Webasto DUAL TOP RHA 100 Installation Manual
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Webasto DUAL TOP RHA 100 Installation Manual

Webasto DUAL TOP RHA 100 Installation Manual

Integrated heater
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See also: Instruction and Installation Manual
Integriertes Heizgerät
Integrated Heater
Riscaldatore integrato
Einbauanweisung
Installation Instructions
Istruzioni di montaggio
DUAL TOP
RHA 100 / 101 / 102

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Summary of Contents for Webasto DUAL TOP RHA 100

  • Page 1 Integriertes Heizgerät Einbauanweisung Integrated Heater Installation Instructions Riscaldatore integrato Istruzioni di montaggio DUAL TOP RHA 100 / 101 / 102...
  • Page 2 Only genuine Webasto parts may be 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 have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.

  • Page 3: Table Of Contents

    Dual Top Inhalt Contents Allgemeine Informationen ............... 1 General .................... 63 Gesetzliche Bestimmungen für den Einbau ........2 Statutory regulations governing installation ....... 64 Verwendung des integrierten Luft-/Wasserheizgerätes ....5 Use of the integrated air / water heater ........67 Weitere Sicherheitsanweisungen ............

  • Page 4: General

    General General For installation and repair of a Webasto Dual Top RHA 100 / 101 / 102 in- tegrated heater you will need technical documentation, a special training by Webasto, special tools and special equipment. You also have to be certified to work on 230 V electric systems.

  • Page 5: Statutory Regulations Governing Installation

    Statutory regulations governing installation Statutory regulations governing installation The Dual Top RHA 100 / 101 / 102 heaters have been type-tested and ap- IMPORTANT proved in accordance with EC Directives 72/245/EEC (EMC) and 2001/56/ Failure to follow the installation instructions and the notes contained EC (heater) with the following EC permit numbers: therein will lead to all liability being refused by Webasto.
  • Page 6 Statutory regulations governing installation 2.1. Extract from Directive 2001/56/EC Annex VII installation in an effectively sealed envelope which also complies with the conditions in paragraph 2.2.2 may be used. Start of extract. 2.2.4. The label (see chapter 7, "Identification plate") referred to ANNEX VII 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.
  • Page 7 Statutory regulations governing installation 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.

  • Page 8: Use Of The Integrated Air / Water Heater

    The integrated Dual Top RHA 100 / 101 / 102 air and water heaters from • If the Dual Top falls to the floor, it must be returned to Webasto for a Webasto are used for heating and to provide hot water in motorhomes safety inspection/repair.

  • Page 9: Installation Example

    Installation example Installation example Fig. 1: Installation example for a Dual Top heater in a motorhome...
  • Page 10 Installation example Interior temperature sensor Water lines Dual Top heater Dual Top cooling-air intake cover Dual Top rubber bellow (heating air adapter) Combustion air intake silencer Exhaust silencer Fuel tank connector Fuel tank 10 Fuel pump 11 LED dashboard 12 Water pump 13 Water tank 14 Cooling air outlet 15 Hot air distribution...

  • Page 11: Heater Installation

    Heater installation 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.
  • Page 12 Heater installation 6.3. Installation location At all sides of the heater there should be at least 20 mm space. Housing cover with Housing cover with inlet interfaces hot air outlet >20 >200 >150 Fig. 3: Dimensions [mm] of the heater •...
  • Page 13 Heater installation 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; +5º • The heater must be fastened at a location in the vehicle which can with- +5º...
  • Page 14 Connecting wiring harness Connect the wiring harness plug X11 (12 poles) to the matching connector of the heater. Fig. 7: Connecting wiring harness of Dual Top RHA 100 Fig. 6: Removing front cover 1. Housing cover with inlet interfaces 2. Fastening screws for housing cover with inlet interfaces 3.
  • Page 15 Installing the heater • The heater is fastened on the load-bearing parts of the vehicle frame • See Webasto product catalogue for different kinds of fixation brackets. using brackets and M8 T-bolts which are integrated in the heater guide • At least 4 fixation points.
  • Page 16 • To minimize energy loss, it is recommended that the hot air hoses which run outside the vehicle be insulated. A basic application possibility for individually fastening the Dual Top is included in the delivery scope. Fig. 10: Fixation brackets and vibrations dampers (Webasto examples)
  • Page 17 Fig. 11). IMPORTANT Use the foam seal approved by Webasto to seal off the heater (and in par- • The minimum distances to the heater from chapter 6.3, "Installation lo- ticular the exhaust pipe) to the outside (see Fig. 12). Webasto assumes no cation"...
  • Page 18 Dual Top can only be fixed in place in one position and the foam See Fig. 14. seal is simultaneously compressed to the proper dimension (see Fig. 15). If you are interested, please contact your Webasto Service Centre. Fig. 13: Compressing the seal 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: Identification Plate

