Spheros DBW 230 Workshop Manual
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Spheros DBW 230 Workshop Manual

Spheros DBW 230 Workshop Manual

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Visit www.butlertechnik.com for more technical information and downloads.
Water heaters
Status: 07/2010
Workshop Manual
DBW 160
DBW 230(2020)
DBW 300
DBW 350
www.butlertechnik.com

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  • Page 1 Visit www.butlertechnik.com for more technical information and downloads. Water heaters Workshop Manual DBW 160 DBW 230(2020) DBW 300 DBW 350 Status: 07/2010 www.butlertechnik.com...
  • Page 2 Visit www.butlertechnik.com for more technical information and downloads. www.butlertechnik.com...

  • Page 3: Table Of Contents

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 Contents Contents Introduction Contents and purpose .......................... 101 Applicability of the manual ........................101 Meaning of accentuations........................101 Further documentation to be used......................101 Safety information and regulations .......................
  • Page 4 Visit www.butlertechnik.com for more technical information and downloads. Contents DBW 160 / 230 (2020) / 300 / 350 Troubleshooting General ..............................501 General fault symptoms ........................501 Troubleshooting – quick diagnostic...................... 503 Fault symptoms............................ 504 5.4.1 Heater does not start when being switched on................. 504 5.4.2 Heater repeatedly switches into malfunction mode approx.
  • Page 5 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 Contents Removal and installation........................806 8.7.1 Heater, removal and installation ....................806 8.7.2 Replacing the temperature limiter....................806 8.7.3 Replacing the control thermostat....................806 8.7.4 Replacing the fan thermostat.....................
  • Page 6 Automatic wiring diagram, DBW 160 with control unit 1553 and switch, system variants and pin allocation 702 Automatic wiring diagram, DBW 230/300 with control unit 1553, 24 volts ............. 704 Automatic wiring diagram, DBW 300/350 with control unit 1553, 24 volts ............. 706 Application example for DBW 160/230/300, 12 and 24 volts, operation with timer and battery switch..

  • Page 7: Contents And Purpose

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 1 Introduction Introduction Further documentation to be used This workshop manual contains all information and in- Contents and purpose structions required for the repair of coolant heaters DBW 160/230/300/350.

  • Page 8: Legal Requirements Regarding The Installation

    Visit www.butlertechnik.com for more technical information and downloads. 1 Introduction DBW 160 / 230 (2020) / 300 / 350 The heater may not be installed in the driver's or passen- Legal requirements regarding the ger's compartments of vehicles. If the heater is neverthe- installation less installed in such a compartment, the installation case must be tightly sealed towards the vehicle interior.

  • Page 9: Suggestions For Improvements And Modifications

    Non-compliance with the installation instructions and the notes contained will lead to exclusion of liability by Spheros. The same applies to repairs not carried out by experts or without the use of original spare parts. This results in the invalidation of the heater's type approval and hence the ECE type approval.
  • Page 10 Visit www.butlertechnik.com for more technical information and downloads. 1 Introduction DBW 160 / 230 (2020) / 300 / 350 Notes www.butlertechnik.com...

  • Page 11: Combustion Air Fan

    2 General Description General Description The heaters of the type DBW 160, 230, 300 and 350 com- prise the following main components: The Spheros DBW 160, 230, 300 and 350 coolant heaters – combustion air fan supplement the vehicle's heating system –...

  • Page 12: General Description

    Visit www.butlertechnik.com for more technical information and downloads. 2 General Description DBW 160 / 230 (2020) / 300 / 350 1 Burner head 6 Temperature limiter 2 Electronic ignition unit 7 Fan thermostat 3 Coolant outlet 8 Heat exchanger 4 Control thermostat 9 Exhaust outlet 5 Fusible link 10 Control unit...
  • Page 13 12 Control unit 4 Fusible link * 5 Control thermostat * 6 Temperature limiter * 7 Coolant outlet 8 Heat exchanger * for components installed in applicable 9 Fuel return heater variants Heater DBW 230, DBW 300 and DBW 350 www.butlertechnik.com...

  • Page 14: Motor

    Heaters are fitted with the following fan types: DBW 160 – side-channel fan, DBW 230 / 300 – radial fan, DBW 350 – two-stage radial fan. 300.62...

