4110309B EVO 40 55 Install Instructions

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Marine Comfort
Marine Comfort
Installation Instructions
Marine Air Heaters
Airtop EVO 40 Diesel

Airtop EVO 55 Diesel
Webasto Part Number : 4110309B In the interests of continued development, we reserve the right to change © Webasto Product (UK) Ltd
Issue No:1 13th November 2014 specifications without prior notice Page 1 of 22
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Marine Comfort
Thank you for choosing Webasto Marine Central Heating
We are certain that you will enjoy many years of satisfactory service from your
Webasto product. Should you require any assistance our approved distributor
and national dealer network are always at your service.
Happy Boating!
For Technical Advice and Spare Parts in the UK, please contact one of the following Approved Webasto Marine
Main Distributors:
East (England) Scotland Ireland Midlands / North West

J.P.C. Limited BOATCRAFT CH Marine Kings Lock Chandlery
Staitheway Road Clyde Marina Nautic House, Marsh Road Booth Lane, Middlewich
Wroxham, Norwich Ardrossan Skibbereen Cheshire
NR12 8RN KA22 8DB Co Cork CW10 0JJ
Tel : 0870 770 2676 Tel: 01294 603047 Tel: 00 353 28 23190 Tel: 01606 737564
Fax : 01603 784295 Fax: 01294 607076 Fax: 00 353 28 22028 Fax: 01606 737551
sales@jpcdirect.co.uk info@boatcraft.info info@chmarine.com sales@kingslock.co.uk
South (England) / Wales Midlands

Keto Ltd Wakering Engineering
25 Albany Park Kings Road
Cabot Lane Evesham
Poole Worcs.
BH17 7BX WR11 3XZ
Tel: 01202 690900 Tel: 01386 768500
Fax: 01202 691900 Fax: 01386 761094
info@ketogroup.com weclheating@gmail.com
Webasto Product UK Ltd

Webasto House, White Rose Way Doncaster Carr, South Yorkshire, DN4 5JH
Telephone (01302) 322232 Fax (01302) 322231
E Mail Address: info@webastouk.com
Website Address : www.webasto.co.uk
WARRANTY Marine Comfort

Your Webasto heater is covered by a full Warranty cover does not apply if the product was not
Manufacturer’s warranty covering defects caused by correctly installed (except as detailed above); is used
faulty manufacture. This warranty period is 24 for any purpose other than that for which it was
months from the point of purchase. designed; has been subject to misuse or neglect in any
way; has been modified without the prior approval of
Claims cannot be accepted where faulty installation Webasto product UK Ltd; has been fitted with non
has caused failure. genuine parts; or has been serviced or repaired other
than by a person approved by Webasto Product UK Ltd.
The warranty does not cover damage through water
ingress, external force, incorrect installation or Warranty cover commences upon the date of purchase
misuse. of the product, or of the equipment into which the
product is installed from new. All warranty claims must
Repairs, both during and after the warranty period, be presented with proof of purchase of the product.
should be carried out by an authorised Webasto
dealer only. Claims for repairs carried out by other
than an authorised Webasto dealer cannot be
accepted.
These conditions do not affect your statutory rights.
If you have any doubts as to who is your local

dealer, please do not hesitate to call Webasto. We
will inform you of your local dealer, who will be
pleased to give you any further information with
regard to your heater, or carry out any work or
repairs you may require.
All warranties are subject to the specific exclusions
detailed below:
Bulbs, line fuses, fuel filters, overheat fuses,

drive belts, glass panels, refrigerant,
receiver drier and lubricants. (Unless their
loss, damage or failure, has been caused by
a defect that falls within the scope of the
warranty cover as detailed above).
Glow plugs, burners, gaskets and seals normally

replaced during routine servicing, will not be
covered by the warranty, either to qualify for,
or within the duration, of any specific
warranty period.
Travelling time and mileage incurred in order to

affect repairs, (unless the installation of the
product is such that it cannot practically be
taken to an authorized repair centre).
These exclusions also preclude any claims for

labour associated with the diagnosis, or repair, of
any defects falling wholly within the scope of the
exclusions.
SERVICE Marine Comfort

