Webasto Air Top 2000 ST, Air Top Evo 40, Air Top Evo 55 Installation Manual
Marine Air Heating Systems
Air Top 2000 ST
Air Top Evo 40
Air Top Evo 55
Installation Manual
For Diesel Powered Marine Vessels
WARNING!- CONCERNING INSTALLATIONS IN GASOLINE POWERED VESSELS!
Installation of a diesel fuel fired auxiliary heater in gasoline powered marine vessels
requires professional knowledge and strict adherence to safety information, special
installation instructions and restrictions. For these reasons, installation of a diesel fuel
fired auxiliary heater in gasoline powered marine 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. Also, all relevant state and provincial licensing regulations if any, governing
the installation and use of auxiliary heating devices in watercraft must be observed.
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
WARNING!
– When heater is in use, the surface of the hot air outlet may become hot to the touch. Contact
with skin may cause burns.
– 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.
– Installation and repair of Webasto heating and cooling systems requires special Webasto
training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you have
successfully completed the factory training course and have the technical skills, technical
information, tools and equipment required to properly complete the necessary procedures.
– 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.
– Improper installation or installation by untrained personnel voids all warranties on this product.
– 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
– 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.
attempting installation.
Air Top 2000 ST - Air Top Evo 40/55 Table of Contents
Contents Page
1. Safety and General Information 5
1.1 Warning Symbols in this Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Regulation for Installation in the Vessel 6
2.1 Legal Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Position of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Combustion Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Hot Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Hot Air Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Automatic Control of the Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Purpose of the Air Heater 8
4. Installation 9
4.1 Recommended Installation and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Air Top 40/55 Installation Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 To Install the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Optional Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Factory Plate / Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Installation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Cold and Hot Air System 13
5.1 External Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Fuel Supply 16
6.1 Removing fuel from vehicle fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Vehicles with Fuel Injection Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Vehicles with Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.5 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Combustion Air System and Exhaust System 21
7.1 Exhaust Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Electrical Connections 23
8.1 Heater Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 Supply Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3 Control Element (Rheostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.4 Control Element (SmarTemp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.5 Control Element (MC04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
9. Pre-Start Checklist 28
10.Operation Instructions 30
10.1 Starting Heater for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
10.2 Control Element Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3 Product Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.Troubleshooting 32
11.1 Error Code Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
11.2 Fault Lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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Table of Contents Air Top 2000 ST - Air Top Evo 40/55
12.Technical Data 34
12.1 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.2 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
12.3 Fuel for Air Top 40/55 B (Gasoline): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
12.4 Fuel for Air Top 40/55 D (Diesel/Heating Oil): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
13.Version 36
14.Annex 37
14.1 Drilling Template: heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
14.2 Legends to the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
14.3 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
www.webasto.us 4 Webasto Thermo & Comfort N.A., Inc.
Air Top 2000 ST - Air Top Evo 40/55 Safety and General Information
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 2000 ST, 40/55 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, and Evo 40/55 air
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: (800) 860-7866 or send a fax to:
(810) 593-6001.
The air heaters covered in this manual can be used to heat and ventilate marine vessel cabins and cockpits.
(Air Top 2000 ST does not feature a ventilation mode). Only Diesel or fuel oil operated auxiliary 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.
These installation instructions are intended to support customers in the installation of Air Top 2000 ST, Air
Top and Air Top EVO 40 / 55 air heaters in marine vessels.
Acknowledged engineering conventions must be observed for the installation work.
1.2 Warning Symbols in this Installation Manual
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual
uses a series of symbols and signal words which are intended to convey the level of importance of the
safety messages. The progression of symbols is described below. Remember that safety messages by
themselves do not eliminate danger and are not a substitute for proper accident prevention measures.
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.
www.webasto.us 5 Webasto Thermo & Comfort N.A., Inc.
Safety and General Information Air Top 2000 ST - Air Top Evo 40/55
IMPORTANT SAFETY INFORMATION – Read Before Proceeding with Installation!
WARNING!
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
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 1-800-860-7866.
• 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
• DO NOT install diesel 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.
FIRED HEATERS ON MARINE VESSELS.
attempting installation.
powered marine vessels.
powered marine vessels.
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, contact an authorized
Webasto marine dealer or Webasto Thermo & Comfort N. A., Inc. directly at: 1-800-860-7866 (USA) or 1800-667-8900 (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
Webasto Thermo & Comfort N.A., Inc. 6 www.techwebasto.com
Air Top 2000 ST - Air Top Evo 40/55 Regulation for Installation in the Vessel
2. Regulation for Installation in the Vessel
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.
