1. DL manuals
  2. Webasto
  3. Heater
  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

    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).

  • 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

    I table of contents 1 about this document . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 2 regulations governing installation . . . . . . . . . . . . . . . . . . .50 3 use / variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 4 heater . . . . . . . . . . . . ....

  • Page 4

    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 1 about this document to enable quick reference to the individual procedures you will find a descriptive symbol...

  • Page 5

    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! ...

  • Page 6

    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 a...

  • Page 7

    Technical information boat air heaters air top 2000 st / evo 40 / evo 55 52 4 heater 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.

  • Page 8

    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). Arr...

  • Page 9

    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 ho...

  • Page 10

    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 requir...

  • Page 11

    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) spac...

  • Page 12

    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 tig...

  • Page 13

    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 fast...

  • Page 14

    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...

  • Page 15

    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 in...

  • Page 16

    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 ...

  • Page 17

    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 connec...

  • Page 18

    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 exam...

  • Page 19

    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, c...

  • Page 20

    Boat air heaters fuel air top 2000 st / evo 40 / evo 55 65 6 fuel supply 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 v...

  • Page 21

    Fuel boat air heaters air top 2000 st / evo 40 / evo 55 66 install the tank extracting device as shown in fig. 17: 1) shorten the immersion tube: the end should be approx. 25 mm above the bottom of the tank or high enough that fuel for the boat engine always remains in the tank. Cut the tube diagona...

  • Page 22

    Boat air heaters fuel air top 2000 st / evo 40 / evo 55 67 the fuel lines must be secured using state-of-the-art fastening elements. Do not damage the fuel line. Intake side: d 1 : inside diameter of fuel line = 2 mm. H 1 : fuel level (tank above fuel pump) [m] s 1 : fuel level (tank below fuel pump...

  • Page 23

    Fuel boat air heaters air top 2000 st / evo 40 / evo 55 68 6.4.1. Pipe material only use steel or plastic fuel lines made from light and temperature- resistant pa11 or pa12 (e.G. Mecanyl-rwtl) in accordance with din 73378 as the fuel pipes. 6.4.2. Connecting 2 fuel lines to a hose fig. 20 shows the ...

  • Page 24

    Boat air heaters fuel air top 2000 st / evo 40 / evo 55 69 6.5. Fuel pump air top 2000 st heaters must only be operated with the fuel pump dp 30. Air top evo 40 / air top evo 55 heaters must only be operated with the fuel pump dp 42. The fuel pump is a combined delivery, metering and shut-off system...

  • Page 25

    Fuel boat air heaters air top 2000 st / evo 40 / evo 55 70 use the flexible mount to install the fuel pump (reduces the transmission of structure-borne noise/ticking)! (see fig. 24). Fig. 22 dp30 fuel pump installation position fig. 23 dp42 fuel pump installation position fig. 24 flexible mount of f...

  • Page 26

    Boat air heaters fuel air top 2000 st / evo 40 / evo 55 71 • recommended fuel line mounting: distance from fuel pump ≥ 20 cm or with a bend to avoid structure-borne noise being transmitted through the pipe. • fuel line secured to wall and not too close to the fuel pump. 6.6. Fuel filter install a su...

  • Page 27

    Fuel boat air heaters air top 2000 st / evo 40 / evo 55 72 6.7. Auxiliary tank 6.8. Special requirements for heaters in boats with petrol engine specific requirements apply to the installation of diesel-operated heaters in petrol engine boats: • the heater must be supplied with fuel from a separate ...

  • Page 28

    Boat air heaters combustion air air top 2000 st / evo 40 / evo 55 73 7 combustion air supply 7.1. Combustion air intake line combustion air intake line: must be arranged that it cannot be blocked by objects keep combustion air intake line as short as possible mounting of combustion air intake line: ...

  • Page 29

    Combustion air boat air heaters air top 2000 st / evo 40 / evo 55 74 7.4. Properties of combustion air intake line 7.5. Combustion air intake silencer note: the combustion air intake line with silencer must not exceed a max. Length of 2.0 m. Caution: the exhaust pipe can be confused with the combus-...

  • Page 30

    Boat air heaters exhaust air top 2000 st / evo 40 / evo 55 75 8 exhaust system 8.1. General 8.2. Exhaust gas outlet outlet arrangement: position the exhaust gas outlet where no splash water can enter the boat. Recommendation: sailing boats: in stern transom. Motor boats: in side wall. At least 60 cm...

  • Page 31

    Exhaust boat air heaters air top 2000 st / evo 40 / evo 55 76 through-hull fitting: choice of design and installation position to minimise rain water in- gress! Only use genuine webasto through-hull fittings! Fit insulation plate ex- actly for thermal isolation from the side wall (minimisation of wa...

