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  4. Air Top 2000 ST B
  5. Installation Instructions Manual

Webasto Air Top 2000 ST B Installation Instructions Manual

Summary of Air Top 2000 ST B

  • Page 1

    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).

  • Page 2

    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 t...

  • Page 3: Contents

    Webasto marine contents 1 safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 2 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 3 installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 4 exhaus...

  • Page 4

    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 a...

  • Page 5

    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 temperat...

  • Page 6

    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: • co...

  • Page 7

    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 s...

  • Page 8

    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.

  • Page 9

    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...

  • Page 10

    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 compa...

  • Page 11

    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 outl...

  • Page 12

    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 longit...

  • Page 13

    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...

  • Page 14

    Boat heating systems exhaust 4 exhaust 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 s...

  • Page 15

    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 • no contact with/ sufficient spacing to temperatu...

  • Page 16

    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! • rep...

  • Page 17

    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 drai...

  • Page 18

    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/ ca...

  • Page 19

    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 n...

  • Page 20

    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 preven...

  • Page 21

    Fuel supply boat heating systems 6.1. Pipe lengths and lifting height the fuel is taken from the boat fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in figure 15. Be sure to observe the maximum permissible fuel intake height and/or ...

  • Page 22

    Boat heating systems fuel supply 6.2. Fuel extraction the following alternatives are available for extracting the fuel for the heater unit: 6.2.1. Fuel standpipe • fuel extraction directly from the boat's fuel tank. • plastic tanks: install the fuel standpipe in the tank fitting. Do not drill into a...

  • Page 23

    Fuel supply boat heating systems 6.3. Fuel line fuel line material (metal/plastic): observe the regional/ national regulations! Fire danger! In the engine compartment, fuel lines must be metal and connecting hoses between individual components must be made of fire-resistant material (in accordance w...

  • Page 24

    Boat heating systems fuel supply • recommended installation: suspended from a solid boat component. • recommended fuel line mounting: distance from metering pump ≥ 20 cm or in an elbow so that no structure-borne noise is conducted through the pipes. • fuel line mounting on wall (see figure 20, top v...

  • Page 25

    Fuel supply boat heating systems 6.6. Auxiliary tank if an auxiliary tank is required for the heater unit fuel supply: it may only be installed by a specialist company for marine applications (with know-how on the required standards, regulations and directives). 6.7. Special information on petrol-dr...

  • Page 26

    Boat heating systems air ducting 7 air ducting 7.1. Heating air intake caution! The heating air intake must be carried out in a clean area without exhaust gases. Never from the engine compartment! • it must not be possible to block the intake opening with stowed articles (requirement from 2001/56/ec...

  • Page 27

    Air ducting boat heating systems 7.2. Heating air ducting 7.2.1. Routing hoses warning! Fire danger! Use only temperature-resistant webasto hot air hoses! Warning! Do not drill into the outer skin of the ship! Danger of drowning! Danger of injury or damage! Route hot air hoses away from contact and ...

  • Page 28

    Boat heating systems air ducting • recommendation for routing hoses through area not to be heated: fit the hose sections with hose insulation to prevent heat loss (webasto thermoduct available as an accessory). 7.2.2. Silencers in air ducting optional special special order only: for air top evo 5500...

  • Page 29

    Air ducting boat heating systems • select the air outlet colour to match the interior, see the accessories catalogue. When using air distributors, the principle that air always takes the path of least resistance applies. The type and orientation of the distributors have exactly the same effect as th...

  • Page 30

    Boat heating systems air ducting determine the resistance points of the planned air ducting: add together the individual resistance points of the components used in the main line. Main line begins at intake point e and ends at open air outlet a (see figure 28). Example: air top evo 5500 total of 268...

  • Page 31

    Air ducting boat heating systems table 1 resistance points table for common air ducting parts 55/60 mm inlet 90 mm inlet [mm] points [mm] points [mm] points intake grille 60 24 --- 90 65 flexible pipe per meter 55 60 30 27 0 90 25 bends in flexible pipe 55 60 10 8 0 0 90 6 reduction 60 -> 55 27 90--...

  • Page 32

    Boat heating systems air ducting hose connector 55 60 12 10 80 5 90 5 90° elbow 80 50 90 77 45° branch 60/60/60 9 90/60/90 8 45° branch 60/60/60 21 80/80/80 50 y-piece 80/55/55 80/60/60 230 201 90/80/80 90/90/90 50 42 t-piece 60/60/60 13 90/90/90 13 t-piece 60/60/60 63 90/90/90 61 table 1 resistance...

  • Page 33

    Air ducting boat heating systems distributor with butterfly valve 55/55/55 60/60/60 20 19 00/00 90/90/90 21 t-piece with thread 60/60/60 8 90/60/90 11 t-piece with thread 60/60/60 36 90/60/90 254 ball outlet 60 24 closeable outlet 60 59 90 50 outlets 60 dia. 45° 139 90 dia. 45° 134 outlets 60 dia. 9...

  • Page 34

    Boat heating systems air ducting 7.2.5. Air ducting examples a): air top 2000 st marine in 9 m/29.5 ft sailboat: b): air top evo 3900 marine in 11 m/36 ft sailboat: c): air top evo 5500 marine in 13 m/42.5 ft sailboat: legend for figure 29: open open or closeable 1) heating air intake 2) y-branch or...

