Cost-Effective and Idle Reducing Technology Engine-Off Heating & Air Conditioning for Off-Highway Machines
Optimum Temperature Equals Optimum Performance
Benefits at a glance:
Get the job done – more efficiently Today’s competitive market demands that projects get done quickly and professionally. Webasto products are designed to improve machine performance and increase operator comfort. When combined, machines and operators are able to perform at their optimal level.
n Less overall engine hours
n Reduced emissions on cold start-up
n Extend the life of DPF’s
n Reduced cost of ownership
n Increase resale value
n Reduced engine idling for lower fuel consumption
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Dial in the cost savings. Reduce Idling. Reduce Costs.
Fuel cost reductions
Reduce machine idling time and keep more money in operator’s pockets.
10% 20% 40% Shovel excavator (148 hp) $465
$930
$1,860
10% reduction of idle time on a 148 hp shovel excavator can save an operator $465.00/year 20% reduction of idle time on a 148 hp shovel excavator can save an operator $930.00/year 40% reduction of idle time on a 148 hp shovel excavator can save an operator $1,860.00/year (1,800 hours of operation and 684 hours of idling in one year, 1.7 gallons of fuel per hour, $4 per gallon of fuel)
10% 20% 40% Wheel loader (527 hp) $4,181
$8,364
$16,729
10% reduction of idle time on a 527 hp wheel loader can save an operator $4,181.00/year 20% reduction of idle time on a 527 hp wheel loader can save an operator $8,364.00/year 40% reduction of idle time on a 527 hp wheel loader can save an operator $16,729/year (2,000 hours of operation and 760 hours idling in one year, 8.6 gallons of fuel per hour, $4 per gallon of fuel)
Idling has a price Webasto’s comfort solutions enable operators to cut costs and efficiently maintain
comfort while their machine is off. Machine operators no longer need to idle equipment to maintain engine heat, reduce fuel gelling and keep cabs warm. Operating engines at a low speed (idling) causes twice the wear on internal parts, which increases maintenance costs and can even shorten the life of the engine over time. Shown above - idling can raise expenses by up to 17%. Idling causes unnecessary fuel consumption and increases machine working hours, both impacting the maintenance cycle as well as machine warranties.
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Engine-Off Cabin Cooling Technology
Polar Cab ES Machinery and operators are expected to work under the harshest conditions. Webasto offers an innovative solution for on-demand engine-off cabin cooling. Operators can turn off engines to reduce emissions, fuel costs, and maintenance costs while remaining cool and comfortable during wait/load times.
Polar Cab ES
Air Handler Polar Cab ES is designed to fit onto a variety of machine sizes. Webasto offers two cabin air-handler options: The Osaka is a floor mounted air handler. The Oakland is a vertical over-head mounted air handler.
Compressor/Condenser Unit with evaporator The Polar Cab ES is a battery driven electric cabin cooling system. When the engine is off, the Polar Cab ES can then be turned on (during wait/load time) to keep cabin temperatures cool and comfortable.
Benefits at a glance:
Technical Specifications
Polar Cab ES with Oakland (universal overhead evaporator)
Polar Cab ES with Osaka (universal vertical floor evaporator)
n Reduces engine hours
Part Number
5011840A
5011850A
n Saves fuel
Max Air Flow evaporator blower
190 cfm (325 m 3 h)
206 cfm (350 m 3 h)
n Maintains cabin temperature
Cooling Capacity
7,000 btu/h (2kW)
7,000 btu/h (2kW)
Referigerant
R134a
R134a
n Increased productivity
Nominal Voltage
24 VDC
24 VDC
Power Consumption
40 amps
40 amps
NOTE: All technical data subject to change, ±10% tolerance on all Specifications. * Dimensions do not include hose and mounting hardware.
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Engine-Off Heating
Air Heaters By drawing in ambient air, passing it over a high efficiency heat exchanger, warming it and discharging it into the cab, a Webasto air heater is able to rapidly heat the cab interior. This extends the work day and increases operator comfort and productivity.