2.2 Legal Provisions
2.2.1 The installation and service of Webasto heaters requires special expertise and training.
Installations and servicing of Webasto products by untrained, unauthorized personnel and endusers 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!
2.3 Position of the Heater
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.
When selecting a mounting location for the heater, keep in mind storage and the movement of gear, i.e.
sail stowage, fender stowage, conduits and service access points, steering gear linkages etc.
In selecting the best mounting location, first consider all installation aspects and the constraints they will
place on the mounting location, i.e. electrical harness routing, fuel pick-up point, fuel line routing, fresh air
and heated air ducting, and most importantly, the exhaust line maximum length and outlet position
www.webasto.us 7 Webasto Thermo & Comfort N.A., Inc.
.
Regulation for Installation in the Vessel Air Top 2000 ST - Air Top Evo 40/55
A cockpit locker or storage compartment is a favored installation area where access to the transom for the
exhaust line routing, fuel tank and fuel line, and cockpit fresh air inlet (cool air return) routing are close at
hand. Refer to Figure 1 on previous page.
As an alternative, the heater can be installed within the engine room of Diesel powered boats, however, in
this location it can be difficult to route the exhaust and other components of the heater.
Keep in mind, components such as the fresh air inlet ducting (cool air return) will have to be inspected for damage on a regular basis to avoid engine room fumes being drawn into the warm air distribution system.
Special Restrictions Concerning Gasoline Powered Vessels!
WARNING!
When installing a Webasto diesel fuel fired air heater in a gasoline powered boat, the heater MUST NOT be
installed in the engine compartment. The Webasto heater must be installed above the top level of the
engine compartment.
The combustion air supply for the heater MUST NOT be drawn from the engine compartment.
The inlet end of the combustion air intake tube must be positioned above the top level of the
engine compartment to prevent the possibility of drawing flammable vapors and gases into the
heater.
2.4 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)
• Parts of the vessel body and other components in the immediate vicinity of the heater must be
protected against excessive heat and the danger of contamination by fuel or oil.
• The internal combustion heater must not pose a fire hazard even when overheated. This requirement is
deemed to have been met if care is taken during installation to ensure an adequate distance from all
parts, as well as adequate ventilation and if fire-resistant materials or heat shields are used.
• The model/serial plate or a duplicate there of must be fitted in such a way that it is still clearly legible
when the heater has been installed in the vessel.
• When positioning the heater, all reasonable precautions must be taken to minimize the risk of personal
injury or damage to items in the vessel.
• A clearly visible indicator within the user’s field of vision must show when the heater is switched on or
off.
2.5 Fuel Connection
• Mount the pump as closely to the fuel tank as possible (see Fig. 18) (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. 16)
• 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.
• Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by
vessel and engine movement.
• Fuel lines must be securely fastened to the vessel every 12 inches (30 cm) or less along the total length
from heater to fuel tank.
Webasto Thermo & Comfort N.A., Inc. 8 www.techwebasto.com
Air Top 2000 ST - Air Top Evo 40/55 Regulation for Installation in the Vessel
• Fuel-carrying components must be protected against excessive heat and are to be installed so that any
drippings or evaporating fuel can neither accumulate nor be ignited by hot components or electrical
equipment.
• The fuel tank must be equipped with a vent cap or ventilated in another way (vent line).
• 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 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 label must be affixed to the fuel fuller neck warning that the heater must be switched off before
refueling. An identical warning must also be included in the manufacturer’s operating instructions.
2.6 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. 21) 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. 21) (drain to be filled with water after installation)
• Do not route exhaust components within 100 mm (4 inches) of flammable materials such as fuel system
components, polyurethane or similar foam insulation, styene sheet installation, wood and paper products,
carpet, glycol reservoirs, coolant lines, electrical wiring, etc.)
2.7 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
2.8 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)
2.9 Hot Air Circulation
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.
• 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
www.webasto.us 9 Webasto Thermo & Comfort N.A., Inc.
Regulation for Installation in the Vessel Air Top 2000 ST - Air Top Evo 40/55
2.10 Electrical System
• Be sure to install an external temperature sensor if air heaters are operated in the fresh-air mode.
2.11 Automatic Control of the Heating System
• When the engine stops, the heating system must cut out automatically and the fuel supply must be
stopped within 5 seconds.
• The heating system may remain in operation if a manual unit has already been activated.
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Air Top 2000 ST - Air Top Evo 40/55 Mode of Operation
3. 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.
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Installation Air Top 2000 ST - Air Top Evo 40/55
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 required for hot air outlet
B. Space requirements for cold air inlet
C. Space requirements for removing heater
D. Heater is supported only by the base
A
B
C
148
47,5
162
>200
25
>45
151
Ø25 Ø24
423
1
2
3
4
5
6
D
2
>80
4. Installation
IMPORTANT!
