Webasto DBW 2010 User manual

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

DBW 2010 / 2016
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . 1
2 Verwendung / Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Einbaubeispiel für DBW 2010 / 2016. . . . . . . . . . . . . . . . . . . 7
5 Einbau Umwälzpumpe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Anschluss an das Kühlsystem des Fahrzeuges . . . . . . . . 10
7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Abgasleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12 Störungen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13 Technische Daten. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of contents
1 Statutory regulations governing installation. . . . . . . . . . . 29
2 Use / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4 Installation example for DBW 2010 / 2016 . . . . . . . . . . . . . 35
5 To install the circulating pump . . . . . . . . . . . . . . . . . . . . . . 36
6 Connection to the vehicle cooling system . . . . . . . . . . . . 38
7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sommaire
1 Dispositions légales concernant le montage . . . . . . . . . . . 57
2 Utilisation / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Exemple d'installation pour le DBW 2010 / 2016 . . . . . . . . 63
5 Installation de la pompe de circulation. . . . . . . . . . . . . . . . 64
6 Raccordement au circuit de refroidissement du véhicule 66
7 Alimentation en carburant . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8 Alimentation en air de combustion . . . . . . . . . . . . . . . . . . . 69
9 Conduite d'échappement . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10 Branchements électriques . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11 Première mise en service . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12 Pannes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13 Caractéristiques techniques . . . . . . . . . . . . . . . . . . . . . . . . 81
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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 following permit numbers:
DBW 2010 EMV: E1 10R 03 1087
DBW 2016 EMV: E1 10R 03 1087
DBW 2010 heater: E1 122R 00 0006
DBW 2016 heater: E1 122R 00 0001
Primarily the regulations of Annex VII of the Directive 2001/56/EC and
Part I and Annex 7 of the directive ECE-R 122 must be observed for the
installation.
NOTE:
The provisions of these Directives are binding within the territory
governed by EU Directive 70/156/EEC and/or EC/2007/46 (binding
for new vehicle types as of 29/04/2009) and should also be
observed in countries in which there are no special regulations!
IMPORTANT:
Failure to follow the installation instructions and the notes contained
therein will lead to all liability being refused by Webasto. The same
applies if repairs are carried out incorrectly or with the use of parts other
than genuine spare parts. This will result in the invalidation of the type
approval for the heater and therefore of its homologation / ECE type
licence.
1.2. Extract from directive ECE-R 122 Part I and Annex 7
Start of extract.
Part I
5.3 Vehicle Installation Requirements for Combustion Heaters and
for Electric Heaters
5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2, heaters shall be installed
according to the requirements of paragraph 5.3.
5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to
comply with the requirements of paragraph 5.3.
5.3.2 Positioning of heater
5.3.2.1 Body sections and any other components in the vicinity of the
heater must be protected from excessive heat and the possibility of fuel
or oil contamination.
5.3.2.2 The heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be met if the installa-
tion ensures an adequate distance to all parts and suitable ventilation,
by the use of fire resistant materials or by the use of heat shields.
5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must
not be positioned in the passenger compartment. However, an installa-
tion in an effectively sealed envelope which also complies with the
conditions in paragraph 5.3.2.2 may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 4, or a duplicate,
must be positioned so that it can be easily read when the combustion
heater is installed in the vehicle.
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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
and must be provided with an effective cap to prevent fuel spillage.
5.3.3.2 In the case of liquid fuel heaters, where a supply separate from
that of the vehicle is provided, the type of fuel and its filler point must be
clearly labelled.
5.3.3.3 A notice, indicating that the heater must be shut down before
refuelling, must be affixed to the fuelling point. In addition a suitable
instruction must be included in the manufacturer’s operating manual.
5.3.4 Exhaust system
5.3.4.1 The exhaust outlet must be located so as to prevent emissions
from entering the vehicle through ventilators, heated air inlets or opening
windows.
5.3.5 Combustion air inlet
5.3.5.1 The air for the combustion chamber of the heater must not be
drawn from the passenger compartment of the vehicle.
5.3.5.2 The air inlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.6 Heating air inlet
5.3.6.1 The heating air supply may be fresh or re-circulated air and must
be drawn from a clean area not likely to be contaminated by exhaust fu-
mes emitted either by the propulsion engine, the combustion heater or
any other vehicle source.
5.3.6.2 The inlet duct must be protected by mesh or other suitable me-
ans.
5.3.7 Heating air outlet
5.3.7.1 Any ducting used to route the hot air through the vehicle must be
so positioned or protected that no injury or damage could be caused if it
were to be touched.
5.3.7.2 The air outlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.8 Automatic control of the heating system
5.3.8.1 The heating system must be switched off automatically and the
supply of fuel must be stopped within five seconds when the vehicle’s
engine stops running. If a manual device is already activated, the hea-
ting system can stay in operation.
ANNEX 7
ADDITIONAL REQUIREMENTS FOR COMBUSTION HEATERS
7 Warning light
7.1 A clearly visible tell-tale in the operator’s field of view shall inform
when the combustion heater is switched on or off.
End of extract.
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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 operates independently of the engine and is connec-
ted to the cooling system, the fuel system and the electrical system of
the vehicle.
The heater is approved for heating the passenger cabin or the driver’s
cab, but not to heat a cargo space used to transport hazardous
substances.
2.2. Version
The water heaters are approved for use with “diesel” fuel.
The heat output is:
– DBW 2010 heater 11.6 kW (10,000 kcal/h)
– DBW 2016 heater 16.0 kW (13,800 kcal/h)
The heaters DBW 2010 are designed for 12 or 24 V.
The heaters DBW 2016 only for 24 V.
Depending on requirements and equipment, a nozzle block preheating
system may be fitted.
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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 submitted to Webasto for approval. If this approval is not
obtained, all warranty and liability claims will be void. The water
heater has been designed, tested and approved for specific bus
