Webasto Air Top 2000ST Installation Instructions Manual

Marine heating systems

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Operating instructions manual (9 pages)

Operating, and servicing instructions (4 pages)

Service and repair manual (60 pages)

Table Of Contents

Installation Instructions Marine heating systems

Air heating:

Air Top 2000ST

Air Top 3500

Air Top 5000

HL 90

Water heating:

Thermo Top C

Thermo 90 ST

DBW 2010, 2016

Thermo 230, 300, 350

Table of Contents

Summary of Contents for Webasto Air Top 2000ST

Page 1 Installation Instructions Marine heating systems ® Air heating: Water heating: ® ® Air Top 2000ST Thermo Top C ® ® Air Top 3500 Thermo 90 ST ® ® Air Top 5000 DBW 2010, 2016 ® ® HL 90 Thermo 230, 300, 350...
Page 2: Table Of Contents
Marine heating system Installation Instructions Table of contents Safety instructions ..................3 General ......................4 Heating system selection ................5 Installation of the heating system..............6 Exhaust......................9 Combustion air supply................12 Fuel supply....................13 Electrics......................18 Air heaters....................19 10 Water heaters....................30 11 Acceptance and Commissioning ...............38 12 Operating instructions ................38 13 Maintenance and Service................39 Symbols used Specific risk of injury or fatal accidents...
Page 3: Safety Instructions
Marine heating system Installation Instructions 1 Safety instructions ® Heating systems should only be installed by an authorized Webasto Partner. ® If you want to install a Webasto heater system yourself: The installation assumes that you have sufficient technical and craft knowledge and skill. Unskilled installation can endanger life! Before first use, the heating system must be checked by an authorized ®...
Page 4: General
Marine heating system Installation Instructions • WARNING! When positioning the exhaust outlet, prevent the re-entry of the exhaust gasses into the warm air system or the accommodation areas. Danger of suffocation! • WARNING! Never feed combustion air into the accommodation areas. Danger of suffocation! •...
Page 5: Heating System Selection
Marine heating system Installation Instructions 3 Heating system selection Criteria for heating system selection • Boat length • region where used, • Season and • Boat form Simplified graphical representation 1. Select the boat length. 2. Go horizontally to the left to the line for the region. 3.
Page 6: Installation Of The Heating System
Marine heating system Installation Instructions 4 Installation of the heating system 4.1 Choosing the location • Install the heating system in a dry location; protected from the ingress of sea water, excessive vibration, heat and engine exhaust gasses • Suit the installation for the type of use/type of boat. Observe: all peripheral components such as maximum permitted exhaust length, on-board wall duct positions, combustion air intake, electrical wiring and cable lengths, distance from fuel tank, routing of warm air hoses, fresh air intake, etc.
Page 7 Marine heating system Installation Instructions Heating system installation in lockers (1), control cabinets (2) or engine compartment (3). 4.2 Equipment orientation Permissible installation locations: see device-specific installation instructions. 0-90˚ 0-90˚ 0-90˚ ® ® Examples of permissible installation locations for Air Top air heating system and Thermo 90 ST water heating system...
Page 8 Marine heating system Installation Instructions 4.3 Heater mounting • Securely mount the equipment (vibration, swell)! • Use a mounting assembly or bracket Air heaters: use the bracket and rubber seals provided under the feet of the equipment. ® Securing Air Top using the mounting bracket •...
Page 9: Exhaust
Marine heating system Installation Instructions 5 Exhaust 5.1 Exhaust system Feed the combustion gasses out of the boat through the exhaust system. 1) Heater; 2) Combustion air intake; 3) Flexible stainless steel exhaust pipe; 4) Condensation drain; 5) Exhaust gas sound absorber; 6) Isolation; 7) Goose neck; 8) On-board duct 5.2 Exhaust outlet Outlet arrangement: •...
Page 10 Marine heating system Installation Instructions Always assemble wall ducts with seals. 5.3 Exhaust pipe 5.3.1 Exhaust pipe Use 2-layer stainless steel flexible exhaust pipe. • Keep the exhaust pipe as short as possible (maximum exhaust pipe length: see device-specific installation instructions). •...
Page 11 Marine heating system Installation Instructions 5.5 Thermal isolation When routing the exhaust pipe, pay attention to: • Avoid contact between the hot exhaust pipes with temperature-sensitive objects such as electrical cables, water pipes, plastic parts, sails or boat hull. • If contact with persons/objects during operation is possible: Insulate the exhaust pipes or fit ®...