Don’t guess … seek advice!
Your local authorised Webasto dealer will be

pleased to help. Check first to determine
whether ‘call out’ charges may be applicable.
Regularly check your Webasto heating system

for the following points:-
 Corrosion on electrical terminals … clean

and spray with an inhibitor as necessary
 Clean running at the exhaust … if not, call

an authorised Webasto dealer
 Ensure that the exhaust outlet and

combustion air intake are ‘free’ and not
blocked or damaged … repair or replace as
required.
 Run your heating system during the

summer, if only for a few minutes each
month, to check that it is operating
satisfactorily and to avoid ‘old’ diesel
collecting in the fuel lines. This avoids
acidity which can destroy components.
Every alternate season, it is recommended that

an authorised Webasto dealer tests the heater
system, and if required, any carbon deposits can
be removed from the heat exchanger.
If the heater takes in sea water or water from a

hose whilst cleaning the boat, - seek the advice
of a Webasto dealer immediately.
Marine Comfort
* EN590 Diesel & BS2869A2 Gas oil. The use of fuels containing high levels of sulphur, water or other contaminants may reduce the time
between services.
POSITIONING OF THE HEATER

Marine Comfort
The heater requires a dry, protected area which will
not be adversely affected by sea water, excessive Permissible mounting orientations are shown below
vibration or fumes e.g. engine exhaust.
The location of the heater must be well clear of any

gas storage or delivery lines. When choosing the 0° <> -90°
position, bear in mind storage and movement of
other gear, i.e. sail stowage warp and fender
stowage, conduits and service access points,
steering gear linkages etc. In selecting the best
position to locate the heater, first consider all
installation aspects and the constraints they will
place on the positioning, i.e. the exhaust maximum -90° <> 0° <> +90°
length, and outlet position, electrical wiring routes,
fuel pick-up point, hot air ducting, fresh air intake
etc.
Do not mount the heater as shown below
A cockpit locker is favoured as a position, where
access to the transom for the exhaust and fuel tank
and cockpit fresh air are all to hand. However, try
not to impinge upon stowage space and do not
install the heater in a position which will allow sails
to rest on any pipes which may be hot.
As an alternative, fit the heater in the engine room,

however, in this position it can sometimes be difficult As can be seen from the above illustrations the heater
to route the exhaust, and the fresh air intake ducting can be mounted in a number of different orientations.
should be examined for damage regularly to avoid The exhaust outlet stub must always point sideways on
fumes being drawn into the air distribution system. downwards only! The warm air outlet must point
sideways or downwards only! The warm air outlet is
For heater mounting, use the pre-drilled stainless shown below. It is easy to distinguish between the warm
steel plate, which is provided in the heater kit. air outlet and cold air inlet as the cold inlet is fitted with a
fan.
Make sure that the mounting plate is secure and
strongly mounted to enable the heater to withstand
“sea shock”. In some cases it may be necessary to Warm Air Outlet Cold Air Inlet
glass fibre a wooden pad at the chosen location to
avoid drilling into the hull of the vessel. It is also
preferable for this plate to be positioned so that the
heater exhaust outlet is vertical. This will provide
optimum running and allow for the vessel’s heel.
Place the heater on the mounting plate after fitting

the rubber gasket on the heater base. Secure the
heater using the four coated M6 nuts and flat
washers provided.
Typical installation of a Webasto Heater in a Sailing Yacht or Motor Cruiser:
1. Webasto Air Heater 2. Fuel Supply 3. Exhaust outlet

4. Combustion Air Intake 5. Warm Air Outlets 6. Fresh Air Intake
EXHAUST SYSTEM Marine Comfort

Length of the combustion air inlet & exhaust lines in
total:
With exhaust silencer: max 2.0m Turn Inwards & overlap
Lagging 50mm to prevent
Without exhaust silencer: max 5.0m fraying
60 Over sleeve using Woven Glass

Lagging if extra protection is
required
52 50
Secure Lagging with
'Worm Drive' type clamps
Leave sufficient exposed exhaust

