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
14
27
39
417
522
628
730
834
9
10
43
11
50
12
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
3

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.
5

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
6

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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Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
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)
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Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
3.2 Heater data
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
2 3
B A C
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Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
3.2.2. 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
23
BAC
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Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
3.3. 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!
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Technical Information Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
• Recommendation: flexible mounting (vibration decoupling, noise re-
duction)!
• Secure the heater onto the bracket with bolts.
•Recommendationwhen mounting on outer skin on FRP boats: lami-
nate woodenpanel 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.
15

Technical InformationMarine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
• 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.
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Cold and hot air Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
Fig. 10 Airintake
4 Cold and hot air
4.1. General
It must not be possible for stowed articles to block the intake
opening .
4.2. 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.
ATTEN TION:
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
Air intake from well-ventilated locker Air intake with intake hose directly
from outside
17

Marine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
Cold and hot air
4.3. 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.
4.4. 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!
4.5. Properties of cold and hot air ducts
Recommended inside diameter of main hot air duct:
•60 mm for Air Top2000 ST
•90 mm for Air TopEvo 40
• 90 mm for Air TopEvo 55
4.6. 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.
18

Cold and hot air Marine Air Heaters
Air Top 2000 ST / Evo 40 / Evo 55
4.7. 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.
– Preventfrom 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
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Marine Air Heaters
Air Top2000 ST / Evo 40 / Evo 55
Cold and hot air
4.8.Air routing examples
Fig. 14 Heating air routing examples
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.
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
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