Webasto Air Top 2000 S, Air Top 3500, Air Top 5000 Installation Instructions
Marine Air Heater Systems
Air Top 2000 S
Air Top 3500
Air Top 5000
Installation Instructions
WARNING!- CONCERNING INSTALLATIONS IN GASOLINE POWERED VESSELS!
Installation of an auxiliary heater in gasoline powered vessels requires professional knowledge
and strict adherence to safety information, special installation instructions and restrictions.
For these reasons, installation of an auxiliary heater in gasoline powered vessels must be
performed by an authorized Webasto marine installation center. Installations must comply with all
applicable American Boat & Yacht Council recommendations and U.S. Coast Guard regulations.
To find an authorized Webasto marine installation center near you, please call (800) 860-7866 toll free
or visit our web site at: www.webasto.us
• Improper installation of Webasto heating and cooling systems can cause fire or the
leakage of deadly carbon monoxide leading to serious injury or death.
• Repair of Webasto heating and cooling systems requires special factory training,
technical information, special tools and special equipment.
• ALWAYS carefully follow Webasto installation instructions and heed all WARNINGS.
• Webasto rejects any liability for problems and damage caused by the system being
improperly installed.
Air Top 2000 S, 3500 & 5000 Marine Table of Contents
Contents Page
Warranty 4
Foreword 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety and Important Information Symbols and their Meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical Data 8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Installation Overview 10
Checklist of Minimum Requirements for the Installation of Heaters on Marine Vessels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Example - Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation 12
General Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Positioning of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Universal Heater Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust System 14
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Through-hull Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust Tube Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Combustion Air Intake Tube Installation 16
Fuel System 17
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Standpipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Pump and Enclosure Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Fuel System Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Heating Air Circuit 20
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heating Air Ducting Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Heating Air Intake Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hot Air Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ducting Layouts - Typical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Electrical System 25
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Harness Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fuse Holder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Element (Rheostat) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Initial Start-up 28
Maintenance/Troubleshooting 29
Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Heater Shuts Off Automatically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heater Emits Black Smoke from Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Self-Diagnostic System (Reading Flash Codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnostic Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Schematics 32
Wiring Schematic - Air Top 2000 / 2000 S with Control Element (Rheostat). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Schematic - Air Top 3500 / 5000 with Control Element (Rheostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Accessories 34
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Warranty
Air Top 2000 S, 3500 & 5000 Marine
LIMITED CONSUMER WARRANTY - BlueHeat MARINE HEATER
Webasto Product North America (WPNA) provides a limited (2) two year consumer warranty to the original purchaser
commencing on the date of purchase. This limited warranty covers parts and labor on all components of the BlueHeat
marine heater against defective materials or workmanship. Damages are limited to repair or replacement of the heater
and must be performed by a WPNA Authorized Marine Sales and Service center.
Proof of original purchase, and date of installation are required to receive limited consumer warranty service.
This warranty applies only when the BlueHeat marine heater has been installed in accordance with WPNA marine
installation instructions, or by a WPNA Authorized Marine Sales and Service Center. Transportation costs are the
responsibility of the owner.
All obligations of WPNA under this warranty shall be terminated if:
Malfunction or damage is caused by rough handling, incorrect use, vandalism, accident, improper installation or
application, adjustment, modification, alteration, unauthorized repair or service, acts of God such as lightning, careless
handling, physical abuse to, or misuse of the BlueHeat marine heater.
To submit a claim per the provisions stated in this limited consumer warranty, contact the WPNA Authorized Marine
Sales & Service Center that sold or installed the heater or the nearest WPNA Authorized Marine Sales & Service Center.
To locate the nearest WPNA Authorized Marine Sales & Service Center, call: 1-800-337-6731 or log on to our web site
at: www.webasto.us
WARRANTY LIMITATIONS AND EXCLUSIONS
WEBASTO PRODUCT NORTH AMERICA, INC. MAKES NO OTHER WARRANTY OF ANY KIND WHATEVER, EXPRESSED
OR IMPLIED; AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
WHICH EXCEED THE ABOVE STATED OBLIGATIONS ARE DISCLAIMED BY WEBASTO PRODUCT NORTH AMERICA, INC.
AND EXCLUDED FROM THIS AGREEMENT.
This limited consumer warranty is void if the owner fails to promptly complete and submit the product registration
card.
This limited consumer warranty gives purchasers specific rights. The purchaser may also be entitled to other rights
which vary from state to state. Some states may not permit Webasto to limit the duration of implied warranties or the
recovery of consequential damages.
Webasto does not authorize any person to create for it other obligation or liability in connection with its heater. This
document contains the entire limited consumer warranty, merging and integrating all related terms and conditions.
ARBITRATION CLAUSE
Any controversy or claim arising out of or relating to this limited warranty or breach thereof shall be settled by
arbitration, administered by the American Arbitration Association in the state of Michigan in accordance with the
Commercial Arbitration Rules of the American Arbitration Association and judgment on the award rendered by the
arbitrator(s) may be entered in any court having jurisdiction thereof.