    Identification plate Identification plate The type label must be positioned so that it cannot be 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).

  • Page 20: Hot Water System

    Hot water system Hot water system The Dual Top complies with all applicable standards for this type of prod- uct. When installing 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).
  • Page 21 Hot water system Always use hoses, which are resistant to pressure (at least 4 bar) and hot The water lines must be routed inside the heating air intake hose. This will water (90 ºC). avoid frozen water lines as long as the heater is operating in a proper mode (see Operating Instructions).
  • Page 22 Hot water system 8.1. Installation information for immersion pump systems The Dual Top application with an immersion pump system requires a Connect the ventilation hose (1) to the cold water line (2) and mount at a “Dual Top Diving Pump” version and two additional ventilation hoses: steep uphill slope to the check valve (8).
  • Page 23 Hot water system Cold water line Drain hose for pressure relief Dual Top ventilation hose valve and solenoid valve “Dual Top Diving 10 Hot water line Pump”heater 11 Housing cover with inlet in- terfaces (service cap) Fig. 20: Dual Top immersion pump version...

  • Page 24: Hot Air System

    (1 hPa corresponds to 1 mbar corresponds to 10 mm water column). The points table for air guide parts in the Webasto air and water heaters accessory catalogue can be used to design the hot air system.
  • Page 25 Hot air system 9.1. Heating air intake 9.1.1. General 9.1.2. Installation NOTE The length of air intake hose outside the interior shall be as short as possi- The heating air has to be drawn from the interior. ble, ideally less than 1 m. This is to avoid heat losses and to protect the water pipes from freezing.
  • Page 26 • Drill a hole in the floor with a diameter of 100 mm. the air flow through both heater outlets is quite similar. See the Webasto air and water heaters accessory catalogue for branches, • Seal off the joint between the floor and the hose with temperature-re- connecting pieces, Y-junctions, outlets, etc.
  • Page 27 • Position of the outlets close to the floor for best air circulation. WARNING Fire danger! Only use high temperature resistant Webasto hot air hoses. The hot air opening is to be positioned in such a way that the air is not blown on to any parts that cannot withstand the heat.
  • Page 28 Hot air system Fig. 24: Hot air distribution Dark colour = below interior, insulated Bright colour = inside interior...

  • Page 29: Cooling Air System

    Cooling air system Cooling air system Cooling air is required to protect the heaters’ electronics and motor against overheating. Cooling air shall be taken from outside and not from inside the vehicle. The air has to be discharged outside the vehicle. The heater is equipped with a motor and a ventilator to transport the cool- ing air.

  • Page 30: Boiler Drainage And Pressure Relief System

    Boiler drainage and pressure relief system Boiler drainage and pressure relief system The heater is equipped with a drainage system that drains the water contents automatically as a protection against frost (boiler water temperature below 6 ºC). It is also possible to drain the unit manually; a pressure relief system that prevents pressure above 3.5 bar inside the boiler.

