Webasto Air Top 2000 ST B User manual

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

Caution: When heater is in use, the surface of the hot air outlet may become hot to the touch. Contact with skin
may cause burns.
Product produces temperatures high enough to ignite surrounding combustible materials such as inflammable
liquids, gases, vapor, and other combustible matter. The heater must be switched off when loading or unloading
inflammable materials to prevent the risk of explosion.
ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
Webasto rejects any liability for problems and damage caused by the system being installed by untrained
personnel.
All fuel fired heating appliances are capable of producing poisonous carbon monoxide gases. Webasto fuel fired
heaters are engineered with state-of-the-art components and safety features to precisely control combustion and
minimize the production of deadly carbon monoxide gas. Nevertheless, due to the confined spaces within marine
vessels, an increased risk of carbon monoxide poisoning causing death or serious injury to personnel is possible if
equipment is improperly installed. Therefore, it is extremely important that the authorized installer fully read and
understand all installation documentation supplied with the heater BEFORE attempting installation. 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.
Webasto heating and cooling systems require qualified and/or professional installation and repair technicians.
Warranty shall be void if not installed by a certified or trained installer/repair technician who has successfully
completed the factory training course for installation and repair of Webasto heating and cooling systems, and has
been provided with the technical information, tools and equipment required to properly complete the necessary
installation/repairs.
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Table of Contents
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27
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417
522
628
730
834
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10
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50
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54
Safety and General Information
Regulations Governing installation
Heater
Cold and hot air
Fuel supply
Combustion air supply
Exhaust system
Electrical Connections
Wiring diagrams
Initial operation
Troubleshooting
Technical data 56
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1 Safety and General Information
1.1 General Information
Webasto Thermo & Comfort North America, Inc. is pleased to provide this installation manual with the Air Top 2000ST / Evo 40 / Evo 55 air heaters. When
installed according to the guidelines stated in this manual, you can expect your customer to enjoy many years of trouble-free heater operation.
This manual represents our latest effort to produce the best technical documentation possible. In our efforts towards continuous, ongoing product
improvement, we encourage our customers to write to us with their comments or criticisms concerning this manual and the Air Top 2000 ST/Evo 40/Evo 55
heating systems.
Please write to us at:
Webasto Thermo & Comfort North America, Inc.
Technical Documentation Group
15083 North Road
Fenton, MI 48430
You are also invited to fill out our online questionnaire concerning our technical documentation and web site at: www.techwebasto.com. If you have any
immediate questions concerning this manual, the installation procedures within or the product itself, please call us at: [phone] or send a fax to: (810)
593-6001.
1.2 Use of the heating system
Solely for use on marine vessels:
- for the pre-heating and heating of ship cabins, cargo holds, personnel and crew transportation areas
- on inland waters and at sea
- for sailing and motor boats
Not suitable for:
- continuous heating of living areas, houseboats, etc.
- for heating and /or drying living beings
The heaters operate independently of the boat's engine. They are connected to the boat's fuel tank and electrical system.
Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
4

