Webasto Air Top 2000 S Installation Instructions Manual
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Webasto Air Top 2000 S Installation Instructions Manual

Marine air heater systems
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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

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Summary of Contents for Webasto Air Top 2000 S

  • Page 1 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...
  • Page 2 • 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.

  • Page 3: Table Of Contents

    Air Top 2000 S, 3500 & 5000 Marine Table of Contents Contents Page Warranty Foreword General ..................5 Scope and Purpose .

  • Page 4: Warranty

    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.

  • Page 5: Foreword

    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.

  • Page 6: Important Safety Information

    • 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 Product N.A., Inc. directly. • DO NOT install fuel fired heaters in engine compartments or areas where equipment must be U.S.

  • Page 7: Symbol Identification

    Air Top 2000 S, 3500 & 5000 Marine Foreword Symbol Identification Symbols that define sections in this manual Mechanical Preparation Fuel Electrical Exhaust Warm Air Ducting Combustion Air Intake Initial Start-up Maintenance/Troubleshooting www.webasto.us Webasto Product N.A., Inc.

  • Page 8: Technical Data

    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.

  • Page 9: 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) 5 Minimum Space Requirement for Warm Air Outlet...

  • Page 10: General Installation Overview

    • 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 •...

  • Page 11: Installation Example - Air Heater

    Air Top 2000 S, 3500 & 5000 Marine General Installation Overview Installation Example - Air Heater Figure 1. Installation Example - Air Heater Legend for Figure 1: 1 Air heater 4 Combustion air intake line 2 Fuel Connection 5 Cool air inlet (return)

  • Page 12: Installation

    Special Restrictions Concerning Gasoline Powered Vessels! WARNING! When installing a Webasto 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.

  • Page 13: Universal Heater Mounting Bracket

    Air Top 2000 S, 3500 & 5000 Marine Universal Heater Mounting Bracket WARNING! 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.

  • Page 14: Exhaust System

    Air Top 2000 S, 3500 & 5000 Marine Exhaust System General Information The permissible lengths, bending radii and diameters stated in the heater manufacturer’s installation manual for your particular heater apply to the installation of the exhaust tubing and system.
  • Page 15 If exhaust gas lines are routed through rooms occupied by persons, these pipes must be replaced with genuine Webasto replacement parts after at least 10 years of service. At the lowermost point of the exhaust gas line, a condensation water drain (see Fig. 4, item 3) can be installed via which the condensation water collecting in the exhaust gas line can be drained off at regular intervals.

  • Page 16: Combustion Air Intake Tube Installation

    Air Top 2000 S, 3500 & 5000 Marine Combustion Air Intake Tube Installation WARNING! Asphyxiation risk! The combustion air required for the heater may only be drawn in from the outside or from spaces that are not occupied by persons e.g. ventilated foredeck box or ventilated *engine compartment (Diesel only).

  • Page 17: Fuel System

    Air Top 2000 S, 3500 & 5000 Marine Fuel System General Information If you are installing the heater under the American Boat & Yacht Council, Inc. (ABYC) guidelines, the advice of a specialist should sought. The Fuel system conforms to Inland Waterways specifications.

  • Page 18: Fuel Pump And Enclosure Installation

    In the case of gasoline powered marine vessels, a separate fuel tank must be provided to supply Diesel fuel to the Webasto air heater. Please note that gasoline fueled Webasto heaters are not recommended nor certified for marine use and must never be installed in marine vessels.

  • Page 19: Fuel System Parameters

    Air Top 2000 S, 3500 & 5000 Marine Figure 8. Fuel Pump and Enclosure Installation Fuel System Parameters Maximum suction height (A) = 1 m (39 in.) Maximum suction length (A + B) = 2 m (78 in.) Maximum delivery length (C + D) = 6 m (234 in.) Maximum delivery height (D) = 3 m (117 in.)

  • Page 20: Heating Air Circuit

    Webasto air heaters feature powerful blowers that are capable of conveying the heating air through long ducting runs for distribution throughout the vessel. Nevertheless, keep ducting runs and turns to a minimum.

  • Page 21: Heating Air Ducting Installation

    Air Top 2000 S, 3500 & 5000 Marine Heating Air Ducting Installation Figure 10 illustrates the installation of an air heater in a sailboat with heating air intake from the cockpit. Figure 11 illustrates the installation of an air heater with recirculating mode of operation in a sailboat.

  • Page 22: Heating Air Intake Options

    The return air for heating is drawn in from the cabin (and any side-rooms) either via flexible ducting or return openings. Use a Webasto fixed open grille to terminate the flexible duct. If the heater is mounted in a locker, use the grille supplied in the kit to ventilate the locker.

