Webasto HL 90 Bedienungsanleitung
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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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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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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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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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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Figure 1: Possible installation location
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Figure 2: Installation drawing
Hole pattern only required if
part 4 is used
2
4
5
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)
7
6
3
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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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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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