Webasto Field Guide

Webasto Field Guide

F I E LD GU I DE Market & Application Resource

1

Service Thousands of sales & service centers nationwide.

Quality Tested and verified to perform in the most demanding climates. Trust Genuine Webasto.

2

Performance Engineered for longer-lasting performance & reliability.

Support Your trusted partner: expert sales & technical support when you need us.

3

Helpful Tools:

n Webasto Regional Sales Managers: They are dedicated to helping you develop your Area of Responsiblity (AOR), by making sales calls with you, helping you stock the right inventory, and being your direct contact to Webasto. n Product Installation Training: Webasto has technical trainers that can come to your locations and train your technicians on how to properly install Webasto products. In turn they will make sure you are equipped to train your sub-dealers. n Technical Hotline: Knowledgeable, technical representatives are available at 800-860-7866 from 8am-5pm EST, Monday - Friday to answer product installation, maintenance or repair questions. n TechWebasto Mobile App: Available free for IOS and Android. A valuable resource tool for almost any question. It provides product specifications to help identify products, fault code reference guide to diagnose and troubleshoot issues and offers repair and maintenance tips. n Free Sales Literature: Call your Sales Manager, Webasto Marketing at 877-9NO-IDLE (877-966-4353) or visit www.webastoliterature.com to order free sales literature. Tips: n Be involved from the beginning, don’t wait for a state/provincial agency to announce an RFP n Network and build relationships with the state/provincial agencies and local EPA collaboratives n Become the Idle Reduction Expert in your area

4

Fuel Savings Calculator How to use: 1. Go to www.techwebasto.com and click on Documentation > Heater > Fuel Savings Calculator

2. Choose the appropriate language.

3. Choose either Thermosystems Calculator or Thermo Top.

4. Select the appropriate product from the pull-down menu.

5. Fill in the blanks including installed cost, number of vehicles, cost of fuel, hourly fuel use for idling, number of idling hours in a 24 hour period, and number of days per week spent in your vehicle.

6. Click Calculate to see the potential fuel savings and payback analysis.

5

Market Matrix

Air Heaters

Coolant Heaters

12 / 24 V 12 V 24 V 12 / 24 V

Truck Classes 3-8 / Cargo Commercial Truck

Municipality

Cargo

Bus (All Types) / RV

School Bus

Shuttle Bus

Coach/ Transit Bus

Recreational Vehicle

Off-Highway / Emergency Off-Highway

Ground Support Equipment

Fire & Rescue

Light & Medium Duty Light & Medium Duty

6

Electric Cooling Systems

Coolant Heaters (continued)

12 / 24 V

12 V

24 V

12 V

24 V

7

8

Class 8 Truck

Bus

Municipalities

Off-Highway

9

Class 8 Truck

Off-Highway Municipalities Bus

11

Points to drive home: Main selling points: n Fast Return on investment n Reduce fuel consumption n Reduce DPF maintenance n Extending engine life n Reducing maintenance costs n Increased driver satisfaction and retention n What are the makes and models of the trucks? n Have you ever used fuel operated heaters or idle-reduction technology? n Do you know how much fuel you use annually? For idling? n Do you want to save fuel? What to ask: Key points: n How many trucks do you have, sleepers and day cabs? Audience: If you are targeting an over the road fleet, you want to reach the decision maker, in most cases this is the Maintenance Director. In the case of a larger fleet, it could be the CFO or Purchasing Director.

12

Product Focus: For a fleet that runs class 8 over the road sleepers,

offer products that will: n Pre-heat the engine n Heat the bunk n Improve DPF performance Air Top 2000 STC: Bunk Heat n Up to 7,000 BTU/h (2.0 kW) n 1.2 - 2.4 Amps (14 - 29 Watts) n Use as little as 1 Gallon (3.7 liters) of fuel in 22 hours Thermo Top Evo: Engine Pre-Heat n Up to 17,200 BTU/h (5.0 kW)

n 3.8 Amps (46 Watts) n Eliminates cold starts

13

14

Class 8 Truck Off-Highway Municipalities Bus

15

Points to drive home: Main selling points: n Save fuel and reduce emissions n Extend engine life and reduce maintenance costs n Reduce electrical costs (no need to plug-in for heat) n Pre-heats engines and provides supplemental interior heat (Scholastic Heater) n Increase the safety of drivers and students n CARB approved and EPA SmartWay verified technology What to ask: Key points: n How many school buses do you have? n How long do you keep the buses before you sell them? When is your next purchase? n Have you ever used fuel operated heaters? n Do you know how much fuel you use annually? For idling? n Do you want to save fuel & keep your children healthy? n Are you able to capture total cost of heating your bus, including power consumption of block heaters? Audience: To successfully sell heaters to a school district, you want to get the attention of the policy maker. This will be the Transportation Supervisor or the Maintenance Supervisor.

