivated and heating operation commences. A fame-out during speed up contro causes a restart, 5 restarts an error ockout of the heater. Shoud no norma combustion be achieved within 120 seconds (for fue operated heaters after approx. 115 seconds), the speed of the combustion and heating air fan is increased for approx. 30 sec and there wi be an automatic repeat start with the gow pug activated and fue dosing pump deactivated (no fue suppy). 304
Air Top 2000 3 Functiona Description 3.2.4 Heating Operation During operation the combustion exhaust gasses fow through the heat exchanger charging its was with combustion heat, which in turn is taken up by the heating air deivered by the heating air fan to be routed to the vehice interior. The temperature of the heating air sucked in is measured by means of a temperature sensor fitted to the air intake side of the air heater or by means of an externay ocated temperature sensor. A temperature beow the one set with the contro eement increases the heater performance up to maximum heat. In order to extend the burner ide period of Diese operated heaters during permanent operation with a heating performance in excess of 1.1 kw, the fue dosing pump deivery rate is reduced every 15 minutes for 20 seconds. A heating performance ess than 1.1 kw causes the fue deivery to the dosing pump to be interrupted every 30 minutes for 4 seconds. Additionay heating operation is briefy suspended every 9 hours ike in contro ide. For Diese-operated heaters this is ony appicabe, if at this time heating performance is ess than 1.1 kw. 3.2.5 Contro Operation During contro operation fan speed and dosing pump rate of deivery are subject to heating performance. The gow pug is deactivated. 3.2.6 Contro Ide After reaching the temperature set with the contro eement, heating performance is controed to decrease. The speed of the combustion and heating air fan sows down and the fue deivery rate to the dosing pump is reduced. When exceeding the air intake temperature set with the contro eement during minimum heating performance, the dosing pump is deactivated after 5 seconds and combustion terminates. Fan speed remains constant for 35 seconds and is then increased to approx. 60% of fu speed for cooing the heater down. the fan then continues to operate at approx. 30% of fu speed unti temperature is beow the temperature set with the contro eement. If temperature fas beow the one set with the contro eement, the heater wi restart (without break away). New settings on the contro eement are executed by the contro unit/heater with a time deay. 3.2.7 Switch-Off Switching the heater off extinguishes the operation indication of the contro eement. If no fue has been deivered or if the air heater is in contro ide, the air heater is deactivated immediatey without run-down. If fue suppy has commenced it wi be immediatey stopped at switch-off. Fan speed remains constant and then decreases within 30 seconds to approx. 60% of fu speed. After this or with the fame sensor detecting no fame, fan speed rises to maximum speed for 60 seconds and run down for 120 seconds is initiated. Rundown is at approx. 60% of fu speed and is deactivated automaticay. Re-activation of the heater during run-down is permitted. Run-down wi be competed first with a subsequent restart. 3.2.8 Functions of the Air Heater in TRS Vehices Appicabe ony for Air Top 2000 D Air Heaters instaed in vehices for the transportation of dangerous goods (TRS). If the heater is deactivated using the contro eement, run-down wi not change. A short run-down (max. 20 seconds) is automaticay activated if: the vehice engine is turned off a conveyor faciity is put into operation The short run-down time depends on the operationa condition at which TRS switch-off occurs. A 15 second run-down with maximum speed is initiated (TRS switch-off) when: air heater is sti in the start phase; stabiization not yet achieved air heater is in norma run-down air heater is in contro ide. A 20 second run-down is switched on in norma combustion operation and in stabiization with the fue deivery immediatey hated maintaining the fan speed for 5 seconds. Then the speed is increased to maximum for 15 seconds within for a run-down. After a TRS switch-off the contro unit is in the error ockout condition. Prior to resuming operation the contro eement has to be set to OFF. 305
