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HL90 EA_de_en_fr.book Page III Wednesday, June 5, 2013 10:17 AM HL 90 Inhaltsverzeichnis Table of contents 1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . . 1 1 Statutory regulations governing installation . . . . . . . . . . . .27 2 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . . 3 2 Use of the air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 3 Montage des Heizgeräts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HL90 EA_de_en_fr.book Page 27 Wednesday, June 5, 2013 10:17 AM HL 90 1 Statutory regulations governing installation Type approvals according to ECE-R 10 (EMC) and ECE-R 122 (Heater) exist for the HL 90 heater. 1.1. Extract from directive ECE-R 122 Part I and Annex 7 Start of extract. See chapter 11, "Technical data" for the approval number. Part I Primarily the regulations of Annex VII of the Directive 2001/56/EG and Part I and Annex 7 of the directive ECE-R 122 must be observed for the installation.
HL90 EA_de_en_fr.book Page 28 Wednesday, June 5, 2013 10:17 AM 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. 5.3.3.2 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.
HL90 EA_de_en_fr.book Page 29 Wednesday, June 5, 2013 10:17 AM 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 substances. The heaters operate independently of the engine and are connected to the fuel tank and the electrical system of the vehicle.
HL90 EA_de_en_fr.book Page 30 Wednesday, June 5, 2013 10:17 AM HL 90 3 To install the heater The standard scope of delivery of the heater consists of: – 1 Heater – 2 Supports – 2 Clamping bands – 2 Turnbuckles – 1 Intake manifold – 1 Fuel metering pump The heater must be installed on a flat surface as shown in Figures 1 and 2. Make the hole pattern as shown in Figure 2. The floor attachment can be aligned within the specified tolerances by loosening or tightening the turnbuckles and clamping bands.
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HL90 EA_de_en_fr.book Page 32 Wednesday, June 5, 2013 10:17 AM HL 90 6 1 7 2 1 Heater 2 Support with clamping belt and turnbuckle 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.
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HL90 EA_en.fm Page 34 Thursday, July 4, 2013 11:44 AM 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).
HL90 EA_de_en_fr.book Page 35 Wednesday, June 5, 2013 10:17 AM HL 90 5 Hot air system Integrating the heater into an existing air system belonging to the vehicle requires careful harmonisation and is not recommended. The air heater can be used both in fresh air mode for heating a passenger compartment and a driver’s cab as well as in recirculated air/fresh air mode for vehicle bodies.
HL90 EA_de_en_fr.book Page 36 Wednesday, June 5, 2013 10:17 AM HL 90 6 Fuel supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in Figure 5. Figure 5: 36 Fuel supply A sign must be affixed to the fuel filler neck warning that the heater must be switched off before refuelling. Maximum fuel intake height S (m) At max. negative pressure (bar) in fuel tank 0.00 -0.10 0.50 -0.06 1.00 -0.
HL90 EA_de_en_fr.book Page 37 Wednesday, June 5, 2013 10:17 AM HL 90 6.1. Fuel supply with fuel extractor In vehicles with large engines (trucks), the fuel must be extracted from the fuel tank or a separate, non-pressurised tank (see Figures 6 and 7). This separate fuel extractor precludes any effect of pressure.
HL90 EA_de_en_fr.book Page 38 Wednesday, June 5, 2013 10:17 AM HL 90 6.2. Fuel lines Only steel, copper and plastic lines of plasticised, light and temperature-stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to DIN 73378 may be used for the fuel lines. Since the lines normally cannot be routed with a constant rising gradient, the internal diameter must not be allowed to exceed a certain size.
HL90 EA_en.fm Page 39 Thursday, July 4, 2013 11:35 AM HL 90 6.3.2. Installation and attachment The metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in Figure 9 in order to ensure effective automatic bleeding. Figure 9: Metering pump without diaphragm damper 6.4. Fuel filter Only a Webasto filter, order no. 487 171, is allowed to be used if the fuel is expected to be contaminated.
HL90 EA_de_en_fr.book Page 40 Wednesday, June 5, 2013 10:17 AM HL 90 7 Combustion air supply Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt or snow and cannot suck in splashing water. The combustion air intake line (internal diameter min. 30 mm) may be up to 5 m in length and contain several bends totalling 360°.
HL90 EA_de_en_fr.book Page 41 Wednesday, June 5, 2013 10:17 AM HL 90 8 Exhaust line Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm or flexible piping of alloyed steel only must be used as the exhaust line. The exhaust pipe is secured to the heater using a clamping collar, for example. Front It must not be possible for condensate or water to collect in the exhaust line.
HL90 EA_de_en_fr.book Page 42 Wednesday, June 5, 2013 10:17 AM HL 90 9 Electrical connections 9.1. Control unit / heater connection The electrical connection of the heaters is made as shown in Figures 16 to 18. Blade-type fuse holder ID no. 148 78A 9.2. Connecting the controls The heater can be switched on and off using the following Webasto controls: - Switch - Cabin thermostat (mechanical) - Digital timer (24 hour) If a digital timer is used, the 8-pin blade terminal type AMP 163-007-0 ID no.
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HL90 EA_de_en_fr.book Page 44 Wednesday, June 5, 2013 10:17 AM HL 90 Item Designation A1 A1 A2 A2 B1 B2 B3 E F1 F1 F2 F2 F3 F3 H1 H1 H2 H2 H3 H4 H5 K1 K2 K3 K4 K5/K6 K5/K6 M HL 90 heater 24 V HL 90 heater 12 V Control unit 24 V Control unit 12 V Flame monitor 12/24 V Temperature limiter 12/24 V Cabin thermostat 12/24 V Glow plug 4V Blade-type fuse 24 V 20 A Blade-type fuse 12 V 20 A Blade-type fuse 24 V 20 A Blade-type fuse 12 V 20 A Blade-type fuse 12 V 10 A Blade-type fuse 24 V 7.
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HL90 EA_de_en_fr.book Page 50 Wednesday, June 5, 2013 10:17 AM HL 90 10 Initial start-up After you have installed the heater, bleed the fuel supply system carefully. NOTE If the fuel lines are long, it may be necessary to switch on several times in order to fill the fuel line to the heater. Conduct a trial of the heater to check all the connections for leaks and to ensure that they are secure. If the heater suffers a fault during operation, the fault must be located and remedied.
HL90 EA_de_en_fr.book Page 51 Wednesday, June 5, 2013 10:17 AM HL 90 11 Technical data Except where limit values are specified, these technical data refer to the usual heater tolerances of ±10 % at an ambient temperature of +20 °C and at the rated voltage. 11.1. Electrical components: Control unit, motor, metering pump, glow plug series resistor, part load resistor, digital timer and switch with lamp are designed for either 12 V or 24 V.
HL90 EA_de_en_fr.book Page 52 Wednesday, June 5, 2013 10:17 AM HL 90 Heater Type ECE homologation Model Heating current Fuel Fuel consumption Full load kW Part load kW Full load kg/h (l/h) Part load % by vol. Rated voltage VOperating voltage VRated power consumption Full load W (not in starting operation) Part load W Max. ambient temperature during operation: - Heater °C - Control unit °C - Metering pump °C Max. storage temperature: - Heater °C - Control unit °C - Metering pump °C Max.
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Im Fall einer mehrsprachigen Version ist Deutsch verbindlich. Die Telefonnummer des jeweiligen Landes entnehmen Sie bitte dem Webasto Servicestellenfaltblatt oder der Webseite Ihrer jeweiligen WebastoLandesvertretung. In multilingual versions the German language is binding. The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country.
