Webasto Air Top 2000 ST B User manual

Boat Air Heaters Installation Instructions
Air Top 2000 ST
Air Top Evo 40
Air Top Evo 55
Trade names :
Air Top 2000 ST D (Diesel/PME)
Air Top Evo 40 D (Diesel/PME)
Air Top Evo 55 D (Diesel/PME)

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.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and
have the appropriate technical documentation, special tools and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course,
you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment
available to ensure that you can complete the installation and repair work properly.
ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS.
Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.

I
Table of Contents
1 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2 Regulations governing installation . . . . . . . . . . . . . . . . . . .50
3 Use / variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5 Cold and hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
6 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
8 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
10 Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
11 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
12 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

49
Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
Note
Mechanical system
Electrical system
Heated air
Fuel
Exhaust
Combustion air
Attention
Technical Information
Excerpt from directive
1AboutThisDocument
To enable quick reference to the individual procedures you will find a descriptive symbol on the top outer edge of each page.

Technical Information Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
50
2 Regulations governing installation
2.1. Statutory regulations governing installation
Permit numbers see Chapter 13, "Technical data".
2.2. Application of combustion heaters on boats
Observe regional authority regulations! Establish which regulations
apply in the area where the boat is to be used. Comply with the
stipulated requirements!
Obtain official approval if necessary!
The cables must be installed and firmly secured such that the wirings
are adequately protected against mechanical and thermal stress.
Requirements relating to the basic unit:
When switched off, it is permissible for combustion heaters to continue
running for max. 40 seconds. Only combustion heaters are to be used
with heat exchangers that are not damaged during their standard
operating period by the reduced afterrunning time of 40 seconds.
2.3. Additional documentation to be used
These installation instructions contain all the information
and instructions necessary to install Air Top 2000 ST / Evo
40 / Evo 55 heaters.
The operating instructions must also be observed.

Boat Air Heaters Technical Information
Air Top 2000 ST / Evo 40 / Evo 55
51
3 Use / variants
3.1. Use
The Webasto Air Top 2000 ST, Air Top Evo 40 and Air Top Evo 55 air
heaters are suitable for:
Preheating and heating ship's cabins, cargo holds, passenger and crew
areas
Use on inland waterways and at sea
Sailing and motor boats of approx. 8 to 24 m in length
Not suitable for:
Continuous heating of living areas, houseboats, etc.
Heating and/or drying living creatures
The heaters operate independently of the boat's engine. They are
connected to the boat's fuel tank and electrical system.
3.2. Variants
Air heater for "diesel" fuel (12 or 24 V):
Air Top 2000 ST D (Diesel)
Air Top Evo 40 D (Diesel)
Air Top Evo 55 D (Diesel)

Technical Information Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
52
4Heater
Fig. 1 Installation example
1. Air heater
2. Cold air intake;
3. Hot air hoses;
4. Air outlet;
5. Fuel pump;
6. Fuel tank;
7. Exhaust line;
8. Room temperature sensor;
9. Control element

Boat Air Heaters Technical Information
Air Top 2000 ST / Evo 40 / Evo 55
53
4.1. Choosing installation location
Install the heater in a dry location, protected from the ingress of sea
water, excessive vibration, heat, engine exhaust gases and soiling by
fuel or oil (requirement from 2001/56/EC).
Arrange the installation to suit the requirements and type of boat! Take
the following into account: all peripheral components, such as permis-
sible length of the exhaust system, position of the through-hull fitting,
combustion air intake, routing of electrical wiring and cable lengths,
distance from the fuel tank, routing of hot air hoses, fresh air intake,
etc.
Take the following into account: the maximum inclination of the boat
must not result in the ingress of sea water through the exhaust gas
outlet.
The inclination must not cause the heater to come in contact with bilge
water.
No obstruction of moving parts (e.g. rudder assembly).
Every reasonable precaution should be taken when positioning the
heater to minimise the risk of injury and damage to personal property
(requirement from 2001/56/EC)
ATTENTION:
Danger of suffocation!
Do not install heater and exhaust system in accommodation
areas.
ATTENTION:
Danger of fire!
Do not install in the vicinity of flammable or temperature-
sensitive objects such as sails, fenders, bulkheads, paper,
gas lines, fuel containers, etc.
When installing in locker or rudder box:
– Only with good ventilation
– Prevent contact with hot parts
– Install a contact barrier around the heating system if
necessary