  • Page 35

    Air ducting boat heating systems 7.2.6. Installation examples fig. 30: installation examples air top evo 3900 marine in 37 m/121 ft sailboat air top evo 5500 marine in 43' sailboat 1. Branch, 90/60/90 2. Air outlet, 60 mm dia., closeable 3. Y-piece, 90/90/90; 4. Air outlet, 90 dia. Open 5. Y-piece, ...

  • Page 36

    Boat heating systems electrical connections 8 electrical connections 8.1. General electrical system • note: observe all information and safety precautions! • mount an operation indicator clearly visible for operators which indicates whether the heating is switched on or off (requirement from 2001/56...

  • Page 37

    Electrical connections boat heating systems connection of main wiring harness on heater unit lever open the cover of the heater unit (with a blunt object) as shown in figure 33. Connect the wiring harness to the control unit of the heater unit (under grey cover). See figure 34. Press the plug until ...

  • Page 38

    Boat heating systems electrical connections air top evo 3900/5500: optional external temperature sensor pull the black terminating resistor off the control unit if external sesnor. Is used. Connect the connector x5 of the wiring harness for the external temperature sensor to this socket. To ensure t...

  • Page 39

    Electrical connections boat heating systems • the heater unit must be protected with a fuse (f1). F = 20 a (12 v) f = 15 a (24 v) • if the mc04 heater control is used with the air top evo 3900/5500, then a 1 a fuse (f3) must be inserted in the fuse holder. • the fuse may only be installed splash-wat...

  • Page 40

    Boat heating systems electrical connections connection of optional external temperature sensor: route the cable of the external temperature sensor up to the installation location of the heater control. The sensor cable is connected to the main wiring harness there, see figure 38. • insert the yellow...

  • Page 41

    Electrical connections boat heating systems 8.5. Control element this switches the heater unit on/off and specifies the setpoint value for the interior temperature. Position: mount easily accessible, visible and protected from water in the interior. The position has no effect on the control behaviou...

  • Page 42

    Boat heating systems electrical connections 8.5.1. Rotary switch connect the heater control (switching on/off and temperature preselection) directly to the wiring harness with the rotary potentiometer. See figure 39. Air top 2000 st: connector x9: premounted connector for heater control. Use the pin...

  • Page 43

    Electrical connections boat heating systems 8.5.2. Air top evo mc04 marine heater control the mc04 heater control is equipped with additional operating modes like eco, plus and ventilation. The mc04 can only be used in combination with air top evo heater units. – produce a cut-out 98 mm wide x 63 mm...

  • Page 44

    Boat heating systems electrical connections 8.5.3. Combination timer use the combination-timer adapter wiring harness for installation and connect in accordance with the wiring diagram (figure 48 and 50). Use the fuses f2 and, if necessary, also f4 for separate display lighting. 8.5.4. Thermo test c...

  • Page 45

    Electrical connections boat heating systems 8.7. Wiring diagram fig. 47: system wiring diagram for air top 2000 st, 12 v/24 v with rotary switch and ventilation switch (option).

  • Page 46

    Boat heating systems electrical connections fig. 48: system wiring diagram for air top 2000 st, 12 v/24 v with combination timer.

  • Page 47

    Electrical connections boat heating systems fig. 49: system wiring diagram for air top evo 3900 and air top evo 5500, 12 v/24 v with rotary switch and ventilation switch (option).

  • Page 48

    Boat heating systems electrical connections fig. 50: system wiring diagram for air top evo 3900 and air top evo 5500, 12 v/24 v with combination timer.

  • Page 49

    Electrical connections boat heating systems fig. 51: system wiring diagram for air top evo 3900 and air top evo 5500, 12 v/24 v with mc04 heater control.

  • Page 50

    Boat heating systems electrical connections 8.8. Legend for circuit diagrams cable cross-sections 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet whi...

  • Page 51

    Electrical connections boat heating systems item description comment a1 heater air top 2000 st/ air top evo 3900/5500 a2 control module control unit 1574 (for air top 2000 st) control unit 1580 (for air top evo 3900/5500) b1 flame monitor only on air top 2000 st petrol units b2 temperature sensor in...

  • Page 52

    Boat heating systems approval and commissioning 9 approval and commissioning before commissioning, the heater unit must be approved by an authorised webasto partner! • only put a heater unit into operation when the system has been completely installed. • carefully bleed the fuel supply system. As a ...

  • Page 53

    Maintenance and service boat heating systems 11 maintenance and service heater units may only be repaired and maintained by an authorised webasto partner. Improper repairs can endanger life! This is both for your own safety and for the safety of others. Regular maintenance of the heating system is r...

  • Page 54

    Boat heating systems technical data 12 technical data except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °c / 68 f and at the rated voltage and in rated conditions. 12.1. Electrical components: control unit, mo...

  • Page 55

    Technical data boat heating systems heater operation air top 2000 st d type test permit emc heater unit e1*72/245*95/54*1085*00 e1*2001/56*0022*00 e1* r122 00 0216*-- model air heater with evaporator burner heat output control range 0.9 - 2.0 kw / 900-2000 btu fuel diesel en 590 pme din en 14214 fue...

  • Page 56

    Boat heating systems technical data heater operation air top evo 3900 marine d air top evo 5500 marine d type test permit e1*72/245*2006/28*5079*__ e1*2001/56*2006/119*0219*__ e1*2001/56*2006/119*0220*__ model air heater with evaporator burner heat flow: - normal (plus) control range 1.5 - 3.5 (3.9)...

  • Page 57

    Webasto product north america 15083 north rd fenton, mi 48430 usa http://www.Techwebasto.Com http://www.Webasto.Com id en t. -n r. 5001479a • 06/ 2010