Webasto DBW 2010 Installation Manual
Bluecool premium
Hide thumbs
Also See for DBW 2010:
- Operating and servicing manual (88 pages) ,
- Workshop manual (78 pages) ,
- Service and repair manual (72 pages)
Table of Contents
Advertisement
Webasto BlueCool Premium
DBW 2010 - Chiller
Installation Manual
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
CAUTION
Advertisement
Table of Contents
Related Manuals for Webasto DBW 2010
Summary of Contents for Webasto DBW 2010
-
Page 1: Installation Manual
– Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. -
Page 3: Table Of Contents
Test Procedures ................. 27 www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... -
Page 4: Foreword
1. Foreword General Webasto Product North America, Inc. is pleased to provide this installation manual with the DBW 2010 designed for the BlueCool Premium System. When used according to the guidelines stated in this manual, you can expect to provide years of trouble-free, enjoyable operation for your customer. -
Page 5: Safety And Important Information
Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto Product. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts. -
Page 6: Symbol Identification
It may also be used to alert against unsafe practices. These symbols are used to alert the installer to important or useful information about proper installation of the equipment. Heater Description Fig. 1 Heater Description of DBW 2010 1 Electronic control unit 10 Ignition electrodes 19 Flame detection photocell... -
Page 7: Heater Dimensions
Foreword Heater Dimensions Fig. 2 Heater Dimensions of DBW 2010 Fig. 3 Heater Tray Mount Dimensions of DBW 2010 Fig. 4 Foot Print - DBW 2010 Tray Mount www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... - Page 8 TUBE FLEX SS 38MM X 5M THRU HULL FITTING 38MM INSULATION TAPE 25FT Manuals / Warranty INSTALL / OPERATION MANUAL P/N 5001077A Heater Parts DBW 2010 MARINE ON TRAY Parts Bag Mounting MOUNTING BRACKET KIT www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
-
Page 9: Installation
• Radial blower on the heat exchanger (arranged on inlet side) up to 131°F (55 °C) • For this reason, a DBW 2010 with a specialized control unit must be used. The heater has a pre-programmed nominal temperature of 126°F (52 °C). -
Page 10: Installation Site / Installation Position
Installation Site / Installation Position The heater must be installed in as low a position as possible to allow the heater and circulating pump to be bled auto- matically. Fig. 5 DBW 2010 Mounting Angle Restrictions Mounting the Heater Step by Step: 1. -
Page 11: Hose Connections To Chiller Unit
Installation Hose Connections to Chiller Unit The DBW 2010 is intragrated into the Chiller unit water circuit via a electrically actuated 3-way valve assembly. Fig. 6 BlueCool Premium System with a DBW 2010 Components: 1. Stop valve at ship’s side inlet 2. - Page 12 Perfect ventilation can be identified by the circulating pump operating almost silently. Poor bleeding may cause the resetting temperature limiter to trip while the heater is operating. Fig. 7 Electrically Actuated 3-way Valve www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
-
Page 13: Fuel System
Note: The heater is equipped with an internal self priming fuel pump. If the fuel tank is higher than the fuel pump, the top of the tank may not be more than 20" above CAUTION the pump. www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... - Page 14 The lines should not be routed downwards from the metering pump to the heater. Unsupported fuel lines must be secured to prevent them sagging. They must be installed in such a way that they cannot be damaged by flying debre and high temperatures (e.g. exhaust line). www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
-
Page 15: Combustion Air Supply
Secure the intake tube to the heater with the provided hose clamps. Secure the tube to the adjacent structures with P-clips or nylon wire ties. www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... -
Page 16: Heater Exhaust
If additional protection is required, it is recommended to over-sleeve with an additional layer of insulation (available from your local Webasto marine dealer). DO NOT connect the heater exhaust into the engine or generator exhaust. Doing so will result in CAUTION unacceptable back-pressure levels and may damage the heater or cause operational failure. - Page 17 Avoid asphyxiation! If the exhaust pipe is routed through the inside of the vessel, exhaust gas tube must be as leakproof as possible: • use only Webasto approved exhaust clamps and firmly tighten clamps. • an approved exhaust sealant can be used on the inside of the exhaust tube at all connection points •...
-
Page 18: Electrical System
TECC Program 412 and Higher with DBW 2010 and Electrical 3-Way Valve Because an external water heater (DBW 2010) is being installed with a BlueCool Chiller Unit, the TECC Card must be reprogrammed for proper operation. This step must be completed in order for proper operation of the DBW 2010. - Page 19 4. To confirm a function change, hit the <F> button once to proceed to the next category and hit the <on / off> button to confirm. 5. Change is successful when the message “NENO” is displayed. For electrical connections between the TECC Card and the DBW 2010, refer to Figures 12, 13, and 15. www.webasto.us Webasto Product N.A., Inc.
- Page 20 Connections on the TECC Card: R1 - Connection C1 R1 - Connection R1 R1 - Connection T1 R1 - Connection C2 R1 - Connection R2 R1 - Connection T2 Fig. 13 Chiller Unit TECC Card www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
-
Page 21: Information About Air Guidance
• The distance between the (hot) air outlet and the (circulating) air inlet must be at least 5’ (1.5m). (Danger of air closed circuit) • Consider the installation complexity (price) • The customer must perform the changeover manually. • Currently unavailable as a single part www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... -
Page 22: Circuit Diagrams
Circuit Diagrams 3. Circuit Diagrams DBW 2010 Circuit Diagram Legend Circuit diagram legend for the DBW 2010 Item Designation Comment Ignition Electronics 6. Temperature coding (temperature at water outlet): Not Used Refer to following circuit diagram legend for further Fuse 15 AMP information. - Page 23 Circuit Diagrams Fig. 15 DBW 2010 Schematic www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
-
Page 24: Initial Start-Up
After the heater is installed and the TECC Card is programmed to reflect Function F4 (Preferred Function), the end user will enjoy seamless comfort control. The TECC Card will now request the DBW 2010 rather than reverse compressor cycling when heat is requested. -
Page 25: Technical Data
Flow rate l/hr. (gal/min) 1650 (7) against 0.15 bar Rated voltage (V) Power Consumption (W) Dimensions 128 (7.16) mm (inch) 94 (3.70) 82 (3.23) Weight kg (lb) 0.85 (1.88) Hose Connections mm (inch) 20 (0.78) www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... -
Page 26: Troubleshooting
Troubleshooting 6. Troubleshooting General Information This section describes trouble shooting procedures for the water heater DBW 2010. Trouble shooting is normally limited to the isolation of defective components. Before trouble shooting, check for and eliminate these defects: CAUTION • - fuel supply (plugged fuel filter) •... -
Page 27: Test Procedures
Turn motor switch (5) motor should run - test motor temperature drops “ON” below 60 °C (140°F). Turn WATER PUMP (4) pump should run - test pump “ON” THIS IS NORMAL. www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com... - Page 28 - If manual test run has been successfully completed, turn heater switch/timer “OFF”, remove the tester and re-connect the control unit. Once done, turn switch/timer “ON”; if heater or a heater component does not respond, control unit is defective; replace control unit and re-test heater. www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
- Page 29 Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
- Page 30 Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
- Page 31 Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.com...
- Page 32 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us Org. 10/2005 Rev. N/A P/N: 5001077A www.techwebasto.com...