Webasto DBW 2010 Operating Instructions Manual
Coolant heaters
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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)
Related Manuals for Webasto DBW 2010
Summary of Contents for Webasto DBW 2010
- Page 1 ,--Jebasto Feel the Drive Coolant Heaters DBW 2010 DBW 2020 DBW 300 Operating Instructions...
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Page 2: Table Of Contents
Operating your Webasto DBW Series Heater ........ - Page 3 DBW S EBASTO ERIES EATERS ONTENTS Dip Switch Programming (Model CDN-1224) ........18 Timer Operation (Model CDN-1224) .
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Page 4: Important Information
• carbon monoxide leading to serious injury or death. Never try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training • course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly. - Page 5 DBW S EBASTO ERIES EATERS NTRODUCTION • When checking the coolant level, proceed in accordance with the vehicle manufacturer’s instructions. • The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based anti-freeze.
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Page 6: General Safety Regulations And Information
DBW S EBASTO ERIES EATERS NTRODUCTION General Safety Regulations and Information The general safety regulations for the prevention of accidents and relevant operating safety instructions must be observed at all times. The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings, Cautions and Notes. - Page 7 DBW S EBASTO ERIES EATERS NTRODUCTION...
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Page 8: Description
18 17 16 15 21 Fuel supply/ return pipes 22 Combustion air adjusting shutter Fig. 1: Major Components of the DBW 2010 Coolant Heater 23 Fuel pump drive gearing 24 Nozzle pre-heater 25 Preheat thermostat (blue & green wires) 26 Air bleed screw... -
Page 9: Coolant Heaters Dbw 2020 / 300
DBW S EBASTO ERIES EATERS ESCRIPTION Coolant Heaters DBW 2020 / 300 11 12 13 1 Electronic control unit 2 Motor 3 Electronic ignition coil 4 Coupler 5 Combustion air fan 6 Fuel solenoid valve 7 Electrode holder 8 Coolant inlet 9 Ignition electrodes 10 Fuel nozzle 11 Overheat fuse (white wires) -
Page 10: Operating Instructions
EATERS PERATING NSTRUCTIONS Operating Instructions Operating your Webasto DBW Series Heater WARNING Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction. -
Page 11: Switching On
NSTRUCTIONS Switching On Before switching the Webasto heater on, open any shut off valves and set vehicle heater controls to the “Hot” position. Depending on the type of control installed, the heater can be operated by the following methods. Timer:... - Page 12 (combustion process is self-sustaining). At this point the heater is working and producing heat. The Webasto heater will cycle on and off until: 1. System coolant reaches operating temperature. 2. The Webasto heater is switched off.
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Page 13: Switching Off
(See timer operating instructions). Or switch the toggle switch or “Instant On” switch on your timer in the vehicle dash to “On”. The heater will start up. 2. When the run time has elapsed on your timer or engine preheating is no longer required, switch the Webasto heater “Off”. The heater will begin the after-run (cool-down) cycle. -
Page 14: Operation With 7-Day Digital Timer
Operation with 7-Day Digital Timer (Model 1529 Shown) The digital timer with 3 time settings permits the Webasto heater to be switched on and off instantly, or automatically at 3 programmable starting times. The operating time of the heater can be pre-selected. - Page 15 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Programmed Heater Operation Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week. Pre-selected Starting Times The pre-selected starting time is the time at which the heater will be switched on automatically. We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours of setting the timer.
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Page 16: Setting The Digital Timer (Models 1529 & 1531)
DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Setting the Digital Timer (Models 1529 & 1531) After the power has been connected, all symbols on the digital display are flashing. The time of the day and the day of the week must be set. All flashing displays and symbols of the timer can be set by means of the buttons. -
Page 17: 7-Day Digital Timer Programming And Operating Instructions (Models 1529 & 1531)
DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS 7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531) Setting the time and Press the button for more than 2 seconds. Time display flashes. day of the week Press the button to set time of day. Wait 5 seconds. Time is now stored. Day of week flashes. - Page 18 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Programming Press button. Memory location number flashes. heater-starting time Press button to preset starting time. Wait 5 seconds. Starting time is now stored. Day of week flashes. Press button to set day of week. Wait 5 seconds. Day of week is now stored. The number of memory location remains on the display.
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Page 19: Operation With 7-Day Electronic Timer Model Cdn-1224
Timer requires dismounting and disconnecting of power source before revising dip switch settings. For complete timer installation and operation instructions, refer to the 7-Day Electronic Timer Model CDN-1224 Operating Instructions manual available from your Webasto agent under part number 907111. -
Page 20: Timer Operation Modes (Model Cdn-1224)
DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Timer Operation Modes (Model CDN-1224) Truck or Bus Operation By flipping one of the dip switches on the back of the unit, the timer can be set for either truck or bus operation. The tables shown below illustrates the timing sequence associated with operation in either of these modes. -
Page 21: Dip Switch Programming (Model Cdn-1224)
DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Dip Switch programming Dip Switch (Model CDN-1224) Location Prior to installing the timer, all dip switches must be set to the requirements of your application. The dip switches allow for setting the clock in either AM/PM mode or 24 hour (military) mode. - Page 22 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Switch 1 & 2 control timer on duration. 60 Minute 120 Minute 30 Minute 90 Minute Switch 3 controls truck vs. bus operation. Switch 4 controls 12 vs. 24 hour clock. Bus Mode Truck Mode 12 hour clock 24 hour clock...
