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

Boat air heaters
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See also: Workshop Manual , Instruction and Installation Manual
Boat 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/PME)
(Diesel/PME)
(Diesel/PME)

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Summary of Contents for Webasto Air Top 2000 ST

  • 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 Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.

  • Page 3: Table Of Contents

    Table of Contents About This Document ......49 Regulations governing installation ....50 Use / variants .

  • Page 4: About This Document

    Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 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. Mechanical system...

  • Page 5: Regulations Governing Installation

    40 seconds. 2.3. Additional documentation to be used These installation instructions contain all the information and instructions necessary to install Air Top 2000 ST / Evo 40 / Evo 55 heaters. The operating instructions must also be observed.

  • Page 6: Use / Variants

    Use / variants 3.1. 3.2. Variants The Webasto Air Top 2000 ST, Air Top Evo 40 and Air Top Evo 55 air Air heater for "diesel" fuel (12 or 24 V): heaters are suitable for: Air Top 2000 ST D (Diesel) ...

  • Page 7: Heater

    Technical Information Boat Air Heaters 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 8 Boat Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 4.1. Choosing installation location Every reasonable precaution should be taken when positioning the  heater to minimise the risk of injury and damage to personal property...
  • Page 9 Technical Information Boat Air Heaters 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 10 Boat Air Heaters Technical Information Air Top 2000 ST / Evo 40 / Evo 55 4.2. Heater data 4.2.1. Dimensions Air Top Evo 40 / Air Top Evo 55 Cold air inlet Cable outlet (optionally on right or left) Hot air outlet...
  • Page 11 Technical Information Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 4.2.2. 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 12 Boat 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 13 Technical Information Boat Air Heaters 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! ...
  • Page 14 Boat 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 15: Cold And Hot Air

    Cold and hot air Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Cold and hot air 5.1. General 5.2. Fresh air mode Cold air is drawn in from the outside, heated and blown into the boat's ATTENTION: interior.
  • Page 16 Boat Air Heaters Cold and hot air Air Top 2000 ST / Evo 40 / Evo 55 5.5. 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 17 Cold and hot air Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 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.
  • Page 18 Silencer in air duct 5.9. Air routing examples 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.
  • Page 19 Cold and hot air Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 5.10. 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...

  • Page 20: Fuel Supply

    Boat Air Heaters Fuel Air Top 2000 ST / Evo 40 / Evo 55 Fuel supply 6.1. 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 21 Fuel Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 6.3. Fuel extractor Fig. 17 Installing a tank extracting device in metal tank Fig. 18 Fuel extractor Install the tank extracting device as shown in Fig. 17: The fuel extractor is a special T-piece with an integrated bubble separator.
  • Page 22 Boat 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 23 • If the fuel pump is equipped with a plastic fuel damper Only use steel or plastic fuel lines made from light and temperature- (e.g. Air Top 2000 ST Diesel) it must be protected with a resistant PA11 or PA12 (e.g. Mecanyl-RWTL) in accordance with DIN protective sleeve (see accessories catalogue) when in- 73378 as the fuel pipes.
  • Page 24 NOTE: – Only use stainless steel hose clips to secure plastic lines. Air Top 2000 ST heaters must only be operated with the fuel pump DP 30. – Metal pipes: ensure cleanliness and neatness while Air Top Evo 40 / Air Top Evo 55 heaters must only be operated with the carrying out the work! Remove all soiling and burrs from fuel pump DP 42.
  • Page 25 Fuel Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Use the flexible mount to install the fuel pump (reduces the transmission of structure-borne noise/ticking)! (see Fig. 24). Fig. 24 Flexible mount of fuel pump NOTE: Fig.
  • Page 26 0° - 90° Fig. 26 Fuel filter, installation position and direction of flow Install a suitable fuel filter (e.g. Webasto fuel filter) if dirty fuel is to be Fig. 25 Fuel line mounting expected. Wherever possible install vertically, deviating by no more than 90°...
  • Page 27 Fuel Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 6.7. Auxiliary tank ATTENTION: If an auxiliary tank is required for the fuel supply to the heater: It must only be installed by a specialist company for marine...

