Webasto DUAL TOP RHA 100 User manual

Integriertes Heizgerät
Integrated Heater
Riscaldatore integrato
Einbauanweisung
Installation Instructions
Istruzioni di montaggio
DUAL TOP
RHA 100 / 101 / 102

Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of
deadly carbon monoxide leading to serious injury or death.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto
training course and have the appropriate technical documentation, special tools and special equipment.
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.
ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS.
Webasto rejects any liability for problems and damage caused by the system being installed by
untrained personnel.

Dual Top
I
Inhalt
1 Allgemeine Informationen ............................................................... 1
2 Gesetzliche Bestimmungen für den Einbau .................................... 2
3 Verwendung des integrierten Luft-/Wasserheizgerätes ................5
4 Weitere Sicherheitsanweisungen .................................................... 5
5 Einbaubeispiel ...................................................................................6
6 Einbau Heizgerät ...............................................................................8
7 Typenschild ......................................................................................16
8 Warmwassersystem ........................................................................ 17
9 Heizluftsystem .................................................................................21
10 Kühlluftsystem ................................................................................ 26
11 Boilerentleerung und Druckausgleichssystem ..............................27
12 Brennstoffversorgung ....................................................................28
13 Brennluftversorgung ......................................................................33
14 Abgassystem ...................................................................................35
15 Elektrische Anschlüsse ....................................................................39
16 Schaltpläne ......................................................................................48
17 Inbetriebnahme des Heizgerätes ...................................................51
18 Störcodeausgabe ............................................................................. 52
19 Prüfung und Inbetriebnahme .........................................................58
20 Technische Daten ............................................................................59
Contents
1 General ............................................................................................ 63
2 Statutory regulations governing installation ............................... 64
3 Use of the integrated air / water heater ...................................... 67
4 Additional safety instructions ....................................................... 67
5 Installation example ....................................................................... 68
6 Heater installation .......................................................................... 70
7 Identification plate ......................................................................... 78
8 Hot water system ........................................................................... 79
9 Hot air system ................................................................................. 83
10 Cooling air system .......................................................................... 88
11 Boiler drainage and pressure relief system .................................. 89
12 Fuel supply ...................................................................................... 90
13 Combustion air supply ................................................................... 95
14 Exhaust system ............................................................................... 97
15 Electrical connections ................................................................... 101
16 Wiring diagrams ........................................................................... 110
17 Starting the heater for the first time .......................................... 113
18 Fault code output ......................................................................... 114
19 Validation and commissioning .................................................... 120
20 Technical data ............................................................................... 121
D
GB

General
63
1 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.
Installation and all other jobs carried out by not certified persons can harm
you, the Dual Top and the vehicle. In that case, Webasto will refuse all lia-
bility.
Only use genuine Webasto parts. See the Webasto air and water heaters
accessory catalogue and Webasto camping catalogue.

Statutory regulations governing installation
64
2 Statutory regulations governing installation
The Dual Top RHA 100 / 101 / 102 heaters have been type-tested and ap-
proved in accordance with EC Directives 72/245/EEC (EMC) and 2001/56/
EC (heater) with the following EC permit numbers:
e1 03 5000
e1 00 0195
Installation is governed above all by the provisions in Annex VII of
Directive 2001/56/EC.
NOTE
The regulations of these guidelines are binding in the scope of the Di-
rective 70/156/EEC and/or 2007/46/EC (for new vehicle models from
29/04/2009) and should also be observed in countries in which there
are no special regulations.
See chapter 2.1, "Extract from Directive 2001/56/EC Annex VII"
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 Quality of Drinking Water,
DIN 2001-2 Drinking Water Supply, DVGW W 291 Cleaning and Disinfec-
tion etc.).
Make sure that during the installation the legal requirements for the per-
mits of the vehicle are not violated, in particular for the heater fixation and
the routing of the exhaust lines.
Installation of the Dual Top RHA 101 / 102 heater and related components
must be in accordance with IEC 60364 (“Electrical installations in caravan
parks and caravans”).
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 gen-
uine spare parts. This results in the type approval of the heater being void-
ed, and with it the general homologation of the vehicle.
NOTE
For vehicles with an EU permit, no entry in accordance with § 19
Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.

