Integriertes Heizgerät
Integrated Heater
Riscaldatore integrato
Einbauanweisung
Installation Instructions
Istruzioni di montaggio
DUAL TOP
03/2009
RHA 100
(für Trinkwasser)
(for drinking water)
(per acqua potabile)
Contents
GB
Contents
1 General .............................................................................................. 1
2 Statutory regulations governing installation ................................. 2
2.1. Extract from Directive 2001/56/EC Annex VII ........................................ 2
3 Use of the integrated air / water heater ........................................ 4
4 Additional safety instructions ......................................................... 5
5 Installation example ........................................................................ 6
6 Heater installation ............................................................................ 8
6.1. General ............................................................................................... 8
6.2. Dual Top connections ........................................................................ 8
6.3. Installation location .............................................................................. 9
6.4. Connecting the wiring harness .......................................................... 11
6.5. Installing the heater ........................................................................... 12
7 Identification plate ......................................................................... 14
8 Hot water system ........................................................................... 15
9 Hot air system ................................................................................. 17
9.1. Heating air intake .............................................................................. 18
9.1.1. General .............................................................................................. 18
9.1.2. Installation.......................................................................................... 18
9.2. Hot air distribution ............................................................................. 20
10 Cooling air system .......................................................................... 22
10.1. Installation ......................................................................................... 22
11 Boiler drainage and pressure relief system .................................. 23
12 Fuel supply ...................................................................................... 24
12.1. General ............................................................................................. 24
12.2. Fuel pump ..........................................................................................25
12.2.1. Installation location .............................................................................25
12.2.2. Installation and attachment .................................................................25
12.3. Fuel extraction. ...................................................................................26
12.4. Fuel lines ............................................................................................27
12.4.1. Routing ............................................................................................... 27
12.4.2. Connecting two pipes with a hose ......................................................28
12.5. Fuel filter ............................................................................................28
13 Combustion air supply .................................................................... 29
13.1. General ..............................................................................................29
13.2. Combustion air intake line ................................................................29
14 Exhaust system ................................................................................31
14.1. General ..............................................................................................31
14.2. Exhaust line ........................................................................................ 32
15 Electrical connections ...................................................................... 35
15.1. Supply voltage connection ..................................................................36
15.2. Interior temperature sensor ................................................................37
15.3. Control Panel connection ...................................................................38
16 Circuit diagram ..............................................................................40
16.1. Legend for circuit diagram ..................................................................41
17 Starting the heater for the first time ............................................. 42
18 Fault lock-out ................................................................................... 43
19 Validation and commissioning .......................................................46
20 Technical data ..................................................................................47
20.1. Fuel for Dual Top RHA 100 .................................................................47
20.2. Technical data ................................................................................... 48
II
Dual Top General
1 General
For installation and repair of a Webasto Dual Top RHA 100 integrated
heater you will need technical documentation, a special training by
Webasto, special tools and special equipment.
Installation and all other jobs carried out by not certified persons can harm
you, the Dual Top and the vehicle. In that case, Webasto will refuse all
liability.
Do NOT install or repair a Webasto Dual Top RHA 100 heater, if you have
not successfully finished the training by Webasto for acquiring the
necessary technical skills. Do NOT install or repair the product, if you do not
have the necessary technical documentation, tools or equipment.
ALWAYS follow the Webasto installation and service instructions and mind
all warning indications.
Only use genuine Webasto parts. See the Webasto air and water heaters
accessory catalogue and Webasto camping catalogue.
Webasto does not take over any liabilities for defects or damages caused
by for installation untrained personnel.
1
Statutory regulations governing installation Dual Top
2 Statutory regulations governing installation
The Dual Top RHA 100 heater has been type-tested and approved in
accordance with EC Directives 72/245/EEC (EMC) and 2001/56/EC (heater)
with the following EC permit numbers:
e1 03 5000
e1 00 0195
Installation is governed above all by the provisions in Annex VII of
Directive 2001/56/EC.
NOTE:
The provisions of these Directives are binding within the territory
governed by EU Directive 70/156/EEC and should similarly be
observed in countries without specific regulations.
See chapter 2.1, "Extract from Directive 2001/56/EC Annex VII"
The Dual Top complies with all applicable standards for this type of
product.
When intalling the Dual Top heater and related components, make sure to
follow all local regulations (e.g. 98/83/EC, DIN 2001-2, DVGW W 291).
