Webasto Wiring Installation guide

Webasto
Brand
Webasto
Model
Wiring
Category
Motorcycle Accessories
Type
Installation guide
Webasto Heating and Cooling
Installation Guide for Kit Numbers:
• 5013571A – VAC Tie-In Harness Kit
• 5013572A – HVAC Tie-In Harness Kit
• 5013563A – Kit VAC HVAC Harness – Independent Add On
Contents
INTRODUCTION .................................................................................................................................................... 3
General Service and Safety Precautions ................................................................................................................ 3
Installation General References ............................................................................................................................ 3
SPECIAL NOTES ....................................................................................................................................................... 4
VAC Wiring Diagram – NEO 1 – Tie In ..................................................................................................................... 5
VAC Wiring Connections – NEO 1 – Tie In............................................................................................................... 6
VAC Wiring Diagram – NEO 1 Independent ............................................................................................................ 7
VAC Wiring Connections – NEO 1 – Independent ................................................................................................ 8
HVAC Wiring Diagram – NEO 2 Tie In ..................................................................................................................... 9
HVAC Wiring Connections – NEO 2 Tie In.......................................................................................................... 10
HVAC Wiring Diagram – NEO 2 Independent ........................................................................................................ 11
Wiring Connections NEO 2 Independent............................................................................................................. 12
HVAC Wiring Diagram – NEO 2+ Tie-In ................................................................................................................. 13
HVAC Wiring Diagram – NEO 2+ Independent ...................................................................................................... 14
HVAC Wiring Diagram – HVAC Independent Board .............................................................................................. 15
VAC Wiring Connections – Independent Board ..................................................................................................... 16
NEO 1 Heat Details ................................................................................................................................................ 17
NEO 2 HVAC Details ............................................................................................................................................. 18
NEO 2+ HVAC Details ........................................................................................................................................... 19
2
Warning: Cancer and Reproductive Harm. www.P65Warnings.ca.gov
– Installation and repair of Webasto heating and cooling systems requires special Webasto
training, technical information, special tools and special equipment.
– NEVER attempt to install or repair Webasto heating or cooling system unless you have
the proper certifications, technical skills, tools, and equipment required to properly
complete the necessary procedures.
– 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.
3
INTRODUCTION
General Service and Safety Precautions
WARNING
Never service, repair, or troubleshoot this system unless you are a professional air
conditioning/refrigeration service person. Improper servicing can lead to serious injury or death from fire,
electric shock, or explosion.
Refrigeration and air conditioning devices are extremely complicated by nature. Servicing, repairing, and
Trouble-shooting these products should be done only by those with the necessary knowledge, training,
and equipment.
Installation General References
• Disconnect the negative battery cable before performing any work on the vehicle’s electrical
system.
• Bare sheet metal, for example around drilled holes, must be treated with anti-corrosive coating.
• Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at
chafing points.
• Fit edge protectors (split fuel hose, grommet, split-loom, etc.) to sharp edges.
• Replace hose clamps as necessary. Hose clamps should be inspected before re-use. Look for
damage to the screw and to the band due to fatigue, corrosion, or improper installation.
4
SPECIAL NOTES
Caution: Remove the three 15A fuses from the relay board and replace them with 20A fuses when an
underbody-mounted condenser is being used.
Be sure the thermostat connectors
are connected to the brass terminals,
not the silver terminals.
The Independent board power and ground lugs are NOT to be used as power and ground take-off points for
other components of this, or other systems.
When making power connections, the battery connections must be made last. Failure to follow this direction
could result in a short circuit and damage to the vehicle or the system being installed.
Before cutting the mounting hole for the controller, be sure there is no structure or wiring behind it that can
be damaged.
In some cases, not all wiring connectors / wires will be used. In these cases, secure the unused connectors /
wires to the wiring harness and protect against damage.
5
VAC Wiring Diagram – NEO 1 – Tie In
Fig. 1
• Insert the blue wire from connector J2 into pin C of the blower harness NEO connector
• Tape any unused wires or connectors and protect against short-circuits
6
VAC Wiring Connections – NEO 1 – Tie In
1
Ground
2
12V constant power
3
NEO controller connections
4
Refrigerant valve or A/C compressor*
5
(not used)
6
Thermostat*
7
12V ignition on
8
Blower ON signal wire
9
Blower connector at NEO controller
10
Blower connector at evaporator
Refer to item #3 above
J1
Red
J2
Blue
J3
Black
J4
Pink
J5
Black
J6
Red
*If applicable
7
VAC Wiring Diagram – NEO 1 Independent
Fig. 3
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
• Insert the blue wire from connector J2 into pin C of the blower harness NEO connector
• Tape any unused wires or connectors and protect against short-circuits
8
VAC Wiring Connections – NEO 1 – Independent
Fig. 4
For independent system connections, refer to the graphic on pages 12 and 13
1
Ground
2
12V constant power
3
NEO controller connections
4
Refrigerant valve
5
Extreme board jumper (not used)
6
Thermostat
7
12V ignition on
8
Blower ON signal wire
9
Blower connector at NEO controller
10
Blower connector at evaporator
Refer to item #3 above
J1
Red
J2
Blue
J3
Black
J4
Pink
J5
Black
J6
Red
9
HVAC Wiring Diagram – NEO 2 Tie In
Fig. 5
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
• Insert the blue wire from the NEO connector into pin C of the blower harness NEO connector
•
Tape any unused wires or connectors and protect against short-circuits
10
HVAC Wiring Connections – NEO 2 Tie In
Fig. 6
1
12V battery power
2
Ignition ON 12V power
3
Battery ground
4
Blower connection at evaporator assembly
5
Blower motor connection at controller
6
Coolant pump
7
Coolant valve
8
Thermostat (if applicable)
9
Refrigerant valve (if applicable)
10
Not used. Insulate and protect the wire
11
Blower ON signal wire
12
AC switch – independent systems only *
13
Condenser fan connection at condenser *
14
Condenser fan connection at extreme board *
*AUsed only in independent systems
11
HVAC Wiring Diagram – NEO 2 Independent
Fig. 7
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
• Insert the blue wire from the NEO connector into pin C of the blower harness NEO connector
• Tape any unused wires or connectors and protect against short-circuits
12
Wiring Connections NEO 2 Independent
Fig. 8
For independent system connections, refer to the graphic on pages 12 and 13
1
12V battery power
2
Ignition ON 12V power
3
Battery ground
4
Blower connection at evaporator assembly
5
Blower motor connection at controller
6
Coolant pump
7
Coolant valve
8
Thermostat
9
Compressor
10
Not used. Insulate and protect the wire
11
Blower ON signal wire
12
Extreme board jumper
13
Condenser fan connection at condenser *
14
Condenser fan connection at extreme board *
*AUsed only in independent systems
13
HVAC Wiring Diagram – NEO 2+ Tie-In
Fig. 9
• Tape any unused wires or connectors and protect against short-circuits
14
HVAC Wiring Diagram – NEO 2+ Independent
Fig. 10
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
• Tape any unused wires or connectors and protect against short-circuits
15
HVAC Wiring Diagram – HVAC Independent Board
Fig. 11
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
• The red paint on the power and ground connection lugs does not indicate positive and negative
connections.
