Webasto DUAL TOP RHA 100 Installation Manual Download Page 11

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Heater installation

6.1.

General

IMPORTANT

The regulations specified in chapter 2, "Statutory regulations governing installation" must be adhered to.

IMPORTANT

The Dual Top may not be lifted at the heating air inlet! This offsets the air fan and causes the heating air impeller to rub or block.

NOTE

Observe the installation details specified by the manufacturer of the relevant vehicle type.

6.2.

Dual Top connections

Fig. 2:

Connections of the heater

Heating air inlet

Water inlet (cold)

Water outlet (hot)

Cooling air inlet

Housing cover with inlet interfaces

Wiring harness outlets

Housing cover with hot air outlet

Exhaust outlet

Drain hose for pressure relief valve and so-
lenoid valve

10 Cooling air outlet
11 Fuel intake
12 Combustion air intake

Summary of Contents for DUAL TOP RHA 100

Page 1: ...Integriertes Heizger t Integrated Heater Riscaldatore integrato Einbauanweisung Installation Instructions Istruzioni di montaggio DUAL TOP RHA 100 101 102...

Page 2: ...e used See also Webasto air and water heaters accessories catalogue NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course you do not hav...

Page 3: ...eizger tes 51 18 St rcodeausgabe 52 19 Pr fung und Inbetriebnahme 58 20 Technische Daten 59 Contents 1 General 63 2 Statutory regulations governing installation 64 3 Use of the integrated air water he...

Page 4: ...ecial tools and special equipment You also have to be certified to work on 230 V electric systems Installation and all other jobs carried out by not certified persons can harm you the Dual Top and the...

Page 5: ...nents make sure to follow all local regulations e g 98 83 EC Quality of Drinking Water DIN 2001 2 Drinking Water Supply DVGW W 291 Cleaning and Disinfec tion etc Make sure that during the installation...

Page 6: ...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 para...

Page 7: ...pulsion 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 a...

Page 8: ...water in motorhomes and similar vehicles The heaters operate independently of the vehicle engine and are connect ed to the fuel tank and the service battery of the vehicle in each case 4 Additional s...

Page 9: ...Installation example 68 5 Installation example Fig 1 Installation example for a Dual Top heater in a motorhome 1 2 3 4 5 6 7 8 9 10 12 13 15 14 16 11...

Page 10: ...Dual Top cooling air intake cover 5 Dual Top rubber bellow heating air adapter 6 Combustion air intake silencer 7 Exhaust silencer 8 Fuel tank connector 9 Fuel tank 10 Fuel pump 11 LED dashboard 12 W...

Page 11: ...or block NOTE Observe the installation details specified by the manufacturer of the relevant vehicle type 6 2 Dual Top connections Fig 2 Connections of the heater 2 3 4 5 7 8 9 10 11 12 6 1 1 Heating...

Page 12: ...30 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 IMPORTANT All materials located in the immediate vicinity of the h...

Page 13: ...r in stallation The information contained in chapter 6 7 Additional information for in terior installation must also be observed for installation within the vehicle The installation location should al...

Page 14: ...aces 3 Opening for Dual Top wiring harness 4 Opening for wiring harness of electric heater Dual Top RHA 101 102 only Connect the wiring harness plug X11 12 poles to the matching connector of the heate...

Page 15: ...d nuts are tightened with a torque of 22 to 25 Nm Mount the heaters brackets and vibration dampers so that the damp ers are compressed by the weight of the heater See Webasto product catalogue for dif...

Page 16: ...ibration dampers fail The brackets must be spaced at least 200 mm apart See Fig 10 To minimize energy loss it is recommended that the hot air hoses which run outside the vehicle be insulated A basic a...

Page 17: ...9 1 Heating air intake 6 7 1 Sealing off of exhaust gas to outside The exhaust gas must always be routed to the outside and may not enter the passenger compartment Also see chapter 2 Statutory regula...

Page 18: ...r after the heater is installed See Fig 14 IMPORTANT To ensure the positioning of the foam seal over the entire service life of the heater the seal must be replaced every time the heater is dismantled...

Page 19: ...damaged and is clearly legible after installing the heater otherwise a duplicate type label must be applied in a highly visible location or in the engine compartment next to the vehicle type label In...

Page 20: ...oolant pipes on the Dual Top are specially equipped with grooves which enable proper fastening and easy removal of the hose connectors if necessary Place a thermostatic mixing valve if required If no...