requirements.
NOTE:
Check the installation situation of the relevant vehicle type.
3.1. Installation position
The heater and circulating pump are to be integrated into the cooling
system (or in a separate heating system).
The heater must be installed in as low a position as possible to allow the
heater and circulating pump to be bled automatically. This is particularly
important as the circulating pump is not self-priming.
The heater must not be installed in the vehicle interior.
If it is not possible to install the heater in the vehicle’s engine bay it may
be installed in a box. The installation box must have sufficient external
ventilation to ensure that a maximum temperature of 85 °C is not
exceeded in the box.
Bear in mind the space required for servicing accessibility (for example
for removing the combustion chamber) (see Figure 1) when installing
the heater.
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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
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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 a duplicate model plate
must be used).
Fig. 2: Position
Fig. 3: Hole pattern
Fig. 4: DBW 2010 model plate (DBW 2016 similar)
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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 position heating system
8 Control element
Forwards
Backwards
Water heating circuit – wall heater and roof duct heating system
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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 stress).
5.1. U 4810 circulating pump
Fig. 6: Delivery rate and flow resistance
U 4810 circulating pump
Delivery rate
(with water at 20 °C)
Flow resistance
(with the pump stopped)
Fig. 7: U 4810 circulating pump installation position
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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 installation position
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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 you do not
use these hoses, the hoses that you do use must comply with DIN 73411.
The hoses must be installed without kinks and (to ensure perfect bleeding
of the heater) rising if possible. Hose connections must be supported by
hose clips to prevent them slipping.
NOTE:
The hose clips must be tightened with a torque of 1.5 Nm.
Only pressure valves with an opening pressure of min. 0.4 bar and max.
2.0 bar may be used in the vehicle’s cooling system or in a separate
heating system.
The cooling system must be bled carefully before using the heater for
the first time or after replacing the coolant. The heater and lines should
be installed in such a way as to ensure static bleeding.
Perfect ventilation can be identified by the circulating pump operating
almost silently. Poor bleeding may cause the resetting temperature
limiter to trip whilst the heater is operating.
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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 mechanical screw connectors are used.
If fuel hoses are used, the hoses supplied by or available from Webasto
must generally be used. If you do not use these hoses, the fuel hoses
that you do use must comply with DIN 73379. Fuel hoses must not be
kinked or twisted and must be secured with clips approx. every 25 cm.
Only the normal steel, copper and plastic lines of plasticised, light and
temperature-stabilized PA 11 or PA 12 (e.g. Mecanyl RWTL) pursuant to
DIN 73378 used in the manufacture of motor vehicles may be used for
the fuel lines, together with the appropriate connectors.
The following must be observed for the installation of fuel lines:
– The lines must be protected from the effects of high temperatures.
IMPORTANT!
The external casing on the heater may reach the ignition
temperature of diesel if it is operated without coolant.
– The lines must be protected from stone damage.
– Dripping or evaporating fuel must not be allowed either to
accumulate or to ignition hot parts or electrical equipment
If a shut-off device is installed in the return line, an information sticker as
shown in Figure 10 is to be affixed where it is clearly visible.
IMPORTANT:
Operation with a closed return line will damage the fuel pump.
Fuel may escape. Danger of fire!
Unsupported fuel lines must be secured to prevent them sagging.
Do not install an additional fuel pump.
See pages 29 and 30 for the statutory regulations.
Fig. 10: Information sticker
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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 max. intake height is used)
– Maximum supply pressure: 0.3 bar.
7.2. Fuel filter
A fuel filter supplied or approved by Webasto must be used (check the
flow direction). To avoid malfunctions the filter or filter insert is to be
replaced before the start of the cold weather.
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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 and cannot suck in splashing water.
Maximum dimensions of the fuel intake line:
– Internal diameter: 55 mm
– Maximum line length: 5 m without the exhaust extension
– Maximum bends: 270 °
The combustion air intake must not be routed above the exhaust outlet.
NOTE:
If the combustion air intake line cannot be installed so that it slopes
downwards, a water drain hole with a diameter of 4 mm is to be made at
its lowest point.
If the heater is installed in a general installation space near the vehicle’s
fuel tank, the combustion air must be taken in from the outside and the
exhaust fumes discharged into the atmosphere. The openings must be
splash-proof.
A ventilation opening measuring at least 20 cm2is required if the heater
is installed in an enclosed box.
The size of the ventilation opening must be increased subject to consul-
tation with Webasto if the temperature in the box exceeds the permitted
ambient temperature of the heater (see Technical data).
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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 mm or flexible piping of alloyed steel only must be used as the
exhaust line. The exhaust pipe is secured to the heater using a clamping
collar, for example. See the statutory regulations for other requirements.
Maximum dimensions of the exhaust pipe:
– Internal diameter: 38 mm
– Maximum line length: 5 m without the combustion air intake extension
– Maximum bend: 270 °
NOTE:
If the exhaust line is installed near heat-sensitive parts, it must be
insulated.
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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 12 (DBW 2016):
System circuit for DBW 2010 / 2016 with SG 1553 control unit and switch.
Connections of the heaters differing from those of the standard variant
(Figures 11 / 12) are shown in Figure 13 (heater variants and plug
assignments), Figures 14 / 15 (nozzle block preheating system) and
Figure 16 (timer).
Use the specified cable cross-sections.
Connect the negative and positive terminals of the heater controller
directly to the battery.
10.2. Connecting the controls
The heater can be switched on and off using the following Webasto
controls:
– Switch, see automatic circuit diagram Figures 11 to 15
– Timer, see circuit diagram Figure 16
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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
suppression set (2x)
Radio interference
suppression