Make sure that during the installation the legal requirements for the
permits of the vehicle are not violated, in particular for the heater fixation
and the routing of the exhaust lines.
IMPORTANT
Failure to follow the installation instructions and the notes contained
therein will lead to all liability being refused by Webasto. The same applies
if repairs are carried out incorrectly or with the use of parts other than
genuine spare parts. This will result in the invalidation of the type approval
for the heater and therefore of its homologation / EC type licence.
NOTE:
For vehicles with an EU permit, no entry in accordance with § 19
Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.
2.1. Extract from Directive 2001/56/EC Annex VII
Start of extract.
ANNEX VII
REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR
INSTALLATION
1. GENERAL REQUIREMENTS
1.7.1. A clearly visible tell-tale in the operator's field of view shall
inform when the combustion heater is switched on or off.
2. VEHICLE INSTALLATION REQUIREMENTS
2.1. Scope
2.1.1. Subject to paragraph 2.1.2, combustion heaters shall be
installed according to the requirements of this Annex.
2.1.2. Vehicles of category O having liquid fuel heaters are
deemed to comply with the requirements of this Annex.
2.2. Positioning of heater
2.2.1. Body sections and any other components in the vicinity of
the heater must be protected from excessive heat and the
possibility of fuel or oil contamination.
2
Dual Top Statutory regulations governing installation
2.2.2. The combustion heater shall not constitute a risk of fire,
even in the case of overheating. This requirement shall be deemed
to be fulfilled if the installation ensures an adequate distance to all
parts and suitable ventilation, by the use of fire resistant materials
or by the use of heat shields.
2.2.3. In the case of M2 and M3 vehicles, the heater must not be
positioned in the passenger compartment. However, an
installation in an effectively sealed envelope which also complies
with the conditions in paragraph 2.2.2 may be used.
2.2.4. The label (see chapter 7, "Identification plate") referred to
in paragraph 1.4, or a duplicate, must be positioned so that it can
be easily read when the heater is installed in the vehicle.
2.2.5. Every reasonable precaution should be taken in positioning
the heater to minimise the risk of injury and damage to personal
property.
2.3. Fuel supply
2.3.1. The fuel filler must not be situated in the passenger
compartment and must be provided with an effective cap to
prevent fuel spillage.
2.3.2. In the case of liquid fuel heaters, where a supply separate
to that of the vehicle is provided, the type of fuel and its filler point
must be clearly labelled.
2.3.3. A notice, indicating that the heater must be shut down
before refuelling, must be affixed to the fuelling point. In addition
a suitable instruction must be included in the manufacturer's
operating manual.
2.4. Exhaust system
2.4.1. The exhaust outlet must be located so as to prevent
emissions from entering the vehicle through ventilators, heated air
inlets or opening windows.
2.5. Combustion air inlet
2.5.1. The air for the combustion chamber of the heater must not
be drawn from the passenger compartment of the vehicle.
2.5.2. The air inlet must be so positioned or guarded that blocking
by rubbish or luggage is unlikely.
2.6. Heating air inlet
2.6.1. The heating air supply may be fresh or recirculated air and
must be drawn from a clean area not likely to be contaminated by
exhaust fumes emitted either by the propulsion engine, the
combustion heater or any other vehicle source.
2.6.2. The inlet duct must be protected by mesh or other suitable
means.
2.7. Heating air outlet
2.7.1. Any ducting used to route the hot air through the vehicle
must be so positioned or protected that no injury or damage could
be caused if it were to be touched.
2.7.2. The air outlet must be so positioned or guarded that
blocking by rubbish or luggage is unlikely.
End of extract.
3
Use of the integrated air / water heater Dual Top
3 Use of the integrated air / water heater
The Webasto Dual Top RHA 100 integrated air / water heater has been
designed to heat and to provide hot water (drinking water) in motor
homes and similar vehicles.
The heater operates independently of the engine and is connected to the
fuel tank and the electrical system of the vehicle.
It is not designed for heating vehicles transporting hazardous substances.
4
Dual Top Additional safety instructions
4 Additional safety instructions
• If the Dual Top falls to the floor, it must be returned to Webasto for a
safety inspection/repair.
• It is not allowed to paint or re-paint the Dual Top heater partly or
completely.
