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. [. . . ] 502) lists the possible failure symptoms as they might occur during the functional sequence of operation. In case of malfunction the failure is to be isolated and removed using this table. It is important to accurately identify the failure symptom. Should the failure symptom not be contained in this table or the trouble not be detected under the specific Failure Symptom shows after . . . . s immediately No start and no illumination of LED on control element No start but LED illuminates Very low speed with no start Wrong cabling, defective fuse immediately immediately Fan or control unit defective or fan blocked Control idle operation: wrong manual control (selected temperature is below air intake temperature)or wrong integration (excessive air intake temperature) Glow plug or flame sensor short or open circuit or control unit defective Fan motor obstructed, binding Flame detection erroneous Voltage to control unit too low Cabling to dosing pump, pump itself or overheat protection defective Intermittent disconnect of connection to dosing pump or to overheat protection No flame: wrong fuel supply quantity, defective or slow fan, coked burner (in particular pilot flame outlet bore), combustion air/exhaust ducting obstructed or heat exchanger coked, dosing pump seized Overheating or voltage too low or component error (flame sensor, glow plug, overheat sensor, dosing pump, burner) or no fuel supply or obstructed combustion air/exhaust ducting Fan motor failure or seizure Motor operates momentarily and then stops Stoppage without run-down Run-down after Run-down after Run-down after and dosing pump does not cycle Run-down after 1 5 1 20 120 40 to 120 Run-down after 230 Run-down during combustion operation Stoppage without run-down during combustion operation during combustion operation Interruption of dosing pump cycling and max. speed for 30 sec with subsequent re-start Flame-out by gas bubbles in fuel delivery or strong wind against exhaust outlet or defective no-flame detection Fig. 502 Failure Symptoms during Operation 502 Air Top 2000 5. 4 Error Code Output (Air Top 2000 Diagnosis) 5 Troubleshooting When equipped with a combination or standard timer a malfunction will cause an error code output to the display of the timer for indication. NOTE When equipped with a control element the error code output is indicated by flashing of the operating indicator/error code indication. The number of flash pulses corresponds to the number indicated in the table below. After a quick pulse train there will always be an error code output. Error code output on display of combination or standard timer F F F F F F F F F F 01 02 03 04 05 06 07 08 09 10 No start (after 2 attempts) Flame out (at least >5) Voltage too low or too high Premature flame detection Flame sensor open or short circuit Temperature sensor open or short circuit Dosing pump open or short circuit Fan motor open or short circuit or wrong speed Glow plug open or short circuit Overheating 503 Air Top 2000 6. 6. 1 6 Functional Tests Functional Tests General CAUTION Set potentiometer slowly; observe end positions. Adjustment may be performed at any electrical system voltage. Clockwise rotation increases the fan speed and decreases the CO2 contents. Counterclockwise rotation decreases the fan speed and increases the CO2 contents. If the setting range is not sufficient (e. g. after replacement of the combustion and heating air fan) the manufacturer's setting may be cancelled according to the procedure described in the following. 6. 2. 1. 2 New Basic Setting This section describes the on-vehicle and off-vehicle testing of the air heater to check its proper operation. WARNING The air heater shall not be operated in enclosed areas like garages or workshops not provided with exhaust venting facilities. 6. 2 Adjustments 6. 2. 1 Adjustment of the CO2 Contents 6. 2. 1. 1 General The CO2 contents of the exhaust is adjusted with the potentiometer on the control 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. After an inadvertent loss of this position it is sufficient to restore its original position. The manufacturer setting may be corrected by rotating the potentiometer. A suitable tool like a small screw driver (2. 5 mm tip) is to be used. CAUTION The manufacturer's setting cannot be restored. Withdraw cover from upper shell according to 9. 2. 1. 1. Rotate potentiometer two times and with no interrupt through its complete setting range (e. g. [. . . ] 9. CAUTION During glow plug installation observe twist lock (see Detail B). That means that the glow has to be inserted so that the contacts point towards the heat exchanger. Otherwise there will be the danger of a short circuit. Feed glow plug (11) into burner insert (5) and arrange cable protective sleeve in slot of burner insert. CAUTION When performing the following step ensure that glow plug is inserted in burner insert fully against stop. [. . . ]