Drillind Dimensions to allow exhaust clamp to be fitted
Thermo 90
Not To Scale Apply Sealant to
Underside of Face
Exhaust Insulation
Swan neck Deck

created in
exhaust
The skin fitting is normally fitted on the transom or
Swan
Swan
neckNeck
cockpit combing. The hull side is acceptable for motor
created
Created in
in Exhaust
Exhaust boats, but bear in mind the bow wave line and beam
EX sea risk. It must also not point in the direction of travel,
Heater
Exhaust Skin
or be susceptible to high land wind pressure, which may
Exhaust skin Fitting blow out the flame within the heater.
Fitting
Silencer
Measure the diameter of the skin fitting to be fitted and

Hull cut the hole using a hole saw.
A suitable pilot hole should be drilled first!
Flexible Exhaust with attached
Flexible Exhaust
Lagging with
attached Lagging  Do not fit the skin fitting below the water line.
Exhaust Connection onto
Heater  Do fit the skin fitting as high as possible to stop
Exhaust Connection - Typical water ingress
Create a swan neck in the exhaust to prevent water
 Do make sure that exhaust clamps are tight to
ingress. The heater requires a dry exhaust, not
avoid gas leakage
water injected.
 Do make sure the exhaust glasses cannot reach
Minimum bend radius: 50mm
the combustion air intake
Total bends
 Do not cover the exhaust with the heater running.
Combustion air pipe: max 270°
Exhaust pipe: max 270°
We recommend the application of a suitable high
temperature sealant being used on all the exhaust
For every 90° of bend in combustion air and exhaust
connections sufficient to fill the corrugations in the
pipes the exhaust system total length must be
flexible pipe ONLY but not enough to block or impair the
de-rated by 500mm.
exhaust system.
The exhaust from the heater must not be
connected to any other exhaust system.
We recommend the use of Webasto PC diagnostics to
verify the exhaust emissions of the installation. Your
Route the flexible exhaust, securely attached in such
local Webasto agent can supply this instrument or may
a way that the heat cannot affect
be able to offer a commissioning / calibration service.
adjacent plastic piping, electric cables etc.
For CO2 emissions refer to the table of specifications in
The exhaust pipe should be wrapped in the woven
this book.
glass protective sock and secured with stainless ties
supplied with the kit. If addition protection is re-
quired, over-wrap with woven glass tape available
from your Webasto Dealer.
FUEL CONNECTION Marine Comfort

If you are installing the heater to Lloyds
specifications, Specialist advice should sought.
The Fuel system conforms to ISO 7840 & the Inland

Waterways specifications when installed correctly
Flared end of copper pipe
as detailed. Always ensure only clean fuel is used.
The heater is designed to run on EN590 Diesel &
BS2869A2 Gas oil. Follow the diagrams below for connecting the fuel
supply and positioning the components, noting the
The use of fuels containing high levels of sulphur, mounting parameters, for the fuel pump, which are
water or other contaminants may increase the critical to ensure correct operation of the heater.
service interval required. Mount the fuel pump using the “P” clip according to
Pump Diagram. Ensure the correct direction of flow is
Several specific regulations apply including the use observed. Depending upon the quality of fuel used and
of flame resistant fuel pipe such as copper pipe, the point where the fuel is extracted from the vessels
and fire resistant fixings. Use a sharp pipe saw and fuel system, an additional water
NOT a hacksaw if the supplied copper pipes are separator and or fuel filter may be required prior to the
shortened. If the pipes are shortened the pipe ends dosing pump.
must be
Ball Valve Fuel Pump
re-flared with a suitable flaring tool as per the Heater
picture below. Ensure afterwards that the bore of
Tank
the pipes are still 2mm. Use a 2mm drill bit as a
gauge. Connect the flared copper pipes with the Fuel Filter &
small black ISO7840 hose pieces to the Fuel Pump, Water Trap
Heater, Standpipe and other fuel system parts that
have a barbed nipple connection and secure with
worm drive clamps. Fuel Supply System - Typical
The Ball Valve, Filter / Separator are optional and may