16

Typical Installation: The Scholastic Heater comes assembled on a tray for installation in a storage compartment as seen below. It is also available in an enclosure box for installation on the bus’s frame rail. The Thermo Top Evo is either mounted in the engine compartment or in an enclosure box on the frame rail.

Scholastic: Engine Pre-Heat n 45,000 BTU/h (13.0 kW)

n 5.0 Amps (60 Watts) n 1” water connectors Thermo Top Evo: Engine Pre-Heat n Up to 17,200 BTU/h (5.0 kW)

n 3.8 Amps (46 Watts) n Eliminates cold starts

17

18

Class 8 Truck

Bus

Municipalities

Off-Highway

19

What to ask: Key points: n How many vehicles do you have in your fleets (garbage/refuse vehicles, work trucks, snow plows)? n What are the makes and models of those vehicles? n How long do you keep the vehicles before you sell them? When is your next purchase? n Have you ever used fuel operated heaters? n Do you know how much fuel you use annually? For idling? n Do you want to save fuel and help the environment? Audience: To successfully sell heaters to a city, county or state entity, you want to get the attention of the Transportation Supervisor. You need buy-in from the policy maker, so start from the top – down. Points to drive home: Main selling points: n Save fuel and reduce emissions n Extend engine life and reduce maintenance costs n No plug-in block heating required n Reduce your impact - maintain a green image n CARB Approved and EPA SmartWay verified technology

20

Air Top 2000 STC: Bunk Heat

n Up to 7,000 BTU/h (2.0 kW) n 1.2 - 2.4 Amps (14 - 29 Watts) n Use as little as 1 Gallon (3.7 liters) of fuel in 22 hours Thermo Top Evo: Engine Pre-Heat n Up to 17,200 BTU/h (5.0 kW) n 3.8 Amps (46 Watts) n Eliminates cold starts Thermo Pro 90: Engine Pre-Heat n Up to 31,000 BTU/h (9.1 kW) n 0.05 - 0.23 gal/h / 0.29 gal/h (0.2 - 0.9 l/h / 1.1 l/h) n 3.1 - 6.6 / 7.3 Amps (37 - 80 / 90 Watts) n Engine pre-heat, auxiliary hydraulic / fuel heat

21

22

Municipalities Bus Class 8 Truck

Off-Highway

23

What to ask: Key points: n What type of equipment are you using? How many of each? n What are the makes and models? n Have you ever used engine heaters or hydraulic fluid heating systems? n Do you know how much fuel you use annually? n Do you want to save fuel? Audience: Off-highway fleets will vary in size and equipment, but the approach is very similar to an over-the-road trucking fleet. You need to get the attention of the decision maker which is usually the Maintenance Supervisor or owner.

Points to drive home: Main selling points: n Reduce engine hours n Fast Return on Investment n Reduce fuel consumption and emissions n Extend engine life n Reduce maintenance costs n No plug-in block heating required n Improve resale value n Warranty time - slow warranty clock

24

Air Top 2000 STC: Operator Cab Heat n Up to 7,000 BTU/h (2.0 kW) n 24 V n .6 - 1.2 Amps (14 - 29 Watts) n Use as little as 1 Gallon (3.7 liters) of fuel in 22 hours

Thermo Pro 50: Engine Pre-Heat n Up to 17,000 BTU/h (5.0 kW) n 24 V n 1.2 - 2 Amps (28 - 46 Watts) n Eliminates cold starts

Polar Cab ES: Engine-Off Operator Cab Air Conditioning n Up to 7,000 BTU/h (2.0 kW) n 24 V n 40 Amps (960 Watts) n Reduce engine hours / saves fuel *Additional larger heaters available

25

E

Air Heaters & Coolant Heaters

26

Air Top 2000 STC

Technical Specifications

Air Top 2000 STC

Heating Capacity

3,100 – 7,000 BTU/h (0.9 – 2.0 kW)

Fuel

Diesel #1, Diesel #2, Arctic, Biodiesel B5 & B20

Fuel Consumption

0.03 – 0.06 gal/h (0.12 – 0.24 l/h)

