Webasto Air Top Evo 5500 User manual

Marine Air Heating Systems
06/2010
5001479A
Installation Instructions
Air Top 2000 ST
Air Top Evo 3900
Air Top Evo 5500
Air Top 2000 ST D (Diesel/PME) (diesel/PME)
Air Top Evo 3900 D (Diesel/PME) (diesel/PME)
Air Top Evo 5500 D (Diesel/PME) (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.
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.

Webasto Marine
Contents
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3 Installing Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
4 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
5 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
6 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7 Air ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
9 Approval and Commissioning . . . . . . . . . . . . . . . . . . . . . .103
10 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
11 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . .104
12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Boat heating systems Safety Precautions
1 Safety Precautions
1.1. Symbols used
Particular risk of injury or fatal accidents
Legal regulations and technical documentation
Danger of fire and explosion
Reference to a special technical feature
Recommendations
• Always observe the following: applicable accident prevention
regulations and workshop and work safety instructions.
• Observe regulations of regional government agencies!
Clarify which regulations apply in the planned area of use
of the boat. Take these into account!
Obtain an official government permit if necessary!
• Observe all warnings!
• Comply with the technical!
• Repairs not carried out properly or without genuine Webasto spare
parts will lead to the warranty being voided by Webasto. This will result
in the homologation approval of the heater unit being voided.
• Only use heater controls approved by Webasto! Otherwise, there is a
risk of malfunctions occurring!
• See the Webasto accessories catalogue for accessories, installation and
assembly parts.
• The installation examples shown in this documentation are for
information purposes only.
No liability claims can be derived from the installation examples
shown.
WARNING!
When positioning the exhaust outlet, always prevent the re-
entry of the exhaust gasses into the heating air system or the
accommodation areas!
Danger of suffocation!
WARNING!
Never remove combustion air from the accommodation
areas!
Danger of suffocation!!

Safety Precautions Boat heating systems
WARNING!
The heating unit must be switched off while refuelling!
WARNING!
Use only fire-resistant fuel lines and temperature-resistant,
thermally insulated heating air hoses!
Fire danger!!
WARNING!
Do not blow hot air directly onto living creatures or
temperature-sensitive parts!

Boat heating systems General
2 General
Using heater units
Solely for use on ships:
• For pre-heating and heating of ship's cabins, cargo holds, passenger
and crew transport areas
• On inland waters and at sea
• For sailing and motor boats of approximately 26 to 79 ft in length
Not suitable for:
• Continuous heating of living areas, houseboats, etc.!
• For heating and/or drying living creatures
Permits
Existing homologation approvals for Air Top heater units in accordance
with EC Directives 72/245/EEC (electromagnetic compatibility) and 2001/
56/EC (heating) with the following homologation approval numbers:
Air Top 2000ST:
• e1*72/245*95/54*1085*00 for electromagnetic compatibility
• e1*2001/56**0022*00 for heating
Air Top Evo 3900/5500:
• e1*72/245*2006/28*5079*__ for electromagnetic compatibility
• e1*2001/56*2006/119*0219*__ for heating Air Top Evo 3900
• e1*2001/56*2006/119*0220*__ for heating Air Top Evo 5500
The regulations of the Directive 2001/56/EC must be observed for
installation.
CE symbol (prescribed in EU for new recreational craft from 2.5 to 24 m in
length)
Relevant standards for installation
– Recreational Craft Directive 94/25/EC
– ISO 8845/46 - Protection against ignition of surrounding flammable
gasses
– ISO 7840 - Fire-resistant fuel hoses
– ISO 9094 - Fire protection for small craft

General Boat heating systems
2.1. Mode of operation
The air heater in the locker draws in outside air through the intake opening
with an integrated fan. The air heated in the heater unit flows into the bow
through connected warm air hoses. The warm air enters the cabins at the
air outlets.
Fuel is supplied from the boat's fuel tank with a separate metering pump.
Power is supplied (for fan, electronics, etc.) from the boat's battery.
The combustion circuit is separated from the heating circuit. This results in
a separate combustion air intake.
The exhaust gas is routed to the outside via the exhaust system.
The interior temperature is adjusted to the selected value with a cabin
temperature sensor and the heater control.
The heater unit constantly compares the actual and the selected
temperature and automatically adjusts the heating capacity accordingly.

