Webasto Air Top 2000 ST Installation Instructions Manual
Marine air heating system
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- Workshop manual (52 pages) ,
- Operating instructions manual (10 pages)
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Summary of Contents for Webasto Air Top 2000 ST
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Page 1: Installation Instructions
Installation Instructions Marine Air Heating Systems Air Top 2000 ST Air Top Evo 3900 Air Top Evo 5500 Air Top 2000 ST D (Diesel/PME) (diesel/PME) Air Top Evo 3900 D (Diesel/PME) (diesel/PME) Air Top Evo 5500 D (Diesel/PME) (diesel/PME) 06/2010... - Page 2 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.
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Page 3: Table Of Contents
Webasto Marine Contents Safety Precautions ....... .55 General .........57 Installing Heater Unit . -
Page 4: Safety Precautions
Comply with the technical! • Repairs not carried out properly or without genuine Webasto spare parts will lead to the warranty being voided by Webasto. This will result in the homologation approval of the heater unit being voided. • Only use heater controls approved by Webasto! Otherwise, there is a... - Page 5 Safety Precautions Boat heating systems WARNING! The heating unit must be switched off while refuelling! WARNING! Use only fire-resistant fuel lines and temperature-resistant, thermally insulated heating air hoses! Fire danger!! WARNING! Do not blow hot air directly onto living creatures or temperature-sensitive parts!
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Page 6: General
Boat heating systems General General Using heater units Relevant standards for installation Solely for use on ships: – Recreational Craft Directive 94/25/EC • For pre-heating and heating of ship's cabins, cargo holds, passenger – ISO 8845/46 - Protection against ignition of surrounding flammable and crew transport areas gasses •... - Page 7 General Boat heating systems 2.1. 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.
- Page 8 Boat heating systems General Air heater; Air outlets; Exhaust system; Heating air intake; Metering pump; Temperature sensor (OPTIONAL) Warm air hoses; Fuel tank; Control element Fig. 1: Example of a sailing yacht...
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Page 9: Installing Heater Unit
Installing Heater Unit Boat heating systems Installing Heater Unit 3.1. Choosing installation location CAUION: Heater unit can overheat! WARNING! • Ensure sufficient spacing to all parts and sufficient Do not install heater unit and exhaust system in accommodation areas! ventilation! (Danger of suffocation in case of improper installation) •... - Page 10 Boat heating systems Installing Heater Unit • Recommendation on 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.
- Page 11 Boat heating systems 3.2. Heating unit dimensions The installation dimensions and the space requirements for maintenance accessibility are shown in Figure 3. Air Top 2000 ST: Air Top Evo 3900/ Air Top Evo 5500: 1) Heating air inlet 6) Space requirement for heating air inlet...
- Page 12 Boat heating systems Installing Heater Unit 3.3. Unit orientation 3.4. Heater unit mounting The specified horizontal and axial angles must not be exceeded. • Securely mount the unit (vibrations, swells)! • Use the bracket and rubber gasket provided under the unit base. •...
- Page 13 Installing Heater Unit Boat heating systems • Recommendation: elastic mounting (vibration decoupling, noise reduction)! • Screw the heater unit onto the bracket with bolts. • Recommendation when mounting on outer skin of FRP boats: laminate on a wooden sheet at the fastening location from the inside to prevent drilling through the outer wall.
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Page 14: Exhaust
Choice of design and installation position: Minimisation of rain water ingress! Fig. 8: Exhaust system • Use only genuine Webasto side wall thru hull! Fit insulating washers exactly for thermal insulation from the side wall (minimisation of water ingress)! If additional sealing is required: use only heat-resistant sealing compound! •... - Page 15 Minimum pipe diameter: 1 in. 4.3.2. Length from exhaust to combustion-air pipe The following maximum total lengths of the combustion air intake and exhaust pipe must be complied with for Air Top 2000 ST, Air Top Evo 3900/5500: – – without exhaust silencer: max.
- Page 16 4.4. Exhaust pipe connections • When routing the exhaust system, make sure: all connections are leak- tight! • Use only hose clamps approved by Webasto! Never use hose clips! Fig. 11: Exhaust insulating hose ≤ 176 • Surface temperature °F ! ≥...
- Page 17 Exhaust Boat heating systems 4.7. Condensed-water drain With an exhaust pipe length > 6.5 ft, fit a condensed-water drain (non- rusting). A) With a T-piece at the lowest point in the exhaust system or B) Use a catch container or a drain hose for condensed water if necessary. The condensed-water drain connection piece is available in various designs.
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Page 18: Combustion Air Supply
Boat heating systems Combustion air supply Combustion air supply 5.1. Combustion air circulation • Do not position the thru hull duct in the direction of travel (otherwise backpressure and water ingress in the intake pipe are possible). Always observe the following: •... - Page 19 Combustion air supply Boat heating systems 5.2. Intake hose • Ensure downhill routing from the heater unit or drill a 5 mm dia. condensed water opening at the lowest point or use a separate condensed-water drain, see Figure 13. • Fit a cap over the end of the hose as protection against ingress (if no thru hull is used).
