Coolant Heaters DBW 2010 DBW 2020 DBW 300 North American Headquarters 3333 John Conley Drive Lapeer, MI 48446 Phone (810) 245-2400 Toll-free (800) HEATER-1 Fax (810) 664-7720 Canadian Operations Toll-free (800) 667-8900 Rev. 11/00 699540 (English) Website: www.webasto.
WEBASTO DBW SERIES HEATERS CONTENTS Introduction Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description General Description . . . . . . . . . . . . . . . . . . . . . . . . . .
WEBASTO DBW SERIES HEATERS CONTENTS Dip Switch Programming (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Timer Operation (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Maintenance Maintenance of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Basic Troubleshooting General Information . . . . . . . . . . . . . . . . . . . . .
WEBASTO DBW SERIES HEATERS INTRODUCTION Introduction Important Information • • • • • • • The heater must be installed according to the “Installation Instructions” and must be examined by an officially recognized, Webasto authorized installation/ servicing facility. When the heater is installed in vehicles used for the transportation of dangerous or inflammable goods, or in boats, the appropriate regulations must be observed. Webasto Thermosystems, Inc.
WEBASTO DBW SERIES HEATERS • • • • • • • INTRODUCTION 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. The pressure setting of the coolant filler cap should be between 0.4 and 2 bar (6 p.s.i. and 28 p.s.i.). The coolant heater may only be operated within the specified operating voltage range designated by type.
WEBASTO DBW SERIES HEATERS INTRODUCTION 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.
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WEBASTO DBW SERIES HEATERS DESCRIPTION General Description Coolant Heater DBW 2010 1 2 3 4 5 23 6 7 25 22 Fig.
WEBASTO DBW SERIES HEATERS DESCRIPTION Coolant Heaters DBW 2020 / 300 1 2 Fig.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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. WARNING Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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: Switch: Using a Timer: Upon pressing the “Instant Heat” button on the timer face, the “Operation Indicator” on the timer lights up and the heater begins operation.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Heater Start-up Sequence: Upon switching on, an operating indicator light will illuminate. The combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 °C (< 32 °F) nozzle preheating is also activated). After approximately 15 seconds the fuel solenoid valve opens allowing fuel to flow to the nozzle where it is atomized and sprayed into the combustion chamber.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Switching Off When heating is no longer required, switch the Webasto heater off. The fuel solenoid valve interrupts the fuel supply and combustion stops. The indicator light turns off. The Combustion air fan and the water pump continue operation for approximately 150 seconds (after-run cycle) purging the combustion chamber of any fumes and cooling the heater. NOTE: Switching the Webasto heater on during the cool-down (after-run cycle) period is allowed.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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. It is possible to program 3 different heating times according to your individual needs. Only one preset starting time can be activated at any one time.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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 and buttons. If the and buttons are not pressed within 5 seconds, the currently displayed time or function will be stored.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531) Setting the time and day of the week Press the button for more than 2 seconds. Time display flashes. Press the or button to set time of day. Wait 5 seconds. Time is now stored. Day of week flashes. Press or button to set day of week. Wait 5 seconds. Day of week is now stored. Viewing the time With ignition “ON”: Continuous display of current time and day of the week.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Programming heater-starting time Press or button. Memory location number flashes. Press or button to preset starting time. Wait 5 seconds. Starting time is now stored. Day of week flashes. Press or button to set day of week. Wait 5 seconds. Day of week is now stored. The number of memory location remains on the display. The timer is now in the programmed mode and switches heater on at the preset time.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Operation with 7-Day Electronic Timer Model CDN-1224 12:00 H T S M T W T F P The 7-Day Electronic Timer Model CDN-1224 permits the Webasto heater to be switched on and off instantly, or automatically. The timer allows for 1 preset start time once within a 24 hour period on any one day up to 7 days in advance. S The current time and weekday must be preset before any other programming features can be accomplished.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS 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. Bus Application Ignition wire is connected and dip switch #3 is in bus mode.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Prior to installing the timer, all dip switches must be set to the requirements of your application. OPEN Dip Switch Location The dip switches allow for setting the clock in either AM/PM mode or 24 hour (military) mode. Also included is the ability to select the desired heater run time of 30, 60, 90 or 120 minutes. Dip switch settings are accessed through a cut out on the rear panel of the timer. Fig.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Switch 1 & 2 control timer on duration. 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 60 Minute 30 Minute 120 Minute 90 Minute Switch 3 controls truck vs. bus operation. Switch 4 controls 12 vs. 24 hour clock.
