Webasto AT2000STC Air Top Heating System Installation Guide

Webasto AT2000STC Air Top Heating System

General Information

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 the use of parts other than genuine Webasto service parts. This will result in the voiding of warranty. All service and repairs have to be carried out by authorized Webasto service dealers.

Purpose of the Air Top Heater

The Webasto Air Top 2000STC air heaters are designed to heat the cabins of boats, trucks, minibuses, 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.

Webasto Air Top Installation Guide – AT2000STC

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.

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

• DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices.

IMPORTANT:

• 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 warranties. All service and repairs have to be carried out by authorized Webasto service dealers.

Purpose of the Air Top Heater

• The Webasto Air Top 2000STC air heaters are designed to heat the cabins of boats, trucks, minibusses, 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.

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 80-120˚C.

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 the 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 of 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.

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

Heater & Floor Mounting Bracket Dimensions

1. Heating Air Inlet
2. Heating Air Outlet
3. Combustion Air Inlet
4. Exhaust Gas Outlet
5. Fuel Inlet
6. Space Requirement for Heating Air Inlet
7. Space Requirement for Installation & Removal of Heater 8 Cable Outlet (Optional Right or Left)

Floor Mounting Bracket

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

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)

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

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.

The combustion air inlet (Fig 3) (3) has a slot to accommodate the wires, ensuring 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.
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.

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.

IMPORTANT

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

IMPORTANT: The exhaust pipe temperature is above 250oC. 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.

Electrical System

Main Harness

Number Function

• 1 Diagnostic Plug
• 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

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) have to be directly connected to the house battery and NOT via a master switch to ensure the correct shutdown cycle of the heater.

620 Ohm Resistor

Please note – The black wire with blue stripes, with the mini spade terminals – labeled 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 authorized dealer to ensure the correct shutdown cycle is maintained and prevent carbon build-up.

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)

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.

Fuel Systems

For caravans, Webasto can supply a 12L plastic fuel tank with a sight level gauge and a quick connection for the fuel line. With Motorhomes, fuel can be sourced out of the vehicle’s own fuel tank via a fuel pick-up supplied with the kit.

Note: When sourcing fuel from the vehicle’s fuel tank, do not cut into the return or supply line for two reasons:

1. Latest model vehicles have highly pressurized fuel systems.
2. If you perform any modifications to the vehicle, you may void the vehicle warranty. Ensure that the clamps are tight on the fuel filter and the fuel pump and follow the direction of the flow as shown by arrows on the fuel filter and the fuel pump for correct operation. The fuel lines can be protected in conduit and cable ties to secure; these are not supplied in the kit.

Installation – Fuel Pump
Ensure that the fuel pump is installed with the clamp, 90-degree elbow, and the rubber mounting bracket supplied in the kit. This will reduce resonation through the vehicle. (Fig 20)

Installation of Fuel Stand Pipe
When fuel is sourced out of the vehicle’s fuel tank, ensure that the stand pipe is installed on a flat surface and cut the stand pipe length so that it is 25mm from the bottom of the tank. See Fig 21/22.

Install the tank extracting device as shown Fig 21
Shorten the immersion tube; the end should be approx. 25 mm off the bottom of the tank. Cut the tube diagonally and ensure you deburr the cut edges. (Fig21)
Drill a 25mm hole on the flat surface of the tank (Fig 22). Ensure you grease the drill bit and drilling surface or apply masking tape beforehand (to catch small drilling chips or swarf entering the fuel tank).
Install the fuel pick-up and tighten the locking nut (the seal should be slightly compressed; applying any locking glue will be advisable).

Fuel Filter
To ensure a clean combustion process, a fuel filter is supplied. Always check the direction of flow as marked on the filter (Fig 23). The filter should be installed between the fuel source and the fuel pump.

Do not substitute the Webasto-supplied fuel filter with non Webasto replacement.

Fuel Line
Only the supplied Fuel Line should be used for the fuel delivery to the heater. Use of any other fuel line will result in a malfunction of the heater and will void the warranty. To ensure correct connections, rubber hose connectors, 10 mm hose clamps, and fuel lines are supplied in the kit.

In case you are not able to use the stand pipe shown Fig 21 (Top mount type), Webasto can supply another option (Fig 24 bottom mount type).
On some motor-home vehicle chassis’ an additional factory fuel spigot may be available at the fuel sender unit, Webasto can supply a connection kit (Fig 25) to suit therefore eliminating the need for a stand-pipe or pick-up.

Ducting Layouts

Sample One Outlet layout

Sample Twin Outlet Layout

Ensure that the hot air and return air outlets are at least 1m away from each other or located in different directions to avoid any short cycle. Any short cycle in the system will affect the performance of the heater.