The best technique is to fit the rubber pipes on to not be part of your kit. All optional parts
the standpipe, fuel pump and the heater nipples mentioned are available from your Webasto Dealer.
and then insert the copper pipe flared ends fully into
the other ends of the rubbers. The reason for this is
The copper fuel pipe used in the system should be:
to ensure there are no gaps inside the rubber pipes
2 mm Inside Diameter
that could harbour air pockets as shown below.
5 mm Outside Diameter
Apply a dab of diesel to the pipe ends before
The copper pipe supplied with the kit meets this
assembly. This will make the installation easier and
standard.
reduce the likelihood of the bore of the rubber pipe
being torn and causing a blockage.
2 mm 5 mm
Fuel pipe dimensions
Ensure that the 2mm I.D. - 5mm O.D supplied copper

pipe is used.
If you fit any additional filter or valves in the fuel
system make sure the pipes / hoses are flared copper
Illustration of how to insert a copper pipe into a rubber joiner. and are connected with ISO7840 50mm long hose
sections clamped at each end.
If other pipe fittings are needed due to different fuel
supply arrangements i.e. in-line filters or water
traps etc other than those supplied these can be
obtained from your Webasto Dealer.
FUEL CONNECTION
(Continued) Marine Comfort
The suction hose length, (Fuel Tank to Fuel Pump)

including the pick up pipe length, (if applicable)
should be no longer than 1.20m, use the 1.2m
copper pipe supplied.
The maximum height of the Heater above the Fuel
Direction of Fuel Flow
Pump should be no more than 3.0m.
The Fuel Pump Must NOT be mounted above the Fuel Pump Orientation
heater or any exhaust pipe.
Ensure the fuel lines are installed securely with rubber
lined P-Clips and routed in such a way that they will not
≤ 1.20m ≤ 8.80m
suffer from mechanical damage.
Do not install the fuel lines adjacent to any heat
source. Do not clip the fuel lines to any exhaust
Heater system. Do not clip any wiring harness or cable to the
Tank fuel lines. When route the pipes try to avoid forming
tight angles in the copper pipe. All bends must be
gentle and sweeping with a large radii.
Fuel System - Pipe Maximum Lengths
Ensure the fuel lines are installed securely with rubber
All fuel lines must be correctly installed and securely lined P-Clips and routed in such a way that they will not
mounted and protected against heat, impact and suffer from mechanical damage.
abrasion damage. Do not install the fuel lines adjacent to any heat
source. Do not clip the fuel lines to any exhaust
Fuel Pump mounting orientation is critical to correct system. Do not clip any wiring harness or cable to the
performance. Mount horizontally using anti vibration fuel lines. When route the pipes try to avoid forming
clip with electrical connector inlet orientated tight angles in the copper pipe. All bends must be
downwards as shown in drawing below. Do not gentle and sweeping with a large radii.
mount close to heat sources, (engines or exhausts).
Ensure pump is mounted to avoid mechanical
damage. The pump must not be mounted more
than 3m below the heater. Refer to the drawing
below for the correct heights etc.
Fuel System - component heights
FUEL STANDPIPE Marine Comfort

CONNECTION
When fitting the Webasto standpipe drill the fuel tank It is possible to use instead of the Webasto standpipe
using a “25mm” hole saw, or using a cone cutter in a piece of pipe that complies with the Webasto
preference to filing. Note: before drilling, grease the standard of 5mm OD & 2mm ID. Below is a picture of
top of the fuel tank around the intended drilling area to how this can be achieved using readily available parts.
collect any swarf which will be present.
Please ensure that the
pipe used complies with
the Webasto fuel pipe
standard of:
5mm OD
2mm ID
Use bonded washers on
the bulkhead connector.
Alternative Standpipe
Webasto Standpipe
A suitable hole needs to drilled to suit either a through
Ensure that the aforementioned guidelines are referred bulkhead connector or a weld in place threaded 'bush'.
to when choosing the positions of components, such If a bulkhead connector is used, use bonded washers,
as the heater and fuel pump. (doubtless seals) between the metal of the tank and
the connector shoulder.
Link the fuel supply from the standpipe to the fuel
pump and from the pump to the heater using the If it is decided to weld in a bush, make sure the male
copper Fuel pipe with the black hose sections as insert has a tapered thread.
unions as described previously. Remember to Flare
the copper pipe ends if any pipes have been Thread a piece of pipe to the specification detailed
shortened. Remove any burrs from the Fuel pipe using above through the fitting into the fuel tank.
a small file and blow any swarf out of the pipes prior to Bend at 90 degrees taking care not to kink the pipe
fitting. and collapse the internal bore.
Lay the fuel pipe straight, preferably running gently Tighten up the nut and olive to secure the connection.
upwards towards the heater to ease the bleeding of Do not over tighten the fitting and crush the pipe.
any air in the fuel line. Avoid tight radius pipe bends as
these cause a resistance in fuel flow. It is preferable to A fuel resistant thread sealant must be used on both
have a wide radius bend. options. Do not use PTFE tape!
Securely clip the pipes at frequent intervals, away from Ensure the penetration into the fuel tank is leak free
any heat source. afterwards.
Please note if any other pipe fittings or inline Valves or