  • Page 15: Nozzle-Block Preheater

    For parts required please refer to parts list. DBW 160 Heating element Nozzle block Thermostat to DBW DBW 160 230(2020).32 to DBW 300.15 Heating element Thermostat DBW 230 / 300 / 350 Nozzle block from DBW 230(2020).33 from DBW 300.15 from DBW 350.01 www.butlertechnik.com...

  • Page 16: Combustion Chamber

    The control unit is the core control element ensuring the chamber where it is burned, thus heating the heat system function and the monitoring of the combustion. exchanger. DBW 160 Control unit 1553 DBW 230(2020).32 DBW 300.15 from DBW 230(2020).33 DBW 300.16 DBW 300.62 without flame pipe DBW 350.01...

  • Page 17: Flame Sensor

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 2 General Description Flame sensor Electronic ignition unit with ignition electrodes The flame sensor monitors the flame during the entire combustion process. The flame sensor acts as a photo- The electronic ignition unit creates the high voltage electric resistor detecting the absence of a flame or as a required to ignite the fuel/air mixture.

  • Page 18: Control Thermostat

    ± 2° C and opening at 42 ± 2° C. fuse Reset button Temperature limiter opens at 107 ± 5° C resetable at 30° C DBW 160 automatic reset at 0° C DBW 230 / 300 / 350 Control thermostat at heater www.butlertechnik.com...

  • Page 19: Fan Thermostat

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 2 General Description U 4810 Recommended for heater DBW U 4814 External control thermostat 2.11 Fan thermostat Recommended for heater DBW The fan thermostat turns the vehicle heater's fan on and 230, 300 and off at coolant temperatures between 30°...

  • Page 20: General

    Visit www.butlertechnik.com for more technical information and downloads. 2 General Description DBW 160 / 230 (2020) / 300 / 350 U 4856 (replaces U 4852) Recommended for heater DBW 230, 300 and 350 U 4852 Recommended for heater DBW 230, 300 and 350 www.butlertechnik.com...

  • Page 21: Operation

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 3 Function Description Function Description 3.2.3 Switch off When the heater is switched off, combustion is stopped. General The operation indicator is turned off, and the purge cycle begins.

  • Page 22: Activation

    Visit www.butlertechnik.com for more technical information and downloads. 3 Function Description DBW 160 / 230 (2020) / 300 / 350 Operation indicator Circulation pump Combustion air fan Electronic ignition unit Solenoid valve Flame sensor Control thermostat Activation Initial cycle Start Safety delay time Combustion mode 10-25 s...

  • Page 23: Electrical Components

    DIN EN 590 (diesel fuel) may be used. According to the diesel-fuel standard DIN EN 590, up to 5% of biodiesel additive is also permissible. Heater DBW 160 DBW 230 DBW 300 DBW 350 ECE approval number according to R10 (EMC) 025038...
  • Page 24 Visit www.butlertechnik.com for more technical information and downloads. 4 Technical Data DBW 160 / 230 (2020) / 300 / 350 Circulation- Operating Nominal power Volume flow Nominal voltage Dimensions Weight pump type voltage range consumption length V – V – width height 1600 (at approx.

  • Page 25: General Fault Symptoms

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 5 Troubleshooting Troubleshooting CAUTION Fault identification is usually limited to the identification of defective components. General The following fault causes have not been considered and should always be checked to eliminate these faults as causes for malfunctions: CAUTION...

  • Page 26: Troubleshooting

    Visit www.butlertechnik.com for more technical information and downloads. 5 Troubleshooting DBW 160 / 230 (2020) / 300 / 350 Fault symptom Possible cause • Excessive system resistance (especially when cold). • Circulation pump defective Heat exchangers (coolant/air) do not dissipate suffi- cient heat because •...

  • Page 27: Troubleshooting – Quick Diagnostic

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 5 Troubleshooting Troubleshooting – Quick diagnostic Heater types: all heaters Fault symptom Check, repair, if required, replace After activation – no function Function indicator – extinguishes after approx. 25 s Combustion air fan –...

  • Page 28: Fault Symptoms

    Visit www.butlertechnik.com for more technical information and downloads. 5 Troubleshooting DBW 160 / 230 (2020) / 300 / 350 Fault symptoms 5.4.1 Heater does not start when being switched on NEIN Hat der Regelthermostat Control thermostat de- Does the control ther- Does the control ther- Regelthermostat defekt,...

  • Page 29: Heater Repeatedly Switches Into Malfunction Mode Approx. 30 S After Being Switched On

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 5 Troubleshooting 5.4.2 Heater repeatedly switches into malfunction mode approx. 30 s after being switched on Check supply lines Does symptom still Electronic ignition Is the buzzing of the Is voltage present on Has thermal fuse F1...