Technical Information Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
54
Recommended installation locations (see Fig. 2):
A) In locker or rudder box if it is well ventilated.
Install a contact barrier around the heating system so that sails,
fenders, bulkheads, etc. do not come in contact with hot parts!
B) In the engine compartment of inboard diesel engines. Condition:
cold air intake from outside, combustion air intake from outside or
from engine compartment if this is well ventilated to the outside!
Fig. 2 Installing heater in locker (1), rudder box (2) or engine
compartment (3)

Boat Air Heaters Technical Information
Air Top 2000 ST / Evo 40 / Evo 55
55
4.2. Heater data
4.2.1. Dimensions Air Top Evo 40 / Air Top Evo 55
1) Cold air inlet
2) Cable outlet (optionally on right or left)
3) Hot air outlet
4) Exhaust gas outlet
5) Fuel inlet
6) Combustion air inlet
A) Space requirements for hot air outlet
B) Space requirements for cold air inlet
C) Space requirements for removing heater
Fig. 3 Dimensions and space requirements [mm] Air Top Evo 40 / Air Top Evo 55
1
6 5 4
2 3
B AC
2

Technical Information Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
56
4.2.2. Dimensions Air Top 2000 ST
1) Cold air inlet
2) Cable outlet (optionally on right or left)
3) Hot air outlet
4) Exhaust gas outlet
5) Fuel inlet
6) Combustion air inlet
A) Space requirements for hot air outlet
B) Space requirements for cold air inlet
C) Space requirements for removing heater
Fig. 4 Dimensions and space requirements [mm] Air Top 2000 ST
1
6 5 4
2 3
BAC

Boat Air Heaters Technical Information
Air Top 2000 ST / Evo 40 / Evo 55
57
4.3. Heater mounting
• Securely mount the heater (vibration, swell)! Use the supplied bracket
and rubber seal under the base.
• This rubber seal must be replaced each time the heater is reinstalled.
• The M6 nuts must be tightened to 6 Nm (-0 Nm, +1 Nm) to mount
the base.
ATTENTION:
Danger of drowning!
There is a danger of drowning when drilling into the boat's
outer skin! Drilling below the water line can cause the boat
to sink!
If the boat is in the water: check the drilling location! Have
leak sealing equipment available beforehand and familiarise
yourself with possible escape routes!
ATTENTION:
A blockage in the heating air rotor can cause the
heater to overheat!
Damage to heater
Make sure that the casing of the heater is clear, i.e. does
not make contact with any other parts, in installed posi-
tion (see Fig. 7).
NOTE:
Installation positions: observe possible inclination of
boat!
Recommended installation position: exhaust gas outlet
routed downward, heater parallel to longitudinal axis of
boat.
Do not install transversely in sailing boats!
Exception: if heater is primarily operated when boat is
moored or in motor boats then installation transverse to
longitudinal axis is permissible.
Fig. 5 Install heater in longitudinal direction in sailing boats!

