Installation Instructions. 40 Series

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1 Marine Roof Installation Instructions 40 Series

2 TABLE OF CONTENTS English INTRODUCTION TECHNICAL SPECIFICATION DESCRIPTION OF THE WEBASTO 40 SERIES INSTALLATION ELECTRICAL CONNECTIONS RESETTING ELECTRICAL DIAGRAM SAFETY SUPPORT CHECKLIST... 23

3 NOTE For installation and repair of Webasto roofs you will need a special training by Webasto, technical documentation, special tools and special equipment. Do NOT install or repair Webasto roofs, if you have not successfully finished the training by Webasto for acquiring the necessary technical skills. Do NOT install or repair Webasto roofs, if you do not have the necessary technical documentation, tools or equipment. ALWAYS follow the Webasto installation and service instructions and mind all warning indications. Webasto does not assume any liabilities for defects or damages caused by for installation untrained personnel. SYMBOLS On each page you can find a symbol of the kind of tasks explained on that page. Mechanical tasks Electrical connections Special parts of the text are marked with these symbols: Indication of danger of injuries or accidents Indication of danger of damaging the product Indication of another source of information Indication of technically special features 3

4 SCOPE OF DELIVERY Top frame (incl. mechanisms) Glass panel assembly (incl. tool bit for fixing screws) Rails, left and right Bag with hardware, rail covers (2 pcs), rail end caps (2 pcs) Grease Isoflex Topas L32 Motor cover incl. fixing screws (optional) Brackets for motor cover incl. fixing screws (2 pcs, optional) Installation instructions Operating instructions OTHER MATERIALS REQUIRED Hardware to fix top frame and rails: screws M4 stainless steel, pan, dome or round head High quality, acid-free, UV resistant, silicon mastic sealant Loctite 243 NECESSARY TOOLS Drilling machine Drills ø 3.2 mm, ø 4.5 mm, ø5mm Countersink drill bit Taps M4, M6 Torx keys Mastic gun Screwdrivers Personnel Perform roof installation with at least 2 persons. This makes the operation easier and reduces the risk of damage. Protection Improper use of tools can lead to injuries or damage to the ship or roof! Thoroughly read tool instructions prior to using. Before using any specialized tools, ensure to know all rules and regulations in your country. Cover interior and exterior of the ship or vehicle with protection materials (covers, cloths, etc.) to reduce the risk of damage. Also wear protective clothing like ear protection, safety shoes, safety goggles and protective gloves. 4

5 1. INTRODUCTION 40 Series The Webasto 40 Series is an electrically operated sliding roof for ventilation purposes. The marine roof has been designed for a large range of applications and can be installed easily in various ships. It is suitable for fitting in area III and usage for ship type with design-category B. All parts are made from high corrosion resistant materials. Webasto 40 Series marine roofs are very easy to install and even retrofit is possible. Product Benefits: Opens and closes quietly Suitable for ventilation of the cabin Glass panel made of 8 mm tempered safety glass Electrical operation Large opening Water-proof and robust Simple installation World-wide service network 5

6 2. TECHNICAL SPECIFICATION R1 R3 R2 R1 W1 L2 L1 Cut out Z L5 X Y R5 R6 R4 W2 R7 H L4 L3 Marine roof 6

7 Description Webasto 40 Series General Part no _ Operation Continuous electric Operation voltage (DC) [V] 12 Power (at 20 A, 12 V) [W] 240 Control panel Rocker switch Installation method Frame and rails screwed on deck / roof / surface Average installation time [h] 4 Frame materials AlMg Si 0.5 Surface treatment Anodized Glass panel Glass, tempered, grey, 8 mm Allowable weight Not designed as walking surface Max. load 70 kg, including weight glass panel assembly (in accordance with ISO 12216) Allowable temperature [ C] -10 to +75 Possibility to use as escape hatch No Cut out dimensions L1 Total length [mm] / -0 L2 Length straight part [mm] 890 W1 Width [mm] 1, / -0 R1 Corner radius, front/rear [mm] 80 ± 2 R2 Cross curvature [mm] 7,620 R3 Front radius [mm] 2,032 Longitudinal curvature [mm] Uncurved Dimensions marine roof L3 Overall length [mm] 1,865 L4 Length glass panel [mm] 1,040 L5 Rail length [mm] 900 W2 Width [mm] 1,378 H Height [mm] 49 R4 Corner radius glass panel, rear [mm] 25 R5 Corner radius glass panel, front [mm] 100 R6 Front radius glass panel [mm] 2,055 R7 Cross curvature [mm] 7,669 Longitudinal curvature [mm] Uncurved Glass panel displacement tilt (Z-direction) [mm] 22 slide (X-direction) [mm] approx. 660 Weight [kg] approx Optics Colour glass panel Interior Glass panel fixation Grey tinted Blank anodized Bolted on mechanism 7

