Webasto DBW 2010 Installation Instructions Manual
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Also See for DBW 2010:
- Operating and servicing manual (88 pages) ,
- Workshop manual (78 pages) ,
- Service and repair manual (72 pages)
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Summary of Contents for Webasto DBW 2010
- Page 1 Wasserheizgeräte Einbauanweisung Water Heaters Installation instructions Appareils de chauffage à eau Notice de montage DBW 2010 / 2016 mit Steuergerät 1553 with Control Unit 1553 avec organe de commande 1553...
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Page 2: Table Of Contents
Installation ........60 Einbaubeispiel für DBW 2010 / 2016....7 Exemple d'installation pour le DBW 2010 / 2016 . -
Page 3: Statutory Regulations Governing Installation
Statutory regulations governing installation 1.2. Extract from directive ECE-R 122 Part I and Annex 7 DBW 2010 / 2016 heaters have been type-tested and approved in Start of extract. accordance with EC Directives ECE-R 122 (heaters) and ECE-R 10 Part I (EMC) with the following permit numbers: 5.3 Vehicle Installation Requirements for Combustion Heaters and... - Page 4 Statutory regulations governing installation DBW 2010 / 2016 5.3.2.5 Every reasonable precaution should be taken in positioning the 5.3.7 Heating air outlet heater to minimize the risk of injury and damage to personal property. 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 5.3.3 Fuel supply...
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Page 5: Use / Version
Use of the water heaters 2.2. Version Webasto DBW 2010 / 2016 water heaters are used in connection with the vehicle’s own heating system The water heaters are approved for use with “diesel” fuel. – to heat the passenger cabin, The heat output is: –... -
Page 6: Installation
– 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. - Page 7 DBW 2010 / 2016 Installation Combustion air intake Exhaust outlet Fuel intake Fuel discharge Space required to remove the burner chamber Coolant intake Max. swivelled burner Coolant outlet Fig. 1: Dimensions of DBW 2010 / 2016 heaters...
- Page 8 Installation DBW 2010 / 2016 3.2. To install DBW 2010 / 2016 heaters 3.3. Model plate The heater may be secured either with four M8 screws or with four bolts The model plate must be protected from damage and must be clearly and nuts (see Figure 3).
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Page 9: Installation Example For Dbw 2010 / 2016
Water heating circuit – wall heater and roof duct heating system Wall heater with fan Heat exchanger at entry point Heater Circulating pump Roof heat exchanger Vehicle engine Driver’s position heating system Control element Forwards Backwards Fig. 5: Installation example for DBW 2010 / 2016 heaters... -
Page 10: To Install The Circulating Pump
To install the circulating pump DBW 2010 / 2016 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). - Page 11 DBW 2010 / 2016 To install the circulating pump 5.2. U 4840 circulating pump 0,50 Delivery rate (with water/glycol 0,40 50/50 at +23 °C) 0,30 Δ p 12/24V 0,20 0,10 0,00 Fig. 8: Delivery rate U 4840 circulating pump Fig. 9:...
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Page 12: Connection To The Vehicle Cooling System
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. -
Page 13: Fuel Supply
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. - Page 14 – 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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Page 15: Combustion Air Supply
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). -
Page 16: Exhaust Pipe
Exhaust pipe DBW 2010 / 2016 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. - Page 17 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...
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Page 18: Electrical Connections
Electrical connections DBW 2010 / 2016 Item Designation Comment A B C D Item Designation Comment A B C D Heater Relay Solenoid valve, flame Control unit SG 1553 monitor Ignition spark Relay Nozzle block preheating ... - Page 19 1.5 mm² grey orange 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm² black 4.0 mm² 6.0 mm² violet white Vehicle’s own cable Fig. 11: System circuit for DBW 2010 with control unit 1553 and switch, see legend on page 44...
- Page 20 Electrical connections DBW 2010 / 2016 Cable cross-sections Cable colours < 7.5 m 7.5 m–15 blue brown 0.75 mm² 1.0 mm² yellow 0.75 mm² 1.0 mm² green 1.0 mm² 1.5 mm² grey orange 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm²...
- Page 21 DBW 2010 / 2016 Electrical connections Cable colours Cable cross-sections blue < 7.5 m 7.5 m–15 brown 0.75 mm² 1.0 mm² yellow 0.75 mm² 1.0 mm² green grey 1.0 mm² 1.5 mm² orange 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm²...
- Page 22 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm² black 4.0 mm² 6.0 mm² violet white Vehicle’s own cable Fig. 14: System circuit for DBW 2010 with control unit 1553, switch and nozzle block preheating system, see legend on page 44...
- Page 23 DBW 2010 / 2016 Electrical connections Cable colours Cable cross-sections < 7.5 m 7.5 m–15 blue brown 0.75 mm² 1.0 mm² yellow 0.75 mm² 1.0 mm² green 1.0 mm² 1.5 mm² grey orange 1.5 mm² 2.5 mm² 2.5 mm² 4.0 mm²...
- Page 24 4.0 mm² 2 to vehicle terminal 75, if present – otherwise terminal 15 4.0 mm² 6.0 mm² 3 Motor vehicle lighting (terminal 58) Vehicle’s own cable Fig. 16: System circuit for DBW 2010 / 2016 with control unit 1553 and timer...
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Page 25: Initial Start-Up
DBW 2010 / 2016 Initial start-up 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 system and the fuel supply system carefully. -
Page 26: Troubleshooting
Troubleshooting DBW 2010 / 2016 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. -
Page 27: Technical Data
DBW 2010 / 2016 Technical data 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 590). -
Page 28: Technical Data
Technical data DBW 2010 / 2016 Heater DBW 2010 DBW 2016 ECE type permit number EMC: E1 10R 03 1087 E1 10R 03 1087 Heating system: E1 122R 00 0006 E1 122R 00 0001 Model High pressure atomiser High pressure atomiser Heating current 11.6... - Page 29 DBW 2010 / 2016 Technical data Circulating pump U 4810 U 4840 Delivery rate 1600 (against 0.15 bar) 1600 (against 0,1 bar) Rated voltage 12 or 24 12 or 24 Operating voltage range 10...14 or 20...28 9...15 or 16...30 Rated power consumption...
- Page 30 Webasto-Landesvertretung. In multilingual versions the German language is binding. The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country. Dans le cas d'une version rédigée en plusieurs langues, l'allemand est alors la langue qui fait foi.