Webasto Thermo 90-TRS Manuel de réparation

List of ContentsAir Top 2000– Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon mo

2.2 Heat ExchangerThe heat exchanger dissipates the heat provided bycombustion to the air delivered by the combustion andheating air fan.Heat Exchange

Control Unit Air Top 2000 Diagnosis2.5 Flame SensorThe flame sensor is a low-Ohm PTC resistor changingits resistance dependent on its heating by the f

3. Functional Description3.1 Functional Description Air Top 2000without Diagnosis (Fig. 301)3.1.1 Control ElementThe control element is used to switch

3.1.5 Control OperationDuring control operation fan speed and dosing pumprate of delivery are subject to heating performance. The glow plug is deactiv

303OnA011 23 45 6 7 8910BC01100% 90% 60% 30% 0D1,3 Hz1,0 Hz0,8 Hz0,6 Hz0 EF010204565 85 102secondstypical(20) (60)(120)Fig. 301 Functional Diagr

3043.2 Functional Description Air Top 2000 Diagnosis3.2.1 Control ElementThe control element is used to switch the air heater onand off, set the desir

3.2.4 Heating OperationDuring operation the combustion exhaust gasses flowthrough the heat exchanger charging its walls with com-bustion heat, which i

3.2.9 Switch-off upon FailureThe control unit recognises failures of individual airheater components and malfunctions in the start se-quence and in no

4. Technical DataAs long as no threshold values are given, the followingtechnical data are understood to include tolerances of±10% usual for heaters a

5. Troubleshooting5.1 GeneralThis section describes troubleshooting procedures forthe Air Heater Air Top 2000 and Air Top 2000 Diagnosis.A malfunction

IList of Contents1. Introduction1.1 Scope and Purpose...

5.3 Failure Symptoms during OperationThe following table (Fig. 502) lists the possible failuresymptoms as they might occur during the functional seque

5.4 Error Code Output (Air Top 2000 Diagnosis)When equipped with a combination or standard timer amalfunction will cause an error code output to the d

6. Functional Tests6.1 GeneralThis section describes the on-vehicle and off-vehicle testing of the air heater to check its proper operation. WARNINGTh

6.3 Components TestingCAUTIONDuring electrical testing always ensure that the controlunit and the component under test are electrically discon-nected

7. Circuit Diagrams7.1 GeneralThe air heater Air Top 2000 Diagnosis may be operatedusing the control element (rated value transmitter/switch)or with t

violet yellowbrownblack blueX1 X4X3X2 X5X1 = Connection, Combustion and Heating Air FanX2 = Connection, Dosing PumpX3 = Connection, Flame SensorX4

ϑ ϑϑItem Nomenclature RemarkA1 Air Heater Air Top 2000A2 Control UnitB1 Flame SensorB2 Temperature SensorB3 Temperature LimiterE Glow PlugF2 Fuse 24V

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

706ϑ ϑϑWire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Colour

II5. Troubleshooting5.1 General...

ϑ ϑϑWire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbl

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Fig. 712 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24V with Control Element and TimerWire Gauges< 7.5 m 7.5 - 15 m0.75 mm

Wire Gauges< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.5 mm22.5 mm24.0 mm21.5 mm21.5 mm22.5 mm24.0 mm26.0 mm2bl brge gn gr or rt swvi wsWire Coloursbluebr

Fig. 714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V TRS Operation with Control Element in Vehicles without Auxiliary Drive714Wire

Fig. 715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not TRS!)715JumperTerminal 15Terminal 58Terminal 30Terminal 31Air Top 200

8. Servicing8.1 GeneralThis section describes the servicing procedures thatmay be performed with the air heater installed.8.2 Work on the Air HeaterPr

9. Repair9.1 General...

The air heater, when used in the ventilation mode ofoperation, may also be employed for heating air ducting without any further accessories. A short c