  • Page 32

    Boat air heaters exhaust air top 2000 st / evo 40 / evo 55 77 8.3. Notes on exhaust pipe the exhaust pipe must be secured to the heater with a clamp suitable for the exhaust pipe. Use suitable insulation material to avoid the dew point dropping below the minimum value. Keep exhaust pipe as short as ...

  • Page 33

    Exhaust boat air heaters air top 2000 st / evo 40 / evo 55 78 condensed-water drain fit a condensed-water drain (non-rusting) if the exhaust pipe is longer than 2 m! A) with a t-piece at the lowest point in the exhaust pipe or b) if the heater itself is at the lowest point: use an exhaust connection...

  • Page 34

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 79 9 electrical connections the free ends of all lines that are not required must be insulated! 9.1. Electrical system, general • observe all information and safety precautions! • install a clearly visible operation indicator to sh...

  • Page 35

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 80 9.3. Connecting heater to connect the heater, remove the control unit cover on the heater and plug in the wiring harness connector at the control unit. Connect voltage supply. To prevent the hot air escaping (heater overheating)...

  • Page 36

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 81 air top 2000 st: the connector for the air top 2000 st must be plugged in as far as point "a". See fig. 36. Air top evo 40 / air top evo 55: remove and dispose of the protective cap on the control unit. Plug connector x5 of the ...

  • Page 37

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 82 9.5. Temperature control install a room temperature sensor in the boat's interior (mandatory for fresh air operation)! The heater continually compares the set temperature (value set at the control element) and the actual tempera...

  • Page 38

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 83 9.5.2. Connecting room temperature sensor route the cable of the room temperature sensor up to the installation lo- cation of the control element. Here connect the sensor cable to the main wiring harness, see fig. 40. Plug cable...

  • Page 39

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 84 9.6.1. Rotary switch connect the control element (on/off and temperature preselection) with rotary potentiometer directly to the wiring harness. See fig. 42. Air top 2000 st: connector x9: preinstalled connector for control elem...

  • Page 40

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 85 9.6.2. Air top evo control element mc04 marine the mc04 heater control element features additional operating modes such as eco, plus and ventilation. The mc04 can only be used in combination with air top evo heaters. – make a 98...

  • Page 41

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 86 9.6.3. Combi timer use the adapter wiring harness to install the combi timer and connect it as shown in the wiring diagram (see “wiring diagrams” from page 87). Use the fuses f2 and, if necessary, also f4 for separate display li...

  • Page 42

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 87 10 wiring diagrams fig. 49 wiring diagram air top 2000 st with rotary switch and ventilation switch (optional) for legend see page 92.

  • Page 43

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 88 fig. 50 wiring diagram air top 2000 st with combi timer, for legend see page 92.

  • Page 44

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 89 fig. 51 wiring diagram air top evo 40 / air top evo 55 with rotary switch and ventilation switch (optional) for legend see page 92 k.

  • Page 45

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 90 fig. 52 wiring diagram air top evo 40 / air top evo 55, with combi timer, for legend see page 92 ign.

  • Page 46

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 91 fig. 53 wiring diagram air top evo 40 and air top evo 55, with control element air top evo multi control (mc04), for legend see page 92 k.

  • Page 47

    Electrical system boat air heaters air top 2000 st / evo 40 / evo 55 92 10.1. Legend to wiring diagrams 10.1.1. Cable cross-sections item description remarks a1 heater air top 2000 st/ air top evo 40 / air top evo 55 a2 control unit control unit 1574 (for air top 2000 st) control unit 1580 (for air ...

  • Page 48

    Boat air heaters electrical system air top 2000 st / evo 40 / evo 55 93 10.1.2. Cable colours 10.1.3. Reference numbers abbreviation colour bl blue br brown ge yellow gn green gr grey or orange rt red sw black vi violet ws white positive at connection 10: continuous heating mode with quick heating f...

  • Page 49

    Mechanical system boat air heaters air top 2000 st / evo 40 / evo 55 94 11 initial operation carefully bleed the fuel supply system after installing the heater. 11.1. Installation / initial operation of air top evo system installation 1. Install the heater in accordance with the installation instruc...

  • Page 50

    Boat air heaters technical information air top 2000 st / evo 40 / evo 55 95 13 technical data if no limit values are specified, the technical data will refer to the usual heater tolerances of 10% at an ambient temperature of +20 °c and at the rated voltage. 13.1. Electrical components the control un...

  • Page 52

    Bei mehrsprachiger ausführung ist deutsch verbindlich. Die telefonnummer des jeweiligen landes entnehmen sie bitte dem webasto servicestellenfaltblatt oder der webseite ihrer jeweiligen webasto landesvertretung. In multilingual versions the german language is binding. The telephone number of each co...