Webasto Air Top 2000 ST Installation Instructions Manual
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Webasto Air Top 2000 ST Installation Instructions Manual

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See also: Workshop Manual
Marine Air Heaters

Installation Instructions

Air Top 2000 ST
Air Top Evo 40
Air Top Evo 55
Trade names :
Air Top 2000 ST D
Air Top Evo 40 D
Air Top Evo 55 D
(Diesel)
(Diesel)
(Diesel)

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Summary of Contents for Webasto Air Top 2000 ST

  • Page 1: Installation Instructions

    Marine Air Heaters Installation Instructions Air Top 2000 ST Air Top Evo 40 Air Top Evo 55 Trade names : Air Top 2000 ST D (Diesel) Air Top Evo 40 D (Diesel) Air Top Evo 55 D (Diesel)
  • Page 2 Therefore, it is extremely important that the authorized installer fully read and understand all installation documentation supplied with the heater BEFORE attempting installation. 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.

  • Page 3: Table Of Contents

    Table of Contents Safety and General Information Regulations Governing installation Heater Cold and hot air Fuel supply Combustion air supply Exhaust system Electrical Connections Wiring diagrams Initial operation Troubleshooting Technical data...

  • Page 4: 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 2000ST / Evo 40 / Evo 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.
  • Page 5 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 1.3 About this Document To enable quick reference to the individual procedures you will find a descriptive symbol on the top outer edge of each page and safety symbols and signal words which are intended to convey the level of importance of the safety messages.
  • Page 6 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 1-800-555-4518.

  • Page 7: Regulations Governing Installation

    Webasto products. The same applies When installing the heater, the maximum inclination of the marine for repairs without using genuine Webasto service parts. This will void the vessel must be taken into account. The heater must not be submerged, heaters “official Marks of Conformity.”...
  • Page 8 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 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.

  • Page 9: Heater

    Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 Heater Air heater Air outlet; Exhaust line; Cold air intake; Fuel pump; Room temperature sensor; Hot air hoses; Fuel tank; Control element Fig. 1 Installation example...
  • Page 10 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 3.1. Choosing installation location Every reasonable precaution should be taken when positioning the  heater to minimize the risk of injury and damage to personal...
  • Page 11 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 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.
  • Page 12 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 Heater data Dimensions Air Top Evo 40 / Air Top Evo 55 Cold air inlet Cable outlet (optionally on right or left) Hot air outlet...
  • Page 13 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 3.2.2. Dimensions Air Top 2000 ST Cold air inlet Cable outlet (optionally on right or left) Hot air outlet Exhaust gas outlet Fuel inlet Combustion air inlet...
  • Page 14 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 ATTENTION: Danger of drowning! There is a danger of drowning when drilling into the boat's outer skin! Drilling below the water line can cause the boat...
  • Page 15 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 ATTENTION: There is a danger of drowning when drilling into the boat's outer skin! Drilling below the water line can cause the boat to sink! If the boat is in the water: check the drilling location! ...
  • Page 16 Marine Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 • 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).

  • Page 17: Cold And Hot Air

    Marine Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 Cold and hot air 4.1. General 4.2. Fresh air mode ATTENTION: Cold air is drawn in from the outside, heated and blown into the boat's Danger of suffocation! interior.
  • Page 18 Marine Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 4.5. Properties of cold and hot air ducts NOTE: For fresh air mode, a room temperature sensor must be Recommended inside diameter of main hot air duct: installed in the cabins to be heated.
  • Page 19 Marine Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 4.7. 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 ...
  • Page 20 Marine Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 4.8. Air routing examples 2000ST EVO 40 EVO 55 1) Cold air intake A: in 9 m sailing boat 2) Y-junction or T-piece...
  • Page 21 Marine Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 4.9. 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 4Air outlet Ø 90 mm, open 5 Y-junction 60/60/60 6 Air outlet Ø...