Features & Benefits: n Up to 22 hours of heat on a single gallon of fuel n Saves Fuel n Reduce emissions n Full diagnostics with PC interface
Air Heater Technical Specifications:
Model
Output
Fuel Type
Fuel Consumption
Rated Voltage
Power Consumption
Dimensions (L x W x H)
Weight
Air Top 2000 STC
7,000 BTU/h (2 kW) 13,300 BTU/h (4 kW) 18,800 BTU/h (5.5 kW)
Diesel Gasoline B20
0.03 - 0.06 gal/h (0.12 - 0.24 l/h) 0.05 - 0.13 gal/h (0.18 - 0.49 l/h) 0.05 - 0.21 gal/h (0.18 - 0.80 l/h)
12 or 24 V 1.17 - 2.4 Amps @ 12 V 0.58 - 1.2 Amps @ 24 V
12.3 x 4.8 x 4.9 in (311 x 120 x 121 mm) 16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm) 16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm)
5.7 lbs (2.6 kg) 13 lbs (5.9 kg) 13 lbs (5.9 kg)
Air Top Evo 40
12 or 24 V
1.25 - 4.58 Amps
Air Top Evo 55
12 or 24 V
1.25 - 10.8 Amps
Air Top 2000 STC
Air Top Evo 40 / 55
Coolant Heaters A Webasto coolant heater draws in cold engine coolant, then heats it and pumps it back to the vehicle’s engine and HVAC system. The result is a pre-heated engine and warm interior. In extreme climates, the heater can be used with additional accessories to warm the fuel, hydraulic fluid, and batteries. Pre-heating engines significantly improves DPF performance.
Features & Benefits: n Provides engine pre-heat & interior cab heat n Saves fuel and eliminates cold starts n Increases productivity & extends hours of operation n Reduces engine hours, wear and maintenance costs n Increase productivity n Reduce DPF’s & improves DPF performance
Coolant Heater Technical Specifications:
Model
Output
Fuel Type
Fuel Consumption
Rated Voltage
Power Consumption
Dimensions (L x W x H)
Weight
Thermo Pro 50
17,000 BTU/h (5 kW) 31,000 BTU/h (9.1 kW) 45,000 BTU/h (13.1 kW) 51,000 BTU/h (15 kW) 80,000 BTU/h (23 kW) 104,000 BTU/h (30 kW) 120,000 BTU/h (35 kW)
Diesel B20
0.08 - 0.17 gal/h (0.27 - 0.63 l/h) 0.05 - 0.29 gal/h (0.2 - 1.1 l/h)
24 V 1.4 - 2.1 Amps @ 24 V
9.1 x 4.1 x 6.4 in (232 x 105 x 193 mm) 15 x 5.5 x 9.13 in (381 x 140 x 232 mm) 24 x 9.8 x 11.6 in (584 x 205 x 228 mm) 18.5 x 7.9 x 7.9 in (470 x 200 x 200 mm) 24 x 9.7 x 8.7 in (610 x 246 x 220 mm) 24 x 9.7 x 8.7 in (610 x 246 x 220 mm) 24 x 9.7 x 8.7 in (610 x 246 x 220 mm)
7 lbs (3.2 kg) 10.8 lbs (4.9 kg) 33 lbs (15 kg) 24.3 lbs (11 kg) 42 lbs (19 kg) 42 lbs (19 kg) 42 lb (19 kg)
Thermo Pro 90
12 or 24 V 3.1 - 7.5 Amps @ 12 V 1.53 - 3.75 Amps @ 24 V
DBW 2010
0.4 gal/h (1.5 l/h) 0.4 gal/h (1.4 l/h) 0.79 gal/h (3 l/h) 1.05 gal/h (4 l/h) 1.16 gal/h (4.4 l/h)
12 or 24 V
5 Amps @ 12 V 2.5 Amps @ 24 V 4.2 Amps @ 24 V
Thermo Top Pro 150 Thermo 230
12 or 24 V
24 V
2.7 Amps @ 24 V
Thermo 300
24 V
4.6 Amps @ 24 V
Thermo 350
24 V
5.8 Amps @ 24 V
Thermo Pro 50
Thermo Pro 90
DBW 2010
Thermo Top Pro 150
Thermo 230 / 300 / 350
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Independant Emissions Testing Lab (IETL)* result verification on the effect of a Webasto pre-heater on the emissions performance of a diesel engine. PM Emissions & DPF Performance
Results Summary
1. Engine start-up temperature has a huge impact on the emissions levels emitted by the engine
2. The test results show a 29% reduction in CO during winter conditions, and a 62% reduction during normal ambient conditions.