Boat heating systems General
Fig. 1: Example of a sailing yacht
1. Air heater;
2. Heating air intake;
3. Warm air hoses;
4. Air outlets;
5. Metering pump;
6. Fuel tank;
7. Exhaust system;
8. Temperature sensor (OPTIONAL)
9. Control element

Installing Heater Unit Boat heating systems
3 Installing Heater Unit
3.1. Choosing installation location
WARNING!
Do not install heater unit and exhaust system in accommodation areas!
(Danger of suffocation in case of improper installation)
• Install the heater unit in a dry location, protected from the ingress of
sea water, excessive vibrations, heat, engine exhaust gasses and soiling
by fuel or oil (requirement from 2001/56/EC).
• Design the installation to suit the requirements and type of boat. Take
the following into account: all peripheral components, such as the
maximum permissible exhaust system length, the position of the on-
board wall ducts, the combustion air intake, the routing of electrical
wiring and cable lengths, the distance from the fuel tank, the routing
of the warm air hoses, the fresh air intake, etc.
• Take the following into account: The maximum inclination of the ship
may not result in the ingress of sea water through the exhaust outlet.
• The inclination may not cause the heater unit to come into contact
with bilge water.
• No obstruction of moving parts (e.g. rudder assembly)!
• Every reasonable precaution should be taken in positioning the heater
to minimise the risk of injury and damage to personal property
(requirement from 2001/56/EC).
CAUION: Heater unit can overheat!
• Ensure sufficient spacing to all parts and sufficient
ventilation!
• Use only fire-resistant materials!
• Install heat shields if necessary!
• 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 control cabinet:
o Only with good ventilation
o Prevent contact with hot parts
o Install a contact barrier around the heating system if
necessary!

Boat heating systems Installing Heater Unit
• Recommendation on installation location:
o In locker or control cabinet if they are well insulated.
Install a contact barrier around the heating system so that sails,
fenders, bulkheads, etc. do not come into contact with hot parts!
o In the engine compartment of inboard diesel engines. Condition:
Heating 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 unit in locker (1), control cabinet (2) or
engine compartment (3)

Installing Heater Unit Boat heating systems
3.2. Heating unit dimensions
The installation dimensions and the space requirements for maintenance accessibility are shown in Figure 3.
Fig. 3: Heating unit dimensions
1) Heating air inlet
2) Heating air outlet
3) Combustion air intake
4) Exhaust gas outlet
5) Fuel intake
6) Space requirement for heating air inlet
7) Space requirement for heating air outlet
8) Space requirement for removing unit
9) Cable outlet (either right or left)
Air Top Evo 3900/
Air Top Evo 5500:
Air Top 2000 ST:

Boat heating systems Installing Heater Unit
3.3. Unit orientation
The specified horizontal and axial angles must not be exceeded.
• Installation positions: observe possible inclination of ship!
• Recommended installation position: Exhaust outlet routed
downward; heater unit parallel to ship's longitudinal axis.
• Do not install transversely in sailboats!
Exception: if heater unit is primarily operated when boat is moored, or
in motorboats then installation transverse to longitudinal axis is also
permissible.
3.4. Heater unit mounting
• Securely mount the unit (vibrations, swells)!
• Use the bracket and rubber gasket provided under the unit base.
• This rubber gasket must be replaced each time the heater unit is
installed.
• The M6 nuts must be tightened to
6 Nm (–0 Nm, +1 Nm) to mount the unit base.
After installation, check that the casing is not in contact with
any parts of the vehicle body. A failure to do this may result in
the blocking of the heating air fan.
Fig. 4: Permissible installation positions for Air Top Diesel air
heater units
Fig. 5: Install heater unit in longitudinal direction in sailboats!
0-90˚ 0-90˚ 0-90˚
Fig. 6: Mounting Air Top with angled retaining bracket
Fig. 7: Ensure that all moving parts can move easily.

