Webasto HL 90 Manuale utente

Luftheizgeräte

Air heaters

Appareils de chauffage à air chaud

Einbauanweisung

Installation Instructions

Notice de montage

HL 90

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HL 90

III

Inhalts erzeichnis

1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . . 1

2 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . . 3

3 Montage des Heizgeräts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Fabrikschild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Heizluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Brennstoff ersorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Brennluft ersorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8 Abgasleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Table of contents

1 Statutory regulations go erning installation . . . . . . . . . . . .27

2 Use of the air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3 To install the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4 Factory plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

5 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

6 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

7 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

8 Exhaust line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

9 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

10 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

11Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

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HL 90

1 Statutory regulations go erning installation

Type approvals according to ECE-R 0 (EMC) and ECE-R 22 (Heater) exist

for the HL 90 heater.

See chapter , "Technical data" for the approval number.

Primarily the regulations of Annex VII of the Directive 200 /56/EG and Part I

and Annex 7 of the directive ECE-R 22 must be observed for the

installation.

NOTE:

The pro isions of these Directi es are binding within the territory

go erned by EU Directi e 70/156/EEC and should similarly be ob-

ser ed in countries without specific regulations!

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 / ECE type licence.

1.1. Extract from directi e ECE-R 122 Part I and Annex 7

Start of extract.

Part I

5.3 Vehicle Installation Requirements for Combustion Heaters and

for Electric Heaters

5.3.1 Scope

5.3.1.1 Subject to paragraph 5.3.1. , heaters shall be installed according to

the requirements of paragraph 5.3.

5.3.1. Vehicles of category O having liquid fuel heaters are deemed to

comply with the requirements of paragraph 5.3.

5.3.2 Positioning of heater

5.3. .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 con-

tamination.

5.3. . The heater shall not constitute a risk of fire, even in the case of over-

heating. This requirement shall be deemed to be met if the installation en-

sures an adequate distance to all parts and suitable ventilation, by the use

of fire resistant materials or by the use of heat shields.

5.3. .3 In the case of M and M3 vehicles, the combustion heater must not

be positioned in the passenger compartment. However, an installation in an

effectively sealed envelope which also complies with the conditions in par-

agraph 5.3. . may be used.

5.3. .4 The label referred to in Annex 7, paragraph 4, or a duplicate, must

be positioned so that it can be easily read when the combustion heater is

installed in the vehicle.

5.3. .5 Every reasonable precaution should be taken in positioning the

heater to minimize the risk of injury and damage to personal property.

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HL 90

5.3.3 Fuel supply

5.3.3.1 The fuel filler must not be situated in the passenger compartment

and must be provided with an effective cap to prevent fuel spillage.

5.3.3. In the case of liquid fuel heaters, where a supply separate from that

of the vehicle is provided, the type of fuel and its filler point must be clearly

labelled.

5.3.3.3 A notice, indicating that the heater must be shut down before refu-

elling, must be affixed to the fuelling point. In addition a suitable instruction

must be included in the manufacturer’s operating manual.

5.3.4 Exhaust system

5.3.4.1 The exhaust outlet must be located so as to prevent emissions from

entering the vehicle through ventilators, heated air inlets or opening win-

dows.

5.3.5 Combustion air inlet

5.3.5.1 The air for the combustion chamber of the heater must not be

drawn from the passenger compartment of the vehicle.

5.3.5. The air inlet must be so positioned or guarded that blocking by rub-

bish or luggage is unlikely.

5.3.6 Heating air inlet

5.3.6.1 The heating air supply may be fresh or re-circulated 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.

5.3.6. The inlet duct must be protected by mesh or other suitable means.

5.3.7 Heating air outlet

5.3.7.1 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.

5.3.7. The air outlet must be so positioned or guarded that blocking by

rubbish or luggage is unlikely.

5.3.8 Automatic control of the heating system

5.3.8.1 The heating system must be switched off automatically and the sup-

ply of fuel must be stopped within five seconds when the vehicle’s engine

stops running. If a manual device is already activated, the heating system

can stay in operation.

ANNEX 7

ADDITIONAL REQUIREMENTS FOR COMBUSTION HEATERS

7 Warning light

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.

End of extract.

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HL 90

2 Use of the air heaters

Webasto HL 90 are heaters are designed

– to heat the cab and the

passenger compartment

– to defrost the vehicle windows

– to heat vehicle bodies.

They are not designed for heating cargo areas used to carry hazardous sub-

stances.

The heaters operate independently of the engine and are connected to the

fuel tank and the electrical system of the vehicle.

They may be used for vehicles with either water or air-cooled engines.

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HL 90

3 To install the heater

The standard scope of delivery of the heater consists of:

– Heater

– 2 Supports

– 2 Clamping bands

– 2 Turnbuckles

– Intake manifold

– Fuel metering pump

The heater must be installed on a flat surface as shown in Figures and 2.

Make the hole pattern as shown in Figure 2.

The floor attachment can be aligned within the specified tolerances by loos-

ening or tightening the turnbuckles and clamping bands.

The screws of the turnbuckles must be tightened to 5 Nm, the bolts (M8) of

the supports must be tightened to 2 Nm.

The installation dimensions and space requirement for service access are

shown in the installation drawing (Figures and 2). The specified horizontal

and axial angles must not be exceeded.

The heater is not allowed to be installed in the passenger compartment.

If the heater is installed on the exterior, ensure that it is fitted in a position

where it is protected from splashing water and spray.

In the case of installations in which the heater surface could be touched in-

advertently or flammable materials could come into contact with the heater

surface, it is obligatory to mount a shield (Webasto accessory) over the heat

exchanger, see Figure 2. For this purpose, the shield is clamped between the

support and the mounting surface in the vehicle, see Figure 3. The position

must be selected so the return pin on the temperature sensor can be reached

through the cut-out in the shield.

The air heater’s heat exchanger can be used for a maximum of 0 years and

must then be replaced by the manufacturer or one of its authorised work-

shops using a genuine spare part. A label must then be affixed to the heater

showing the date of sale of the heat exchanger and the wording “Genuine

spare part”. If exhaust pipes pass through compartments used by people,

the pipes must also be replaced by genuine spare parts after 0 years.

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HL 90

Figure 1: Possible installation location

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HL 90

Figure 2: Installation drawing

Hole pattern only required if

part 4 is used

A Fuel connection with fuel hose

B5x9 DIN 73379

B Space required for removing

glow plug and flame monitor

C Hole pattern in the floor of the

installation space

Heater

2 Support with clamping belt and turn-

buckle

3 Exhaust outlet extension with

flex pipe, øi 38

4 Intake manifold (only required if

combustion air should be drawn

in directly from the outside, not via a

grille or gills)

5 Intake pipe extension with

flex. pipe, øi 30.5

6 Return pin on temperature limiter

7 Shield

(only required in certain installation

positions of the heater)

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HL 90

Figure 3: To install the shield

Shield is clamped under

the support

Hole in the shield for reaching the

return pin on the temperature limiter

Webasto accessory

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HL 90

4 Factory plate

The model plate must be positioned so that it cannot be damaged and must

be clearly legible when the heater is installed (otherwise a duplicate model

plate must be used).

The installer must ensure that the year of initial start-up is indelibly marked

on the model plate (see Figure 4).

Figure 4: Factory plate corresponding to HL 90/24 V heater

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