  • Page 30: Heater Requires Several Attempts To Start

    Visit www.butlertechnik.com for more technical information and downloads. 5 Troubleshooting DBW 160 / 230 (2020) / 300 / 350 5.4.3 Heater requires several attempts to start NEIN Fuel pump defective, Fuel level has sunk Tritt bei den Brennstoffspiegel ist Brennstoffpumpe replace it.

  • Page 31: Heater Creates Black Smoke

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 5 Troubleshooting 5.4.5 Heater creates black smoke Are combustion air Are the gas ducts of Is there vacuum or Motor speed (see intake pipe or exhaust- the heat exchanger overpressure at the Section 6) too low.

  • Page 32: Heater Creates White Smoke

    Visit www.butlertechnik.com for more technical information and downloads. 5 Troubleshooting DBW 160 / 230 (2020) / 300 / 350 5.4.6 Heater creates white smoke Does the heater Does the heater Does the heater produce produce smoke after it produce smoke for smoke during operation (also erratically)? has been shut off?

  • Page 33: General

    Measure CO and smoke spot number and compare with applicable diagram. Voltage setting at 500 m above sea level DBW 230(2020)( < = .32) ( < = .15) DBW 300 Fuel-pump pressure 10 bar Voltage setting at 500 m above sea level DBW 160 (atomiser: 0.3 gph)

  • Page 34: Checks Of Individual Components

    Visit www.butlertechnik.com for more technical information and downloads. 6 Function Checks DBW 160 / 230 (2020) / 300 / 350 Checks of individual components NOTE The intake duct may be rotated by 180°. 6.3.1 Check of flame sensor resistance NOTE The glass body of the flame sensor and the sight glass (see Fig.) must be cleaned if soiled.

  • Page 35: Check And Adjustment Of Ignition Electrodes

    – Adjust gap by bending electrodes and verify using the Testing requires a testing device. Testing devices (0 to 15 gauge as shown. bar display range) are available from Spheros main dealers. CAUTION The electronic ignition unit must be removed.

  • Page 36: Check Of Burner Motor

    Turn on heater. – Measure speed (at nominal voltage, the speeds must be within the specified ranges). DBW 160 ..4050 – 4950 DBW 230 ..5220 – 6380 DBW 300 ..5220 – 6380 DBW 350 ..5040 – 6160 6.3.6 Check of solenoid valve...
  • Page 37 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 6 Function Checks Notes www.butlertechnik.com...
  • Page 38 Visit www.butlertechnik.com for more technical information and downloads. 6 Function Checks DBW 160 / 230 (2020) / 300 / 350 www.butlertechnik.com...

  • Page 39: General

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 7 Circuit diagrams Wiring diagrams General information The wiring diagrams and application examples (Fig. 701 to 704) show possible circuits for the heaters DBW 160, 230 (2020), 300 and 350.
  • Page 40 Visit www.butlertechnik.com for more technical information and downloads. 7 Circuit diagrams DBW 160 / 230 (2020) / 300 / 350 C C C a a a b b b e e e l l l o o o c o o o l l l u u u s s s r r r blue...
  • Page 41 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 7 Circuit diagrams Pos. Designation Comment A B C D Pos. Designation Comment A B C D Heater Relay Solenoid valve; flame sensor Control unit CU 1553 Electronic ignition...
  • Page 42 1.5 mm 2 1.5 mm 2 2.5 mm 2 violet 2.5 mm 2 4.0 mm 2 white 4.0 mm 2 6.0 mm 2 Fig. 702 (page 1 of 2) Automatic wiring diagram, DBW 230/300 with control unit 1553, 24 volts www.butlertechnik.com...
  • Page 43 Relay Heater motor Relay Light; Ensure good ground connection! control-thermostat opera- tion Fig. 702 (page 2 of 2) Automatic wiring diagram, DBW 230/300 with control unit 1553, 24 volts www.butlertechnik.com...
  • Page 44 Visit www.butlertechnik.com for more technical information and downloads. 7 Circuit diagrams DBW 160 / 230 (2020) / 300 / 350 Leitungsfarben blau braun gelb grün grau orange schwarz violett weiß C C C a a a b b b e e e l l l o o o c o o o l l l u u u...
  • Page 45 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 7 Circuit diagrams Pos. Designation Comment A B C D Pos. Designation Comment A B C D Heater floating Relay (in pos. A1) for burner motor Control unit CU 1553...
  • Page 46 Visit www.butlertechnik.com for more technical information and downloads. 7 Circuit diagrams DBW 160 / 230 (2020) / 300 / 350 C C C a a a b b b e e e l l l o o o c o o o l l l u u u s s s r r r blue...
  • Page 47 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 7 Circuit diagrams Notes www.butlertechnik.com...
  • Page 48 Visit www.butlertechnik.com for more technical information and downloads. 7 Circuit diagrams DBW 160 / 230 (2020) / 300 / 350 www.butlertechnik.com...