Filters etc are fitted into the fuel line that contain
compression fittings make sure they do not contain
brass olives as these are too brittle.
Only use copper olives. When using copper olives
there is less chance of distorting the copper pipe.
If the supplied standpipe is too long for the fuel tank

ascertain the correct length, (normally 4~5 inch from
tank bottom) then using a very sharp knife blade score
the pipe diameter and snap the excess off.
Ensure the standpipe is leak free after installation.
COMBUSTION Marine Comfort

AIR INTAKE
Do not extract combustion air from passenger
compartments.
The heater is pre-assembled with a 60cm length

of combustion air pipe. This should be placed in
such a position to provide dry, cool air to the
heater unit.
If mounted in the engine room, ensure that no

foreign bodies enter the intake pipe.
Do not let the pipe hang down if a potential

exists for bilge water to enter the pipe if the
vessel heels over in heavy seas.
The combustion air pipe supplied is the

maximum length permitted and should not be
extended.
Do not extract combustion air from the vessel’s

engine air intake or filter system.
HEATING AIR INTAKE Marine Comfort

(Not combustion air)
The air for heating may be drawn from a cabin via
flexible ducting and re-circulated.
In recirculation type installations use the internal
temperature sensor.
The air can be drawn from outside if required but this

will increase the time to heat the cabin.
In this type of installation use the external
temperature sensor. Be sure to mount the sensor
away from sources of heat and out of direct sunlight.
All installations will vary but in general try to mount

the sensor at the mid point between the floor and
ceiling.
If the heater is mounted in a locker use the grille

supplied in the kit to ventilate the locker.
Locate the air intake grille close to the heater intake,
so that outside air is drawn in, in preference to the
locker air.
Avoid the grille being placed so that water, fumes or

spray can enter the heater. It is not necessary to
connect the grill to the heater with flexible ducting,
unless there is a risk of contaminating air reaching
the heater.
If the heater is fitted in the engine room, use flexible

ducting to draw in fresh cabin air or external air to
avoid engine room air being used. Do not induct
engine room or bilge air into the heating air intake.
IT IS IMPORTANT THAT A SUPPLY OF CLEAN

AIR REACHES THE HEATER THROUGHOUT ITS
OPERATION.
HOT AIR OUTLETS Marine Comfort

Both recirculation and fresh air modes are possible.
For fresh air mode it must be ensured that the hot air Vent Nozzle
is taken from an area protected from the ingress of
Flexflyte Ducting
water and fluff etc.
Hose Clamps
For fresh air mode an external temperature sensor
must be fitted in the appropriate zone.
Inside the control unit there is a temperature sensor,