  • Page 28: Combustion Air Supply

    Boat Air Heaters Combustion air Air Top 2000 ST / Evo 40 / Evo 55 Combustion air supply 7.1. Combustion air intake line Arrange the end of the combustion air intake line as a gooseneck, as  illustrated. Prevent water from entering through the intake opening.
  • Page 29 Combustion air Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 7.5. Combustion air intake silencer NOTE: The combustion air intake line with silencer must not exceed NOTE: a max. length of 2.0 m. A combustion air intake silencer must be installed if the length of the combustion air intake line is less than 0.5 m.

  • Page 30: Exhaust System

    Boat Air Heaters Exhaust Air Top 2000 ST / Evo 40 / Evo 55 Exhaust system 8.1. General 8.2. 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 Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 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-...
  • Page 32 Length of exhaust pipe and combustion air intake line For suitable models see the Webasto accessories catalogue. For the Air Top 2000 ST / Evo 40 / Evo 55, the following maximum total lengths of the combustion air intake line and exhaust pipe must be com- plied with: –...
  • Page 33 Exhaust Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Condensed-water drain 8.5. Thermal insulation Fit a condensed-water drain (non-rusting) if the exhaust pipe is longer Observe the following points when installing the exhaust pipe: than 2 m! ...

  • Page 34: Electrical Connections

    For connector designations see the legend and wiring diagrams, Page 87. 9.2. Wiring harnesses Fig. 33 and Fig. 34 show the wiring harnesses for Air Top 2000 ST and Air Top Evo 40 / Air Top Evo 55 Fig. 33 Wiring harness Air Top 2000 ST...
  • Page 35 Electrical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Fig. 35 Removing control unit cover 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.
  • 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 Electrical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 9.5.1. Installing room temperature sensor Mount the sensor in a favourable/suitable position in the room to be heated. The distance to the control element is  2.5 m due to the cable length.
  • Page 38 Boat Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 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.
  • Page 39 Electrical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 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 element.
  • Page 40 Boat Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 9.6.2. Air Top Evo control element MC04 Marine The MC04 heater control element features additional operating modes MC04 control element such as ECO, PLUS and VENTILATION.
  • Page 41 Air Top Evo 40 / Air Top Evo 55: Connector X9c (brown, red, green/white) can be connected to the op- Connector X9c (see Fig. 47) can also be used for Webasto Thermo Test tional Telestart remote control or the ThermoCall remote control.

  • Page 42: Wiring Diagrams

    Boat Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 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 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 Fig. 51 Wiring diagram Air Top Evo 40 / Air Top Evo 55 with rotary switch and ventilation switch (optional) for legend see Page 92...
  • Page 45 Electrical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Fig. 52 Wiring diagram Air Top Evo 40 / Air Top Evo 55, with Combi timer, for legend see Page 92...
  • Page 46 Boat 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 92...
  • Page 47 Electrical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 10.1. 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 48 Boat Air Heaters Electrical system Air Top 2000 ST / Evo 40 / Evo 55 10.1.2. Cable colours 10.1.3. Reference numbers Abbreviation Colour Positive at connection 10: Continuous heating mode with quick heating function for as long blue as ignition is on.

  • Page 49: Initial Operation

    Mechanical system Boat Air Heaters Air Top 2000 ST / Evo 40 / Evo 55 Initial operation Faults If a malfunction occurs, the operating indicator will show a flash code or NOTE: the Combi timer a fault code F .

  • Page 50: Technical Data

    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 52 Landesvertretung. In multilingual versions the German language is binding. The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country. Bij een meertalige versie is de Duitse versie bindend.

This manual is also suitable for:

Air top evo 55Air top evo 40Air top evo 40 dAir top evo 55 d

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