The regulations governing installation on pages 7-10 must be adhered to.
The heater must not be operated without the control unit cover (this will cause the heater to overheat)
The installation instruction manual supplied with the heater must always be observed.
4.1 Recommended Installation and Service Tools
• Digital Multi-Meter - Should be a good quality VAO meter.
• 1/2 Heavy-Duty, low speed drill with good quality, sharp drill bits and a selection of hole saws.
• Mounting/ Drilling Templates.
4.2 Installation Location
• 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!
• 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!
Figure 1. Dimensions of the Air Top EVO 40/55 Heater
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Air Top 2000 ST - Air Top Evo 40/55 Installation
6
311
> 20
120
6
Ø 22
Ø 22
130
120
121
>155
29
> 20> 20
Dimensions in millimeters
1
2
3
4
5
6
7
8
1. Hot air inlet
2. Hot air outlet
3. Combustion air inlet
4. Exhaust gas outlet
5. Fuel Intake
Figure 2. Dimensions of the Air Top 2000 ST Heater
4.3 To Install the Heater
The M6 nuts used to install the heater must be tightened with a torque of 6 Nm ±1 Nm (4.4 lb.-ft ± 74 lb.ft).
The installation dimensions and space requirement for service access are shown in the installation drawing
(Figure 1). The specified horizontal and axial angles must not be exceeded (Figure 3).
Figure 3. Recommended Installation Position for Heaters
6. Space required for hot air outlet
7. Space required for removing the heater
(service)
8. Cable outlet (either right or left)
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.
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Installation Air Top 2000 ST - Air Top Evo 40/55
Ø 7.5
Ø 29 Ø 28
Ø 7.5
12
Ø 7.5
18
55
44
01020304050
Ø7.5
Ø7.5
Ø7.5
Ø26
Ø26
18
12
44
55
Figure 4. Install heater unit in longitudinal direction in sailboats!
A seal (Figure 6) must
time the heater is installed. The support area for the heater foot must be flat. A special tool can be
purchased from Webasto to drill the holes and, if necessary, smooth the support area. The seal can
compensate for unevenness of max. 1 mm
Warning!
The seal or foam gasket or both must be replaced each time the heater is removed and reinstalled.
be fitted between the heater and the vessel body. This seal must be replaced each
.
Figure 5. Rubber Seal Dimensions (Left: Air Top EVO 40/55) (Right: Air Top 2000 ST)
Figure 6. Rubber Seal (Left: Air Top EVO 40/55) (Right: Air Top 2000 ST)
4.4 Universal Heater Mounting Bracket
WARNING!
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Drowning risk! Be absolutely sure where you are drilling or punching holes! Inadvertently drilling large
holes through the hull of a vessel below the waterline can result in massive water intake in very short
order. Always be aware of your surroundings should you have to make an escape in an emergency.
Air Top 2000 ST - Air Top Evo 40/55 Installation
Ensure that all moving part can move freely
For heater mounting, use the pre-drilled stainless steel mounting bracket, which is provided with the kit.
Make certain that the bracket is mounted securely to enable the heater to withstand “sea shock.” In some
cases it may be necessary to fiberglass a wooden pad in place at the mounting location to avoid drilling into
or through the hull of the vessel.
It is also preferable to position the bracket so that the heater exhaust outlet is vertical-down. This will provide
optimum heater operation and allow for vessel’s heel.
Figure 7. Universal Heater Mounting Bracket (Air Top EVO 40/55 and Air Top 2000 ST) ???
Place the heater on the mounting bracket. Ensure the rubber gasket on the base of the heater is in place.
Secure the heater using the provided hardware.
IMPORTANT!
After installation, check that the heater casing is not in contact with any parts of the vessel body.
A failure to do this may result in the hot air fan binding internally (Figure 8).
Figure 8. Installation
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Installation Air Top 2000 ST - Air Top Evo 40/55
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 familiarize yourself with possible escape routes!
4.5 Factory Plate / Label
The model/serial number plate of the heater must be positioned so that it cannot be damaged and must be
clearly legible when the heater is installed (otherwise a duplicate model plate must be used).
Inapplicable years must be erased from the model plate.
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Air Top 2000 ST - Air Top Evo 40/55 Installation
5Air heater
6 Fuel Connection
7 Exhaust gas tube
8 Combustion air intake tube
9 Cool air inlet (return)
10 Heated air outlets
4.6 Installation Example
Figure 9. Installation example (installation conditions dependent on vessel type)
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