3 Functiona Description Air Top 2000 3.2.9 Switch-off upon Faiure The contro unit recognises faiures of individua air heater components and mafunctions in the start sequence and in norma operation. The air heater is deactivated and enters the error ockout mode under the foowing conditions: fame sensor open or short circuit temperature sensor open or short circuit gow pug open or short circuit fan motor open or short circuit or fan speed wrong dosing pump open or short circuit overheating ow votage beow 10 Vot or high votage above 15 Vot in excess of 20 seconds for 12 Vot heaters ow votage beow 20 Vot or high votage above 30 Vot in excess of 20 seconds for 24 Vot heaters A switch-off ike in switch-off wi be performed. In case of overheating there wi be no fue suppy. After run-down the contro unit is in the error ockout mode. The operation indication outputs a fash code. For error unock the air heater has to be switched off momentariy (at east 2 seconds) to be switched on 306
Air Top 2000 4 Technica Data 4. Technica Data As ong as no threshod vaues are given, the foowing technica data are understood to incude toerances of ±10% usua for heaters at an ambient temperature of +20 C and at nomina votage and conditions. Eectrica Components: Contro unit, combustion air fan, dosing pump, timer*, gow pug and contro eement are for 12 or 24 Vots operation. The components temperature imiter and fame detector are independent of votage. *not for TRS Air Heater Operation AT 2000 B AT 2000 D Mark of conformity ~ S 277 ~ S 270 Heater type Air heater with evaporator burner Heat fow Contro range 1.1 2.0 kw 0.9 2.0 kw Type of fue Fue Diese/Fue oi (EL) Fue consumption Contro range 0.1.. 0.2 kg/h (0.16..0.27 /h) 0.1.. 0.21 kg/h (0.12.. 0.24 /h) Nomina votage 12 Vot 12 Vot 24 Vot Operation votage 10 15 Vot 10 15 Vot 20 30 Vot Rated power consumption Contro range 9...22 W Permitted ambient temp.: Heater: - operation - storage Dosing pump: - operation - storage Contro eement: - operation - storage Voume fow of heating air against 0.5 bar CO 2 in exhaust (perm. functiona range) Contro range Max. Max. 9.5 10.5-40 +40 C -40 +85 C -40 +20 C -40 +85 C -40 +75 C -40 +85 C Permitted combustion air intake temperature -40... +20 C Setting range for indoor temperature +10... +45 C 70 m 3 /h 9.5 12.0 Dimensions air heater Weight, heater Length 322 ± 2 mm Width 130 ± 1 mm Height 122 ± 1 mm 2.6 kg 401
Air Top 2000 5 Troubeshooting 5. Troubeshooting 5.1 Genera This section describes troubeshooting procedures for the Air Heater Air Top 2000 and Air Top 2000 Diagnosis. A mafunction in air heaters Air Top 2000 Diagnosis outputs an error code to the dispay of the combination or standard timer. When equipped with a contro eement the operating indicator fashes. In addition a heater checkout may be performed using a persona computer (refer to operating instructions PC air heater diagnosis). CAUTION Troubeshooting requires profound knowedge about structure and theory of operation of heater components and may ony be performed by skied personne. In cases of doubt refer to Sections 2 or 3 for functiona interreations. Ony for TRS operation After a TRS switch-off or power appication by vehice main power switch operation and the contro eement to ON, the contro unit wi be in error ockout. Prior to reactivation the contro eement must be set to OFF or the instant heat switch on the combination or standard timer be operated. CAUTION Troubeshooting is normay imited to the isoation of defective components. The foowing causes for troube are not considered and shoud aways be checked for to excude them as cause for troube: corrosion on connector oose contact on connector wrong crimping on connector corrosion on eectrica wiring and fuses corrosion on battery terminas If individua components are checked, the contro unit eectrica connections must be disconnected. After any correction of a faiure a functiona test has to be performed in the vehice. 5.2 Genera Faiure Symptoms The foowing tabe (Fig. 501) ists the possibe faiure symptoms. Faiure Symptom Probabe Cause Remedy Air heater switches No combustion after start or repeat Switch off heater momentariy and off automaticay start switch on once again Fame extinguishes during operation Heater overheats Operation indication fashes Vehice eectrica system votage too ow Switch off heater momentariy and switch on once again Check heat air ducting for obstructions, aow heater to coo down, switch off heater momentariy and switch on once again Charge battery Switch off heater momentariy and switch on once again Heater expes back fumes Combustion air and/or Check combustion and exhaust exhaust ducting bocked ducting for obstructions Fig. 501 Genera Faiure Symptoms 501