Rated Voltage

12 or 24 V

Operating Voltage Range

10.5 – 16 or 21 – 32 V

Rated Input

1.25 – 2.45 Amps (14 – 29 Watts)

Air Flow

55 cfm (93 m 3 /h)

Dimensions (L x W x H)

12.25 x 4.78 x 4.85 in (311 x 120 x 121 mm)

Weight

5.73 lbs (2.6 kg)

Main selling points: n Provide rapid cab heat without idling n Save thousands of dollars a year in fuel – use as little as 1 Gallon (3.7 liters) of fuel in 22 hours n Quiet operation ensures a restful night’s sleep n Full diagnostics with PC interface available n 3,100 – 7,000 BTU/h (0.9 - 2.0 kW) heat output

27

Air Top Evo 40/55

Technical Specifications

Air Top Evo 40

Fuels

Diesel, Biodiesel

Gasoline

Nominal Voltage

12 V

24 V

12 V

Heating Capacity, Control Range/Boost Fuel Consumption, Control Range/Boost

5,100 – 12,000 / 13,650 BTU/h (1.5 – 3.5 / 4.0* kW)

5,800 – 12,000 / 13,650 BTU/h (1.7 – 3.5 / 4.0* kW)

0.05 – 0.11 / 0.13 gal/h (0.18 – 0.43 / 0.49 l/h)

0.07 – 0.14 / 0.15 gal/h (0.25 – 0.51 / 0.58 l/h)

Rated Power Consumption, Control Range/Boost @ 12 V Operating Temperature Range Heating Air Volume Flow Against 0.5 mbar, ​Control Range/Boost

1.25 –3.3 / 4.58 Amps (15 – 40 / 55 W)

–40 to +104 °F (–40 to +40 °C)

77.7 / 82.4 cfm (132 / 140 m 3 /h)

Dimensions (L x W x H)

16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm)

Weight

13 lbs (5.9 kg)

Automatic Altitude Compensation ECE Approval Number ECE R122 (​heating) ECE Approval Number ECE R10 (EMC)

7,218 ft (2,200 m)

E1 00 0385

E1 04 5529

Air Top Evo 55

Fuels

Diesel, Biodiesel

Gasoline

Nominal Voltage

12 V

24 V

12 V

Heating Capacity, Control Range/Boost Fuel Consumption, Control Range/Boost

5,100 – 17,000 / 18,800 BTU/h (1.5 – 5.0 / 5.5** kW)

5,800 – 17,000 / 18,800 BTU/h (1.7 – 5.0 / 5.5** kW)

0.05 – 0.16 / 0.18 gal/h (0.18 – 0.61 / 0.67 l/h)

0.07 – 0.19 / 0.21 gal/h (0.25 – 0.73 / 0.80 l/h)

Rated Power Consumption, Control Range/Boost @ 12 V Operating Temperature Range Heating Air Volume Flow Against 0.5 mbar, ​Control Range/Boost

1.25 –7.9 / 10.8 Amps (15 – 95 / 130 W)

–40 to +104 °F (–40 to +40 °C)

117 / 129.5 cfm (200 / 220 m 3 /h)

Dimensions (L x W x H)

16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm)

Weight

13 lbs (5.9 kg)

Automatic Altitude Compensation ECE Approval Number ECE R122 (​heating) ECE Approval Number ECE R10 (EMC)

7,218 ft (2,200 m)

E1 00 0386

E1 04 5529

28

Thermo Top Evo

Technical Specifications

Thermo Top Evo

Heating Flow (Partial Load / Full Load)

8,600 - 17,200 BTU/h (2.5 - 5.0 kW)

Fuel

Diesel, Arctic Diesel

Nominal Voltage (Suitability for special fuels) Operating Voltage Power Consumption including coolant pump Currant Consumption During Start-up at 12 V

12 V 10 to 16.5

41 W

14 Amps

Fuel Pump / Coolant Pump

DP 42 / U4847 econ

Noise Emission [dB]

61

Dimensions (L x W x H)

8.54 x 3.58 x 5.79 in (217 x 91 x 147 mm)

Weight

4.6 lb. (2.1 Kg)

Diagnostic

Blink Code, Diagnostic Tool

Main selling points: n Provide engine pre-conditioning without idling n Eliminates cold starts n Reduce DPF maintenance costs n Approximately 2 hours of operation eliminates overnight idling and plug-ins for heating n Full diagnostics with PC interface available n Reduce PM emissions by up to 66% at start-up n Up to 17,200 BTU/h (5.0 kW) heat output