Page 21: ...as possible and free of kinks All hose connections must be secured in a way that they can withstand pressure and are watertight also cold water hoses The thermal expansion of the water can cause pres...

Page 22: ...ction for the ventilation hose 1 and the check valve 8 must lie ABOVE the vehicle water tank 7 No drain traps Connect the ventilation hose 4 to the hose which runs through the hous ing cover with inle...

Page 23: ...mersion pump version 2 4 10 9 11 5 2 Cold water line 4 Dual Top ventilation hose 5 Dual Top Diving Pump heater 9 Drain hose for pressure relief valve and solenoid valve 10 Hot water line 11 Housing co...

Page 24: ...e connected hot air system has to be minimised Maximum pressure drop be tween the inlet and outlet side of the hot air line 3 0 hPa at maximum speed of heating air ventilator 1 hPa corresponds to 1 mb...

Page 25: ...irt or small particles will fall or be sucked in Mount an air grille on the heating air intake if necessary It s recommended to extend the inlet above floor level Be careful that no fluids may be spil...

Page 26: ...outlets etc made of high temperature re sistant materials The housing cover with hot air outlet see Fig 2 is equipped with two hot air outlets to which the hot air hoses must be connected Both hot air...

Page 27: ...minimum the length of the hot air hoses routed outside the passenger compartment should be as short as possible and should be insulated Hose routing as straight as possible large curves Avoid compress...

Page 28: ...Hot air system 87 Dark colour below interior insulated Bright colour inside interior Fig 24 Hot air distribution...

Page 29: ...r This motor works independently from the hot air system that has an own motor and ventilator 10 1 Installation Mount a grille on the cooling air inlet of the heater Also mount a cooling air inlet cov...

Page 30: ...ses water is drained off via a hose outlet exiting at the bottom of the heater The water is discharged under the vehicle The drain hose of the pressure relief valve and the solenoid valve No 9 Fig 2 s...

Page 31: ...ig 26 NOTE A notice indicating that the heater must be shut down before refuelling must be affixed to the fuelling point A sticker is provided in the delivery scope Internal diameter i 2 mm Length suc...

Page 32: ...fuel line s suction side is not more than 1 4 m In case the length of the fuel line s suction side is more than 1 4 m the fuel pump has to be installed separate from the heater In this case extend the...

Page 33: ...re at the connection point to the fuel line does not exceed the in chapter 12 1 General specified values The line from the T junction towards the fuel pump should run down wards 2 The fuel can be take...

Page 34: ...tions 12 4 1 Routing The lines should be routed upwards from the fuel pump to the heater to facilitate automatic bleeding Avoid passing or crossing of hot areas e g crossing of exhaust line at a dista...

Page 35: ...n Fig 32 Ensure that there are no leaks 1 clip 2 air or gas bubble 12 5 Fuel filter No fuel filter is to be used in the heater fuel system Due to the danger of frost for the moisture contained in the...

Page 36: ...t be taken from a position that is as cool as possible and protected from splashing water 13 2 Combustion air intake line A connection to heater 22 mm dia B silencer An intake line is required for com...

Page 37: ...must not point in the driving direc tion See Fig 35 Combustion air intake hose should point downwards from the heater If this is not possible make a condensate drain hole with a diameter of 4 mm at it...

Page 38: ...itted to reduce the noise level The silencer should ideally be installed near the heater not more than 0 20 m distance followed by a long tail pipe min 1 m for best noise level reduction The silencer...

Page 39: ...rom the end of the exhaust pipe to ensure that the angle 45 to 70 is achieved IMPORTANT If the exhaust pipe end is other than as shown it will pose a fire risk See Fig 42 The complete exhaust system m...

Page 40: ...the entrance door of the living cell Avoid that the exhaust pipe can touch ground or pavement including traffic calming measures Fig 39 Elbows cast left and bent pipe right Fig 40 Prevent the formati...

Page 41: ...exhaust A Flow exhaust fumes 45 to 70 downwards and at side to avoid exhaust bag under vehicle B End exhaust line nearly aligned with side of vehicle body C End exhaust line cut horizontally to avoid...

Page 42: ...e vehicle it should be ensured that no lines can be pinched Fig 43 Schematic diagram of electrical connections for Dual Top RHA 100 with heater control 1 DUAL TOP RHA 100 2 Wiring harness external 3 M...

Page 43: ...AL TOP RHA 101 102 2 Wiring harness external 3 Programmable heater control 4 Vehicle s leisure battery 5 Fuse 5 A 6 Fuse 10 A 7 Fuse 15 A 8 Fuel pump 9 Interior temperature sensor 10 Wiring interior t...