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Air Top 2000 S, 3500 & 5000 Marine
Foreword
Foreword
General
The air heaters covered in this manual can be used to heat and ventilate marine vessel cabins and cockpits
(Air Top 2000 S does not feature a ventilation mode). Only Diesel or fuel oil operated heaters are
approved for installation on marine vessels.
Installation accessories can be found in our accessories list for boats/ships. The recommended accessories
for the heaters are designed to facilitate the selection of suitable components, but are not all required (or
complete) for all installation variants.
Scope and Purpose
These non-binding installation instructions are intended to support customers in the installation of Air Top
2000 S / Air Top 3500 / Air Top 5000 air heaters in marine vessels.
Acknowledged engineering conventions must be observed for the installation work.
Safety and Important Information Symbols and their Meaning
Warning
This symbol is used to highlight that non-compliance with instructions or procedures can
result in serious injuries or death to personnel.
Caution
This symbol is used to highlight that non-compliance with instructions or procedures may
cause damage to equipment.
Attention
This symbol is used to highlight and draw specific attention to important information.
Flammable or Combustible
This symbol is used to highlight and draw specific attention to flammable or combustible
materials or risks.
Reference
This symbol is used to draw attention to important information provided in Webasto or
Manufacturer Manuals.
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Foreword
IMPORTANT SAFETY INFORMATION – Read Before Proceeding with Installation!
WARNING!
• DO NOT install fuel fired heaters in unventilated passenger compartments or confined cargo holds
• DO NOT install fuel fired heaters in engine compartments or areas where equipment must be U.S.
• DO NOT install Gasoline
• DO NOT install fuel fired heaters in the engine compartment of Gasoline
• DO NOT draw combustion air from the engine compartment of Gasoline
• ALWAYS switch fuel fired heaters off during refueling or when in a refueling area.
Air Top 2000 S, 3500 & 5000 Marine
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 you fully read and understand all installation documentation supplied with
your heater BEFORE
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 Product N.A., Inc., directly at 1-800-555-4518.
unless authorized in writing by a Webasto installation specialist or Webasto Product N.A., Inc. directly.
Coast Guard rated “Ignition Proof.”
attempting installation.
fired heaters on marine vessels.
powered marine vessels.
powered marine vessels.
WARNING! - CONCERNING INSTALLATIONS IN GASOLINE POWERED VESSELS!
Installation of an auxiliary heater in gasoline powered vessels requires professional knowledge and
strict adherence to safety information, special installation instructions and restrictions. For these
reasons, installation of an auxiliary heater in gasoline powered vessels must be performed by an
authorized Webasto marine installation center. Installations must comply with all applicable American
Boat & Yacht Council recommendations and U.S. Coast Guard regulations.
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 information concerning special marine applications or marine applications you are not sure of,
contact an authorized Webasto marine dealer or Webasto Product N. A., Inc. directly at:
1-800-555-4518 (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.
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Air Top 2000 S, 3500 & 5000 Marine
Symbol Identification
Symbols that define sections in this manual
Foreword
Mechanical Preparation
Electrical
Warm Air Ducting
Fuel
Exhaust
Combustion Air Intake
Maintenance/TroubleshootingInitial Start-up
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Technical Data
Air Top 2000 S, 3500 & 5000 Marine
General Information
Unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient temperature
of +20 °C (+68 °F) and at the rated voltage and conditions.
Fuel Requirements (Diesel/):
Diesel fuel, heating oil and kerosene are suitable fuels for the heater. Any negative effect caused by additives is not
known. Any addition of waste oil is not permitted.
When changing to cold-resistant fuels, the heater must be operated for approximately 15 minutes to ensure that the
fuel metering pump is filled with the new fuel.
Electrical Components:
Control unit, motor, fuel metering pump, light bulb in the digital timer and pencil-type glow pin are designed either for
12-volt or 24-volt operation.
The digital timer, temperature limiter and flame detector are voltage-independent components.
Heater Operation AT 2000 S D AT 3500 D AT 5000 D
Mark of Approval ~ S 306 ~ S 303
Type Air heater with vaporizing type burner (Ferro-Tec)
Heat Output Control Range
Boost (30 min.)
Fuel Diesel Diesel Diesel
Fuel Consumption Control Range
Boost (30 min.)