5
Installation example Dual Top
5 Installation example
16
15
14
13
12
11
10
9
8
Fig. 1: Installation example for heater in camper
6
1
2
3
4
5
6
7
Dual Top Installation example
1 Interior temperature sensor
2 Water lines
3 Webasto Dual Top RHA 100 heater
4 Cooling air intake adapter
5 Webasto dual adapter
6 Combustion air intake silencer
7 Exhaust silencer
8 Fuel tank connector
9Fuel tank
10 Fuel pump
11 LED dashboard
12 Water pump
13 Water tank
14 Cooling air outlet
15 Hot air distribution
16 Control Panel
7
Heater installation Dual Top
6 Heater installation
6.1. General
IMPORTANT
The regulations specified in chapter 2, "Statutory regulations governing installation" must be adhered to.
NOTE:
Observe the installation details specified by the manufacturer of the relevant vehicle type.
6.2. Dual Top connections
23 4 5
Fig. 2: Connections of the heater
1 Heating air inlet
2 Water inlet (cold)
3 Water outlet (hot)
4 Cooling air inlet
5 Intake cap
6 Wiring harness outlets, left and right
7 Outlet cap
8
61
78910111213
8 Exhaust outlet
9Drain valve hose
10 Pressure relief valve hose
11 Cooling air outlet
12 Fuel intake
13 Combustion air intake
Dual Top Heater installation
6.3. Installation location
At all sides of the heater there should be at least 20 mm space.
>20
256
>20
Fig. 3: Dimensions [mm] of the heater
• Space requirement for hot air outlet > 150 mm
• Length 530 mm
• Space requirement for air inlet > 200 mm
• Width 352 mm
• Height 256 mm
• Space requirement at sides > 20 mm
• Space above the heater > 20 mm
352
Intake cap
>200
530
Outlet cap
>150
9
Heater installation Dual Top
Find a suitable location for the heater.
Space for the heater:
• Make sure to have sufficient space at all sides of the heater.
See Fig. 3;
• Heater has to be fixed to elements of the vehicle that can withstand a
weight of 35 kg;
• All parts above the water crossing level (specified for the vehicle);
• Possibility to remove the heater;
• Possibility to access and remove the intake cap of the heater.
The heater shall be fitted on the exterior of the vehicle. Ensure that the
heater is fitted in a position where it is protected from splashing water.
Orientation of the heater:
The heater has to be mounted in a horizontal position (tolerance ± 5º),
with exhaust outlet and cooling air outlet port pointing downwards.
See Fig. 4.
+5º
-5º
Fig. 4: Required installation position
+5º
-5º
IMPORTANT
Make sure that after installation the casing of the heater is not in contact
with any parts of the vehicle body. Ensure that all moving parts can move
easily. A failure to do this may result in the hot air fan, cooling air fan or
another part blocking.
Fig. 5: Heater casing must not touch vehicle body
10
Dual Top Heater installation
6.4. Connecting the wiring harness
Connect the wiring harness plug X11 (12 poles) to the matching
connector of the heater.
1
2
3
Fig. 6: Removal front cover
1. Intake cap
2. Intake cap fixing screws
3. Opening for wiring harness Dual Top.
Fig. 7: Connection wiring harness
11
Heater installation Dual Top
6.5. Installing the heater
• Mount the M8 hammerhead bolts in the guide rails of the heater and
use brackets to attach the heater to supporting parts of vehicle chassis.
• Vibration dampers should be used. Tighten the M8 hammerhead bolts
and nuts with a torque of 22 - 25 Nm.
• Mount heater, brackets and vibration dampers in such a way that
dampers will be compressed by the weight of the heater.
• See Webasto camping catalogue for different kinds of fixation brackets.
• At least 4 fixation points.
Fig. 8: Possible fixation methods (front view)
• Fixation of the heater only on the top or on one of the sides is not
sufficient.
• Install the heater in such a way that it will not fall from the vehicle in
case the vibration dampers fail.
See Fig. 8
12
Dual Top Heater installation
Fig. 9: Fixation brackets and vibrations dampers (examples)
13
Identification plate Dual Top
7 Identification plate
The identification plate must be positioned so that it cannot be damaged
and must be clearly legible when the heater is installed (otherwise a
duplicate identification plate must be used).
Inapplicable years must be erased from the identification plate and the
current year must be readable.
14
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