A Plug connection Control unit, 2-pin 
B Plug connection Control unit, 6-pin 
B5 Thermostat Nozzle block preheating 
C Plug connection Control unit, 8-pin 
F1 Temperature fuse Any polarity 
F2 Fuse 8 A Blade-type fuse DIN 72581 
F3 Fuse 8 A Blade-type fuse DIN 72581 
F4 Fuse Blade-type fuse DIN 72581 
F5 Fuse Blade-type fuse DIN 72581 
F6 Fuse Blade-type fuse DIN 72581 
H1 Light, green Indicator 
H2 Light,
circulating pump
if controlled via S4 
K1 Relay Circulating pump; negative
for heater
K2 Relay Heater motor
K3 Relay Light, control thermostat
operation
K4 Relay Ignition spark generator
K5 Relay Solenoid valve, flame
monitor
K6 Relay Nozzle block preheating 
K7 Relay Vehicle heating fan 
M1 Motor Circulating pump 
M2 Motor Combustion air fan 
M3 Motor Vehicle fan 
R Flame monitor Photoresistor, any polarity 
R1 Motor resistor Power resistor 
R2 Resistor,
heating cartridge
Nozzle block preheating 
S1 Switch Heater on/off 
S3 Switch on water tap Contact open when water
tap closed

S4 Switch for on/off,
circulating pump separate

S6 Switch Vehicle fan 
X1 Plug connector, 2-pin 
X2 Plug connector, 1-pin 
X3 Plug connector, 2-pin 
X5 Plug connector, 4-pin 
Y1 Solenoid valve Any polarity 
A Fitted in heater
B Parts supplied loose
C Only if required
D In vehicle
Set assignment
Possible depending on scope of supply or version
Item Designation Comment A B C D
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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 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
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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 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
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