Webasto SPM Products for the Defence Market

Webasto SPM Products for the Defence Market

One Vehicle

Global Capability

Design & Application Considerations ‘We understand the unique demands of this market’

Environmental ( - 46°C &

+ 49oC, 70%RH )

Electro Magnetic Compatibility Electro Magnetic Pulse Shock and Vibration Chemical Resistance Validation Testing Other Defence Standards Contract Responses and Tendering Integrated Logistics Support

Product Validation ‘Meeting tough standards is at the core of Webasto development’ F Functional I Integration D Durability E Environmental S Stress

A suite of test plans that validate basic product performance, installation characteristics, lifetime, performance under severe environmental influences, and failure modes under extreme stress

WESTA Electronics Specification Webasto have consolidated a number of electronic standards from our customers, into a single specification that ensures all electronic products comply with the most difficult of specifications. In many cases, this standard provides the desired level of immunity required by defence specifications.

Product Validation Sample Test



Fuel Types NATO Common Fuel Policy Kerosene Based Fuel

Used in aircraft, logistics vehicles, motor cycles, engineering equipment, fighting vehicles…..

Webasto heaters have been proven to operate on NATO F34, F44, JP8…. Suitability for such fuels is written into Webasto Design Standards Please refer to product data for specific information

Handling Shock and Vibration Shock and Vibration Levels as contained in Military Environmental Standards are consulted Tracked Vehicle vibrations are particularly severe Webasto Products may need external intervention to meet these conditions Automotive rubber mountings simply amplify the vibrations

Partnership with a supplier of specialist mountings provides predictive calculations Please refer to product data for specific information

EMC Requirements

Please refer to product data for specific information

EMC Suppression Conventional suppression methods (capacitors) are inadequate and interfere with heater controls Consideration has to be given for conducted and radiated emissions and immunity as well as induced EMP spikes Radio Frequency Interference Filter are employed, comprising: Feed Through Capacitors Magnetic Inductances Sealed Conductive Housing

Suppresses Low Frequency Interference

Full conductive enclosure of product is used, comprising: Metal Enclosures Screened Harnesses Ground Bonding

Suppresses High Frequency Interference

Sample EMC Test Airtop 5000 MIL 461E CE102


Sample EMC Test Thermo 50 MIL 461E CE102


Sample EMC Test Thermo 50 MIL 461E RE102


EMC Compliance Thermo 50 MIL 461E RE102


Sample EMC Test Thermo 50 MIL 461E RE102


Proven Applications Webasto products have been proven in numerous defence related applications including: •Logistic Vehicles •Rough Terrain Support Vehicle •Heavy Artillery •Command Posts •Personnel Carriers •Patrol Boats •Shelters •Engineering Equipment •Rapid Deployment Vehicles •Fire Tenders •Water Tankers •Future Battlefield Systems

Proven Applications France RVI Caesar / Sherpa

HVAC Unit in collaboration with Kalori – Additional potential for T90M

Sweden BAE Hagglunds

AT5000 for rear car heating, selected following successful ABC testing

Germany Puma

Thermo 90ST – 2 heaters per vehicle

Germany KMW Boxer

Thermo 90.21S Mil461 Heater

USA AM General HMMWV

Thermo 90 Heater

Proven Applications Sweden Hagglunds SEP

Airtop 5000 application installed in prototype

UK LR Rapid Response

AT3500 Rapid Demount

UK Supacat

Front Box (RFI Protected)

UK Insys

AT2000 Self contained heater pack inc fuel and batteries

Germany Leopard

DBW 2020 as standard equipment

Proven Applications Germany MAN X Type

DFS Internal Roof Mounted Air Conditioner

UK Vickers CRAAV

HL90M, especially adapted HL90 with Radio Suppression

UK Alvis Sultan

T50M, adapted for EMC protection and supplied with full installation kit

UK BAE Terrier

T90M heater adapted for EMC Protection and deep wading

UK ATL Pinzgauer

3kW Radio Suppressed 24v Air Conditioner based on CC4E

Proven Applications UK Penman Mobile Ops

AT3500M application to meet DefStan 59-41 ClassA

Singapore STK Bronco

T90M + AT3500M

Singapore STK Terex

HL90M

UK Leyland “DROPS”

Retro-fit split air conditioning system to meet climatic conditions A1

Australia ADI

AT2000 in EMC Protected enclosure required to replace 220V shelter heating

Centre of Competence – Defence Systems Webasto Product UK has, throughout its history, been successful in winning numerous Defence competitive tender contracts as a result of providing innovative climate control solutions and detailed support to the 1st tier Defence Equipment Manufacturers.

