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® ®
Marine heating system Installation Instructions Table of contents 1 2 3 4 5 6 7 8 9 10 11 12 13 Safety instructions ........................................................................................3 General ...........................................................................................................4 Heating system selection .............................................................................5 Installation of the heating system.................................................
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 Webasto® Partner! DANGER This is both for your safety and for the safety of third persons.
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! • WARNING! The heating system must be turned off while refueling. • WARNING! Use only fire resistant fuel lines and temperature proof thermally insulated heating air hoses.
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. Go vertically downwards to the line for the season when used. 4. Go horizontally to the right. a) Water heater: Follow the boat type line vertically downwards in the lower triangle.
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.
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 • • • Installation locations: consider possible ship inclination.
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 • • • Recommendation: flexible mountings (decoupling oscillations, noise reduction) Secure the heater unit with screws to the mounting assembly.
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: • Position the exhaust outlet where as little water spray can enter as possible. Recommendation: Sail boat: in the stern transom.
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). • Route the exhaust pipe as straight as possible (permissible number of bends, smallest permissible curve radius: see device-specific installation instructions).
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 shielding. Use suitable exhaust pipe insulation: see the Webasto® parts catalog.
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! • Intake location: no intake of exhaust gasses (from heater and/or engine). 6.1.1 • • • No on-board ducts needed. Intake area must be at ambient pressure and be sufficiently ventilated to the outside.
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. Air intake arrangement: cannot be blocked by objects. Intake hose as short as possible. Permissible intake length: see device-specific installation instructions.
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. Plastic tanks: install tank take-off in tank fitting. Do not drill into a plastic tank. Suitable tank take-off for metal tanks: see parts catalog and/or scope of delivery.
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. When selecting the fuel extractor, pay attention to the available pipe diameter. 7.
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. Use flexible mountings for the metering pump (reduces the transmission of impeller noise/ticking). • • Recommended installation: suspended from solid boat structures.
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). 7.
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. Fit an operating indication that is clearly visible for the operator that shows whether the heating is switched on or off.
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. The warm air enters the cabins through outlets. Fuel is supplied by separate metering pumps from the boat’s fuel tank.
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. Use grilles or intake protection so that foreign objects cannot be drawn into the heater. It is possible to use the warm air intake for fresh-air operation or recirculation. 9.
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. • Hot air circulation: avoid compressing or pinching the hot air hoses. Recommended hose routing around corners • • • • Do not route hot air hoses through the bilge.
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 Recommendation: For Air Top 5000® systems with short hot air supply hoses, use a silencer in the intake and/or outlet side (noise level reduction). See the parts catalog.
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). • Choose an outlet color that matches the interior, see the parts catalog. When using air distributors, the principle applies that air always takes the route of least resistance.
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. Example: Air Top 5000® Air line No. Components 1 Intake grille, Ø 90 mm 2 1 m hot air hose, Ø 90 mm curved 3 0.5 m hot air hose, Ø 90 mm straight 4 0.4 m hot air hose, Ø 90 mm straight 5 Branch, 90/60/90 6 1 m hot air hose, Ø 90 mm straight 7 0.
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. in mm Poin ts Id. Dim.
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: Legend: open Heater intake; open and/or closable Y-branch or T-piece; Outlet With the Air Top 5000® do not reduce the main line diameter from 90 to 80 mm. If continuous use of 90 mm is not possible, it is better to use a Y-piece 90/80/80 and produce two 80 mm main strings.
Marine heating system Installation Instructions 9.4.
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. Position: easily accessible, visible and protected from water. The position has no effect on the control behavior.
Marine heating system Installation Instructions Places for removing the controller cover Connector locations for single cable harness to heater according to illustration. Plugs are coded over sockets. Connections: 1) AT 3500/5000ST® cable harness; 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.
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. Then it flows through the initial pipes of the heating circuit to the various heat exchangers (e.g.
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 • Advantages: small weight, corrosion-resistant, good insulating properties, easy to install • Only use pipes with a temperature resistance ≥ 100°C. • Consider the temperature expansion coefficient.
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 ® 20 mm Thermo 90 ST DBW 2010/2016® 20 mm 38 mm Thermo 230/300/350® Pipe diameter in side branches: keep at least to the connection diameter of the heat exchangers (heating elements, blower heat exchanger, convectors). 10.3.
Marine heating system Installation Instructions Circulation principles Legend (also see images on page 35). 1. Heater unit 2. Circulation pump 3. Buffer vessel 4. Convector 5. Heating element 6. Blower heat exchanger 7. Filler and overpressure valve 8. Pressure expansion vessel 9. Thermostat valve 10. Interior room thermometer 11. 3-way valve 12. Boiler 13. Engine 14.
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. Convectors: good heat output with good air circulation and wide construction, silent. Achieve fireplace effect. See illustration (side view).
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. Recommendation: use a pre-installed ”Webasto® Plug&Heat Water station“ (circulation control with connections).
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 90ST®). Polarity not important. If length is not sufficient, use an extension cable (accessory). 3. Connect control (on/off switch) to cable harness. 4. Circulation pump (each type separately).
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.
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: • • • • • • • • • • • With a do-it-yourself installation by customers: Check the heating system for correct installation, if necessary, rectify installation faults.
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 guarantee card to Webasto®. Keep the purchase receipt. Inform the insurer of the installation (adjustment of the amount insured). 13 Maintenance and Service Heating systems should only be repaired and maintained by an authorized Webasto® Partner.
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 www.techwebasto.com Rev. 5/2007 P/N 5001402A © 2007 Webasto Product N.A., Inc.