Rated Voltage 12/24 Volts 12/24 Volts 12/24 Volts
Operating Voltage Range 12 Volt
24 Volt
Rated Power Consumption Control Range 9-22 Watts 15-36 Watts 15-90 Watts
Permissible Ambient Temperature
Heater: - operation
- storage
Metering Pump: - operation
- storage
Control Element: - operation
- storage
Combustion Air Intake
Temperature
Setting Range for Interior
Temperature
Flow Rate of Heating Air Against
0.5 mbar
Maximum +40 °C (+104 °F)
Maximum
0.9 - 2.0 kW 1.5 - 3.5 kW 1.5 - 5.0 kW
5.5 kW
0.12 - 0.24 l/h 0.17 - 0.42 l/h 0.17 - 0.60 l/h
0.66 l/h
10 - 15 Volts
20 - 30 Volts
-40 °C ... +40 °C (-40 °F ... +104 °F)
-40 °C ... +85 °C (-40 °F ... +185 °F)
-40 °C ... +20 °C (-40 °F ... +68 °F)
-40 °C ... +85 °C (-40 °F ... +185 °F)
-40 °C ... +75 °C (-40 °F ... +167 °F)
-40 °C ... +85 °C (-40 °F ... +185 °F)
+10 °C ... +45 °C (+50 °F ... +113 °F)
3
70 m
/h 139 m3/h 218 m3/h
10.5 - 15 Volts
21 - 30 Volts
10.5 - 15 Volts
21 - 30 Volts
CO
Content in Exhaust Gas
2
(operating range maximum)
Dimensions of Heater
(Millimeters)
Weight of Heater 2.6 kg (5.73 lb) 5.9 kg (13.0 lb)
Table 1: Technical Data
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9.5 ... 10.5
Vol.-%
Length 311mm
Width 120mm
Height 121mm
9.5 ... 12.0 Vol.-%
Length 425mm
Width 148mm
Height 148mm
Air Top 2000 S, 3500 & 5000 Marine
Technical Data
Dimensions
The mounting dimensions as well as the space required for the performance of servicing work are shown in the
following figures.
Air Top 2000 S
Legend for Air Top 2000 S (above) and Air Top 3500 & 5000 (below):
1 Electrical Cable Access (Right or Left)
2 Combustion Air Inlet
3 Fuel Inlet Tube
4 Exhaust Gas Outlet
5 Minimum Space Requirement for Warm Air Outlet
6 Minimum Space Requirement for Cool Air Inlet
7 Minimum Space Requirement for Heater Removal
Air Top 3500 & 5000
Permissible installation positions for
Air Top 2000 S, Air Top 3500 and
Air Top 5000 air heaters.
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0 – 90° 0 – 90°0 – 90°
General Installation Overview
Air Top 2000 S, 3500 & 5000 Marine
Checklist of Minimum Requirements for the Installation of Heaters on Marine Vessels
Installation Location of Heater
• Install heater in a location that will prevent it from being submerged in the bilge water when the vessel is heeling
• As a rule, to be installed in the foredeck box or locker (to keep exhaust lines short)
Fuel Connection
• Mount the pump as closely to the fuel tank as possible (see Fig. 9, page 19)
(maximum 1.2 meter long suction line, maximum 9 meter pressure line)
• Install pump with an anti vibration, sound deadening mount
• Always use a fuel filter (see Fig. 7, page 18 and Webasto accessories)
• Do not mount pump on frames (noise transmission)
• Provide for dedicated fuel extraction, i.e. use separate tank extraction device (standpipe), do not extract fuel from
engine’s supply line. Do not “Tee” into engine fuel delivery or return lines.
Exhaust Gas System
• Exhaust gas outlet: on sailing vessels to be located at the upper stern (due to heeling) on motor boats on the sides
(owing to submerging of the upper stern)
• Install exhaust gas outlet at least 500 millimeters (20 inches) above the water line
• Always route lines with a goose-neck bend (see Fig. 4, page 15) preventing water from entering the system when
the vessel is heeling
• Always use a sealed exhaust muffler (if applicable to your installation)
• Maximum overall length of the exhaust tube is 5 meters (16.5 feet) without muffler or 2 meters (6.5 feet) with a
muffler installed.
• The total radius of bends should not exceed 270 degrees (large radii to be selected)
• Always insulate the exhaust tubes
• A condensation water drain is necessary with exhaust line lengths greater than 3 meters (10 feet) and optional on
shorter lengths (see Fig. 4, page 15) (drain to be filled with water after installation)
Combustion Air System
• Air to be drawn from ventilated foredeck box or ventilated locker or *engine room (*Diesel engines only)
• Check that intake openings are unobstructed
Heating Air Intake
• Air to be drawn from ventilated foredeck box or ventilated locker, not from the engine room (ensure that intake
openings are kept unobstructed)
• Optionally, fresh air or recirculated air may be drawn in using a distributing piece with control flap (Webasto
accessory)
Hot Air Circulation
• In the saloon, large, non-closable air outlet nozzles are to be used
• In backrooms, use small air outlet nozzles; they may be closable
• At least one air outlet nozzle with an outlet diameter appropriate for the heater must always be open
• Keep length of the air duct lines as short as possible to achieve good heat circulation without excessive flow
restriction on the heating system overall
Electrical System
• Be sure to install an external temperature sensor if air heaters are operated in the fresh-air mode
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Air Top 2000 S, 3500 & 5000 Marine
Installation Example - Air Heater
General Installation Overview
Figure 1. Installation Example - Air Heater
Legend for Figure 1:
1Air heater
2 Fuel Connection
3 Exhaust gas line
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4 Combustion air intake line
5 Cool air inlet (return)
6 Heated air outlets
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