5 Troubeshooting Air Top 2000 5.3 Faiure Symptoms during Operation The foowing tabe (Fig. 502) ists the possibe faiure symptoms as they might occur during the functiona sequence of operation. In case of mafunction the faiure is to be isoated and removed using this tabe. It is important to accuratey identify the faiure symptom. Shoud the faiure symptom not be contained in this tabe or the troube not be detected under the specific faiure symptom isted, in emergencies assistance by our service technicians may be requested (Te. 089 / 8 57 94-512). Overheating and dosing pump faiure are aways indicated additionay after run-down by the fashing LED of the contro eement. In a cases of troube aso a defective contro unit may be the cause shoud a other components turn out to be serviceabe. Faiure Symptom No start and no iumination of LED on contro eement No start but LED iuminates Very ow speed with no start shows after...s immediatey immediatey immediatey Possibe Causes Wrong cabing, defective fuse Fan or contro unit defective or fan bocked Contro ide operation: wrong manua contro (seected temperature is beow air intake temperature)or wrong integration (excessive air intake temperature) Motor operates momentariy 1 and then stops Stoppage without run-down 5 Run-down after 1 Run-down after 20 Run-down after 120 and dosing pump does not cyce Run-down after 40 to 120 Run-down after 230 Gow pug or fame sensor short or open circuit or contro unit defective Fan motor obstructed, binding Fame detection erroneous Votage to contro unit too ow Cabing to dosing pump, pump itsef or overheat protection defective Intermittent disconnect of connection to dosing pump or to overheat protection No fame: wrong fue suppy quantity, defective or sow fan, coked burner (in particuar piot fame outet bore), combustion air/exhaust ducting obstructed or heat exchanger coked, dosing pump seized Run-down Stoppage without run-down Interruption of dosing pump cycing and max. speed for 30 sec with subsequent re-start during combustion operation during combustion operation during combustion operation Overheating or votage too ow or component error (fame sensor, gow pug, overheat sensor, dosing pump, burner) or no fue suppy or obstructed combustion air/exhaust ducting Fan motor faiure or seizure Fame-out by gas bubbes in fue deivery or strong wind against exhaust outet or defective no-fame detection Fig. 502 Faiure Symptoms during Operation 502
Air Top 2000 5 Troubeshooting 5.4 Error Code Output (Air Top 2000 Diagnosis) When equipped with a combination or standard timer a mafunction wi cause an error code output to the dispay of the timer for indication. When equipped with a contro eement the error code output is indicated by fashing of the operating indicator/error code indication. The number of fash puses corresponds to the number indicated in the tabe beow. After a quick puse train there wi aways be an error code output. Error code output on dispay of combination or standard timer F 01 No start (after 2 attempts) F 02 Fame out (at east >5) F 03 Votage too ow or too high F 04 Premature fame detection F 05 Fame sensor open or short circuit F 06 Temperature sensor open or short circuit F 07 Dosing pump open or short circuit F 08 Fan motor open or short circuit or wrong speed F 09 Gow pug open or short circuit F 10 Overheating 503