Technical Information Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
58
• Recommendation: flexible mounting (vibration decoupling, noise re-
duction)!
• Secure the heater onto the bracket with bolts.
• Recommendation when mounting on outer skin on FRP boats: lami-
nate wooden panel onto the fastening location from the inside to
prevent drilling through the outer skin.
.
• Determine space requirements and installation position
– Air Top 2000 ST:
see Fig. 3 and Fig. 7
– Air Top Evo 40 / Air Top Evo 55:
see Fig. 4 and Fig. 8
• Do not exceed inclination angle (see Fig. 8).
Fig. 6 Mounting Air Top with bracket
NOTE:
After installation check that the casing is not in contact with
any part of the boat's body. Failure to do this may result in
the heating air fan blocking.
Fig. 7 Ensure ease of movement of all moving parts!
ATTENTION:
There is a danger of drowning when drilling into the
boat's outer skin!
Drilling below the water line can cause the boat to sink!
If the boat is in the water: check the drilling location!
Have leak sealing equipment available beforehand and
familiarise yourself with possible escape routes!
Fig. 8 Permissible installation positions of diesel-operated air
heaters
ATTENTION:
The base seal must be replaced when removing and
reinstalling a heater.

Boat Air Heaters Technical Information
Air Top 2000 ST / Evo 40 / Evo 55
59
• Except for the year of installation, remove all the year numerals on
the type label.
• Secure heater. Tighten the M6 nuts to 6 Nm (–0 Nm, +1 Nm).
• If the type label is not visible after installing the heater: use the type
label duplicate.
NOTE:
After installing the heater, the type label should be clearly
visible in a well-protected position.

Cold and hot air Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
60
5 Cold and hot air
5.1. General
It must not be possible for stowed articles to block the intake opening
(requirement from 2001/56/EC).
5.2. Fresh air mode
Cold air is drawn in from the outside, heated and blown into the boat's
interior. This renews the cabin air and reduces humidity. Ensure there are
enough ventilation openings in the cabins! A room temperature sensor
must be installed for temperature control, preferably in the saloon. In
summer, ventilation is also possible (when comfort control element is
used).
Draw in cold air directly from lockers or rudder boxes if they are dry,
clean and free of odours and exhaust gases.
For proper ventilation, ensure the intake diameter = 1.5 x hose diame-
ter of the heater.
Otherwise, use an intake hose for intake from the outside.
Prevent water from entering through the intake opening.
ATTENTION:
Danger of suffocation!
The cold air intake must be from a clean area with no ex-
haust gases.
Cold air intake never from the engine compartment!
NOTE:
The direct intake of hot air must be avoided (see Fig. 9).
It is not permitted to short-circuit the air flow.
Fig. 9 Cold air inlet and hot air outlet
Fig. 10 Air intake
Air intake from well-ventilated locker Air intake with intake hose directly
from outside

Boat Air Heaters Cold and hot air
Air Top 2000 ST / Evo 40 / Evo 55
61
5.3. Recirculated air mode
In recirculated air mode, the air to be heated is taken from the interior
area. The advantage of this is that heating takes place faster due to more
effective heat utilisation. However, the humidity is not reduced or the
room air not renewed in this mode.
No room temperature sensor needs to be installed. The heater uses the
sensor integrated in the control unit.
5.4. Position of hot air openings
All areas in the boat can be evenly heated with an appropriate air
distribution system. For this purpose, branch off several side branches
from the main line to reach all cabins. The air, and therefore the heat
flow, can be influenced by suitable selection of the branches and hose
diameters.
See the accessories catalogue for branches, connecting elements, Y-
junctions, air outlets, etc. made from temperature-resistant material.
A free flow of air into the cabins provides the most effective cabin
heating and air circulation!
Only use one or two air outlets per cabin!
5.5. Properties of cold and hot air ducts
Recommended inside diameter of main hot air duct:
• 80 mm for Air Top 2000 ST
• 80 mm for Air Top Evo 40
• 90 mm for Air Top Evo 55
5.6. Layout of cold and hot air ducts
Maximum differential pressure between intake and pressure side of
heater:
• Air Top 2000 ST: 2.0 hPa
• Air Top Evo 40: 2.0 hPa
• Air Top Evo 55: 3.0 hPa
NOTE:
For fresh air mode, a room temperature sensor must be
installed in the cabins to be heated.
WARNING:
Risk of injury!
Do not blow hot air directly onto living creatures or
temperature-sensitive objects.
NOTE:
Only materials with a thermal resistance of 130 °C (short-
term 150 °C) are to be used for the hot air duct.
ATTENTION:
Use without cold air intake hose
Risk of injury by rotating heating air rotor
If used without the cold air intake hose, install the sup-
plied mesh guard over the intake
ATTENTION:
The heating output will be reduced if this pressure differen-
tial is exceeded.