  • Page 49: Vehicle Servicing

    5 work is carried out on the vehicle). years. • The heater should be checked by a Spheros service Heater test run workshop at regular intervals, at the latest at the be- ginning of a heating period.

  • Page 50: Swinging The Burner Head Open And Closed

    Fuel pump and atomiser nozzle - in DBW 160 to 5.0 Nm + 1 Nm, – Solenoid valve - in DBW 230(2020) / 300 / 350 to 8.0 Nm +/- 10%. – Electronic ignition unit 4. Connect electrical connections, if necessary.

  • Page 51: Connection To The Vehicle's Cooling System

    10 litres. must be secured by hose clamps unless mechanical As a rule, the coolant hoses supplied by Spheros must be threaded joints are used. used. Otherwise, hoses in compliance with DIN 73411 or better must be used.

  • Page 52: Service And Maintenance

    Visit www.butlertechnik.com for more technical information and downloads. 8 Service and Maintenance DBW 160 / 230 (2020) / 300 / 350 Coolant heating circuit – Wall heater and roof-duct heating system Supply Return 1 Wall heater with fan 2 Heat exchanger at entry point 3 Heater 4 Circulation pump 5 Heat exchanger in roof area...

  • Page 53: Combustion Air Supply

    DBW 230 to .32 / DBW 300 to .15: 80 mm • Max. permissible suction height: 2 m DBW 230 from .33 / DBW 300 from .16: 70 mm • Max. permissible supply pressure: 0.3 bar. DBW 350 70 mm –...

  • Page 54: Removal And Installation

    Visit www.butlertechnik.com for more technical information and downloads. 8 Service and Maintenance DBW 160 / 230 (2020) / 300 / 350 Removal and installation 8.7.3 Replacing the control thermostat NOTE CAUTION The procedure for replacing the control thermostat is the When the heater is installed, only the following disassem- same for installed or uninstalled heaters.

  • Page 55: Replacing The Combustion Chamber

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 8 Service and Maintenance 8.7.9 Replacing the combustion chamber NOTE The procedure for replacing the combustion chamber is the same for installed or uninstalled heaters. For replacement process, see 9.2.15.

  • Page 56: Start-Up

    Visit www.butlertechnik.com for more technical information and downloads. 8 Service and Maintenance DBW 160 / 230 (2020) / 300 / 350 Start-up 8.8.2 Bleeding the fuel-supply system When the heater is switched on, the fuel pump draws in After installation of the heater, the coolant circuit and the fuel, filling the heater's entire fuel supply system.

  • Page 57: General

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair Repair General This section describes permissible repair work on unin- stalled heater systems. Any further disassembly will void the warranty. For re-assembly, only spare parts from the corresponding spare-parts kits must be used.

  • Page 58: Measures On Components In Disassembled Condition

    Special tool Gap dimension 0.15 +/- 0.05 9.1.1.2 Visual inspection of the combustion chamber Only DBW 230/300/350: NOTE Check hub of the combustion air fan for cracks, check DBW 300.62 is not provided with a flame pipe shroud (rear panel) for strength.
  • Page 59 12 V heaters with control unit 1553, order no. 968 89A • 24 V heaters with control unit 1553, order no. 989 71A Heating element Heating element Thermostat Nozzle block Thermostat Nozzle block DBW 160 DBW 230 / 300 / 350 www.butlertechnik.com...
  • Page 60 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 Implementation with DBW 160 7. Snap female disconnects into the 2-pin connector housing to connect the heating element. NOTE With DBW 160 heaters, the disk and the nut in the NOTE retrofit kit are not required.
  • Page 61 The polarity in the following work step is not impor- NOTE tant. • With DBW 230 / 300 heaters, the tab in the retrofit kit is not required. 10. Make female disconnects for connection of heating element snap into the 2-pin connector 1.
  • Page 62 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 Pos. Designation Comment Heater Control unit CU 1553 Connector, 6-pin Thermostat for nozzle-block preheating Fuse Flat fuse as per DIN 72581 Fuse Flat fuse as per DIN 72581 16 A (12 V);...

