User manual WEBASTO 2000 B SERVICE MANUAL

[. . . ] List of Contents Air Top 2000 Air Heater Air Top 2000 D (Diesel) Air Top 2000 B (Gasoline) Service and Repair Manual NOTE Technical changes in this issue of the manual compared with its previous issue are identified with a vertical change bar on the lefthand side of columns. ­ Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. ­ Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. ­ NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. ­ ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS. [. . . ] NOTE New settings on the control element are executed by the control unit/heater with a time delay. l l the vehicle engine is turned off a conveyor facility is put into operation The short run-down time depends on the operational condition at which TRS switch-off occurs. A 15 second run-down with maximum speed is initiated (TRS switch-off) when: l l l air heater is still in the start phase; stabilization not yet achieved air heater is in normal run-down air heater is in control idle. A 20 second run-down is switched on in normal combustion operation and in stabilization with the fuel delivery immediately halted 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 control unit is in the "error lockout" condition. Prior to resuming operation the control element has to be set to "OFF". 305 3 Functional Description Air Top 2000 3. 2. 9 Switch-off upon Failure The control unit recognises failures of individual air heater components and malfunctions in the start sequence and in normal operation. The air heater is deactivated and enters the error lockout mode under the following conditions: l l l l l l l l flame sensor open or short circuit temperature sensor open or short circuit glow plug open or short circuit fan motor open or short circuit or fan speed wrong dosing pump open or short circuit overheating low voltage below 10 Volt or high voltage above 15 Volt in excess of 20 seconds for 12 Volt heaters low voltage below 20 Volt or high voltage above 30 Volt in excess of 20 seconds for 24 Volt heaters A switch-off like in "switch-off" will be performed. For error unlock the air heater has to be switched off momentarily (at least 2 seconds) to be switched on 306 Air Top 2000 4. Technical Data 4 Electrical Components: Technical Data As long as no threshold values are given, the following technical data are understood to include tolerances of ±10% usual for heaters at an ambient temperature of +20 °C and at nominal voltage and conditions. Control unit, combustion air fan, dosing pump, timer*, glow plug and control element are for 12 or 24 Volts operation. The components temperature limiter and flame detector are independent of voltage. *not for TRS Air Heater Mark of conformity Heater type Heat flow Type of fuel Fuel consumption Nominal voltage Operation voltage Rated power consumption Permitted ambient temp. : - operation Heater: - storage - operation Dosing pump: - storage Control element: - operation - storage Operation AT 2000 B ~ S 277 Air heater with evaporator burner AT 2000 D ~ S 270 Control range 1. 1 ­ 2. 0 kW Fuel 0. 9 ­ 2. 0 kW Diesel/Fuel oil (EL) 0. 1 . . 15 Volt Control range Permitted combustion air intake temperature Setting range for indoor temperature Volume flow of heating air against 0. 5 bar CO2 in exhaust (perm. 12. 0 Length 322 ± 2 mm Width 130 ± 1 mm Height 122 ± 1 mm 2. 6 kg Weight, heater 401 Air Top 2000 5. 5. 1 5 Troubleshooting Troubleshooting General This section describes troubleshooting procedures for the Air Heater Air Top 2000 and Air Top 2000 Diagnosis. A malfunction in air heaters Air Top 2000 Diagnosis outputs an error code to the display of the combination or standard timer. In addition a heater checkout may be performed using a personal computer (refer to operating instructions PC air heater diagnosis). CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of heater components and may only be performed by skilled personnel. In cases of doubt refer to Sections 2 or 3 for functional interrelations. NOTE Only for TRS operation After a TRS switch-off or power application by vehicle main power switch operation and the control element to "ON", the control unit will be in "error lockout". Prior to reactivation the control element must be set to "OFF" or the instant heat switch on the combination or standard timer be operated. CAUTION Troubleshooting is normally limited to the isolation of defective components. The following causes for trouble are not considered and should always be checked for to exclude them as cause for trouble: corrosion on connector loose contact on connector wrong crimping on connector corrosion on electrical wiring and fuses corrosion on battery terminals If individual components are checked, the control unit electrical connections must be disconnected. After any correction of a failure a functional test has to be performed in the vehicle. 5. 2 General Failure Symptoms The following table (Fig. 501) lists the possible failure symptoms. Failure Symptom Air heater switches off automatically Probable Cause No combustion after start or repeat start Flame extinguishes during operation Heater overheats Operation indication flashes Remedy Switch off heater momentarily and switch on once again Switch off heater momentarily and switch on once again Check heat air ducting for obstructions, allow heater to cool down, switch off heater momentarily and switch on once again Charge battery Switch off heater momentarily and switch on once again Check combustion and exhaust ducting for obstructions Vehicle electrical system voltage too low Heater expels black fumes Combustion air and/or exhaust ducting blocked Fig. 501 General Failure Symptoms 501 5 5. 3 Troubleshooting Failure Symptoms during Operation Air Top 2000 failure symptom listed, in emergencies assistance by our service technicians may be requested (Tel. [. . . ] Carefully bend up locking tab (4) and withdraw flame sensor (1) from burner insert (5). Perform work on components after disassembly (see 9. 1. 1). 9. 2. 6. 2 Installation 1. 904) into heat exchanger and bring combustion tube (6) in assembly position. 1 mm ø) (see Detail A). 9. 2. 5. 2 Installation CAUTION Route cable of flame sensor below fuel pipe. [. . . ]