Cold and hot air Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
62
5.7. Installing cold and hot air ducts
Do not route the ducts through the bilge.
Hot air ducts in damp areas: use temperature-resistant, flexible, metal
spiral-reinforced plastic hoses.
Secure cold and hot air ducts at all connections.
In stowage areas:
Use a perforated metal cover, for example, to protect the ducts from
damage by cargo.
Recommended:
Routing through bulkheads:
Use wall lead-through as shown in Fig. 11.
See the Webasto accessories catalogue.
Secure ducts:
– With hose clips at all connecting elements.
– Prevent from chafing, see Fig. 12.
Recommendation
for routing hoses through area not to be heated: insulate the hose sec-
tions to prevent heat loss.
Fig. 11 Recommended duct lead-through in bulkheads
Fig. 12 Recommended routing around corners

Boat Air Heaters Cold and hot air
Air Top 2000 ST / Evo 40 / Evo 55
63
5.8. Silencer in air duct
Recommendation: For Air Top 2000 ST / Evo 40 / Evo 55 units with short
air duct, use silencer on intake and/or outlet side (reduction in noise
level). See the accessories catalogue.
5.9. Air routing examples
Fig. 13 Silencer for reducing noise level
Fig. 14 Heating air routing examples
2000ST
EVO 40
EVO 55
A: in 9 m sailing boat
B: in 11 m sailing boat
C: in 13 m sailing boat
1) Cold air intake
2) Y-junction or T-piece
3) Air outlet
The main duct must not be reduced from 90 to 80 mm for Air Top Evo 55!
If 90 mm is not possible throughout, it is better to use Y-junction 90/80/
80 and thus create two 80 mm main ducts.

Cold and hot air Boat Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
64
5.10. Installation examples:
Fig. 15 Installation examples:
37' sailing boat 1 Branch 90/60/90
2 Air outlet Ø 60 mm, can
be closed off
3 Y-junction 90/90/90
4 Air outlet Ø 90 mm, open
5 Y-junction 60/60/60
6 Air outlet Ø 90 mm, can
be closed off
7 T-piece 90/60/90
43' sailing boat

Boat Air Heaters Fuel
Air Top 2000 ST / Evo 40 / Evo 55
65
6Fuelsupply
6.1. General
The fuel filler neck must not be located in the interior of the boat and
must be fitted with a well-sealing cap to prevent fuel from escaping
(requirement from 2001/56/EC).
Protect the boat hull/components in the vicinity of the heater from
heat/contamination by fuel/oil!
6.2. Fuel extraction
The following alternatives are available for extracting fuel for the heater:
6.2.1. Tank extracting device
• Fuel take-off directly from the boat's fuel tank.
• Plastic fuel tanks: install the tank extracting device in the tank fitting.
Do not drill into a plastic fuel tank.
• For suitable tank extracting device for metal tanks see the accessories
catalogue or scope of delivery.
ATTENTION:
Danger of fire!
If the heater takes the fuel from a separate additional tank,
the fuel type and the filler neck must be clearly marked.
(Requirement from 2001/56/EC).
NOTE:
– Fuel take-off must take place with virtually no pressure.
– If taking fuel from the return line make sure that the line
is not blocked by non-return valves.
Fig. 16 Example of fuel supply Air Top heaters
1) Fuel pump
2) Fuel extractor
3) Tank extracting device
4) Fuel tank
5) Fuel line
6) Heater