Air Top 2000 6 Functiona Tests 6. Functiona Tests 6.1 Genera This section describes the on-vehice and off-vehice testing of the air heater to check its proper operation. WARNING The air heater sha not be operated in encosed areas ike garages or workshops not provided with exhaust venting faciities. 6.2 Adjustments 6.2.1 Adjustment of the CO 2 Contents 6.2.1.1 Genera The CO2 contents of the exhaust is adjusted with the potentiometer on the contro circuit board.the air heater is preset by the manufacturer with respect to the combustion and heating air fan fitted. After adjustment by the manufacturer the potentiometer is in center position (Fig. 601). After an inadvertent oss of this position it is sufficient to restore its origina position. The manufacturer setting may be corrected by rotating the potentiometer. A suitabe too ike a sma screw driver (2.5 mm tip) is to be used. CAUTION Set potentiometer sowy; observe end positions. Adjustment may be performed at any eectrica system votage. Cockwise rotation increases the fan speed and decreases the CO 2 contents. Countercockwise rotation decreases the fan speed and increases the CO2 contents. If the setting range is not sufficient (e.g. after repacement of the combustion and heating air fan) the manufacturer s setting may be canceed according to the procedure described in the foowing. 6.2.1.2 New Basic Setting CAUTION The manufacturer s setting cannot be restored. 1. Withdraw cover from upper she according to 9.2.1.1. 2. Switch on air heater. 3. Rotate potentiometer two times and with no interrupt through its compete setting range (e.g. max. - min.- max.). 4. Adjust desired CO 2 contents (Fig. 601). 5. Switch off air heater. 6. Pug on cover and secure. CO 2 + CO 2 + Air Top 2000 Diagnosis Air Top 2000 without Diagnosis Fig. 601 Adjustment of CO2 Contents 601
6 Functiona Tests Air Top 2000 6.3 Components Testing CAUTION During eectrica testing aways ensure that the contro unit and the component under test are eectricay disconnected from each other. 6.3.1 Gow Pug Resistance Test During eectrica testing of the gow pug using a digita mutimeter, the foowing readings shoud be obtained: Gow pug 12 Vot (red) 24 Vot (green) Resistance at 25 C: 0.324... 0.360 Ω 1.3... 1.44 Ω Test current: < 5 ma < 5 ma 6.3.2 Fame Sensor Resistance Test During eectrica testing of the fame sensor using a digita mutimeter, the foowing readings shoud be obtained: Cod test: Resistance at 25 C: Test current: 2.6... 3.4 Ω < 5 ma Hot test: Resistance at 800-1000 C: 12... 15 Ω (ceramic rod red hot over a ength of approx. 20 mm) Test current: < 5 ma 602
Air Top 2000 7 Circuit Diagrams 7. Circuit Diagrams 7.1 Genera The air heater Air Top 2000 Diagnosis may be operated using the contro eement (rated vaue transmitter/switch) or with the contro eement and a combination or standard timer. The circuit diagrams (Figs. 703 to 708 and 714) show the possibe circuits 12 or 24 Vot with contro eement combination timer contro eement and standard timer contro eement for TRS combination timer for TRS TRS operation for vehices without auxiiary drive The air heater Air Top 2000 without Diagnosis may be operated using the contro eement (rated vaue transmitter/switch) or with the contro eement and a timer. The circuit diagrams (Figs. 709 to 713) show the possibe circuits 12 or 24 Vot with contro eement contro eement and timer contro eement for TRS Fig. 702 shows the termina pin assignment. Fig. 701 shows the termina pin assignment. X1 X2 X3 X4 X5 vioet back brown yeow bue X1 X2 X3 X4 X5 = Connection, Combustion and Heating Air Fan = Connection, Dosing Pump = Connection, Fame Sensor = Connection, Gow Pug = Connection, Temperature Limiter Fig. 701 Termina Pin Assignment, Air Top 2000 Diagnosis 701
7 Circuit Diagrams Air Top 2000 X1 X2 X3 X4 X5 vioet back brown yeow bue X1 X2 X3 X4 X5 = Connection, Combustion and Heating Air Fan = Connection, Dosing Pump = Connection, Fame Sensor = Connection, Gow Pug = Connection, Temperature Limiter Fig. 702 Termina Pin Assignment, Air Top 2000 without Diagnosis 702
Air Top 2000 7 Circuit Diagrams 2 Item Nomencature Remark A1 Air Heater Air Top 2000 A2 Contro Unit B1 Fame Sensor B2 Temperature Sensor B3 Temperature Limiter E Gow Pug F2 Fuse 24V 10A/12V 15A Fat Fuse SAE J 1284 H1 LED green (in item S1) Operation indication M Motor S1 Contro Eement Rated Vaue Setting Switch X1-X5 Connection 2-poe of item A2 X6 Connection 8-poe of item A2 X7 Connection 4-poe of item S X8 Connection 2-poe X9 Connection 2-poe of item A2 X11 Connection 6-poe of item A2 X12 Connection 1-poe Diagnosis (K-wire) Y1 Dosing Pump 2 b br ge gn gr or rt sw vi ws Wire Gauges < 7.5 m 7.5-15 m 0.75 mm 2 1.0 mm 2 2.5 mm 2 4.0 mm 2 Wire Coours bue brown yeow green grey orange red back vioet white 2.5 mm 2 4.0 mm 2 6.0 mm 2 Connection X11/2 and X11/3 for TRS function ony Fig. 703 Circuit Diagram Automatic Contro Air Top 2000 Diagnosis, 12V/24V with Contro Eement 703