Statutory regulations governing installation
65
2.1. Extract from Directive 2001/56/EC Annex VII
Start of extract.
ANNEX VII
REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR
INSTALLATION
1. GENERAL REQUIREMENTS
1.7.1. A clearly visible tell-tale in the operator's field of view shall
inform when the combustion heater is switched on or off.
2. VEHICLE INSTALLATION REQUIREMENTS
2.1. Scope
2.1.1. Subject to paragraph 2.1.2, combustion heaters shall be
installed according to the requirements of this Annex.
2.1.2. Vehicles of category O having liquid fuel heaters are
deemed to comply with the requirements of this Annex.
2.2. Positioning of heater
2.2.1. 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 contamination.
2.2.2. The combustion heater shall not constitute a risk of fire,
even in the case of overheating. This requirement shall be deemed
to be fulfilled if the installation ensures an adequate distance to all
parts and suitable ventilation, by the use of fire resistant materials
or by the use of heat shields.
2.2.3. In the case of M2 and M3 vehicles, the heater must not be
positioned in the passenger compartment. 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 paragraph 1.4, or a duplicate, must be positioned so that it can
be easily read when the heater is installed in the vehicle.
2.2.5. Every reasonable precaution should be taken in positioning
the heater to minimise the risk of injury and damage to personal
property.
2.3. Fuel supply
2.3.1. The fuel filler must not be situated in the passenger
compartment and must be provided with an effective cap to
prevent fuel spillage
2.3.2. In the case of liquid fuel heaters, where a supply separate
to that of the vehicle is provided, the type of fuel and its filler point
must be clearly labelled.
2.3.3. A notice, indicating that the heater must be shut down
before refuelling, must be affixed to the fuelling point. In addition
a suitable instruction must be included in the manufacturer's
operating manual.
2.4. Exhaust system
2.4.1. The exhaust outlet must be located so as to prevent
emissions from entering the vehicle through ventilators, heated air
inlets or opening windows.
2.5. Combustion air inlet
2.5.1. The air for the combustion chamber of the heater must not
be drawn from the passenger compartment of the vehicle.
2.5.2. The air inlet must be so positioned or guarded that blocking
by rubbish or luggage is unlikely.

Statutory regulations governing installation
66
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.
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 air through the vehicle
must be so positioned or protected that no injury or damage could
be caused if it were to be touched.
2.7.2. The air outlet must be so positioned or guarded that
blocking by rubbish or luggage is unlikely.
End of extract.

Use of the integrated air / water heater
67
3 Use of the integrated air / water heater
The integrated Dual Top RHA 100 / 101 / 102 air and water heaters from
Webasto are used for heating and to provide hot 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 safety instructions
• If the Dual Top falls to the floor, it must be returned to Webasto for a
safety inspection/repair.
• It is not allowed to paint or re-paint the Dual Top heater partly or com-
pletely.

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

Installation example
69
1 Interior temperature sensor
2 Water lines
3 Dual Top heater
4 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
9Fueltank
10 Fuel pump
11 LED dashboard
12 Water pump
13 Water tank
14 Cooling air outlet
15 Hot air distribution
16 Control Panel

Heater installation
70
6 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
23 4 5
789101112
61 1 Heating air inlet
2 Water inlet (cold)
3 Water outlet (hot)
4 Cooling air inlet
5 Housing cover with inlet interfaces
6 Wiring harness outlets
7 Housing cover with hot air outlet
8 Exhaust outlet
9 Drain hose for pressure relief valve and so-
lenoid valve
10 Cooling air outlet
11 Fuel intake
12 Combustion air intake

Heater installation
71
6.3. Installation location
At all sides of the heater there should be at least 20 mm space.
• Space requirement for hot air outlet > 150 mm
• Length 530 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 heater must be heat-resistant (> 100 °C).
Fig. 3: Dimensions [mm] of the heater
352
256
530 >150
>200
>20
>20
Housing cover with
inlet interfaces
Housing cover with
hot air outlet

Heater installation
72
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;
• The heater must be fastened at a location in the vehicle which can with-
stand a weight of 35 kg;
• All parts above the water crossing level (specified for the vehicle);
• Possibility to remove the heater;
• Possibility to access and remove the housing cover with inlet interfaces of
the heater.
We recommend installing the heater on the exterior of the vehicle to save
space.Please also see
chapter 6.6, "Additional information for exterior 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 always be protected against splash water and
possible soiling.
Orientation of the heater:
The heater has to be mounted in a horizontal position (tolerance ± 5º),
with exhaust outlet and cooling air outlet port pointing downwards.
See Fig. 4.
IMPORTANT
Make sure that after installation the casing of the heater is not in contact
with any parts of the vehicle body. Ensure that all moving parts can move
easily. A failure to do this may result in the hot air fan, cooling air fan or
another part blocking.
Fig. 4: Required installation position
Fig. 5: Heater casing must not touch vehicle body
+5º
-5º
+5º
-5º