8 3. DESCRIPTION OF THE WEBASTO 40 SERIES The Webasto 40 Series scope of delivery contains all the documents required for installation and operation. Pushing the open/close switch electrically operates the roof (see operating instructions). Continuously pushing button opens the roof to the desired position: first tilt, then slide. The roof stops moving during opening when it has reached the max. tilt position. Release button and press it again to open the roof to the max. slide open position. Continuously pushing button closes the roof to the desired position. The motor attached to the roof's frame opens and closes the roof via cables. The glass panel slides inside the frame and the rails. The electrical supply is via the wiring from the vessels power supply and the switch. The system is designed to operate with 12 V DC. Control panel Tilt / slide open Close 8

9 4. INSTALLATION Marine roof must be installed on surface with shape specified below. Deck / roof / surface must be sufficiently strong at installation point. If not, reinforcement is required. Deck / roof / surface shape: Lengthwise: uncurved, straight. Cross direction: curved, R = 7,620 mm Rails must be placed on a flat, uncurved surface. Unscrew 2x2 bolts M6x30 at front side of glass panel. Bolts have special heads and require special tool bit. Tool bit included in scope of delivery. Remove glass panel assembly from top frame. R S T Note the location of all parts: R: Bolt M6x30 S: Nylon ring T: Glass panel assembly U: Isolation sleeve V: Connecting bracket U V 9

10 R1 W1 R3 R2 L2 L1 R1 Cut aperture in deck / roof / surface according to drawing at the left. L1 = / -0 mm L2 = 890 mm W1= 1, / -0 mm R1= 80±2mm R2 = 7,620 mm R3 = 2,032 mm Place top frame unit in cut out and fixate Aluminium or steel deck / roof / surface: Drill fixing holes ø 3.2 mm. Other materials (e. g. polyester): Connection must be secure and watertight. Important: Do not damage seal when drilling holes. Remove top frame. Aluminium or steel deck / roof / surface: Cut thread M4 in fixing holes ø 3.2 mm. Apply bead of sealant along contour of roof cut out. Also around fixing holes. Place top frame again. 10

11 Aluminium or steel deck / roof / surface: Place and tighten fixing screws to 4 Nm. Important: Do not damage seal when placing and tightening fixing screws. Place optional brackets for motor cover on inside of top frame: - left and right from motor beam - as far as possible to the outside 1) insert into upper lip of top frame 2) slide downwards into lower lip 3) fixate brackets with screws M Place motor cover over brackets and motor beam. Mark position of ø 3.2 mm screw holes in brackets and motor beam on motor cover. Drill 3 holes ø 4.5 mm in front of motor cover at marked positions. Countersink all 3 holes from outside. Note: only in case switch will be installed in motor cover: cut out square hole for switch. Place motor cover over brackets and motor beam again and fixate with 3 self tapping screws. 11

12 Make electrical connections. See chapter 5. Place glass panel assembly on top of top frame and attach it to LH and RH connecting brackets with 2x2 bolts M6x30. Align glass panel assembly with top frame. Max. deviation left-right and front/rear = 2 mm. R S Install 4 bolts (R) through nylon rings (S), glass panel (T), isolation sleeves (U) and screw into connecting brackets (V). Note: apply Loctite 243 on threads. Tighten screws to 4 Nm. T U V Slide rails through sliding mechanisms. 12

13 Ensure that rails are placed on a flat, uncurved surface. R front Align rails with rear beam of top frame. Align rails: With closed roof: Note: ensure that rails are parallel and perpendicular to rear beam of top frame. Measure distance between rails near sliding bracket. 13

14 Drill fixing holes H1 ø 5 mm and cut thread M6 in deck / roof / surface (LH and RH). Place fixing screws in holes H1, just hand-tight. Use pan, dome or round head screws. Alternative fixation with self tapping screws: - drill holes with correct diameter - place screws in holes H1 H1 front H1 Open roof completely. If necessary, close the roof enough to access the last hole in each rail. Check if distance between rails is same as measured before. 14

15 Drill rear fixing holes H3 ø 5 mm and cut thread M6 in deck / roof / surface. Place fixing screw in each hole, just hand-tight. Alternative fixation with self tapping screws: drill holes with correct diameter place screws in holes H3 rear H3 H3 H2 Close roof again, drill remaining fixing holes H2 ø 5 mm and cut thread M6 in deck / roof / surface. Alternative fixation with self tapping screws: drill holes with correct diameter H2 15

16 Remove rails. Apply bead of sealant around all fixing holes. Place rails and all fixing screws. Tighten fixing screws to 4 Nm. grease grease Apply thin layer of grease (Isoflex Topas L32) to inside of rails to ensure smooth sliding. H Check if there is grease on inside of guides (H). If not, apply a thin layer of grease (Isoflex Topas L32) to inside of guides (H) to ensure smooth sliding. H (H) grease 16

Place rail end caps in back side of rails and tighten set screws. Tightening torque 1 Nm. rear Press rail covers into rails and cut excessive length.

