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  5. Installation Instructions Manual

Webasto DBW 2010 Installation Instructions Manual

Summary of DBW 2010

  • Page 1

    Wasserheizgeräte water heaters appareils de chauffage à eau einbauanweisung installation instructions notice de montage dbw 2010 / 2016 mit steuergerät 1553 with control unit 1553 avec organe de commande 1553 1303560c_dbw 2010 ea_degbfr.Book page 1 tuesday, march 5, 2013 9:05 am.

  • Page 2

    Dbw 2010 / 2016 inhaltsverzeichnis 1 gesetzliche bestimmungen für den einbau . . . . . . . . . . . . 1 2 verwendung / ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 einbaubeispiel für...

  • Page 3

    Dbw 2010 / 2016 statutory regulations governing installation 29 1 statutory regulations governing installation 1.1. Statutory regulations governing installation dbw 2010 / 2016 heaters have been type-tested and approved in accordance with ec directives ece-r 122 (heaters) and ece-r 10 (emc) with the...

  • Page 4

    Statutory regulations governing installation dbw 2010 / 2016 30 5.3.2.5 every reasonable precaution should be taken in positioning the heater to minimize the risk of injury and damage to personal property. 5.3.3 fuel supply 5.3.3.1 the fuel filler must not be situated in the passenger compartment an...

  • Page 5

    Dbw 2010 / 2016 use / version 31 2 use / version 2.1. Use of the water heaters webasto dbw 2010 / 2016 water heaters are used in connection with the vehicle’s own heating system – to heat the passenger cabin, – to defrost the vehicle windows and – to preheat water-cooled engines. The water heater op...

  • Page 6

    Installation dbw 2010 / 2016 32 3 installation important: – the statutory regulations governing installation on pages 29 and 30 must be adhered to. – if the water heater is to be operated in a separately installed heating system, prior to installation an installation planning report must al- ways be...

  • Page 7

    Dbw 2010 / 2016 installation 33 fig. 1: dimensions of dbw 2010 / 2016 heaters 3,4 1 5 8 2 6 8 6 1 combustion air intake 2 exhaust outlet 3 fuel intake 4 fuel discharge 5 space required to remove the burner chamber 6 coolant intake 7 max. Swivelled burner 8 coolant outlet 1303560c_dbw 2010 ea_degbfr....

  • Page 8

    Installation dbw 2010 / 2016 34 3.2. To install dbw 2010 / 2016 heaters the heater may be secured either with four m8 screws or with four bolts and nuts (see figure 3). 3.3. Model plate the model plate must be protected from damage and must be clearly legible when the heater is installed (otherwise ...

  • Page 9

    Dbw 2010 / 2016 installation example for dbw 2010 / 2016 35 4 installation example for dbw 2010 / 2016 fig. 5: installation example for dbw 2010 / 2016 heaters 1 wall heater with fan 2 heat exchanger at entry point 3 heater 4 circulating pump 5 roof heat exchanger 6 vehicle engine 7 driver’s positio...

  • Page 10

    To install the circulating pump dbw 2010 / 2016 36 5 to install the circulating pump the circulating pump is installed as shown in figure 7 (u 4810) and 9 (u 4840). Note the installation position. Note: the pump ports and connection lines from the water intake and water outlet must be flush (no stre...

  • Page 11

    Dbw 2010 / 2016 to install the circulating pump 37 5.2. U 4840 circulating pump fig. 8: delivery rate u 4840 circulating pump 12/24v bar l/h q Δ p 0,50 0,40 0,30 0,20 0,10 0,00 0 350 700 1050 1400 1750 2100 2450 2800 delivery rate (with water/glycol 50/50 at +23 °c) fig. 9: u 4840 circulating pump i...

  • Page 12

    Connection to the vehicle cooling system dbw 2010 / 2016 38 6 connection to the vehicle cooling system the heater is connected to the vehicle cooling system as shown in figures 1 and 5. The system must contain at least 10 litres of coolant. The water hoses supplied by webasto must always be used. If...

  • Page 13

    Dbw 2010 / 2016 fuel supply 39 7 fuel supply the fuel is taken from the vehicle fuel tank or from a separate fuel tank. 7.1. Fuel lines fuel lines are to be installed with a gradient wherever possible to pre- vent air inclusions. Connections within the line are to be secured with hose clips if no me...

  • Page 14

    Fuel supply dbw 2010 / 2016 40 7.1.1. Maximum dimensions of the fuel lines: – internal diameter for intake and return line: 6 mm (other diameters to order). – maximum line length for each intake and return line: 10 m – maximum intake height: 2 m (we recommend the installation of a foot valve if the ...

  • Page 15

    Dbw 2010 / 2016 combustion air supply 41 8 combustion air supply under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt or snow an...