29

Thermo Pro 50

Technical Specifications

Thermo Pro 50

Heating Capacity

8,500 – 17,000 BTU/h (2.5 – 5.0 kW)

Fuel Consumption

0.08 – 0.17 gal/h (0.3 – 0.65 l/h)

Fuels (Suitability for special fuels)

JP8, Diesel 1, Diesel 2, Arctic

Rated Voltage

24 V

Rated Power Consumption

1.2 – 2 Amps (28 – 46 Watts)

Dimensions (L x W x H)

8.6 x 3.6 x 5.8 in (218 x 91 x 147 mm)

Weight

4.8 lbs (2.2 kg)

Main selling points: n Auxilliary heating with up to 17,000 BTU/h (5.0 kW) of heating power n The lightest heater in its class n Tested to -50° F (-46° C) n Compact size allows installation in a wide range of vehicles and equipment n High product quality with long service life n Automatic high altitude adjustment up to 11,000 feet (3,350 m) n Coolant inlet & outlet ports can be rotated 180°

n Remote mounted coolant pump n Reduce DPF maintenance costs

30

Thermo Pro 90

Technical Specifications

Thermo Pro 90

Heating Capacity (Control range / Boost) Fuel Consumption (Control range / Boost)

6,100 – 26,000 BTU/h / 31,000 BTU/h (1.8 – 7.6 kW / 9.1 kW)

0.05 – 0.23 gal/h / 0.29 gal/h (0.2 – 0.9 l/h / 1.1 l/h)

Fuels (Suitability for special fuels)

JP8, Diesel 1, Diesel 2, Arctic, Biodiesel (PME)

Rated Voltage

12 or 24 V

Rated Power Consumption (Part load - full load / Boost) @ 12 V

3.1 - 6.6 / 7.3 Amps (37 - 80 / 90 Watts)

Operational Temperature Range

- 40° to +176° F (- 40° to +80° C)

Dimensions (L x W x H)

15 x 5.2 x 9.1 in (381 x 131 x 232 mm)

Weight

10.8 lbs (4.9 kg)

Main selling points: n Auxilliary heating for heavy vehicles and machines, offering up to 31,000 BTU/h (9.1 kW) of heating power n Arctic Start function provides quick pre-heat even in extremely cold temperatures n Low heater power consumption due to highly efficient design n High product quality with long service life n Automatic altitude adjustment up to 11,000 feet (3,350 m) n Flexible mounting options available n Quiet operation n Reduce DPF maintenance costs

31

DBW 2010

Technical Specifications

DBW 2010

Heating Capacity

45,000 BTU/h (13.0 kW)

Fuel

Diesel #1, Diesel #2, Arctic, Biodiesel B5 & B20

Fuel Consumption

0.4 gal/h (1.5 l/h)

Rated Voltage

12 or 24 V

Operating Voltage Range

10 – 14 or 20 – 28 V

Rated Input

5 Amps (60 W) without pump

Dimensions (L x W x H)

23 x 8.1 x 9 in (584 x 205 x 228 mm)

Weight

33 lbs (15 kg)

Main selling points: n Eliminates cold starts n Pre-heats large engines n Provides interior cab heat n 45,000 BTU/h (13.0 kW) output n Fast Return on Investment n CARB approved and EPA SmartWay verified n Reduce DPF maintenance

32

DBW 300

Technical Specifications

DBW 300

Heating Capacity

104,000 BTU/h (30.0 kW)

Fuel

Diesel #1, Diesel #2, Biodiesel B20

Fuel Consumption

1.05 gal/h (4.0 l/h)

Rated Voltage

12

Rated Power Consumption

10.8 Amps (130 W) without pump

Dimensions (L x W x H)

27 x 9.5 x 11 in (680 x 240 x 279 mm)

Weight

48 lbs (22 kg)

Main selling points: n Engine pre-heat for large engines n Provides interior cab heat n Heats hydraulic fluid with optional accessories n 104,000 BTU/h (30 kW) output n Eliminates cold starts

n Reduce DPF maintenance n Fast Return on Investment

33

Thermo 300

Technical Specifications

Thermo 300

Heating Capacity

102,000 BTU/h (30 kW)

Fuel

Diesel #1, Biodiesel B2

Fuel Consumption

1.2 gal/h (4.5 l/h)

Rated Voltage

24 V

Rated Power Consumption

4.6 Amps (110 W)

Dimensions (L x W x H)