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Page 20: Fuel Supply
Fuel Supply Fuel Supply • During installation, be sure to observe: national or local guidelines. Ask your local authorised Webasto partner if necessary. • 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). - Page 21 Fuel Supply Boat heating systems 6.1. Pipe lengths and lifting height The fuel is taken from the boat fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in Figure 15.
- Page 22 When selecting the fuel extractor, note boat engine always remains in the tank. Cut the tube diagonally. the diameters of the pipes present. Deburr the cut edges. See the Webasto accessories catalogue for a suitable fuel extractor.
- Page 23 Fuel Supply Boat heating systems 6.3. Fuel line 6.4. Metering pump Fuel line material (metal/plastic): Observe the regional/ The metering pump is controlled via a separate wiring harness and feeds national regulations! the fuel into the combustion chamber of the heater unit depending on the required heating capacity.
- Page 24 AT 2000 ST and Air Top Evo 3900/5500 diesel heating units If the metering pump is equipped with a plastic fuel damper (e.g. Air Top 2000 ST Diesel), then it must be protected with a protective sleeve (see accessories catalogue) when being installed in the engine compartment.
- Page 25 Fuel Supply Boat heating systems 6.6. Auxiliary tank If an auxiliary tank is required for the heater unit fuel supply: it may only be installed by a specialist company for marine applications (with know-how on the required standards, regulations and directives). 6.7.
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Page 26: Air Ducting
Boat heating systems Air ducting Air ducting 7.1. Heating air intake • Prevent water from entering through the intake opening. CAUTION! The heating air intake must be carried out in a clean area without exhaust gases. Never from the engine compartment! •... - Page 27 7.2.1. Routing hoses • Recommendation: Routing through bulkheads: use wall ducts as shown in the illustration (protection against chafing). See the Webasto WARNING! accessories catalogue. Fire danger! Use only temperature-resistant Webasto hot air hoses!
- Page 28 • Recommendation for routing hoses through area not to be heated: fit the hose sections with hose insulation to prevent heat loss (Webasto All desired areas in the boat can be evenly heated with an appropriate air Thermoduct available as an accessory).
- Page 29 Table 1 lists common components and their resistance points. For the complete range of parts: see Webasto accessories catalogue. Before installing the air ducting system, make sure: the permissible total sum of the resistance points in the main branch...
- Page 30 Boat heating systems Air ducting Example: Air Top Evo 5500 Determine the resistance points of the planned air ducting: add together the individual resistance points of the components used in the main line. No. Component Resistance Main line begins at intake point E and ends at open air outlet A (see Points Figure 28).
- Page 31 Air ducting Boat heating systems Table 1 Resistance points table for common air ducting parts 55/60 mm inlet 90 mm inlet [mm] Points [mm] Points [mm] Points Intake grille Flexible pipe per meter Bends in flexible pipe 90-->60 Reduction 60 -> 55 90-->80 90°heating air manifold...
- Page 32 Boat heating systems Air ducting Table 1 Resistance points table for common air ducting parts 55/60 mm inlet 80 mm inlet 90 mm inlet [mm] Points [mm] Points [mm] Points Hose connector 90° elbow 90/60/90 45° branch 60/60/60 45° branch 60/60/60 80/80/80 80/55/55...
- Page 33 Air ducting Boat heating systems Table 1 Resistance points table for common air ducting parts 55/60 mm inlet 90 mm inlet [mm] Points [mm] Points [mm] Points Distributor with 55/55/55 00/00 90/90/90 butterfly valve 60/60/60 T-piece with 60/60/60 90/60/90 thread T-piece with 60/60/60 90/60/90...
- Page 34 Boat heating systems Air ducting 7.2.5. Air ducting examples Air Top 2000 ST Marine in 9 m/29.5 ft sailboat: Legend for Figure 29: Air Top Evo 3900 Marine in 11 m/36 ft sailboat: open Air Top Evo 5500 Marine in 13 m/42.5 ft sailboat:...
- Page 35 Air ducting Boat heating systems 7.2.6. Installation examples Air Top Evo 3900 Marine in 37 m/121 ft sailboat 1. Branch, 90/60/90 2. Air outlet, 60 mm dia., closeable 3. Y-piece, 90/90/90; 4. Air outlet, 90 dia. open Air Top Evo 5500 Marine in 43' sailboat 5.
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Page 36: Electrical Connections
8.2. Wiring harnesses • Note: observe all information and safety precautions! Figure 31 and Figure 32 show the wiring harnesses for Air Top 2000 ST and Air Top Evo 3900/5500. • Mount an operation indicator clearly visible for operators which... - Page 37 See Figure 34. Press the plug until a "click" is heard (locking). Air Top Evo On the Air Top 2000 ST the plug must engage at point “a”. 3900/5500 “a” Fig. 32: Wiring harness of Air Top Evo 3900/5500...
- Page 38 Boat heating systems Electrical connections Air Top Evo 3900/5500: OPTIONAL External Temperature Sensor 8.3. Power Supply Pull the black terminating resistor off the control unit if external sesnor. • Heating unit power supply: from the boat's service battery (not the is used.
