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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 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik...

  • Page 2

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

  • Page 3

    Dbw 2010 / 2016 statutory regulations governing installation 27 1 statutory regulations governing installation 1.1. Statutory regulations governing installation type approvals according to ece-r 10 (emc) and ece-r 122 (heater) exist for the dbw 2010 / dbw 2016 heaters. See chapter 13, "technical dat...

  • Page 4

    Statutory regulations governing installation dbw 2010 / 2016 28 5.3.2.5 every reasonable precaution should be taken in positioning the hea- ter 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 ...

  • Page 5

    Dbw 2010 / 2016 use / version 29 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 30 3 installation important: the statutory regulations governing installation (see chapter 1, "statutory regulations governing installation") must be adhered to. Note: check the installation situation of the relevant vehicle type. 3.1. Installation position the heater an...

  • Page 7

    Dbw 2010 / 2016 installation 31 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 visit www.Butlertechnik.Com ...

  • Page 8

    Installation dbw 2010 / 2016 32 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 33 4 installation example for dbw 2010 / 2016 fig. 5: installation example for dbw 2010 / 2016 heaters 1 wall heater with fan 2 heater 3 circulating pump 4 vehicle engine 5 driver’s position heating system 6 control element forwards backwards ...

  • Page 10

    To install the circulating pump dbw 2010 / 2016 34 5 to install the circulating pump the circulating pump is installed as shown in figure 7 (u 4840). Note the in- stallation position. Note: the pump ports and connection lines from the water intake and water outlet must be flush (no stress). 5.1. U 4...

  • Page 11

    Dbw 2010 / 2016 connection to the vehicle cooling system 35 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 12

    Fuel supply dbw 2010 / 2016 36 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 mec...

  • Page 13

    Dbw 2010 / 2016 fuel supply 37 7.1.1. Maximum dimensions of the fuel lines: – internal diameter for intake and return line: 6 mm (other diameters to or- der). – maximum line length for each intake and return line: 10 m – maximum intake height: 2 m (the installation of a check valve is recom- mended ...

  • Page 14

    Combustion air supply dbw 2010 / 2016 38 8 combustion air supply under no circumstances may the combustion air be taken from areas occu- pied by people. The combustion air intake opening must not point in the di- rection of travel. It must be located so that it cannot become clogged with dirt or sno...

  • Page 15

    Dbw 2010 / 2016 exhaust pipe 39 9 exhaust pipe the opening of the exhaust pipe must not point towards the front of the ve- hicle. 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....

  • Page 16

    Electrical connections dbw 2010 / 2016 40 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 9 (dbw 2010), figure 10 (...

  • Page 17

    Dbw 2010 / 2016 electrical connections 41 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 18

    Electrical connections dbw 2010 / 2016 42 fig. 9: system circuit for dbw 2010 with control unit 1553 and switch, see legend on page 40 and 41 model with temperature fuse only visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 19

    Dbw 2010 / 2016 electrical connections 43 fig. 10: system circuit for dbw 2016 with control unit 1553 and switch, see legend on page 40 and 41 model with temperature fuse visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 20

    Electrical connections dbw 2010 / 2016 44 fig. 11: system circuit for dbw 2016 rail with control unit 1553 and switch, see legend on page 40 and 41 model with temperature fuse visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 21

    Dbw 2010 / 2016 electrical connections 45 fig. 12: unit variants and plug assignments, see legend on page 40 and 41 model with temperature fuse and temperature limiter model with temperature fuse and fan thermostat model with temperature fuse, temperature limiter and fan thermostat visit www.Butlert...

  • Page 22

    Electrical connections dbw 2010 / 2016 46 fig. 13: system circuit for dbw 2010 with control unit 1553, switch and nozzle block preheating system, see legend on page 40 and 41 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 23

    Dbw 2010 / 2016 electrical connections 47 fig. 14: system circuit for dbw 2016 with control unit 1553, switch and nozzle block preheating system, see legend on page 40 and 41 b5 r2 ws x5 1 2 3 4 87 30 85 86 k6 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechni...

  • Page 24

    Initial start-up dbw 2010 / 2016 48 11 initial start-up note: refer to the safety instructions in the operating and maintenance instruc- tions. The operating and maintenance instructions must be read through without fail before starting the heater. After you have installed the heater, bleed the wate...

  • Page 25

    Dbw 2010 / 2016 troubleshooting 49 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 26

    Technical data dbw 2010 / 2016 50 13 technical data except where limit values are specified, these technical data refer to the usu- al heater tolerances of ±10 % at an ambient temperature of +20 °c and at the rated voltage. 13.1. Fuel diesel fuel in accordance with din en 590 is suitable as fuel. We...

  • Page 27

    Dbw 2010 / 2016 technical data 51 heater dbw 2010 dbw 2016 ece type permit number emc: heating system: e1 10r- 04 6955 e1 122r- 00 0006 e1 10r- 04 6955 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...

  • Page 28

    Technical data dbw 2010 / 2016 52 circulating pump u 4840 delivery rate i/h 1600 (against 0,1 bar) rated voltage v- 12 or 24 operating voltage range v - 9...15 or 16...30 rated power consumption w 30 dimensions mm (tolerance ±3 mm) mm mm length 135 width 95 height 48 weight kg 0,4 visit www.Butlerte...

  • Page 29

    Visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.

  • Page 30

    Ident-nr. 1303560 d05 • 12/13 • errors and omissions excepted • printed in germany • © webasto thermo & comfort se, 2013 webasto thermo & comfort se postfach 1410 82199 gilching germany visiting address: friedrichshafener str. 9 82205 gilching germany technical extranet: http://dealers.Webasto.Com o...