17 Place rail end caps in back side of rails and tighten set screws. Tightening torque 1 Nm. rear Press rail covers into rails and cut excessive length. Trim interior of vessel if desired. Warning: Install and keep the emergency key in close proximity of the roof for manual operation. Finish the installation and check the function of the marine roof. 17

18 5. ELECTRICAL CONNECTIONS Webasto customer Determine switch position and install it. Connect battery 12 V DC. Red: + 12 V DC, continuous, with fuse 20 A. Orange: + 12 V DC, continuous, with fuse 20 A. Green/yellow: (minus) br = brown ge = yellow gn = green or = orange rt = red sw = black Attach connector wiring harness to motor. See electrical diagram (chapter 7.) Note: Ensure there is at least 20 A available. Note: In case there s a 24 V DC power supply, use a 24 V - 12 V DC convertor that can handle at least 20 A. 2 additional connections are necessary for switch illumination (see illustration): - Orange: + 12 V DC - Green: (minus) rt Other wires: - Red: Motor close - Black: Motor (minus) - Brown: Motor open sw gn or br br gn or rt sw = brown = green = orange = red = black 18

19 Different switch: In case another switch is used to operate the roof, it must be with potential-free and normally-open contacts. Connect the wiring to the switch as follows: - Black and red => close roof - Black and brown => open roof 6. RESETTING When necessary, the marine sliding roof can be operated manually. The driving shaft of the motor can be turned with the emergency key (F) to open or close the roof. Important: Do not attempt to function the roof electrically during manual override operation. F If the roof is operated manually with the emergency key (F), the control system must be reset. Reset procedure: Note: Before beginning the reset procedure, ensure there is a minimum of 20 A available.. - Press and hold the close button to close the roof as far forward as possible. - Release the close button. - Within 1 second press and hold the close button. - While continuing to hold the close button; after 10 seconds the glass panel moves with small steps until it s completely closed and the motor produces a loud click sound. - Now, release the close button. The system has been reset. 19

20 7. ELECTRICAL DIAGRAM Webasto customer Z 1 = motor with control unit marine roof 2 = connector 3 = fuse 20 A 4 = battery 12 V DC 5 = switch marine roof Red wire: + 12 V DC, continuous, with fuse 20 A Orange wire: + 12 V DC, continuous, with fuse 20 A Green wire: (minus) Cut and lengthen wires if necessary. All wiring must be able to handle 20 A. br ge gn or rt sw = brown = yellow = green = orange = red = black 20

21 8. SAFETY Do not use the roof as an escape hatch! Ensure that another hatch is accessible for emergencies. When closing the sunroof, make sure to keep all body parts and/or obstructions away from the opening to prevent injury! Do not stand or walk on the roof! 21

22 9. SUPPORT For more details and updates, please check Webasto's technical websites: USA: Others: 22

23 10. CHECKLIST Check installation and functionality. See also Operating Instructions. INSTALLATION Clean All parts clean before operating roof. No dirt, dust and small particles. Examples: No small particles in rails, guides or mechanism (from drilling holes for fixation top frame and rails): causes damage and corrosion of rails. No dust in mechanism (e.g. from sanding wooden parts). Grease Isoflex Topas L32 grease on inside of guides and rails. Fuse Correct fuse in wiring. Alignment rails Position rails - in accordance with Installation Instructions - exactly in line with marine roof and cut out - parallel Sealing Glass panel assembly must compress seal at complete outline of roof FUNCTION Roof must run smoothly. Must open and close completely and correctly. Open Close 23

24 In multilingual versions the English 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. Ident-No A 11/12 Errors and omissions excepted Printed in The Netherlands Webasto Thermo & Comfort SE, 2012 Webasto Thermo & Comfort SE Postfach Gilching Germany Visitors address: Friedrichshafener Str Gilching Germany Webasto Product North America, Inc North Road, Fenton, MI 48430, USA Phone: Fax: info-us@webasto.com Internet: Internet: Technical Extranet: Nur innerhalb von Deutschland Tel.: ( 0,14/Min. aus dem deutschen Festnetz) technikcenter@webasto.com

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