WEBASTO DBW SERIES HEATERS Setting the Electronic Timer (Model CDN-1224) 1 Time Display 2 Heater on/off indicator LED (green) OPERATING INSTRUCTIONS 2 H 3 T 1 12:00 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 S 5 M T W T F P S 5 Days of the week LED’s (red) 6 Function buttons Set Clock Set Timer 6 Fig.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Clock Programming (Present Time and Day) • • Depress buttons ‘Set’ and ‘Display’ simultaneously to start programming NOTE: Time display will begin to flash. AND Heater on/off manual Depress button ‘Day’ to select day of week. Day • Depress button ‘Hour’ to select correct hour. NOTE: If the dip switch setting is in the AM/PM mode, the red PM LED will respond. Timer on/off Hour • Depress button ‘Minute’ to select correct minute.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Timer Programming (Timed Heater Start Setting) • • Depress buttons ‘Set’ and ‘Timer on/off’ simultaneously to start programming. NOTE: The yellow ‘T’ LED will flash Depress button ‘Day’ to select day heater is to come on. AND Heater on/off manual Day • Timer on/off Depress button ‘Hour’ to select correct hour. Hour • Depress button ‘Minute’ to select correct minute. Display Minute • Depress button ‘Set’ to end timer programming.
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS Timer Operation (Model CDN-1224) Manual Operation To manually turn the heater on, press the heater on/off manual button. The heater on/off indicator LED (green) will come on. Press this button a second time to turn the heater off. Heater on/off manual Day Timer Operation Depress the timer on/off button to activate or deactivate the timer.
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WEBASTO DBW SERIES HEATERS MAINTENANCE Maintenance of the Heater To ensure functional reliability of the heater the following maintenance must be performed: • • • • • check combustion air inlet and exhaust outlet for contamination and clean as required. outside the heating season the heater should be operated with the vehicle engine cold approximately every four weeks for 10 minutes setting the heating system to "warm" and opening all appropriate coolant flow control valves.
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WEBASTO DBW SERIES HEATERS 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.
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING Malfunctions The DBW Series of coolant heaters are designed with automatic, self-monitoring systems that will shut the heater off in the event of a problem. The heater will switch itself off automatically if combustion does not start after the heater has been switched on, or if the flame goes out, or if the heater overheats. The operation indicator light will go out to signify a problem.
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING 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.
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING Sequence of Events - DBW Series Heaters The normal sequence of events illustrated here may be used in conjunction with the malfunction identification table to help determine heater problems. Table 3: Sequence of Events 30 NOTE: After the correction of a malfunction, a functional test must always be performed with the heater installed in the vehicle in its operational position.
WEBASTO DBW SERIES HEATERS Technical Data TECHNICAL DATA Heater Mark of conformity General Information DBW 300 ~ S 136 ~ S 164 High pressure fuel atomizing nozzle Heat output kW/h (BTU/h) Fuel Electrical components: Permissible operating ambient °C (°F) temperature range (heater, control unit, circulation pump) 13.1 (45,000) 23.
WEBASTO DBW SERIES HEATERS TECHNICAL DATA U 4810 and U 4846 Coolant Pump Data Recommended coolant circulation pumps for DBW 2010 heaters. Coolant Circulation Pump Volume flow U 4810 l/h (US. Gal/min) U 4846 1600 (6.0) @ 0.15 bar 1650 (7.0) @ 0.15 bar Nominal voltage V 12 or 24 12 or 24 Operating voltage range V 10 ... 14 or 20 ... 28 10 ... 14 or 20 ... 28 Nominal power consumption W 25 28 length width height 173 mm (6.8 in.) 94 mm (3.7 in.) 77 mm (3.0 in.) 128 mm (7.16 in.) 94 mm (3.
WEBASTO DBW SERIES HEATERS TECHNICAL DATA U 4814, U 4851 and U 4852 Coolant Pump Data Recommended coolant circulation pumps for DBW 2020 and DBW 300 heaters. Coolant Circulation Pump Volume flow U 4814 l/h (US. Gal/min) U 4851 & U 4852 5200 (22.9) @ 0.15 bar 6000 (26.4) @ 0.4 bar Nominal voltage V 12 or 24 24 Operating voltage range V 10 ... 14 or 20 ... 28 18 ... 32 Nominal power consumption W 104 209 length width height 221 mm (8.7 in.) 100 mm (3.94 in.) 105 mm (4.14 in.) 285 mm (11.
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North American Headquarters 3333 John Conley Drive Lapeer, MI 48446 Phone (810) 245-2400 Toll-free (800) HEATER-1 Fax (810) 664-7720 Canadian Operations Toll-free (800) 667-8900 Rev. 11/00 699540 (English) Website: www.webasto.