  • Page 16

    Exhaust pipe dbw 2010 / 2016 42 9 exhaust pipe the opening of the exhaust pipe must not point towards the front of the vehicle. The exhaust pipe opening must be located so that it cannot become clogged with snow and mud. Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 ...

  • Page 17

    Dbw 2010 / 2016 electrical connections 43 10 electrical connections 10.1. Heater connection important high voltage: danger of death. Disconnect the plug connection to the vehicle before you open the heater. The electrical connection of the heaters is made as shown in figure 11 (dbw 2010) or figure 1...

  • Page 18

    Electrical connections dbw 2010 / 2016 44 item designation comment a b c d a1 heater a2 control unit sg 1553 4 ignition spark generator 5 thermostat control thermostat (internal) 7 thermostat fan thermostat 8 thermostat temperature limiter thermostat 10 ignition electrodes 61.3 interference suppress...

  • Page 19

    Dbw 2010 / 2016 electrical connections 45 fig. 11: system circuit for dbw 2010 with control unit 1553 and switch, see legend on page 44 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white cable cross-sections vehicle’s own cable 7.5 m–15 m 0.75 mm² ...

  • Page 20

    Electrical connections dbw 2010 / 2016 46 fig. 12: system circuit for dbw 2016 with control unit 1553 and switch, see legend on page 44 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white cable cross-sections vehicle’s own cable 7.5 m–15 m 0.75 mm² ...

  • Page 21

    Dbw 2010 / 2016 electrical connections 47 fig. 13: unit variants and plug assignments, see legend on page 44 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white cable cross-sections vehicle’s own cable 7.5 m–15 m 0.75 mm² 1.0 mm² 0.75 mm² 1.0 mm² 1....

  • Page 22

    Electrical connections dbw 2010 / 2016 48 fig. 14: system circuit for dbw 2010 with control unit 1553, switch and nozzle block preheating system, see legend on page 44 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white cable cross-sections vehicle’...

  • Page 23

    Dbw 2010 / 2016 electrical connections 49 fig. 15: system circuit for dbw 2016 with control unit 1553, switch and nozzle block preheating system, see legend on page 44 b5 r2 ws x5 1 2 3 4 87 30 85 86 k6 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet ...

  • Page 24

    Electrical connections dbw 2010 / 2016 50 fig. 16: system circuit for dbw 2010 / 2016 with control unit 1553 and timer cable cross-sections vehicle’s own cable 7.5 m–15 m 0.75 mm² 1.0 mm² 0.75 mm² 1.0 mm² 1.0 mm² 1.5 mm² 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm² 4.0 mm² 6.0 mm² item designation comment a b c ...

  • Page 25

    Dbw 2010 / 2016 initial start-up 51 11 initial start-up note: refer to the safety instructions in the operating and maintenance instructions. The operating and maintenance instructions must be read through without fail before starting the heater. After you have installed the heater, bleed the water ...

  • Page 26

    Troubleshooting dbw 2010 / 2016 52 12 troubleshooting 12.1. Fault lock-out if it recognises one of the following fault features, the heater will conduct a fault lock-out. – if there is undervoltage, approx. 10 – 25 seconds after the voltage drops below the switching threshold. – if no combustion sta...

  • Page 27

    Dbw 2010 / 2016 technical data 53 13 technical data except where limit values are specified, these technical data refer to the usual heater tolerances of 10 % at an ambient temperature of +20 °c and at the rated voltage. 13.1. Fuel the diesel fuel specified by the manufacturer must be used (din en 5...

  • Page 28

    Technical data dbw 2010 / 2016 54 heater dbw 2010 dbw 2016 ece type permit number emc: heating system: e1 10r 03 1087 e1 122r 00 0006 e1 10r 03 1087 e1 122r 00 0001 model high pressure atomiser high pressure atomiser heating current kw (kcal/h) 11.6 (10,000) 16.0 (13,800) fuel diesel (din en 590) di...

  • Page 29

    Dbw 2010 / 2016 technical data 55 circulating pump u 4810 u 4840 delivery rate i/h 1600 (against 0.15 bar) 1600 (against 0,1 bar) rated voltage v- 12 or 24 12 or 24 operating voltage range v - 10...14 or 20...28 9...15 or 16...30 rated power consumption w 25 30 dimensions mm (tolerance 3 mm) mm mm l...

  • Page 30

    Im fall einer mehrsprachigen version ist deutsch verbindlich. Die telefonnummer des jeweiligen landes entnehmen sie bitte dem webasto servicestellenfaltblatt oder der webseite ihrer jeweiligen webasto-landesvertretung. In multilingual versions the german language is binding. The telephone number of ...