This work has involved full systems design, extensive product application, comprehensive test validation procedures and rigorous field performance trials. This has resulted in an extensive wealth of knowledge in Defence systems development and created a range of products that are proven in-service.

Heating and Winterisation Products

Winterisation Systems Webasto, with a long history of providing ‘stand alone’ heating systems for vehicles, has developed products, systems and know-how to assist manufacturers in Tactical Vehicle design and which will ensure compliance with the temperature related requirements of DefStan 23-8, NATO and other similar National standards.

Engine Pre – Heating

Crew Heating

Battery Heating

Fuel Tank Heating

Wading Capability

EMC Protection

Snow Blinds

Winterisation Systems

Winterisation Systems Snow Blinds to all visibility areas and critical openings

Combustion Heater for engine, cabin and system heating

Winterisation Systems Pre-Heating, insulation and additional crew compartment heating

Airtop Air Heaters

Heat

Airtop

2000

3500

Airtop 5000

0.9 –

1.5 –

1.5 –

Output

2.0kW

3.5kW

5.0kW*

Airflow

70m3/hr

139m3/hr

218m3/hr

max

max

max

0.12 – 0.24

0.17 – 0.42

0.17 – 0.60

l/hr

l/hr

l/hr

9 – 22W

15W – 36W

15W – 80W

Input

80W Start

80W Start

80W Start

Noise

48 – 56dba

41 – 55dba

41 – 61dba

490 x 180 x

555 x 190 x

555 x 190 x

185mm

220mm

220mm

Fuel Cons’

Electrical Features Integrated Diagnostic Capability Low Power Consumption Quiet Operation Variable Heat Output Integrated Control Unit Ceramic Glowpin Technology Unique ‘Ferrotech’ Burner Cartridge DefStan 59-41 Suppression AVTUR Compatible

Airtop

Level Size

*5.5kW on ‘boost’ version

Weight

7kg

12kg

12kg

Airtop Air Heaters Self contained air heater for independent operation

Minimum of 4 hours operation Automatic recharge when mains power connected

Air Top Heaters - NBC (ABC) Protection AT5000 Testing by Bundeswehr Special Version with Dosing Pump Wire Through Top Cover

HL90 Air Heater HL90

Heat

6.5 &

Output

9.0kW

Airflow

310m3/hr max

Fuel Cons’

0.86 – 1.20 l/hr

Electrical

96 – 160W

Input Size Features Pressurised combustion chamber allows for exhaust lengths up to 5m Dual heat output increases the range of applications Thermostat sensing re-circulated air temperature Renowned burner technology with proven durability AVTUR Compatible High standard of RFI Suppression

650 x 300 x 315mm

Weight

22kg

Typical Applications Large Combat Vehicles Shelter Heating Cargo Heating

Thermo 50 Coolant Heater Thermo 50

Heat

2.2 &

Output

5.0kW

Coolant Flow Fuel Cons’

0.27 – 0.63 l/hr

Electrical

34 – 50W

Input Features • Stainless Steel Enclosure • Dual heat output reduces energy consumption as system warms up • Renowned burner technology with proven durability • Thermostat valve prioritises heated circuit • AVTUR Compatible • Application designed to : DefStan 59-41 Class A—DRE 03 DefStan 59-41 for Ripple, Surges and Spikes

Size

380 x 180 x 200mm

Weight

10kg

Typical Applications Winterisation supporting engine, crew or auxiliary equipment heating

Thermo 90 Coolant Heater Thermo 90

Heat Output

1.8 – 9.1kW

Coolant Flow Fuel Cons’

0.19 – 1.10 l/hr

Electrical

37 – 90W

Input Size

310 x 133 x 235mm

Weight

5.5kg

Features • Pressurised combustion chamber allows for exhaust lengths up to 5m • The most compact heater in it’s class • Variable heat output increases the range of applications • Integrated diagnostic capability • Unique “Ferrotec” Burner technology • AVTUR Compatible • Ceramic Glowpin Technology • Application proven to : DefStan 59-41 Class A—DRE 03 DefStan 59-41 for Ripple, Surges and Spikes

Typical Applications Winterisation supporting engine, crew or auxiliary equipment heating

DBW2020 Coolant Heater DBW2020

Heat

24kW

Output Coolant

Typical Applications Winterisation supporting engine, crew or auxiliary equipment heating for Heavy Tactical Vehicles Specialist heating, cleaning and cooking units

Features • Pressure Burner System providing rapid startup and temperature rise • Simple and adaptable control system

Depends on

Flow

pump

Fuel Cons’

3,0l/hr

Electrical

120W

Input Size Weight

680x240x279 24kg

Waterproofing Modern military operations demand the ability to undertake deep wading operations with the minimum of preparation.