Note
Exhaust
Mechanical system
Electrical system
Heated air
Fuel
Combustion air
Attention
Technical Information
Flammable or
Combustible
Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
1.3 About this Document
To enable quick reference to the individual procedures you will find a descriptive symbol on the top outer edge of each page and safety symbols and signal words which are
intended to convey the level of importance of the safety messages. The symbols are described below. Remember that safety messages by themselves do not eliminate danger
and are not a substitute for proper accident prevention measures.
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If you have any doubts, safety concerns or question concerning the installation documentation or the procedures within, do not hesitate to seek professional advice
from your authorized Webasto marine dealer or Webasto Thermo & Comfort N.A., Inc., directly at 1-800-555-4518.
•DO NOT install fuel fired heaters in unventilated passenger compartments or confined cargo holds unless authorized in writing by a
Webasto installation specialist or Webasto Thermo & Comfort N.A., Inc. directly.
•DO NOT install fuel fired heaters in engine compartments or areas where equipment must be U.S. Coast Guard rated “Ignition Proof.”
•DO NOT install Gasoline fired heaters on marine vessels.
•DO NOT install diesel fuel fired heaters in the engine compartment of Gasoline powered marine vessels.
•DO NOT draw combustion air from the engine compartment of Gasoline powered marine vessels.
•ALWAYS switch fuel fired heaters off during refueling or when in a refueling area.
CAUTION!
Location of heater, fuel system and components, wiring and control devices and installation of warm air ducting are important
for proper operation. Failure to comply with the installation instructions provided may result in poor operation or damage to
heater and vessel components.
CAUTION!
The installation instructions within this manual are intended to be used as general installation guidelines only.
For i nformation concerning special marine applications or marine applications, contact an authorized Webasto marine
dealer or Webasto Thermo & Comfort N. A., Inc. directly at: 1-800-860-7866 (USA) or 1-800-667-8900 (Canada).
ATTENTION:
It is the installer’s responsibility that the installation complies with all applicable American Boat & Yacht Council and U.S. Coast Guard
regulations. Also, all relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating
devices in watercraft must be observed.
Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
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2 Regulations governing installation
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.
Read this installation manual in its entirety before installing this
equipment.
In the following we would like to provide some useful advice and tips
which, when followed, will ensure that the heating system fully meets
your specific needs.
The installation instruction manual supplied with the heater must always
be observed.
2.1 General Installation Notes
When installing the heater, the maximum inclination of the marine
vessel must be taken into account. The heater must not be submerged,
for example, in the bilge water when the vessel is in an inclined position.
The heater must be installed horizontally and parallel with the
longitudinal axis of the vessel. The positional changes that are normal
during heeling are acceptable.
The installation location should not be situated next to the berths or
adjacent to the salon, if possible.
The heating air (cool air return) must not be extracted from the engine
room.
DO NOT store flammable material in the vicinity of the heater and its
exhaust gas line. This also applies to flammable liquids, dusts, vapors and
gases.
Resilient mounting of the heater is recommended in order to absorb
vibrations. In most cases, this results in a significant noise reduction.
The installation and service of Webasto heaters requires special expertise
and training. Installations and servicing of Webasto products by untrained,
unauthorized personnel and end-users voids all warranties and releases
Webasto Thermo & Comfort North America, Inc. and Webasto authorized
distributors, dealers and their personnel from responsibility for damage to
Webasto products, any resulting collateral property damage and personal
injury.
2.2.2 Any use, operation, installation, modification or application of the
product not described in Webasto manuals, or subjecting the product to
extreme or unusual conditions beyond the limits of specified performance
characteristics is misuse of the product. Failure to comply with all
installation instructions is a misuse of Webasto products. The same applies
for repairs without using genuine Webasto service parts. This will void the
heaters “official Marks of Conformity.”
IMPORTANT!
All relevant state and provincial licensing regulations if any, governing the
installation and use of auxiliary heating devices must be observed!
2.2 Legal Provisions
Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
7

Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
CAUTION!
When heater is in use, the surface of the hot air outlet may become hot to the touch. Contact with skin may cause burns.
Fire risk! The heating system can overheat.
•Pay attention to maintaining a sufficient distance and sufficient ventilation for all parts.
•Use only fire resistant materials.
•If necessary, fit a heat shield.
•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 a locker or control cabinet;
•Only with good ventilation
• Prevent contact with hot parts
• If necessary, create a contact barrier around the heating system
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Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
3 Heater
Fig. 1 Installation example
1. Air heater 4. Air outlet; 7. Exhaust line;
2. Cold air intake; 5. Fuel pump; 8. Room temperature sensor;
3. Hot air hoses; 6. Fuel tank; 9. Control element
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Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
3.1. Choosing installation location
Install the heater in a dry location, protected from the ingressof sea
water, excessive vibration, heat, engine exhaust gases and soiling by
fuel or oil.
Arrange theinstallation to suit the requirementsandtype of boat! Take
the following into account: all peripheral components, such as permis-
siblelength of the exhaust system, position of the through-hull fitting,
combustionair intake, routing of electrical wiring and cable lengths,
distancefrom the fuel tank, routing of hot air hoses,freshair intake,
etc.
Takethe following into account: the maximum inclination of the boat
must not result in the ingress of sea water through theexhaust gas
outlet.
The inclinationmust 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 whenpositioning the
heater to minimize the risk of injury and damage to personal
property
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
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