  • Page 22: Fuel Supply

    Marine Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 Fuel supply 5.1. General ATTENTION: Danger of fire! If the heater takes the fuel from a separate additional tank, the fuel type and the filler neck must be clearly marked. .
  • Page 23 Marine Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 5.3. Pipe lengths and delivery head When installing the fuel line make sure that it is kept as short as possible. See Fig. 19. The pipe must be installed such as to protect it from being damaged.
  • Page 24 Marine Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 The fuel lines must be secured using state-of-the-art fastening elements. Do not damage the fuel line. Intake side: : Inside diameter of fuel line = 2 mm.
  • Page 25 Marine Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 Parameter Value For installation kits for metal fuel lines see the accessories catalogue. Length of intake pipe l max. 5 Length of pressure pipe l max. 10...
  • Page 26 Air Top 2000 ST / Evo 40 / Evo 55 5.4. 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.
  • Page 27 Marine Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 The fuel pump outlet must be as shown in Figure 24 below 5.5. Auxiliary tank (check-marked images) when installing the enclosure. This ATTENTION: will ensure the fuel metering pump is in the correct If an auxiliary tank is required for the fuel supply to the horizontal plane for proper operation and fuel metering.

  • Page 28: Combustion Air Supply

    Marine Air Heaters Combustion air Air Top 2000 ST / Evo 40 / Evo 55 6.3. Combustion air intake directly from outside Combustion air supply Use a separate through-hull fitting if intake from a ventilated area is WARNING! Asphyxiation risk! The combustion air required for the ...
  • Page 29 Combustion air Marine Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 6.5. Combustion air intake silencer 6.4. Properties of combustion air intake line NOTE: CAUTION: A combustion air intake silencer must be installed if the The exhaust pipe can be confused with the combus- length of the combustion air intake line is less than 0.5 m.

  • Page 30: Exhaust System

    Marine Air Heaters Exhaust Air Top 2000 ST / Evo 40 / Evo 55 Exhaust system 7.1. General 7.2. Exhaust gas outlet ATTENTION: Generation of heat by incorrect positioning of ex- haust pipe outlet! Injuries or damage to property caused by fire Pay attention to installation position.
  • Page 31 Exhaust Marine Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Through-hull fitting: Choice of design and installation position to minimize rain water in-  gress! Only use genuine Webasto through-hull fittings! Fit insulation plate ex- ...
  • Page 32 Approved hose clamps for mounting exhaust pipes 7.4. Length of exhaust pipe and combustion air intake line For the Air Top 2000 ST / Evo 40 / Evo 55, the following maximum total lengths of the exhaust pipe must be complied with: Exhaust line...
  • Page 33 Exhaust Marine Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 7.5. Thermal insulation Observe the following points when installing the exhaust pipe: Avoid contact between the hot exhaust pipe and temperature-sensi-  tive objects such as electrical wiring, water lines, plastic parts, sails or...

  • Page 34: Electrical Connections

    For connector designations see the legend and wiring diagrams, Page 47. 8.2. Wiring harnesses Fig. 33 and Fig. 34 show the wiring harnesses for Air Top 2000 ST and Air Top Eva 40 Air Top Eva 55 Fig. 33 Wiring harness Air Top 2000 ST...
  • Page 35 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 40/55 Fig. 35 Removing control unit cover 8.3. 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.
  • Page 36 Correspondingly position the cable grommet on the wiring harness to en- The connector for the Air Top 2000 ST must be plugged in as far as point sure that the cable lead-through is sealed off in the control unit cover.
  • Page 37 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.5.1. Installing (optional) room temperature sensor Mount the sensor in a favorable/suitable position in the room to be heated. The distance to the control element is ≤ 2.5 m due to the cable length. Use a room temperature sensor with a 5 m long cable for greater distances, see the Webasto accessories catalogue.
  • Page 38 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.5.2. Connecting (optional) 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.
  • Page 39 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.6.1. Rotary sw itch 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 element.
  • Page 40 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.6.2. Air Top Evo control element MC04 Marine MC04 control element The MC04 heater control element features additional operating modes such as ECO, PLUS and VENTILATION.
  • Page 41 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.6.3. Control Element (SmarTemp) Connection (2000ST ONLY): The NOTES Control Panel should be installed in a suitable location on a flat surface if – Always make sure there are no obstacles behind the mounting possible in a visible area.
  • Page 42 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 8.7. PC diagnosis Air Top 2000 ST: The wires (gn/ws, br/ws) are used to read out any faults and the operating hours and enable CO calibration with the Webasto Thermo Test PC Di- agnosis (only for Webasto service workshops).