  • Page 31: Fuel Supply

    Fuel supply Fuel supply 12.1. General The fuel is typically taken from the vehicle’s own fuel tank. It may also be taken from a separate fuel tank (accessory). The permissible values for the maximum pressure at the fuel pump entry side are shown in Fig. 26. NOTE A notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point.
  • Page 32 Fuel supply 12.2. Fuel pump The DP40 fuel pump is a combined delivery, metering and a shut-off sys- 12.2.2. Installation and attachment tem and is subject to certain installation criteria (see Fig. 26 and Fig. 28). The fuel pump installation position is limited as shown in Fig. 28 in order to ensure effective automatic bleeding.
  • Page 33 1 - fuel extractor 2 - sealing ring 3 - tank extracting device 3) Webasto fuel extractor. See Fig. 31. Observe the installation instructions for different fuel extractor types. Fig. 29: Connection to vehicle’s fuel line with a Webasto fuel con- nector...
  • Page 34 Avoid passing or crossing of hot areas (e.g. crossing of exhaust line) at a distance of less than 100 mm without using thermal shields. Fig. 31: Webasto fuel extractor Fuel lines must be tightened to the vehicle’s chassis to prevent sagging.
  • Page 35 Fuel supply 12.4.2. Connecting two pipes with a hose The correct procedure for connecting fuel lines with hosing is shown in Fig. 32. Ensure that there are no leaks. Correct Wrong Fig. 32: Pipe / hose connection 1 = clip 2 = air or gas bubble 12.5.

  • Page 36: Combustion Air Supply

    Combustion air supply Combustion air supply 13.1. General 13.2. Combustion air intake line The air for the combustion chamber of the heater may not be taken out of the vehicle passenger compartment (extract from 2001/56/EC). Length of the combustion air inlet line max.
  • Page 37 Combustion air supply NOTE Combustion air intake hose should point downwards from the heater. If The intake opening for combustion air must be located so that it cannot this is not possible, make a condensate drain hole with a diameter of 4 mm become clogged with dirt or snow.

  • Page 38: Exhaust System

    Exhaust system Exhaust system 14.1. General See chapter 2, "Statutory regulations governing installation" for require- ments on exhaust system. NOTE An exhaust silencer must be fitted to reduce the noise level. The silencer should ideally be installed near the heater (not more than 0.20 m distance);...
  • Page 39 A fixing bracket is required no further than 150 mm from the end of to be connected to the heater using a Webasto exhaust clamp. An exhaust the exhaust pipe to ensure that the angle 45 to 70° is achieved.
  • Page 40 Exhaust system • Exhaust outlet should be on the opposite side of the entrance door of the living cell. • Avoid that the exhaust pipe can touch ground or pavement, including traffic calming measures. Fig. 41: Avoid the line becoming clogged with dirt Fig.
  • Page 41 Exhaust system (front view) 45 ~ 70º Fig. 42: Location and direction of exhaust A: Flow exhaust fumes 45 to 70º 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 that ambient wind can enter.

  • Page 42: Electrical Connections

    Interior temperature sensor Wiring harness (external) Fuse 10 A 10 Wiring interior temperature sensor Manual/programmable heater control Fuse 15 A Vehicle’s leisure battery Fuel pump Fig. 43: Schematic diagram of electrical connections for Dual Top RHA 100 with heater control...
  • Page 43 Electrical connections DUAL TOP RHA 101 / 102 Fuel pump 14 Wiring 230 V Wiring harness (external) Interior temperature sensor 15 230 V power supply Programmable heater control 10 Wiring interior temperature sensor 16 Dashboard LED Vehicle’s leisure battery 11 Receiver Telestart / Fuse 5 A Thermo Call (option) Fuse 10 A...
  • Page 44 Electrical connections 15.1. Supply voltage connection Use 12 V DC only. Ensure that you take it directly from the vehicle‘s leisure battery. No additional switches may be used with the exception of the Control Pan- el switch. Switching the heater on and off shall only be done with the Dual Top Control Panel.
  • Page 45 Electrical connections 15.2. Interior temperature sensor The remote interior temperature sensor must be installed at medium height in the interior on vertical surfaces. Make sure that the inside temperature sensor is not positioned: • in the direct current of hot air (from the vehicle‘s own heating system or the hot air heater);...
  • Page 46 Electrical connections 15.3. Connecting instrument panel LED (only for programmable heater control) • Make a hole where 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 the Con- trol Panel.
  • Page 47 Electrical connections 15.4. Connection to manual heater control • Determine the best position of the Control Panel. The Control Panel must be located in the driver's field of view. It should be visible and accessible for the operator. However at the same time, it must not be accessible to children. –15°...
  • Page 48 (optional for programmable Control Panel). NOTE: The Dual Top RHA 100 heater can easily be retrofitted with the program- mable heater control. This provides the user with additional comfort func- tions which are not available in the manual heater control (e.g. program- mable digital timer etc.).
  • Page 49 Fig. 52: Installing programmable heater control Connector X2 is for: – Webasto Thermo Test PC-diagnosis and – Webasto Telestart / Thermo Call (optional). Disassembly Control Panel Place 1 or 2 suction 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.
  • Page 50 Electrical connections 15.5.1. 230 V connection Installation of the 230 V connection shall be carried out by personnel certified for 230 V electric systems. Heater 1 Installation must be in accordance with IEC 60364. Connect to 230 V power supply. Heater 2 Install relay box in such a way that demanded protection class is real- ized.