- Page 23 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Setting the Electronic Timer (Model CDN-1224) 12:00 1 Time Display 2 Heater on/off indicator LED (green) 3 Timer active status LED (yellow) 4 Clock time status LED (red) This LED will be on during PM time when AM/PM dip switch setting is selected 5 Days of the week LED’s (red) 6 Function buttons...
- Page 24 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Clock Programming (Present Time and Day) Display • Depress buttons ‘Set’ and ‘Display’ simultaneously to start programming NOTE: Time display will begin to flash. Minute Heater on/off • Depress button ‘Day’ to select day of week. manual •...
- Page 25 DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Timer Programming (Timed Heater Start Setting) Timer • Depress buttons ‘Set’ and ‘Timer on/off’ simultaneously to start programming. on/off NOTE: The yellow ‘T’ LED will flash Hour Heater on/off • Depress button ‘Day’ to select day heater is to come on. manual Timer •...
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Page 26: Timer Operation (Model Cdn-1224)
DBW S EBASTO ERIES EATERS PERATING NSTRUCTIONS Timer Operation (Model CDN-1224) Manual Operation Heater To manually turn the heater on, press the heater on/off manual button. The heater on/off indicator LED on/off manual (green) will come on. Press this button a second time to turn the heater off. Timer Operation Depress the timer on/off button to activate or deactivate the timer. - Page 27 IMPORTANT: Heater fault codes can be read using PC Diagnostics, however, the heater lockout reset must be manually performed using the procedure stated above. If you have any questions, contact our technical support team at (800) 860-7866 or via email at: info-us@webasto.com.
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Page 28: Maintenance Of The Heater
(point of time when weather conditions cause increased use of equipment) the fuel filter or filter cartridge must be replaced to prevent malfunctions. • the heater should be checked on regular intervals by a Webasto service agent, the latest before the beginning of the heating season. - Page 29 DBW S EBASTO ERIES EATERS AINTENANCE...
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Page 30: Basic Troubleshooting
Basic Troubleshooting CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components. Troubleshooting and fault correction should only be performed by Webasto trained, skilled personnel unless otherwise stated in this manual. General Information This section describes troubleshooting procedures for DBW Series coolant heaters. Troubleshooting is normally limited to the isolation of defective components. -
Page 31: Malfunctions
The fuse can be identified by the two white wires protruding from its top. The fuse is screwed hand tight into a dry well plug. Do not over tighten the fuse when replacing. On all other DBW 2010 heaters not equipped with an overheat fuse, simply correct the cause of overheating and allow the heater to cool down. -
Page 32: Malfunction Identification - Dbw Series Heaters
DBW S EBASTO ERIES EATERS ASIC ROUBLESHOOTING Malfunction Identification - DBW Series Heaters This table is intended to assist the swift diagnosis of simple malfunctions, which have obvious symptoms. It cannot replace the detailed knowledge of an expert workshop. For assistance, please contact one of the workshops recommended in the list of service stations. -
Page 33: Sequence Of Events - Dbw Series Heaters
DBW S EBASTO ERIES EATERS ASIC ASIC ROUBLESHOOTING ROUBLESHOOTING Sequence of Events - DBW Series Heaters The normal sequence of events illustrated here may be used in conjunction NOTE: with the malfunction identification table to help determine heater problems. After the correction of a malfunction, a functional Table 3: Sequence of Events... -
Page 34: Technical Data
DBW S EBASTO ERIES EATERS ECHNICAL Technical Data Heater DBW 2010 DBW 2020 DBW 300 Mark of conformity ~ S 129 ~ S 136 ~ S 164 Heater design principle High pressure fuel atomizing nozzle General Information Heat output kW/h (BTU/h) 13.1 (45,000) -
Page 35: U 4810 And U 4846 Coolant Pump Data
ERIES EATERS ECHNICAL ECHNICAL ECHNICAL ECHNICAL U 4810 and U 4846 Coolant Pump Data Recommended coolant circulation pumps for DBW 2010 heaters. Coolant Circulation Pump U 4810 U 4846 Volume flow l/h (US. Gal/min) 1600 (6.0) @ 0.15 bar 1650 (7.0) @ 0.15 bar... -
Page 36: U 4814, U 4851 And U 4852 Coolant Pump Data
DBW S EBASTO ERIES EATERS ECHNICAL U 4814, U 4851 and U 4852 Coolant Pump Data Recommended coolant circulation pumps for DBW 2020 and DBW 300 heaters. Coolant Circulation Pump U 4814 U 4851 & U 4852 Volume flow l/h (US. Gal/min) 5200 (22.9) @ 0.15 bar 6000 (26.4) @ 0.4 bar Nominal voltage... - Page 37 Replacement parts are covered for six (6) months or the remainder of the original warranty period, whichever is longer. The intent of the Webasto warranty is to protect the original end-user of the heater from defects and provide free repair and replacement of defective parts in the manner provided herein. During the warranty period, the exclusive remedy will be for Webasto, at their discretion, to repair or replace those parts which are demonstrated to be defective in material or workmanship.
- Page 40 Webasto Thermo & Comfort N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 11/00 Rev. 3/2017 P/N. 699540 www.techwebasto.com...