Y - Piece
which operates the heater in the appropriate heat
output range in conjunction with the control panel
Warm Air Ducting with Flexflyte Ducting and Y Piece - Typical
(MC-04) depending on the intake temperature and
the position of the control knob on the MC-04.
The heat output is controlled such that after the The heater will check the internal temperature rise
selected interior temperature has been reached automatically each time it is switched on. If this is above
quickly, it is then kept at this selected value. the specified limits, the start is cancelled and error
message F10 is displayed. To ensure the heaters
The recommended internal diameter of the main functional stability the flow resistance of the connected
section of the hot air output line should be 90mm for hot air ducting system must be reduced.
the EVO 5500 and 80mm for the EVO 3900.
Refer to the flow points table when designing a hot air
Only materials that can permanently withstand 130°C ducting system.
may be used for the hot air ducting. The hot air
opening is to be positioned in such a way that the air When calculating the resistance points only take into
is not blown on to any parts that cannot withstand the account the main trunk of the duct system. Do not work
heat. out the points for each branch coming off the main
trunk.
The maximum pressure drop between the inlet and
outlet side of the hot air line should not exceed the
following:
Evo 3900 2.0hPa

Evo 5500 3.0hPa
(1 hPa corresponds to 1 mbar. This also equals

10mm WC Water Column).
ct
Du
60mm Duct
m
m
80
The following diagram indicates the duct system with

tin
~
c
Du
ct
“Y” branches and outlets. Use the clamps provided

Du
of
k
un
to secure duct joints.

m
Tr
m
n
80
Avoid long runs of ducting; they are inefficient and

ai
-M
60mm Duct
~
could lead to over heating.

n
ct
io
Du
ct
se
m
is
th
m
A heater is more efficient when venting the hot air

of
80
ts
~
in
into free cabin space rather than being confined to a

po
ct
Du
e
nc
“rabbit warren” of ducting.

ta
m
sis
m
re
80
e
th
It is not always necessary to take outlets to every

ate
ul
lc
point where heat is required. The pressure of the

Ca
fan, (particularly with minimal ducting), is effective at

reaching most parts of the boat.
Keep the duct runs as straight as possible and avoid

running ducts where they could become crushed or
broken.
HOT AIR OUTLETS Marine Comfort

Flow Points Table
Heater Max number of resistance points Min. diameter of main ducting
EVO 3900 200 80mm

EVO 5500 250 80mm
Marine Comfort
Mount the remote temperature sensor in a position
ELECTRICS that will accurately measure the saloon cabin air
temperature. Do not mount the sensor above or near
For detailed schematic refer to Fig. 37 on page 73 hot air outlets, as this will affect the heater operation.
of the Webasto User & Installation guide included Fit the connector plugs as shown below, carefully!
with the heater kit. The wires are fitted with pre-crimped terminals, simply
Locate a suitable onboard DC power supply and push into the supplied plugs and check they are
check the voltage requirements of the heater are secure. Then plug to the two plugs together.
compatible. Use the supplied cable harness / wiring
loom for the electrical connections. Ensuring all
power is switched off while making the electrical
connections and remains off until the installation is
complete.
Remove the top clip on cover and connect the large
multi pin plug to the heater. Also connect the re-
Fit plug onto main harness And fit the other smaller
mote temperature sensor plug if required at the
plug onto the temp sensor
same time. The cable may exit either side of the
harness.
unit. Replace the cover ensuring the grommet is in
place.
See below for details on heater connections. Note,
only use the internal air temp sensor when the The Fuel Pump is connected by means of a separate
warm air circuit is re-circulating, i.e. cabin air is two core cable set. One end has the plug ready fixed
passed into the heater air inlet. If the air inlet is tak- and this is plugged directly into the fuel pump. The
en from outside the cabin use the remote air sensor other end needs the plugs fitting. The reason for this is
supplied. Do not confuse combustion air with re to allow the installer to manoeuvre the cable through
circulation / cabin air. bulkheads or glands easier than trying to pass a large
plug block.
Fuel pump extension Lead order of assembly
Using the plastic plug With the metal clip.

The two wires in the lead, (Brown & Blue) are
not polarity conscious and can be fitted either
way around in the plug. Slide on white seals.
Strip 5mm off insulation from the two wires.
Crimp on the pins. And insert into the plastic
plug. The terminals need to exit the other end
through the centre slots until a clip is heard
when they lock into position.
Heater above shown with the remote air temp

sensor connected
Fuel Pump Cable from the Heater

The cable coming from the heater combustion
air inlet is pre fitted with the water seals and
crimped on pins. To complete the assembly,
the two pins on the heater lead are inserted
into the black plastic plug Without the metal
locking clip. When this has been done plug this
connector into the fuel pump extension lead
plug that you have just fitted.
Heater above shown with the internal air temp

sensor fitted
ELECTRICS Marine Comfort
The Power supply side of the harness is connected as

follows:-
RED Wire = DC+ Positive

BROWN Wire = DC- Negative
Connect the RED wire to the switched pole of the

battery isolator. Mount the supplied fuse carrier and fit
the appropriate fuse:
12V Variants = 20A Fuse Yellow

24V Variants = 15A Fuse Blue
A third fuse is also supplied, (1A Black).