Installing Heater Unit Boat heating systems
• Recommendation: elastic mounting (vibration decoupling,
noise reduction)!
• Screw the heater unit onto the bracket with bolts.
• Recommendation when mounting on outer skin of FRP boats:
laminate on a wooden sheet at the fastening location from the inside
to prevent drilling through the outer wall.
WARNING!
There is a danger of drowning when drilling into the ship's
outer skin! Drilling below the water line can cause the ship 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!

Boat heating systems Exhaust
4Exhaust
4.1. Exhaust system
Route the combustion gasses out of the boat via the exhaust system.
4.2. Exhaust outlet
Outlet arrangement:
• Position the exhaust outlet where no splash-water can enter the boat.
Recommendation:
Sailboats: on stern transom.
Motorboats: on side wall.
CAUTION!
Do not position the exhaust thruhullbelow or next to ventilation
equipment, window openings or the heating air inlet
(otherwise danger of suffocation)!
• At least 24 in above the water line so that no water can enter when
the boat heels
• Do not connect to the engine or generator exhaust system (higher
pressures; damage to heater unit!)
• Not in the direction of movement of the boat (high wind pressure)
• Not where it can easily be covered, e.g. by the fender.
Side wall thru hull:
• Choice of design and installation position: Minimisation of rain water
ingress!
• Use only genuine Webasto side wall thru hull! Fit insulating washers
exactly for thermal insulation from the side wall (minimisation of water
ingress)!
If additional sealing is required: use only heat-resistant sealing
compound!
• Side wall thruhull: Not sealable; not with self-opening valves!
Fig. 8: Exhaust system
1) Heater unit
2) Combustion air intake
3) Flexible stainless-steel exhaust pipe
4) Condensed-water drain
5) Exhaust silencer
6) Insulation
7) Gooseneck
8) Ship's side duct

Exhaust Boat heating systems
• Mount side wall duct with pipe socket angled facing upward. 4.3. Exhaust pipe
4.3.1. Exhaust pipes
• Keep the exhaust pipe as short as possible.
• Route the exhaust pipe as straight as possible (permissible total bends
< 270°; smallest permissible bending radius 2 in)!
• No contact with/ sufficient spacing to temperature-sensitive objects,
such as electrical cables, water pipes, plastic parts, sails or boat hull!
• Minimum distance from wall: ≥1in!
• Minimum pipe diameter: 1 in.
4.3.2. Length from exhaust to combustion-air pipe
The following maximum total lengths of the combustion air intake and
exhaust pipe must be complied with for Air Top 2000 ST,
Air Top Evo 3900/5500:
–
– without exhaust silencer: max. 5.0 m
Fig. 9: Side wall duct
3x ø5.5mm 1x ø40mm
top
outside inside
1) Gasket
2) Counterflange
3) Bolt/washer/nut
4) Side wall
5) Webasto marking

Boat heating systems Exhaust
4.3.3. Exhaust pipes in accommodations
WARNING!
Do not install heater unit and exhaust system in
accommodation areas!
(Danger of suffocation in case of improper installation)
• If this is unavoidable: use rigid stainless-steel pipes with a wall
thickness of ≥1 mm!
• Replace pipes with new ones after ≤10 years!
• Do not position detachable connection points in accommodation
areas!
• Use sealing compound resistant to high temperatures!
4.4. Exhaust pipe connections
• When routing the exhaust system, make sure: all connections are leak-
tight!
• Use only hose clamps approved by Webasto!
Never use hose clips!
4.5. Thermal insulation
Observe the following when routing the exhaust system:
• Avoid contact between the hot exhaust system and temperature-
sensitive objects, such as electrical cables, water pipes, plastic parts,
sails or the boat hull!
• If contact with persons/objects is possible during heating: Insulate the
exhaust pipe or fit shielding. Use suitable exhaust-gas insulation: see
the Webasto accessories catalogue.
• Surface temperature ≤176 °F!
• Minimum distance from walls ≥1in.
4.6. Gooseneck
Last section of the exhaust pipe: gooseneck sloping downward
to the outlet (due to possible ingress of water).
Height of the gooseneck: ≥1 in.
Fig. 10: Approved hose clamps for mounting exhaust pipes
Fig. 11: Exhaust insulating hose