Page 44: ...se fuses 15 A 10 A 5 A Fuses must be connected to the correct wires in each case observe colour 5 A red blue cable 10 A red black cable 15 A red cable Make sure that the yellow part is pushed into eac...

Page 45: ...close to heat sources placed in direct sunlight for example on the dashboard installed inside a locker installed behind curtains or the like Make sure that cabin air can flow freely around the sensor...

Page 46: ...the Control Panel shall be placed e g in the dash board The LED must be located in the driver s field of view Connect the wiring See Fig 48 Extend the wire from the LED to plug X5 pin 6 that goes into...

Page 47: ...le to children 15 best viewing angle 15 Make sure that there is enough space behind the place where the Con trol Panel shall be placed Drill a hole at the desired installation location see Fig 50 Conn...

Page 48: ...f the Control Panel It should be visible and accessible for the operator However at the same time it must not be accessible to children 15 best viewing angle 15 Make sure that there is enough space be...

Page 49: ...tion cups on the Control Panel Alternatively slide flat smooth material e g plastic card under the control panel at the left and right hand side Pull to remove the Control Panel out of the adapter Mak...

Page 50: ...heater to the relay box is limited to a maximum of 3 m 5 Connect 230 V wiring to relay box 6 Connect connector X6 8 pole of the external wiring harness to the relay box 7 Connect wiring harness electr...

Page 51: ...Wiring diagrams 110 16 Wiring diagrams Fig 55 Circuit diagram for Dual Top RHA 100 1 3 4 7 6 5...

Page 52: ...Wiring diagrams 111 Fig 56 Circuit diagram for Dual Top RHA 101 102 1 3 4 to 8 6 2 5 to X5 8 7 Not in scope of delivery...

Page 53: ...bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white Item Description Comment X0 Plug connector 2 pin To control panel X1 Plug connector 2 pin 2 pcs to electric hea...

Page 54: ...infect and rinse the entire water supply system See Operating Instructions chapter Maintenance how to disinfect the water supply system Fill the water tank and water system Use only drinking water and...

Page 55: ...t at least 5 seconds and then switch the heater on If serious malfunctions such as overheating or failure to start reoccur the heater is locked and can be put back into service by deleting the failure...

Page 56: ...y remove possible blocking objects reset heater by switching off for at least 5 sec 06 Overheating or exceeding gradient water temperature sensor Check water level reset heater by switching off for at...

Page 57: ...essary wait until ventilators stop running 2 Switch off Dual Top by pressing on off button 3 Replace fuse 15 A for at least 5 seconds Now the heater is reset Deleting failures can also be done with th...

Page 58: ...ness relay box to heater Check relay box and connections relay box Message 07 Fuel pump short circuit Fuel pump short circuit to ground OR relay box cable or connection relay box is defective Check fu...

Page 59: ...age 19 n a n a Message 20 Failure heating air temperature sensor Hot air temperature sensor disconnection Check routing of cable avoid that it is pinched or crushed check the connectors Reset heater b...

Page 60: ...eater Check relay box and connection relay box Check Control Panel and connections Control Panel Check for overheating see messages 10 11 12 13 and 14 Reset heater by pressing OK or switching off for...

Page 61: ...Instructions Consists of 2 parts WARRANTY CERTIFICATE Should remain with customer in booklet CONTROL CARD Must be sent to the Webasto national company by the installation partner The installation par...

Page 62: ...sel according to DIN EN 590 specified by the manufacturer must be used Class EL heating oil L heating oil or PME bio diesel must not be used Fuel additives have no negative influences on the heater If...

Page 63: ...range 10 5 to 15 V Current input at 12 V Summer operation Winter operation heating and hot water Stand by 1 A 0 5 to 7 A 0 001 A Rated power consumption Control range 15 to 65 W EN 1646 Max ambient t...

Page 64: ...4 0 bar Pressure water pump central water supply Maximum 2 5 bar Heater dimensions Length 530 2 mm Width 352 1 mm Height 256 1 mm Weight w o water contents 20 kg 21 kg Heater Operation DUAL TOP RHA 1...

Page 65: ......

Page 66: ...Ident Nr 9021215B 01 11 nderungen und Irrt mer vorbehalten Gedruckt in Deutschland Webasto AG GCS 2011 Webasto AG Postfach 80 D 82132 Stockdorf Germany National Hotline 01805 93 22 78 0 14 Min aus dem...

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