Rather than removing the heater from the vehicle, as with conventional coolant heaters, the military prepared version of Thermo 90 can remain on the vehicle, and has been developed to enable submersion to 1m depth, simply by sealing the exhaust outlet and combustion air inlet points. Air Heaters can be equipped with ‘rapid demount’ kits to facilitate stowage in operations where the crew space becomes flooded

Fuel System The problem of moisture in diesel fuel and the formation of wax, both associated with cold climate operations, are well known. By inserting a heating element into the fuel tank, the energy provided by the Webasto coolant heater can be utilized to heat the fuel at the point it is taken from the tank.

Battery Heating As the ambient temperature falls, so the efficiency of the battery decreases and it also becomes increasingly difficult to re-charge.

An insulated battery compartment,supported by a heating element located adjacent to the battery and fed from the Webasto coolant heater, will enable the battery to accept charge current more quickly following an engine start.

Snow Blinds

Where vehicles are exposed to sub zero conditions for extended periods, the build up of snow and ice on windscreens, radiators and air intakes will increase the vehicle preparation time before full drivability is achieved. Snow blinds installed to these areas will compliment the pre-heating equipment installed and significantly shorten the time to operational readiness. Snow blinds are tailored to specific vehicles and applications.

Air Conditioning and HVAC Products

Air Conditioning Options Internal Roof Mounted Air Conditioner

CC5 Roof Mounted Air Conditioner

High Performance Split System Air Conditioner

Demountable Self Contained Unit – 24V

The Webasto A/C unit requires an adapter to fit into the roof hatch, manufactured of Aluminum and Stainless Steel components, weighing approx 30kg Air Conditioner Technical Data: 24 Volt System R134a Refrigerant 121.25 lbs L x W x H (43.7” x 30.5” x 8.5”) Initial current draw of 68 Amps System recirculates air within vehicle compartment Power provided utilizing NATO Slave receptacle

C 5 (M) External Roof Mount Units Ideally suited for retrofitting to vehicles where internal space is at a premium. An important benefit of such systems is that the delivery of chilled air is positioned to optimise the cooling effects and airflow within the vehicle. Dependent on performance requirements, Compressors can be driven from the engine, or from a self-contained 24-volt drive system. Features 5kW Cooling Performance Optimum Air Distribution High Airflow – 630m3/hr Compact Dimensions Aerodynamic Design RFI Suppression Capable

Internal Roof Mount Units

In consideration of air transportability and the vehicle design profile, an internal roof mounted system, mirroring the benefits of the external units, have been developed to suit the available space envelope within the vehicle. Cooling Capacity

7kW

Airflow

1100m3/hr

Dimensions

1050 x 770 x 370 mm

Weight

45kg

Electrical Input

40A at 24V

Split Air Conditioning Systems Commercial “Off the Shelf” products adapted to cater for: Vehicle Layout Performance Demand RFI Suppression

24v Portable Air Conditioner

Metal Casing to aid Radio Suppression

Industry Standard Evaporator

Sanden Compressor driven by Webasto 24v Drive Motor

High Performance Condenser 3kW Cooling Power

24v Integrated Air Conditioner Mechanical compressor drive not possible on vehicle Electric Drive and Air Conditioning parts integrated into vehicle

Electrical system recognises power availability EMC Performance to DefStan 59-41 Class A 3kW Cooling Power

Integrated HVAC

Webasto has considerable skill in the field of Truck HVAC. This experience has been applied to manufacture systems for low volume military vehicles

HVAC Units Fully integrated heating, ventilation and air conditioning units are designed in partnership with vehicle manufacturers, to provide full climate control from bespoke and compact, integrated units. Possible Features Full EMC Screening Wading Capability High Heating and Cooling Performance Powerful Airflow Environmentally Friendly Refrigerant

HVAC – Wading Capability

5kW Heating Performance RFI Screened Complies to Military Wading Standards Bespoke Design in Plastic Construction

HVAC – EMI Suppressed

5kW Heating Performance Can be designed for specific outputs RFI Screened to high standard Ducted air delivery to individual crew members Stainless Steel to facilitate chemical washdown

U4818 Water Pump Features Application of the proven magnetic clutch from the U4852 Use of high quality materials Pump does not have any parts fitted subject to wear 100% compatible to U4815 EMC compliant

Benefits Permanent and total sealing ensured, even in case of pump failure Excellent reliability Pump is maintenance free => no maintenance costs Switching/replacement of U4815 without extra efforts possible Tested for Leopard II, NATO Mil Std. 461 D planned

Emergency Escape Hatch

Proven sunroof technology Existing components Choice of aperture size Flexibility of roof radius Choice of panel material Easy to operate