• Attach the ground cable to a clean and secure chassis ground near the extreme board.
16
Condenser Information – Fuse Usage
Condenser Name Dimensions
L x W x H – in (mm)
Fuse size installed in extreme
board
Capri (rooftop) 32 X 23.6 X 5.9
(815 X 600 X 150) 15 amp
Valencia (rooftop) 37.5 X 23.6 X 5.9
(955 X 600 X 150) 20 amp
Underbody 28.5 X 17.7 X 4.1
(725 X 450 X 105) 20 amp
VAC Wiring Connections – Independent Board
Fig. 12
NOTE: The Independent board power and ground lugs are NOT to be used as power and ground
take-off points for other components of this, or other systems.
Refer to system specific diagrams for basic system connections. Independent system connections are below.
Caution: Remove the three 15A fuses from the relay board and replace them with 20A fuses when an
underbody-mounted condenser is being used.
Caution: All power connections are to be made at the battery. Failure to follow this instruction will cause
damage to kit components.
• Tape any unused wires or connectors and protect against short-circuits
17
XXX
XXX
NEO 1 Heat Details
Fig. 13
J1 – Output for compressor
clutch/condenser fan
J2 – Input enable - compressor
clutch/condenser fan
J3 – Ground
J4 – Backlight
J5 – Ground
J6 - +12V DC
L – Blower low speed
M – Blower medium speed
H – Blower high speed
B - +12V DC (B+)
C – Output enable - compressor
clutch/condenser fan
NEO 2 Tie-In Details
Fig. 14
L – Blower low speed
M – Blower medium speed
H – Blower high speed
B - +12V DC
C – Blower ON
1 - +12V DC
2 – Water valve
3 – water valve
4 – Not used
5 – Coolant pump (+)
6 – Not used
7 – Not used
8 – Ground
9 – Ignition (+)
10 – Water valve feedback
11 – Water valve ground
12 – Backlight control
13 – Not used
14 – Not used
15 – Blower ON (+)
18
NEO 2 Independent Details
Fig. 15
L – Blower low speed
M – Blower medium speed
H – Blower high speed
B - +12V DC
C – Blower ON
1 - +12V DC
2 – Water valve
3 – water valve
4 – Not used
5 – Coolant pump (+)
6 – A/C clutch (+)
7 – Not used
8 – Ground
9 – Ignition (+)
10 – Water valve feedback
11 – Water valve ground
12 – Backlight control
13 – Not used
14 – Not used
15 – Blower ON (+)
19
If you have any questions, contact our technical support team at (800) 860-7866 or via email
at technical@webasto.com.
NEO 2+ HVAC Details
Fig. 16
1 - +12VDC
9 – Ignition (+) (independent)
Engine ON (tie-in systems)
2 – Water Valve (-)
10 – Water Valve Reference
3 – Water Valve (+)
11 – Output Sensor / Water Valve
Ground
4 – Input Temperature Sensor
(NTC 10K Ω @ 77°F (25°C)
12 – Output Sensor
(NTC 10K Ω @ 77°F (25°C)
5 – Coolant Pump (+)
13 – Blower Low
6 – Compressor (+)
14 – Blower Medium
7 – Internal Temperature Sensor
(ground)
(NTC 10K Ω @ 77°F (25°C)
15 – Blower High
8 – GND
In multilingual versions the English language is binding. The telephone number of the respective country is shown on the
Webasto service center leaflet or can be found on the website of your Webasto subsidiary.
Dans le cas d’une version rédigée en plusieurs langues, l’anglais est alors la langue qui fait foi. Pour trouver le numéro de
téléphone du pays concerné, veuillez consulter le dépliant des points-service Webasto ou la page web de la représentation
Webasto de votre pays.
Webasto Thermo & Comfort N.A., Inc.
15083 North Road
Fenton, MI 48430
Technical Assistance Hotline
USA: (800) 860-7866
Canada: (800) 667-8900
www.webasto.us
www.techwebasto.com
Org. 11/2019 Rev. 04/2023
im_5013589a_hvac_wiring
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Webasto Wiring Installation guide

Webasto
Brand
Webasto
Model
Wiring
Category
Motorcycle Accessories
Type
Installation guide
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