- Page 39 Electrical connections Boat heating systems 8.4. Temperature control • The heater unit must be protected with a fuse (F1). F = 20 A (12 V) Install external temperature sensors in the boat's interior (mandatory for F = 15 A (24 V) fresh air operation).
- Page 40 Boat heating systems Electrical connections Connection of OPTIONAL external temperature sensor: Route the cable of the external temperature sensor up to the installation location of the heater control. The sensor cable is connected to the main wiring harness there, see Figure 38. •...
- Page 41 Electrical connections Boat heating systems 8.5. Control element This switches the heater unit ON/OFF and specifies the setpoint value for the interior temperature. Position: mount easily accessible, visible and protected from water in the interior. The position has no effect on the control behaviour. Various heater controls with different operating ranges are available, see the accessories catalogue.
- Page 42 The rotary knob should be installed as shown in figure 41. preselection) directly to the wiring harness with the rotary potentiometer. See Figure 39. Air Top 2000 ST: Connector X9: premounted connector for heater control. Use the Pink cable for the ventilation switch (optional). Install a grounding cable to the switch when using a ventilation switch.
- Page 43 MC04 heater control Observe coloured markings Fig. 44: Installing MC04 heater control Optional connection for: – Telestart/Thermo Call – Webasto Thermo Test diagnosis Heater units wiring harness Fig. 43: Connection diagram for Air Top Evo 3900/5500 with MC04 heater control...
- Page 44 Thermo Test Connection / PC Diagnosis Air Top Evo 3900/5500: Air Top Evo 3900/5500: Connector X9c (see Figure 45) can be used for Webasto Thermo Test Connector X9c (br, rt, gn/ws) can be connected to the thermo test PC diagnosis.
- Page 45 Electrical connections Boat heating systems 8.7. Wiring diagram Fig. 47: System wiring diagram for Air Top 2000 ST, 12 V/24 V with rotary switch and ventilation switch (option)
- Page 46 Boat heating systems Electrical connections Fig. 48: System wiring diagram for Air Top 2000 ST, 12 V/24 V with combination timer...
- Page 47 Electrical connections Boat heating systems Fig. 49: System wiring diagram for Air Top Evo 3900 and Air Top Evo 5500, 12 V/24 V with rotary switch and ventilation switch (option)
- Page 48 Boat heating systems Electrical connections Fig. 50: System wiring diagram for Air Top Evo 3900 and Air Top Evo 5500, 12 V/24 V with combination timer...
- Page 49 Electrical connections Boat heating systems Fig. 51: System wiring diagram for Air Top Evo 3900 and Air Top Evo 5500, 12 V/24 V with MC04 heater control...
- Page 50 Boat heating systems Electrical connections 8.8. Legend for circuit diagrams Cable cross-sections < 7.5 m 7.5 - 15 m 0.75 mm 1.0 mm 1.0 mm 1.5 mm 1.5 mm 2.5 mm 2.5 mm 4.0 mm 4.0 mm 6.0 mm Cable colours blue brown yellow...
- Page 51 Overheating sensor Overheating guard X8 - Plug connection Temperature sensor External Glow plug/Flame monitor On Air Top 2000 ST glow plug Plug connection to item Y1 only Plug connection to item P Fuse 24 V 15 A/12 V 20 A...
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Page 52: Approval And Commissioning
30 minutes to refresh the fuel in the line. • Following installation (or acceptance by an authorised Webasto partner), return the guarantee card to Webasto! Keep the purchase receipt! • Inform the insurance company of the installation (adjustment of the... -
Page 53: Maintenance And Service
• Replacing fuses: only use fuses with the prescribed rating! • Only use genuine accessories/genuine spare parts/parts from other manufacturers approved by Webasto! Maintenance and service work is due at the following intervals: Annually: • Check electrical connectors and contacts for corrosion. -
Page 54: Technical Data
Boat heating systems Technical data Technical data Except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °C / 68 F and at the rated voltage and in rated conditions. 12.1. - Page 55 Technical data Boat heating systems Heater Operation Air Top 2000 ST D Type test permit e1*72/245*95/54*1085*00 heater unit e1*2001/56*0022*00 E1* R122 00 0216*-- Model Air heater with evaporator burner Heat output Control range 0.9 - 2.0 kW / 900-2000 BTU...
- Page 56 Boat heating systems Technical data Heater Operation Air Top Evo 3900 Marine D Air Top Evo 5500 Marine D Type test permit e1*72/245*2006/28*5079*__ e1*2001/56*2006/119*0219*__ e1*2001/56*2006/119*0220*__ Model Air heater with evaporator burner Heat flow: Control range - Normal (Plus) 1.5 - 3.5 (3.9) kW 1.5 - 5.0 (5.5) kW Fuel Diesel EN 590, Kerosene...
- Page 57 Webasto Product North America 15083 North Rd Fenton, MI 48430 http://www.techwebasto.com http://www.webasto.com...