  • Page 43: Wiring Diagrams

    Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 Wiring diagrams Wiring diagram Air Top 2000 ST with SmarTemp Control, for legend see Page 44 Fig. 50...
  • Page 44 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 Legend to wiring diagram for Air Top 2000 ST with SmarTemp Control only Item Description Comment Heater Air Top 2000 ST  Diagnostic K cable...
  • Page 45 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 Fig. 51 Wiring diagram Air Top 2000 ST with rotary switch and ventilation switch (optional) for legend see Page 48...
  • Page 46 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 Fig. 52 Wiring diagram Air Top Evo 40 / Air Top Evo 55 with rotary switch and ventilation switch (optional) for legend see Page 48...
  • Page 47 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 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 48...
  • Page 48 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 9.1. Legend to wiring diagrams Item Description Remarks Rotary switch control element ON switch and temperature selector Item Description Remarks Switch Ventilation Heater Air Top 2000 ST/...
  • Page 49 Marine Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 9.1.2. Cable colours 9.1.3. Reference numbers Abbreviation Colour Positive at connection 10: blue Continuous heating mode with quick heating function for as long as ignition is on.

  • Page 50: Initial Operation

    Check for proper fuse tap connection. Verify the correct fuses are in the specified locations per the installation manual. Ensure heater and vehicle fuse boxes are closed and secure. Was the Webasto fuse block installed in a location protected from water and / or moisture? Ensure battery is mounted securely and connections are properly tightened.
  • Page 51 Marine Air Heaters Operation Instructions Air Top 2000 ST / Evo 40 / Evo 55 FUEL SYSTEM Complete (Yes/No/Comments) Is the standpipe properly mounted in the fuel tank? (sealed, structural integrity maintained). Validate the standpipe does not interfere with function of sending unit by checking fuel gauge for proper operation before completing installation of tank.
  • Page 52 Has the vehicle interior, engine compartment, trunk & glove compartment been inspected for cleanliness after installation. Has user manual placed in glove box? Is the vehicle clock time correct after disconnecting the battery? If you have any questions, contact our technical support team at (800) 860-7866 or via email at: info-us@webasto.com.
  • Page 53 Operation Instructions Marine Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Carefully bleed the fuel supply system after installing the heater. NOTE: As a result of the low fuel consumption the heater must be switched on several times to fill the fuel line and prime the system.

  • Page 54: Troubleshooting

    Marine Air Heaters Troubleshooting Air Top 2000 ST / Evo 40 / Evo 55 Troubleshooting Causes: The heater is shut down (fault lock-out) if: 11.1 Error Code Output – No or incorrect start -If an error occurs, the unit outputs a fault code via the control –...
  • Page 55 15 minutes to fill the fuel system with the new fuel. The units Air Top 2000 ST D, Air Top Evo 40 D and Air Top Evo 55 D are also approved for use with biodiesel (FAME) conforming to...

  • Page 56: Technical Data

    Marine Air Heaters Technical Data Air Top 2000 ST / Evo 40 / Evo 55 Heater Air Top 40 D Air Top Evo 55 D Air Top 2000ST Type approval: EMC E1 03 5529 E1 03 5529 e1*72/245*95/54*1085*00 Type approval: Heating...
  • Page 57 Technical Data Marine Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Heater Air Top 40 D Air Top Evo 55 D Air Top 2000ST Heater height [mm] 162 ± 1 162 ± 1 121 ± 1...
  • Page 58 Marine Air Heaters Notes Air Top 2000 ST / Evo 40 / Evo 55...
  • Page 59 Marine Air Heaters Notes Air Top 2000 ST / Evo 40 / Evo 55...
  • Page 60 Webasto Thermo & Comfort N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org. 5/2015 Rev. 12/2015 P/N: 5011424A...

This manual is also suitable for:

Air top evo 40Air top evo 55

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