This fuse is for the control electronics and is used on
12 or 24v systems.
Connect the BROWN wire to the Negative battery

terminal. If a battery computer is fitted to the vessels
electrical installation connect the BROWN to the
LOAD side of the shunt.
1 AMP (Black Fuse)

15 AMP (Blue Fuse 24v)
20 AMP (Yellow Fuse 12v)
Other Connections
At the same end of the wiring hardness as the fuses
dealt with above, you will find a Red wire with a Black
stripe. Do not connect this wire. Insulate and tie back.
This wire is not used on the EVO AT series of heaters.
Controls
The heater is supplied with a Evo M series controller.
For operating details refer to the enclosed booklet that
was shipped with the Evo M.
Connecting the Evo M controller is very simple.
Decide upon a suitable location.
Cut out a hole 97mm Wide and 63mm Tall.
Plug in the two 4 pin plugs to the rear of the controller.
Note the plugs are polarised and colour coded, Red
plug to Red socket and Blue plug to Blue socket.
Insert controller, fit screws and clip bezel on top
Marine Comfort
Marine Comfort
Marine Comfort
Marine Comfort
Marine Air Heater Installation Checklist
Installation Check Points Yes / No
1 Heater securely mounted at the correct angle
2 Additional Product ID label affixed to opposite side of heater
3 Fuel Dosing Pump securely mounted within anti vibration clip
4 Fuel Dosing Pump mounted clear of external heat sources
5 Fuel Dosing Pump mounted level
6 Fuel Dosing Pump electrical connector angled downwards
7 Fuel Dosing Pump is protected from mechanical damage
8 Standpipe cut at the correct length
9 Standpipe installed securely and leak free
10 Fuel lines all flared
11 Flared ends of fuel lines still 2mm ID after flaring
12 Fuel lines fixed securely along their entirety
13 Fuel lines are routed away from external heat sources
14 Fuel lines are protected or routed so as to prevent accidental damage
15 Fuel lines terminated with ISO7840 rubber hose sections
16 ISO7840 rubber hose sections pushed fully onto heater inlet and fuel pump flared stubs
17 Flared ends of copper pipes push fully into ISO7840 rubber hose sections
18 Fuel lines fitted with hose clamps securely
19 The heater is mounted no more than 3m above the fuel dosing pump
20 Distance between fuel standpipe inlet tip to the dosing pump is not more than 1.2m
21 Distance between the dosing pump and the heater is not more than 8.8m
22 The fuel being used is either EN590 Diesel or BS2869A2 Gas oil.
23 The fuel is visually free from contamination of water, solids.
24 There exists an adequate supply of fuel in the tank
25 Exhaust flexible pipe is securely fixed at both ends to prevent gas leakage
26 Exhaust is lagged with thermal insulation
27 Exhaust insulation is secured with stainless steel ties
28 Exhaust is safely secured / routed to prevent damage to adjacent parts
29 Exhaust has a 'swan neck' formed to prevent the ingress of sea water
30 Exhaust skin fitting is mounted as high as possible above the waterline
31 Exhaust emissions have been checked and adjusted using PC diagnostics tool
32 Combustion air pipe has been installed on the correct port on the heater
33 Combustion air pipe is not drawing air from inside the passenger compartment.
34 The fuel pump plug has been correctly assembled and the rubber seals are in place
Marine Comfort
Installation Check Points Yes / No