Page 12: Combustion Air Supply
Marine heating system Installation Instructions 6 Combustion air supply 6.1 Combustion air circulation Observe carefully: • Intake from are well ventilated from the outside at ambient pressure and/or directly from the outside. Do not extract intake air from accommodation/cabins. Danger of suffocation! •...
Page 13: Fuel Supply
Marine heating system Installation Instructions 6.2 Intake hose • Use is optional, not mandatory. • Drill a Ø 5 mm condensation opening in the downward line from the heater and/or use a separate condensation drain, see illustration. • Fit a cap over the end of the hose as a protection against ingress. •...
Page 14 Marine heating system Installation Instructions Permissible pipe lengths and lifting heights 7.2 Fuel take-off For taking off the fuel for the heater there are the following alternatives: 7.2.1 Tank take-off device • Fuel take-off directly from the boat’s fuel tank. •...
Page 15 Marine heating system Installation Instructions 7.2.3 Fuel extractor Fuel extractor with in-built blister separator The fuel extractor is a special t-piece with an integrated blister separator. Installation is possible in the feed to the engine if no priming pump is available in the tank, or in the engine return feed if this reaches nearly to the bottom of the tank.
Page 16 Marine heating system Installation Instructions • Fit the metering pump close to the tank. Distance from the tank take-off is ≤ 1.2 m. • Install the pump in a dry/cool area. Do not install in the bilge. • Pay attention to the pump flow direction. •...
Page 17 Marine heating system Installation Instructions 7.5 Fuel filter Use of a fuel filter is necessary for protecting from contamination. Install before the metering pump. If installing in the engine compartment, use only fire-resistant types in accordance with ISO 7840. 7.6 Auxiliary tank If an auxiliary tank is required for the heating system fuel supply: installation only by a specialist in marina applications (know-how about applicable standards, regulations and directives).
Page 18: Electrics
Marine heating system Installation Instructions 8 Electrics • Heating system power supply: from the boat’s service battery (not the starter batteries for the driving engine because of the risk of discharge). • Electrical connection: see device-specific installation instructions. • Note: all data and safety instructions. •...
Page 19: Air Heaters
Marine heating system Installation Instructions 9 Air heaters 9.1 General Use Heating and ventilation of - Ships cabins - Bridges Installation accessories: see parts catalog. 9.2 Method of operation Air heating in lockers draws in outside air over in-built fans and hot air intakes. The air heated in the heater flows through warm air hoses towards the bow.
Page 20 Marine heating system Installation Instructions 9.3 Hot air intake WARNING! Hot air intake from a clean area without exhaust gasses. Not from the engine compartment. • The intake opening can not be blocked by stowed articles. • Intake through an inlet hose leads to pressure losses. Consider this in the resistance calculations.
Page 21 Marine heating system Installation Instructions 9.4 Hot air circulation 9.4.1 Routing the hoses ® WARNING! Fire risk! Only use temperature-resistant Webasto hot air hoses. WARNING! Do not drill into the outer skin of the ship. Risk of drowning. Risk of injury or damage. Route hot air hoses away from contact and insulate them. •...
Page 22 Marine heating system Installation Instructions • Secure the hoses: with hose clamps on all joints. • Recommendation for hose routing through areas not to be heated: fit hoses with hose ® insulation to prevent heat loss (Webasto Thermoduct available as accessory). 9.4.2 Silencers in air circulation ®...
Page 23 Marine heating system Installation Instructions • Free flow into the cabins enables the best cabin heating and air circulation. • Only use one or two outlets per cabin. • Position of the outlet: close to the floor (best air circulation). •...
Page 24 Marine heating system Installation Instructions Determine the resistance points of the planned air lines: total the separate resistance points in the main line and add the components used. Main line begins at intake point E and ends at open outlet A. ®...
Page 25 Marine heating system Installation Instructions ® Resistance points Air Top Air heating system ® ® ® AT 2000/S/ST : 325 P AT 3500/ST : 550 P AT5000/ST : 375 P 55/60 mm inlet 80 mm inlet 90 mm inlet Dim. Poin Dim.