Exhaust Boat heating systems
4.7. Condensed-water drain
With an exhaust pipe length > 6.5 ft,fit a condensed-water drain (non-
rusting).
A)With a T-piece at the lowest point in the exhaust system or
B) Use a catch container or a drain hose for condensed water if necessary.
The condensed-water drain connection piece is available in various
designs.
Fig. 12: Condensed-water drain connection piece

Boat heating systems Combustion air supply
5 Combustion air supply
5.1. Combustion air circulation
Always observe the following:
• Intake from an area well ventilated from the outside at ambient
pressure and/or directly from outside
WARNING:
Do not extract combustion air from accommodation areas/
cabins! Danger of suffocation!
• Intake location: no intake of exhaust gases from heater unit and/or
engine!
5.1.1. Intaking combustion air from an area well ventilated from
the outside (locker, storage area or engine compartment)
• No thru hull required
• Intake area must be at ambient pressure and sufficiently ventilated to
the outside.
• When intake is from the engine compartment: the ventilation fan of
the engine compartment may not produce any gauge pressure or
vacuum in the engine compartment.
5.1.2. Intaking combustion air directly from outside
• Use separate thru hull if intake from a ventilated area is not
possible.
• Design the end of the intake hose as a gooseneck as shown. Prevent
water from entering through the intake opening.
• Do not position the thru hull duct in the direction of travel (otherwise
backpressure and water ingress in the intake pipe are possible).
• Drill a drain hole at the lowest point as shown.
•Route the hose kink-free.
Fig. 13: Combustion air intake from outside through a thru hull
outlet.

Combustion air supply Boat heating systems
5.2. Intake hose
• Ensure downhill routing from the heater unit or drill a 5 mm dia.
condensed water opening at the lowest point or use a separate
condensed-water drain, see Figure 13.
• Fit a cap over the end of the hose as protection against ingress (if no
thru hull is used).
• Air inlet arrangement: cannot be blocked by objects (requirement from
2001/56/EC).
• Keep intake hose as short as possible.
For permissible lengths, see Section 4.3.2.
• Fasten the intake hose: with a hose clamp on the intake connection
piece of the heater unit and with pipe clamps or cable ties on fixed
built-in parts.
•OPTIONAL: intake silencers (intake noise).
•Please note: if the metering pump cable is routed out of the intake
connection piece, prevent pinching off the cable when installing the
intake hose by drilling a 1/4" hole at the top of the intake (AT 2000 ST only)
Do not use metal intake hoses.
•
Route the hose kink-free.

Boat heating systems Fuel Supply
6 Fuel Supply
• During installation, be sure to observe: national or local
guidelines. Ask your local authorised Webasto partner if
necessary.
• The fuel filler neck may not be located in the interior of the boat and
must be provided with a well-sealing cap to prevent fuel from escaping
(requirement from 2001/56/EC).
• If the heater unit takes the fuel from a separate additional
tank, then the fuel type and the filler neck must be clearly
marked (requirement from 2001/56/EC).
• A notice, indicating that the heater must be shut down before
refuelling, must be affixed to the fuelling point (requirement from
2001/56/EC).
• Protect the boat hull/components in the vicinity of the heater unit
against the effect of heat/contamination by fuel/oil.
Fig. 14: Example of Air Top heater unit fuel supply
1) Metering pump
2) Fuel inlet
3) Tank inlet
4) Tank
5) Fuel line
6) Heater unit