  • Page 51: Wiring Diagrams

    Wiring diagrams Wiring diagrams Fig. 55: Circuit diagram for Dual Top RHA 100...
  • Page 52 Wiring diagrams Not in scope of delivery! to X5 to 8 Fig. 56: Circuit diagram for Dual Top RHA 101 / 102...
  • Page 53 Plug connector, 8-pin To relay box (only for RHA 101 / 102) Plug connector, 12-pin To Dual Top RHA 100 / 101 / 102 heater Wire end 4x to relay box, 1 to earth (only for RHA 101 / 102)

  • Page 54: Starting The Heater For The First Time

    Starting the heater for the first time Starting the heater for the first time • After you have installed the heater, bleed the fuel supply line carefully. NOTE Due to the low fuel consumption the heater may have to be switched on several times to fill the fuel line completely.

  • Page 55: Fault Code Output

    (can be recognised from the noise of the heater). peated sequence of long RED flashes. This procedure is repeated until the Deleting failures can also be done with the Webasto Thermo Test PC-Diag- heater is switched off. The meaning of the number of red flashing pulses nosis.
  • Page 56 Check connections of Control Panel. Check fuse 15 A. Check wiring harness. Contact a Webasto service station. No start (after 2 attempts to start) Check fuel supply (enough fuel, at least 8 ltr.; check fuel connection and tubes), reset heater (by switching off for at least 30 sec.)
  • Page 57 To reset the fault, confirm message by pressing OK (if provided) or switch Now the heater is reset. off the Dual Top for at least 5 seconds. Deleting failures can also be done with the Webasto Thermo Test PC-Diag- nosis. 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 failures.
  • Page 58 Control Panel connections of Control Panel. Check fuse 15 A. Check wiring harness. Contact a Webasto service station. Message 02 No start (after 2 attempts to start) Check fuel supply (enough fuel, at least 8 ltr.; check fuel connection and tubes), No start of combustion reset heater (by pressing OK or switching off for at least 30 sec.)
  • Page 59 Control unit (heater) fault / heater locked Put heater back into service (see above this table) and restart heater. Failure control unit Contact a Webasto service station. Message 18 Interior temperature sensor Check routing of cable, avoid that it is pinched or crushed,...
  • Page 60 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 at least 5 sec.) Contact a Webasto service station. Message 35 230 V overheating relay short circuit See message 27.

  • Page 61: Validation And Commissioning

    WARRANTY CERTIFICATE: Should remain with customer (in booklet). CONTROL CARD: Must be sent to the Webasto national company by the installation partner. The installation partner fills in the respective technical information and the installation date for its customer and applies its stamp.

  • Page 62: Technical Data

    Technical data Technical data Except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10 % at an ambient temperature of + 20 °C and at the rated voltage and in rated conditions. 20.1.
  • Page 63 Technical data 20.2. Technical data Heater Operation DUAL TOP RHA 100 DUAL TOP RHA 101 DUAL TOP RHA 102 Type approval heater: e1 00 0195 EMC: e1 03 5000 Model Air heater with Air heater with evaporator burner and electric heating device...
  • Page 64 Technical data Heater Operation DUAL TOP RHA 100 DUAL TOP RHA 101 DUAL TOP RHA 102 Overpressure valve 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 ±...
  • Page 66 Webasto AG Postfach 80 D - 82132 Stockdorf Germany National: Hotline: 01805 93 22 78 (€ 0,14/Min. aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com www.webasto.de www.webasto-outdoors.com Bei mehrsprachiger Ausführung ist Deutsch verbindlich. International: In multilingual versions the German language is binding.

This manual is also suitable for:

Dual top rha 102Dual top rha 101

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