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
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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 Fahrzeugs . . . . . . . . . . . . 9
7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 Abgasleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11 Erstinbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12 Störungen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13 Technische Daten. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table of contents
1 Statutory regulations governing installation . . . . . . . . . . . 27
2 Use / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Installation example for DBW 2010 / 2016 . . . . . . . . . . . . 33
5 To install the circulating pump. . . . . . . . . . . . . . . . . . . . . . 34
6 Connection to the vehicle cooling system . . . . . . . . . . . . . 35
7 Fuel supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sommaire
1 Dispositions légales concernant le montage . . . . . . . . . . . 53
2 Utilisation / version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Exemple d'installation pour le DBW 2010 / 2016 . . . . . . . 59
5 Installation de la pompe de circulation . . . . . . . . . . . . . . . 60
6 Raccordement au circuit de refroidissement du véhicule. . 61
7 Alimentation en carburant . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Alimentation en air de combustion . . . . . . . . . . . . . . . . . . 64
9 Conduite d'échappement . . . . . . . . . . . . . . . . . . . . . . . . . 65
10 Branchements électriques . . . . . . . . . . . . . . . . . . . . . . . . . 66
11 Première mise en service . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12 Pannes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13 Caractéristiques techniques. . . . . . . . . . . . . . . . . . . . . . . . 76
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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 data" for the approval number.
Installation is governed above all by the provisions in Part I and Annex 7 of
Directive ECE-R 122.
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 over-
heating. This requirement shall be deemed to be met if the installation en-
sures 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 installation 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
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
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 refu-
elling, 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 fumes
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 means.
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 sup-
ply of fuel must be stopped within five seconds when the vehicle’s engine
stops running. If a manual device is already activated, the heating 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
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 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 (DIN EN 590) .
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 sys-
tem may be fitted.
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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 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 im-
portant 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 ventila-
tion to ensure that a maximum temperature of 85 °C (storage temperature,
60 °C in operation) 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 heat-
er.
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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
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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 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
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
Water heating circuit – wall heater
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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 4840 circulating pump
Fig. 6: 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/gly-
col 50/50 at
+23 °C)
Fig. 7: U 4840 circulating pump installation position
"Area for fastening clamp
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