Enclosing the heater

1. Ensure that the area around the heater is not jam packed while using the compartment as storage as the heater itself and any ducting will get hot (70-80oC).
2. The heater can be boxed but it is recommended to have some breathing holes or grills on the enclosure to allow airflow in and around the heater.
3. The ducting has to be secured and ensure it cannot be crushed.
4. Ensure the ducting connections are properly secured by the clamps supplied in the kit.
5. In cases where no return air duct has been applied, ensure you install the 60mm open grill to the return (heating) air side of the heater as supplied in the kit.

DANGER: At no point should a hot vent be located or directed towards a person or areas where people are sitting. The hot air outlet temperature can be between 80o-120oC.
The heat SHOULD BE directed away from all body parts.

Starting the Heater for the First Time

1. Ensure all ducting is connected and secured.
2. Ensure all fuel connections and clamps are connected and secured.
3. Ensure sufficient fuel is available from your fuel source.
4. Ensure that the battery connections are connected and secured.
5. Ensure the supplied fuse has been installed. (Check amperage).
6. Turn the heater to 100% or MAX.
7. Ensure you bleed the fuel system. (See Fuel line bleeding tip).
8. It will take at least 5 mins before you will experience hot air out of the hot air vents.
9. Leave the heater running for at least an hour.

Start-up Sequence
The glow plug and the combustion air fan start the operation and combustion process (the audible combustion sound of the combustion air fan and the ticking of the fuel pump will be noticeable). The fuel will be delivered and the combustion air fan speed will accelerate and provide hot air.

Switching Off
When heating is no longer required, switch the heater off by means of the controller on the heater. Never turn the heater off by the main power supply.
The combustion will be extinguished, followed by a shutdown cooling cycle.

Fuel Line Bleeding Tip

• Turn the heater on with the start-up sequence and the process of the fuel pump will operate. During this operation fuel will be delivered to the heater. Depending on the length of the fuel line this may take a few attempts.
• During the process, the heater will try to start twice and if the fuel has not been delivered, it will show a fault code of F01 – No start (after 2 attempts to start).
• You will need to reset the heater by following the reset procedure – see Page 16, Section 9.

You will need to reset the heater by following the reset procedure – see Page 16, Section 9.

Basic Layout of Complete Installation

F2 (10A) {Fig. 13 Pg 9}

| 10| FUEL LINE
4| HOT AIR OUTLET| 11| EXHAUST PIPE
5| HOT AIR OUTLET DUCT| 12| COMBUSTION AIR INTAKE PIPE
6| FUEL PUMP| 13| RETURN (HEATING) AIR INTAKE

GRILL

7| FUEL FILTER|  |

Reset Procedures

Rotary Control
When the controller starts to flash, disconnect the power supply to the heater by:

1. Whilst the controller is in the on position & code flashing, remove the fuse (15A) or disconnect power to theheater
2. Turn the dial switch to off
3. Wait for a few minutes
4. Re-install the fuse
5. Restart the heater

Multi-Control Set-Up & Operations Guide

Set-Up

1. Menu Name
2. Menu Symbols
3. Time Setting
4. Activated Time
5. On / Off Button
6. Control Knob

Initial Start-Up
When the Control unit is connected for the first time, a message about the Setting/Configuration of the heater is displayed.

Press the control knob and the On/Off Button simultaneously for 3 seconds
Select your Heater (Note: AirTop Evo 40/55 is displayed as AT 40/55) Press the Control Knob
Select the current Day Press the Control Knob
Select the current Time – turn the Control Knob clockwise to select Hour, press the Control Knob to confirm, then turn the Control Knob clockwise again to select the Minutes, press the Control Knob to set.
Press the Control Knob

If your heater was not selected correctly at Initial Start-Up a Manual Reset is required. Press the On/Off Button to go to the Main Menu Screen and follow the following steps.

• Select the symbol “Settings”

• Press the Control Knob

• The “Quick Start” menu is displayed

• Turn the Control Knob clockwise 10 times until “Reset” is displayed

• Select “Reset” by pressing the Control Knob

• Press the Control Knob to confirm. The Control Knob is now restarted

• During the restart of the Control Knob, an Hourglass will quickly appear Press the Control Knob and the On/Off Button simultaneously for 3 seconds The Control is now ready for use.
  Select your Heater (Note: AirTop Evo 40/55 is displayed as AT 40/55)

• Press the Control Knob

Timer Set-Up
It is possible to program the Timer Setting 7 days in advance. The heater switches on automatically at the programmed time. Up to 3 time settings per day can be set, with a total of 21 time settings for the week.
Before the timer can be activated, make sure that the:

• Time and current day of the week are set,

• The heater is switched off

• The “Timer” symbol has been selected in the main menu

• Press the Control Knob “Add Timer” screen is displayed

• Press the Control Knob in order to add a new timer

• Turn the Control Knob to select chosen “Day” Press the Control Knob to confirm the selection

• Turn the Control Knob to choose the desired Switch On time (Hour) Press the Control Knob to confirm
  Turn the Control Knob again to choose the Minutes

• Press the Control Knob to confirm

• Turn the Control Knob to choose the desired Switch OFF time (Hour) Press the Control Knob to confirm

• Turn the Control Knob again to choose the Minutes

• Press the Control Knob to confirm

• Select the “Heating” operation mode from the Main Menu screen

• Turn the Control Knob to choose the desired heating mode

• Options available: Eco (Power Saving Mode); Normal (Comfort Heating); Boost (Rapid Heat) Press the Control Knob to confirm the selection
  NOTE: Eco and Boost modes are not available for the AT2000STC

• Turn the Control Knob in order to choose the desired temperature (Temperature range: 5 – 35⁰C)
  Press the Control Knob to confirm the selection

• The programmed timer is saved and shown on the display

• Press the Control Knob to activate the programmed time
  “Activate” message will appear on the display
  Repeat the process to add timers (3 timer settings per day, 21 per week)

Preventive Maintenance

To ensure trouble-free operation of your Webasto heater, please observe the following:

1. Operate the heater for at least an hour once a month, regardless of the season
2. Keep the return air inlet and hot air outlet free of obstructions to prevent overheating
3. Keep combustion air inlet and exhaust outlet tube free of dirt and obstructions
4. Change fuel filter annually (depending on the usage)
5. Bio Diesel or any fuel additive is not permitted
6. 15A fuse for both 12V and 24V heaters

IMPORTANT
Note: The build-up of Carbon is not a warrantable condition. Situations that may cause Carbon build-up in the heater are:

• Under Voltage: the system should have at least 12.5-13V;
• Low current: the system requires 7-8A for the initial start-up phase for 120 seconds and once the flame is established the glow plug goes out and the heater continues running at 2-3A;
• Under size wire: where extensions are made to the battery positive & negative cables only, ensure that correct wire size is used;
• Fuel system: poor fuel quality, air pockets in the fuel line or running out of fuel;
• Combustion system: any blockage or restriction in the combustion air tube or at the silencer;
• Exhaust system: any blockage or restriction in the exhaust muffler or pipe;
• Isolation switch or circuit breaker: can prevent the heater from performing a correct shutdown cycle. The battery positive & negative wires should be connected directly to the battery;
• Electrical connections: poor battery connections, poor Earth, loose fuses, and improper crimping of terminals or plugs.

The build-up of Carbon is not a product malfunction however; the above listed are external factors that could affect the performance of the heater.

Fault Code

In the event of a failure, a flash code will be generated on the indicator light of the Rotary Control (On/Off) switch. In order to make a correct analysis, it is necessary to understand the fault code. The flashing code will be visible during the cool-down period of the operation.
During the flash code event you will see five quick flashes followed by a sequence of slow flashes, the sequence of slow flashes is the actual fault code. The five quick flashes are only an indication that a fault has occurred.

Count only the slow sequence of the flashes to obtain the current fault code.

Heater Flashing Fault Code Description

Heater Digital Multi Control display Fault Code Description

YouTube Tutorial Links
YouTube tutorial on how to configure the multi-controller to the correct model of heater, when there is T12 error. https://www.youtube.com/watch?v=qhXJOSPkqIM
YouTube tutorial on the operation of the multi-controller.
https://www.youtube.com/watch?v=vvXBKKA8n6U
YouTube tutorial to learn more about general troubleshooting AT2000STC
https://www.youtube.com/watch?v=WfA-xpvCWHg
YouTube tutorial when ‘No Power’
https://www.youtube.com/watch?v=VfteUuccgwQ
YouTube tutorial on the exhaust & air intake system
https://www.youtube.com/watch?v=WfA-xpvCWHg

Digital Multi Controller error table

Optional Parts

Note: The comprehensive one and two outlet kits are supplied with all necessary components required for installation, however should additional items be required for more complex installations please use the above list or contact your nearest Webasto Authorised dealer.

Webasto Thermo & Comfort Australia Pty Ltd

• ADDRESS: 423-427 The Boulevarde, Kirrawee NSW 2232 Australia
• [email protected]
• www.webasto.com
  Ph: +61 (0)2 8536 4800

Air Top 2000STC Installation Guide 2018 | Webasto Thermo & Comfort Australia Pty Ltd.

References

• Webasto Group - Feel the Drive
• Webasto Group - Provider for Original Equipment & Customized Solutions

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