3. Pre-heating the engine does not have a significant effect on the Hydrocarbon emissions.
4. NO x emissions were reduced by around 40% by pre-heting the engine to 155 ° F.
5. PM emissions have a significant effect and were reduced by 66% by pre-heating the engine during the cold weather conditions. Pre-heating also provided a 27% reduction in PM emissions during normal ambient conditions. This will help in longevity of the DPF life and can avoid more frequent regenerations and cleaning intervals.
How Engine-Off Heating technology works
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3. With Engine-Off Heating technology – Longer stop: If the engine continues to cool down, the webasto coolant heater also switches on automatically. The temperature of the engine and cabin remain stable.
4. Without Engine-Off Heating technology – Engine off: When the engine is switched off, heat is no longer distributed to the cabin interior through circulating coolant. The thermal energy stored in the engine is lost; the cabin interior and engine cool down.
2. With Engine-Off Heating technology – Quick stop: Residual heat in the engine is used by the heater, as the Webasto circulation pump keeps residual heat moving through the cooling system. The temperature in the cabin interior remains stable.
1. Engine running: The engine generates heat, which is circulated via the heater core.
Engine
Coolant heater
Pump on
Pump off
Cabin interior heat exchange system
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DPF Solutions for the Off-Highway Market
n Up to 66% reduction in PM during startup n Up to 40% reduction in NOX n Up to 62% reduction in CO during startup based on ambient temperature n Increases exhaust temps rapidly, aiding in catalyst activity n Emission reduction at high ambient temperature n Emission benefit to pre-heat year round Independent testing shows that using a Webasto coolant heater to pre-heat an engine can significantly improve DPF performance.
How to extend the life of DPFs Diesel particulate filters are necessary to adhere to existing and future emission regulations. But they’re also an additional expense. When an engine is idling, the combustion temperature is too low for the DPF to run efficiently. The system has to be cleaned more frequently and parts wear more quickly. Automated Engine-Off heating therefore also helps extend the life of particulate filters.
n Reduce Face Plugging
n Reduce Wet Stacking
n Reduce Filter Overloading
n Reduce Costly DPF Maintenance
n Reduce Component Failures
n Reduce DEF Tank and Injector Issues
n Reduce Emission Burdens
n Reduce Fuel Costs
n Eliminates Cold Starts
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Webasto representations worldwide
For over a century, Webasto has continued to set new technological standards – in both the original equipment sector and the aftermarket. As one of the 100 biggest suppliers in the automotive industry worldwide, we develop and produce roof systems, including convertible solutions, as well as heating, cooling and ventilation systems. Our products help provide a better operator and driving experience on the road, more comfort and security, as well as increased efficiency for cars, commercial and special vehicles, off-highway machinery, motor homes and boats. An outstanding network of production facilities and dealers guarantees high-quality products, installation standards and services worldwide.
Webasto Thermo & Comfort North America, Inc. 15083 North Road Fenton, Michigan 48430 USA Toll Free: 800-860-7866 Phone: 810-593-6000 webasto.com
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