Water Heaters Installation Instructions BBW 46 DBW 46 Be sure to read these Operating Instructions prior to putting the heater into operation.
BBW 46 / DBW 46 Table of Contents Page Installation Instructions 1 Legal Provisions 1 Installation Location 2 Installation Example BBW 46 / DBW 46 3 Connection to the Cooling System 5 Re-Positioning of Circulating Pump 5 Fuel Circuit Connection 5 Combustion Air Supply 8 Exhaust Gas Pipe 8 Electrical Connections 8 Allocation of Telestart T60 9 Installation of Telestart Receiver 9 Circuit Diagrams 12 Initial Start-Up 13 Technical Data 14 Version 15 I
BBW 46 / DBW 46 Installation Instructions Legal Provisions for Installation For testing the heater in accordance with Section 19, 20 or 21 StVZO (German Regulations Authorising the Use of Vehicles for Road Traffic) the following regulations are primarily to be observed (Section 22 a StVZO): NOTE: These provisions are binding within the scope of the StVZO and should also be observed in countries where no special locally applicable regulations are in effect! Within the scope of the StVZO ”General Design Certi
BBW 46 / DBW 46 Installation Location 2 Preferably, the heater should be installed in the engine compartment in the splash-water protected area of the front fenders or at the splash wall. The heater should be installed at a level as low as possible so as to ensure automatic venting of the heater and the circulating pump. . This is of special importance since the circulating pump is not of the self-priming type.
BBW 46 / DBW 46 Cable harness Fuel line Heater fuel line Exhaust gas line Water circuit Fig 3: 1 2 3 4 5 6 7 Installation example of BBW 46 / DBW 46 heating device in a passenger car (inline integration) Radiator Cooling water thermostat Water pump (of vehicle engine) Vehicle engine with standard equipment Water heater Battery Fuse holder 8 9 10 11 12 13 14 Control unit Relay (for vehicle fan) Regulating valve of vehicle heating Heat exchanger of vehicle heating Vehicle heating fan Switch for vehicle
BBW 46 / DBW 46 Cable harness Fuel line Heater fuel line Exhaust gas line Water circuit Fig 4: 1 2 3 4 5 5A 6 4 Installation example of BBW 46 / DBW 46 heating device in a passenger car (thermostat integration) Radiator Cooling water thermostat Water pump(of vehicle engine) Vehicle engine with standard equipment Water heater Non-return valve Battery 7 8 9 10 11 12 13 Fuse holder Control unit Relay (for vehicle fan) Regulating valve for vehicle heating Heat exchanger, vehicle heating Vehicle heating
BBW 46 / DBW 46 Connection to the Vehicle’s Cooling System The integration of the heater into the cooling circuit is to be performed in the flow line of the vehicle’s heat exchanger. The heater is to be connected to the vehicle’s cooling system in accordance with Figs 3, 4, 5 and 6. A minimum of 4 litres of coolant must be maintained in the cooling circuit.
BBW 46 / DBW 46 Fuel Supply Details on the permissible pressure at the fuel extraction point are contained in the table below. Permissible fuel feed height H (m) at max. permissible overpressure (bar) in fuel line 0.00 1.5 1.25 1.4 2.50 1.3 3.75 1.2 5.00 1.1 6.25 1.0 7.50 0.9 l2 l1 to engine from tank 8.75 0.8 10.00 0.7 Permissible fuel suction height S (m) at max. permissible underpressure (bar) in fuel tank petrol diesel l2 l1 0.00 -0.15 -0.15 0.50 -0.11 -0.11 1.00 – -0.
BBW 46 / DBW 46 If the heater is installed in vehicles with petrol injection systems it must therefore be determined whether whether the fuel pump is mounted inside or outside the tank. Where the fuel pump is located inside the tank, the fuel can only be drawn from the return pipe in which case it must be ensured that the return pipe extends almost to the bottom of the tank. If this is not the case, it is possible to extend the return pipe.
BBW 46 / DBW 46 Combustion Air Supply Electrical Connections The combustion air required must be drawn in from the outside of the vehicle. Control Unit/Heater Connection The electrical connection of the heaters is to be performed in accordance with Fig. 16. The combustion air should be drawn in at a splash-water protected location. The combustion air intake opening must be so located that the possibility of clogging due to contamination is remote. It must not point in the direction of travel.
BBW 46 / DBW 46 Tuning of Telestart T60 Handheld Transmitter and Receiver NOTE: Each receiver can be allocated 2 handheld transmitters. Wait 5 seconds - Briefly press the ”Start” button. Start - Place batteries in battery compartment. - Pull antenna out of transmitter approx. 5 cm. Operation indicator on transmitter is flashing. Wait 15 seconds 25 1 A 5 1 A A - Briefly press the ”Off” button. Wait 10 seconds Interrupt voltage supply for at least 10 seconds by removing the 15A flat fuse (blue).
BBW 46 / DBW 46 Installation of Antenna NOTE: Preferably, the antenna should be installed in the interior of the vehicle, at the top in the centre of the windshield or rear window. If installed at different locations, the range is likely to be diminished. For an optimal reception, a distance of 2 ± 0.5 cm from the windshield edge is to be maintained (Fig. 15). The cable should be routed upward, beneath the panelling in the vehicle roof and then directed to the right or left to the chassis member.
BBW 46 / DBW 46 B1 E B2 R1 X1 F3 5 2 6 3 M2 B C 2 1 4 1 D 8 4 2 1 (75) 15 30 61 W1 rt A M1 7 3 6 2 W1 sw/rt F4 X1 Y1 3 4 vi 4 2 5 br 5 gn/ws 6 1 W1 2 1 2 3 6 4 1 7 8 S3 rt/bl X2 Y2 P 5 9 5 2 ge 8 rt bl br 8 ge A2 1 3 gr 6 X1 3 2 7 ge X1 4 F2 F1 1 7 sw br 8 10 12 7 9 11 A 2 bl/ge 6 rt 6 5 4 3 2 1 5 1 B3 12V 24V Y W1 R2 rt ws/sw 87 K7 87 br br br 86 85 30 br sw E2 S2 F3 ϑ A1 M M2 M1 10 ge X2 1 2 ge ws 9 ϑ R1 M 7
BBW 46 / DBW 46 Wire Colours Wire Cross-Sections < 7.5 m 0.5 mm 2 0.75 mm 1.5 mm 2.5 mm 4.0 mm 12 7.5 - 15 m 2 2 2 2 0.75 mm 1.5 mm 2.5 mm 4.0 mm 6.0 mm 2 2 2 2 2 bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white Pos.
BBW 46 / DBW 46 Initial Operation Malfunctions Fault Lock-Out Due to Undervoltage NOTE: The safety information contained in the Operating Instructions have to be adhered to! Fault Lock-Out Due to Malfunctions of the Heater In the case of an undervoltage of 9.5 ± 0.
BBW 46 / DBW 46 Technical Data Unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient temperature of +20°C and at the rated voltage. Fuel for BBW 46 (Petrol): The type of fuel specified by the vehicle manufacturer is suitable as fuel for the heater. Fuel for DBW 46 (Diesel): The diesel fuel specified by the vehicle manufacturer is suitable as fuel for the heater.
BBW 46 / DBW 46 Version Type DBW 46 Supplementary Heater Water heater for ”diesel” fuel Type BBW 46 Supplementary Heater Water heater for ”petrol” fuel The BBW 46 / DBW 46 water heaters are designed for 12-volt or 24-volt operation.