  • Page 63: Replacing The Temperature Limiter

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair Disassembly and assembly 9.2.1 Replacing the temperature limiter 9.2.1.1 Removal 1. If required, Remove nut (4, Fig. 901) and take off protective cap (3).
  • Page 64 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 DBW 160 / 230 / 300 / 350 1 control thermostat 2 connecting block 3 protective cap 4 nut 5 angular bracket 6 hexagon head plug 7 thermal fuse 8 temperature limiter...

  • Page 65: Replacing The Fan Thermostat

    - in DBW 160 to 5.0 Nm + 1 Nm, 4. Carry out measures on components in disassembled - in DBW 230 / 300 / 350 to 8.0 Nm +/- 10%. state (see 9.1.1). 4. If required, connect fuel lines.
  • Page 66 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 1 control unit 1553 2 retaining clamp 3 burner head Fig. 902 Replacement of the control unit (not available with DBW 1 split pin 2 nut (2) 3 bolt (2)

  • Page 67: Replacing The Motor

    Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair 9.2.7 Replacing the motor 9.2.7.2 Installation 1. Locate motor (14, Fig. 904) and fasten to flange (13) 9.2.7.1 Removal by means of serrated lock washers (10) and bolts (11).

  • Page 68: Replacing The High-Pressure Nozzle

    Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 9.2.8 Replacing the high-pressure nozzle 9.2.11 Replacing the flame sensor 9.2.8.1 Removal 9.2.11.1Removal 1. Swing burner head open (see 8.5.1). 1. Swing burner head open (see 8.5.1). 2.
  • Page 69 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair 1 solenoid valve 11 high-pressure nozzle 21 washer (4) 2 heating element 12 disk 22 banjo bolt (2) 3 retaining clamp 13 circlip 23 bolt (4) 4 ignition cable (2)

  • Page 70: Replacing The Fuel Pump

    Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 9.2.13 Replacing the fuel pump 9.2.14.2Installation 1. Place sealing ring (5, Fig. 907) on solenoid-valve 9.2.13.1Removal body (4). 2. Insert spring (7) and pin (6) into stud (8). 1.
  • Page 71 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair DBW 230 / 300 / 350 1 disk 2 serrated lock washer 3 nut 4 thermostat 5 bolt 6 tab DBW 160 7 nozzle-block plate Fig.

  • Page 72: Replacing The Heat Exchanger

    Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 9.2.17 Replacing the heat exchanger 9.2.19.2 Installation 1. Slide combustion chamber (1, Fig. 908) into heat 9.2.19.1 Removal exchanger (2) until it makes contact. 2.

  • Page 73: Replacing The Nozzle Block

    - in DBW 160 to 5.5 Nm + 1 Nm, 4. Torque bolts to 5.5 Nm. - in DBW 230 / 300 / 350 to 8.0 Nm +/- 10%. 5. Locate pressure line (16) and torque bolt-connections 6. Install engine (see 9.2.7.2).

  • Page 74: Replacement Of The Combustion Air Fan

    Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 DBW 160 DBW 350 DBW 230 / DBW 300 1 bolt (3) 4 Combustion air fan 2 washer (3) 5 nozzle-block plate...
  • Page 75 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 9 Repair Notes www.butlertechnik.com...
  • Page 76 Visit www.butlertechnik.com for more technical information and downloads. 9 Repair DBW 160 / 230 (2020) / 300 / 350 www.butlertechnik.com...
  • Page 77 Packaging, Storage and Shipping 10.1 General Heaters or components to be sent to Spheros GmbH for testing or repair must be cleaned and packaged in such a way that they will not be damaged during handling, trans- port and storage.
  • Page 78 Visit www.butlertechnik.com for more technical information and downloads. 10 Packaging, Storage and Shipping DBW 160 / 230 (2020) / 300 / 350 Notes 1002 www.butlertechnik.com...
  • Page 79 Visit www.butlertechnik.com for more technical information and downloads. DBW 160 / 230 (2020) / 300 / 350 A Appendix Appendix A Regular maintenance www.butlertechnik.com...
  • Page 80 In such cases please contact your Spheros partner. temperatures. Check / maintenance work...

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