35 Electrical plugs are securely and correctly installed into the sockets on the heater body
36 The power supply requirements of the heater match those of the power supply used
37 Power supply positive cable is connected direct to the battery isolator load side
38 Power supply negative cable is connected to battery negative terminal, (shunt excepted)
39 Power supply cables are securely connected
40 The fuses are ok
41 The fuses are correctly inserted into the carriers
42 The fuses are the correct size
43 The plug supplying the fuel pump is securely connected to the pump
44 The electrical connections on all plugs, sockets and terminations corrosion free
45 The heater wiring harness is securely clipped to prevent heat or mechanical damage
46 The connectors and terminations are not under any strain

47 The battery is charged sufficiently to operate the heater
48 The two coloured plugs, (RED & BLUE) are fitted to the MC04 controller correctly.
49 The Ducting system has been designed not to exceed the total resistance points in the table.
50 The Ducting system is not in contact with materials unable to tolerate heat exposure.
51 The Ducting system is not crushed or pinched.
52 The Ducting system is secured with clips / fixings.
53 The Ducting system is not in contact with exposed electrical parts that could cause arcing.
54 The Ducting system does not have excessive number is tight or obtuse bends.
55 External air temp sensor is used when installed in NON recirculation mode. MANDATORY.
56 External air temp sensor is mounted at a mid point between floor and ceiling.
57 The internal air temp sensor is ONLY used in recirculation mode. MANDATORY
58 Combustion air is drawn from a non passenger space / cabin. Engine room is ok.

4110309B EVO 40 55 Install Instructions

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Airtop EVO 40 Diesel

Thank you for choosing Webasto Marine Central Heating

East (England) Scotland Ireland Midlands / North West

South (England) / Wales Midlands

Webasto Product UK Ltd

WARRANTY Marine Comfort

These conditions do not affect your statutory rights.

If you have any doubts as to who is your local

Bulbs, line fuses, fuel filters, overheat fuses,

Glow plugs, burners, gaskets and seals normally

Travelling time and mileage incurred in order to

These exclusions also preclude any claims for

SERVICE Marine Comfort

Your local authorised Webasto dealer will be

Regularly check your Webasto heating system

 Corrosion on electrical terminals … clean

 Clean running at the exhaust … if not, call

 Ensure that the exhaust outlet and

 Run your heating system during the

Every alternate season, it is recommended that

If the heater takes in sea water or water from a

POSITIONING OF THE HEATER

The location of the heater must be well clear of any

As an alternative, fit the heater in the engine room,

Place the heater on the mounting plate after fitting

Typical installation of a Webasto Heater in a Sailing Yacht or Motor Cruiser:

1. Webasto Air Heater 2. Fuel Supply 3. Exhaust outlet

EXHAUST SYSTEM Marine Comfort

60 Over sleeve using Woven Glass

Leave sufficient exposed exhaust

Swan neck Deck

Measure the diameter of the skin fitting to be fitted and

FUEL CONNECTION Marine Comfort

The Fuel system conforms to ISO 7840 & the Inland

The Ball Valve, Filter / Separator are optional and may

Fuel pipe dimensions

Ensure that the 2mm I.D. - 5mm O.D supplied copper

The suction hose length, (Fuel Tank to Fuel Pump)

Fuel System - component heights

FUEL STANDPIPE Marine Comfort

Please note if any other pipe fittings or inline Valves or

If the supplied standpipe is too long for the fuel tank

Ensure the standpipe is leak free after installation.

COMBUSTION Marine Comfort

The heater is pre-assembled with a 60cm length

If mounted in the engine room, ensure that no

Do not let the pipe hang down if a potential

The combustion air pipe supplied is the

Do not extract combustion air from the vessel’s

HEATING AIR INTAKE Marine Comfort

The air can be drawn from outside if required but this

All installations will vary but in general try to mount

If the heater is mounted in a locker use the grille

Avoid the grille being placed so that water, fumes or

If the heater is fitted in the engine room, use flexible

IT IS IMPORTANT THAT A SUPPLY OF CLEAN

HOT AIR OUTLETS Marine Comfort

Inside the control unit there is a temperature sensor,

Evo 3900 2.0hPa

(1 hPa corresponds to 1 mbar. This also equals

The following diagram indicates the duct system with

“Y” branches and outlets. Use the clamps provided