Heater installation
73
6.4. Connecting wiring harness
1. Housing cover with inlet interfaces
2. Fastening screws for housing cover with inlet interfaces
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 heater.
Fig. 6: Removing front cover
1
2
3
4
Fig. 7: Connecting wiring harness of Dual Top RHA 100
Fig. 8: Connecting wiring harness of Dual Top RHA 101 / 102

Heater installation
74
6.5. Installing the heater
• The heater is fastened on the load-bearing parts of the vehicle frame
using brackets and M8 T-bolts which are integrated in the heater guide
rails.
• To prevent breaks within the heater and noises, it is necessary to use vi-
bration dampers.
The M8 T-bolts and 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 different kinds of fixation brackets.
• At least 4 fixation points.
• Fixation of the heater only on the top or on one of the sides is not suf-
ficient.
• Install the heater in such a way that it will not fall from the vehicle in
case the vibration dampers fail.
See Fig. 9
Fig. 9: Possible fixation methods (front view)

Heater installation
75
6.6. Additional information for exterior installation
• Install the heater in such a way that it will not fall from the vehicle in case the vibration 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 application possibility for individually fastening the Dual Top is included in the delivery scope.
Fig. 10: Fixation brackets and vibrations dampers (Webasto examples)

Heater installation
76
6.7. Additional information for interior installation
IMPORTANT
Both the Dual Top and the hot air hoses must be installed firmly closed off
outside the range of the vehicle occupants and parts which are not tem-
perature-resistant (e.g. in an installation box or behind furniture, see
Fig. 11).
• The minimum distances to the heater from chapter 6.3, "Installation lo-
cation" (Fig. 3) must be complied with.
• All materials in the immediate vicinity of the heater must be heat-resist-
ant (> 100 °C).
• The Dual Top must be installed so that no parts which are not heat-re-
sistant can fall on the heater or block the air inlet and outlet.
• Accidental touching by the vehicle occupants must be avoided.
• The heater should be accessible when maintenance or repairs are car-
ried out.
• To ensure uniform air circulation, a ventilation opening of at least
100 cm2must be provided. Also see chapter 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 regulations
governing installation" for requirements of exhaust system and
chapter 14, "Exhaust system".
IMPORTANT
Use the foam seal approved by Webasto to seal off the heater (and in par-
ticular the exhaust pipe) to the outside (see Fig. 12). Webasto assumes no
liability for defects or damage resulting from the use of other materials.
First, a hole in the size and with the spacing of the two sections of the seal
must be drilled in the vehicle floor. The seal can be used as a template for
this purpose.
Then a clear positioning of the heater must be ensured. After the installa-
tion, the heater may not change either its position or that of the seal.
Fig. 11: Example of installation box with minimum inside dimensions
Bottom openings for exhaust
gas, cooling air, combustion air
and water drainage
L
B
HL (Length) ≥880 mm
B (Width) ≥392 mm
H (Height) ≥306 mm
Fig. 12: Webasto foam seal for interior installation

Heater installation
77
As the escaping exhaust gases can reach extremely high temperatures, a
temperature-resistant (up to 90 °C) sealing compound should be used to
seal off the floor.
When installing the heater, the following must also be ensured for sealing
off to the outside:
• The seal is evenly compressed to 60 %.
See Fig. 13.
It is advisable to use vibration dampers with a height of 30 mm for this
purpose.
• The exhaust pipe should be a minimum distance of 25 mm to the seal
and the vehicle floor 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.
NOTE
To guarantee proper, secure positioning of the heater and the foam seal,
we recommend the "Dual Top Inside Application Kit". Using the bottom
plate, the Dual Top can only be fixed in place in one position and the foam
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
60%
Fig. 14: Distance of exhaust pipe from seal and vehicle floor
Fig. 15: "Dual Top Inside Application Kit "
≥25 mm

Identification plate
78
7 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).
Inapplicable years must be erased from the identification plate and the cur-
rent year must be readable.

Hot water system
79
8 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).
NOTE
During and after installation of the water system, it must be ensured that
no dirt can enter into the water circuit.
To avoid leaks, 10 mm standard hose connector should be used to connect
water lines or hoses to the heater (e.g. John Guest/ASP). The coolant 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 quick connection system is used, secure the lines at all connection
points in a way that they can withstand pressure and are watertight.
• Fasten the hoses in a way that they cannot be damaged
(e.g using hose clips).
1 Vehicle’s water tank
2 Water pump
3 Cold water line
4 Water outlets
5 Optional thermostatic mixing valve
6 Hot water line
7 Dual Top heater NOTE
The internal diameter of the hot water lines should be at least 8 mm.
Fig. 16: Water system (scheme)
Fig. 17: Water line connection (example)
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