  • Page 23: Ducting Layouts - Typical

    Air Top 2000 S, 3500 & 5000 Marine Ducting Layouts - Typical 1 Open Air Inlet Nozzle - 60mm P/N 398551 5 Ducting - 60mm ... P/N 398497 2 Ducting - 60mm ... P/N 398497 6 Air Outlet Nozzle - 60mm .
  • Page 24 Air Top 2000 S, 3500 & 5000 Marine Ducting Layouts - Continued 1 Open Air Inlet Nozzle - 90mm P/N 91569A 9 Air Outlet Nozzle - 90mm ..P/N 91569A 2 Ducting - 90mm x 1.5m ..P/N 5000266A 10 Ducting - 60mm x 2m.

  • Page 25: Electrical System

    Air Top 2000 S, 3500 & 5000 Marine Electrical System General Information Electrical connections are to be carried out in accordance with the circuit diagrams contained in this installation manual. Main power leads must have a minimum cross-sectional area of 4.0 mm (AWG 10 Gauge) and should be routed a short as possible.

  • Page 26: Fuse Holder Installation

    (see arrows in Figure 16). Figure 16. Removal of Control Unit Cover The Air Top 2000 S will have an eight-way socket whereas the Air Top 3500 & 5000 will have a twelve-way socket. Refit the control unit cover with the harness grommet in place.

  • Page 27: Control Element (Rheostat) Installation

    Air Top 2000 S, 3500 & 5000 Marine Control Element (Rheostat) Installation ATTENTION Since the control element is not affected by temperature, it can be mounted virtually anywhere suitable within the vessel as long as it can be easily reached by the user during heater operation.

  • Page 28: Initial Start-Up

    Air Top 2000 S, 3500 & 5000 Marine Initial Start-up Before starting the heater for the first time, check your installation for: • routing and securing of wiring, fuel line, exhaust/combustion air tubes and hot air outlet/return air ducting. •...

  • Page 29: Maintenance/Troubleshooting

    For the purpose of this manual, only those items as they pertain to installation will be covered under troubleshooting. For malfunctions beyond the scope of this manual, please call Webasto Product N. A., Inc. directly at 1-800-555-4518 (USA) or 1-800-667-8900 (Canada).

  • Page 30: Heater Shuts Off Automatically

    The heater will automatically shut off if a malfunction occurs. To clear a malfunction, turn the control element knob to off, wait 2 seconds and turn on once again to reset the heaters control unit. Should the heater fail to start or continues to malfunction, consult your Webasto specialist. Heater Emits Black Smoke from Exhaust Check the combustion air intake tube and exhaust tube for obstructions or damage.

  • Page 31: Diagnostic Code Table

    Corrosion at connections more than 20 seconds Loose connections 4X Flashes (F 04) Defective flame sensor Replace flame sensor - Air Top 2000 S only Premature flame Defective flame sensor/ Replace flame sensor/glow pin - Air Top 3500/5000 detection glow pin...

  • Page 32: Schematics

    Schematics Air Top 2000 S, 3500 & 5000 Marine Wiring Schematic - Air Top 2000 / 2000 S with Control Element (Rheostat) Figure 22. Wiring Schematic - Air Top 2000 / 2000 S (12 and 24 Volt) Air Top 2000...

  • Page 33: Wiring Schematic - Air Top 3500 / 5000 With Control Element (Rheostat)

    Air Top 2000 S, 3500 & 5000 Marine Schematics Wiring Schematic - Air Top 3500 / 5000 with Control Element (Rheostat) Figure 23. Wiring Schematic - Air Top 3500 / 5000 (12 and 24 Volt) Heater - Air Top 3500 / 5000...

  • Page 34: Accessories

    Accessories Air Top 2000 S, 3500 & 5000 Marine Air Top 2000 S Part Number Description 88206A ..7-Day Digital Timer Model 1531 with 3 Programmable Settings and Temperature Control 398551 ..Hot Air Outlet Nozzle with 360 Degree Directional Adjust - 60 Millimeter 87389A .
  • Page 35 Air Top 2000 S, 3500 & 5000 Marine Accessories Air Top 3500 / 5000 Part Number Description 88206A ..7-Day Digital Timer Model 1531 with 3 Programmable Settings and Temperature Control 91569A ..Return Air Inlet or Hot Air Outlet (Flat Mount - Non Directional) - 90 Millimeter 87389A .
  • Page 36 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 01/2004 Rev. N/A P/N 5000700A www.techwebasto.com...

This manual is also suitable for:

Air top 3500Air top 5000

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