803> 25 mm25Hole PatternFig. 802 Webasto Fuel Tank Tap* Use fuel tank tap only on metal fuel tanksFig. 803 Fuel Tapping from Plastic Tank(tapping

Connection of 2 Pipes with HoseThe proper connection of fuel lines with hoses is shownin Fig. 805.Fig. 805 Pipe/Hose Connection8.6.3 Dosing PumpThe d

8.6.5 Combustion Air SupplyCombustion air must under no circumstances be ex-tracted from rooms with persons. The combustion airinlet must not point to

8.6.8 Electrical Connections8.6.8.1 Connection Air Heater, Control ElementElectrical connection is according to Circuit DiagramAutomatic Control (see

807Fig. 814 Example of an Installation1 Control Element2 Air Heater3 Dosing Pump and Anti-Vibration Mount4 Fuel Filter (Accessory)5 Fuel Tap6 Exhaust

8.7 Removal and InstallationCAUTIONIn installed condition only the following removal and dis-assembly procedures are allowed, the upper housingshell b

80945132Fig. 815 Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis)1 Plug Connections2 Control Unit3 Screw (2)4 Loc

810Fig. 816 Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)1 Plug Connections2 Control Unit3 Screw (2)4 Lock Washer (2)5

8118.8 Installation of new Control UnitsCAUTIONWhen replacing the control unit the following must be ob-served:When replacing the control unit Air Top

List of Figures301 Functional Diagram (Air Top 2000 without Diagnosis)...

8.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) TRS1. Remove control unit according to 8.7.2.1.2. Remove leaf spring contacts of grey and vio

9. Repair9.1 GeneralThis section describes the repairs that may be per-formed on the air heater Air Top 2000 and Air Top 2000Diagnosis serial no. 30.0

9.1.2.2 Removal of External Temperature Sensor(Air Top 2000 without Diagnosis)GeneralThe heater Air Top 2000 regulates the desired tempera-ture the be

90312534YYXXZZFig. 901 Removal of Housing Components/Covers1 Cover, Electrical Connection2 Upper Housing Shell3 Cover, Heating Air Outlet4 Lower Hous

Fig. 902 Replacement of Combustion Air Fan (Removal)1 Heating Air Intake2 Insulation3 Seal2139049.2.2 Replacement of Control UnitNOTEThe procedure fo

9.2.4 Replacement of Combustion Air Fan9.2.4.1 Removal1. Remove air heater (see 8.7.1.1).2. Remove control unit (see 8.7.2.1).3. Remove seal (3 Fig.

9.2.5 Replacement of Flame Sensor9.2.5.1 Removal1. Remove air heater (see 8.7.1.1).2. Remove control unit (see 8.7.2.1).3. Remove combustion air fan

907876312125410911131 Flame Sensor2 Spoiler3 Screw (4)4 Locking Tab5 Burner Insert6 Combustion Tube7 Gasket8 Heat Exchanger9 Cable Grommet10 Cable Gro

908Detail ADetail BStarting Air BoreTwist LockFig. 904 Disassembly of Heat Exchanger (Sheet 2 of 2)9 RepairAir Top 2000

9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger9.2.7.1 Removal1. Remove air heater (see 8.7.1.1).2. Remove control unit (see 8

1. Introduction1.1 Scope and PurposeThis repair shop manual is intended to support famil-iarized personnel in the repair of air heaters Air Top2000 of

10. Packaging/Storage and Shipping10.1GeneralThe air heater and its components shipped to WebastoThermosysteme GmbH for inspection or repair are to be

The heater must not be installed in the passenger or driver compartments of busses. Should the heater never-theless be installed in such a compartment

Metal lines must be used. These may not heat to morethan 110 °C should there be the possibility of contact within the room interior. Protective device

2. General DescriptionThe air heater Air Top 2000 and Air Top 2000 Diagnosiswith serial no. 30.000 and up operating to the evaporatorprinciple basical