24 x 9.75 x 8.675 in (610 x 246 x 220 mm)

Weight

42 lbs (19 kg)

Main selling points: n Provides engine pre-heat and interior cab heat n Heats hydraulic fluid with optional hydraulic system warmer n 102,000 BTU/h (30 kW) n Eliminates cold starts n Reduce DPF maintenance

34

Scholastic

Technical Specifications

DBW 2010

Heating Capacity

45,000 BTU/h (13.0 kW)

Fuel

Diesel #1, Diesel #2, Arctic, Biodiesel B5 & B20

Fuel Consumption

0.4 gal/h (1.5 l/h)

Rated Voltage

12 or 24 V

Operating Voltage Range

10 – 14 or 20 – 28 V

Rated Input

5.0 Amps (60 Watts) without pump

Dimensions (L x W x H)

23 x 8.1 x 9 in (584 x 205 x 228 mm)

Weight

33 lbs (15 kg)

Main selling points: n Preheats the engine to eliminate cold starts and extends engine life n Accelerates and maintains window defrosting and defogging n Provides in-duty supplemental heat for increased driver and passenger comfort n Reduces vehicle emissions eliminating unnecessary idling n Stops white smoke at engine start-up and eliminates diesel knock n 1” water connections n High-capacity water pump for increased heat distribution n Built-in bleed valve to purge air from system n Reduce DPF maintenance

35

SmarTemp Control 2.0 for Webasto Air Heaters

On/Off Button

Smart Indicator LED‘s n Red for Heat Mode n Blue for Vent Mode n Blinking Red for Diagnostic Codes

Ambient Temperature Display

Menu Select Button

Ergonomic Comfort Dial

Set Temperature Display

Main selling points: n 24 hour programmable heater start time n Displays heater fault codes n Easy USB connection for PC diagnostics n Displays set temperature and ambient bunk temperature n Password protected options for preventive

SmarTemp Control fx 2.0 for Webasto Coolant Heaters maintenance reminders, low voltage disconnect threshold, adjustable run time, Fahrenheit & Celsius measurements

Day Indicator

On/Off Button

Smart Indicator LED‘s n Red for Heat Mode n Blinking Red for Diagnostic Codes n Adjustable Low Voltage Disconnect

Time Indicator

Mode & Timer Indicators

Heater On Icon

Select Button Timer On Indicator

Ergonomic Comfort Dial

Remaining Time Indicator

Main selling points: n 7 day timer with up to 4 different timer settings per day n Diagnostic code descriptions and blink codes n Error Code List (last 5 errors) n Adjustable low voltage diconnect (LVD) threshold n Adjustable Duration Time (10-120 minutes / 10 minute step)

36

Polar Cab ES

Twister Controller

Technical Specifications

Polar Cab ES

Dimensions (W x D x H)

24.1x 16.5 x 16.1in (613x 419x 410mm)

Weight Compressor/Condenser

84 lbs. (38 kg)

Polar Cab ES with Oakland (universal overhead evaporator)

Oakland - Overhead Evaporator

Max Air Flow evaporator blower

190 cfm (325 m 3 h)

Cooling Capacity

7,000 BTU/h (2kW)

Referigerant

R134a

Nominal Voltage

24 VDC

Rated Power Consumption

40 amps (960 Watts)

Dimensions ( W x D x H) Evaporator

14.6 x 11.1 x 6.2 in (370.5 x 281.4 x 158 mm)

Weight Evaporator

8 lbs (3.5 kg )

Polar Cab ES with Osaka (universal vertical floor evaporator)

Osaka - Floor Mounted Evaporator

Max Air Flow evaporator blower

206 cfm (350 m 3 h)

Cooling Capacity

7,000 BTU/h (2kW)

Referigerant

R134a

Nominal Voltage

24 VDC

Rated Power Consumption

40 amps (960 Watts)

Dimensions ( W x D x H) Evaporator

13 x 7.9 x 12.6 in (330 x 200.1 x 321mm)

Weight Evaporator

12 lbs (5.5 kg )

Main selling points: n Cooling capacity 7,000 BTU/h (2 kW) n Reduces engine hours n Saves fuel n Maintains cabin temperature n Compact 24 V variable speed electric compressor

37

Webasto Thermo & Comfort North America, Inc. 15083 North Road Fenton, Michigan 48430 USA Toll Free: 800-860-7866 Phone: 810-593-6000 webasto.com

38