Page 26 Marine heating system Installation Instructions 9.4.5 Air circulation example ® A): Air Top 2000ST Marine in 9 m sailing boat: ® B): Air Top 3500 Marine in 11 m sailing boat: ® C): Air Top 5000 Marine in 13 m sailing boat:...
Page 27 Marine heating system Installation Instructions 9.4.6 Installation examples ® Air Top 3500 Marine in 37 foot sailing boat ® Air Top 3500 Marine in 43 foot sailing boat 1 Branch 90/60/90; 2 Outlet Ø 60 mm shuttered; 3 Y-piece 90/90/90; 4 Outlet Ø90 open;...
Page 28 Marine heating system Installation Instructions 9.5 Temperature control Install external temperature sensors in boat interior (mandatory for fresh air operation). The heating system compares the interior temperature with the set value and adjust the heating capacity automatically. 9.5.1 Operating control Shows the set value for the interior temperature.
Page 29 2) External temperature sensor; 3) AT 2000ST cable harness ® ® Principles of connection of the main components for the Air Top 2000ST and Air Top 3500/5000 as shown in the illustration. Details of wiring: see device-specific installation instructions. ® ®...
Page 30: Water Heaters
Marine heating system Installation Instructions 10 Water heaters 10.1 General Use: Heating boat cabins, bridges, consumption water heating. System accessories depending on the size, equipment and function. See the parts catalog. 10.2 Method of operation A water/glycol mixture is pumped through the heating system by a circulation pump, where it is heated.
Page 31 Marine heating system Installation Instructions 10.3 Water circulation 10.3.1 Pipe material selection Hot water circulation: Plastic and copper pipes or rubber hoses can be used. Material selection depends on boat type, operating conditions (salty sea air) and customer requirements. Plastic pipes •...
Page 32 Marine heating system Installation Instructions 10.3.2.2 Minimum pipe diameter The pipe diameter of the main pipe depends on the diameter of the heating system water connection. ® Thermo Top C 20 mm ® Thermo 90 ST 20 mm ® DBW 2010/2016 20 mm ®...
Page 33 Marine heating system Installation Instructions Circulation principles Legend (also see images on page 35). 1. Heater unit 6. Blower heat exchanger 11. 3-way valve 2. Circulation pump 7. Filler and overpressure valve 12. Boiler 3. Buffer vessel 8. Pressure expansion vessel 13.
Page 34: Heat Exchanger
Marine heating system Installation Instructions Install a bleed valve (automatic or manual): at high point or near difficult to reach locations; in return line. 10.4 Heat exchanger Possible heat exchangers: Plate heater body: small weight, flat construction, even heat distribution, relatively large surface for good efficiency, silent.
Page 35 Marine heating system Installation Instructions 10.5 Consumption water heating Consumption water heating by an additional boiler for showering, rinsing, washing, etc. Integration into open and closed water heating system possible. Use of a 3-way valve allows consumption water heating in summer without heating the boat. ®...
Page 36 Marine heating system Installation Instructions 10.7 Electrics Interfaces to 4 main components. 1. Power supply: from battery, directly from the boat’s supply system. ® 2. Metering pump: connect cable harness to metering pump (only for Thermo Top C and Thermo ®...
Page 37 Marine heating system Installation Instructions Installation example Schematic representation of a water heating system with blower heat exchangers and consumption water heating in a motorboat. 1) Y-junction; 2) Outlet Ø 55 mm; 3) Outlet Ø 80 mm; 4) Salon heat exchanger; 5) Pilot’s heat exchanger; 6) Pilot’s window heat exchangers;...
Page 38: Acceptance And Commissioning
Marine heating system Installation Instructions 11 Acceptance and Commissioning ® Before commissioning, the heating system must be checked by an authorized Webasto partner! Charges are liable for the acceptance. ® The following commissioning instructions apply only for authorized Webasto Partners: •...
Page 39: Maintenance And Service
Marine heating system Installation Instructions • Operate the heating system roughly once each month (also in summer) for approx.30 minutes to refresh the fuel in the pipes. • ® After installation (and/or acceptance by an authorized Webasto Partner) return the ®...
Page 40 Webasto Product (UK) Ltd. Webasto House, White Rose Way Doncaster Carrington South Yorkshire DN4 5JH Phone: +44 1302 32 22 32 www.webasto-marine.com Subject to modification...

This manual is also suitable for:

Air top 3500 Thermo 90 st Air top 5000 Dwb 2016 Thermo 230 Thermo 300 ... Show all

Webasto Air Top 2000ST Installation Instructions Manual

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