Technical data

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List of Contents

BBW46/DBW46

List of Contents

1. Introduction

1.1 Scope and Purpose ............................................................................................................................... 101

1.2 Meaning of Warnings, Cautions, and Notes .......................................................................................... 101

1.3 Additional Documentation to be used .................................................................................................... 101

1.4 Safety Information and Regulations....................................................................................................... 101

1.4.1 General Safety Notes .................................................................................................................. 101

1.5 Legal Provisions for Installation ............................................................................................................. 102

1.6 Corrections and Improvements.............................................................................................................. 103

2. General Description

2.1 Combustion Air Fan with Intake Muffler................................................................................................. 202

2.2 Heat Exchanger ..................................................................................................................................... 202

2.3 Burner Head with Combustion Pipe....................................................................................................... 202

2.4 Circulation Pump.................................................................................................................................... 202

2.5 Flame Sensor......................................................................................................................................... 203

2.6 Glow Plug............................................................................................................................................... 203

2.7 Temperature Sensor.............................................................................................................................. 203

2.8 Temperature Limiter............................................................................................................................... 203

2.9 Temperature Fuse ................................................................................................................................. 203

3. Functional Description

3.1 Sequence of Operation.......................................................................................................................... 301

3.1.1 Switch On .................................................................................................................................... 301

3.1.2 Combustion Operation................................................................................................................. 301

3.1.3 Switch Off .................................................................................................................................... 302

3.1.4 Error Lockout ............................................................................................................................... 302

4. Technical Data

................................................................................................................................................ 401

5. Troubleshooting

5.1 General .................................................................................................................................................. 501

5.2 General Fault Symptoms ....................................................................................................................... 501

6. Functional Checkouts

6.1 General .................................................................................................................................................. 601

6.2 Adjustments ........................................................................................................................................... 601

6.2.1 Adjustment of CO

Contents ....................................................................................................... 601

6.3 Components Testing.............................................................................................................................. 601

6.3.1 Temperature Sensor Resistance Check...................................................................................... 601

6.3.2 Flame Sensor Check ................................................................................................................... 601

7. Circuit Diagrams

7.1 General .................................................................................................................................................. 701

Summary of content (40 pages)

PAGE 1
BBW 46 / DBW 46 List of Contents List of Contents 1. Introduction 1.1 1.2 1.3 1.4 Scope and Purpose ............................................................................................................................... 101 Meaning of Warnings, Cautions, and Notes .......................................................................................... 101 Additional Documentation to be used ....................................................................................................
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BBW 46 / DBW 46 8. List of Contents Servicing 8.1 8.2 8.3 8.4 8.5 8.6 General ...................................................................................................................................................801 Work on the Heater.................................................................................................................................801 Work on the Vehicle..............................................................................................................
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BBW 46 / DBW 46 List of Figures List of Figures 301 Functional Diagram..................................................................................................................................... 303 501 General Failure Symptoms ......................................................................................................................... 501 701 702 Connector Pin Assignment ..............................................................................................................
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BBW 46 / DBW 46 1. 1.1 Introduction Scope and Purpose This repair shop manual is intended to support familiarised personnel in the repair of water heaters BBW 46 and DBW 46 of the fuel and Diesel type. The heater may only be operated with the specified type of fuel (Diesel or with fuel oil EL) and the appropriate type of electrical installation. 1.
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BBW 46 / DBW 46 1 Introduction The heater must not be installed in the passenger or driver compartments of vehicles. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior. There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 60 °C in the installation box. Excessive temperatures may cause malfunctions.
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BBW 46 / DBW 46 • Fuel reservoirs for carburettor fuel must not be located immediately behind the vehicle front fairing. They must be away from the engine to prevent fuel fires in case of accidents. This does not apply to towing vehicles with open cockpit. All fuel reservoirs offered in the Webasto Accessories Catalogue are suitable for a maximum operating pressure of 0.15 bar overpressure.
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BBW 46 / DBW 46 2.
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BBW 46 / DBW 46 2 General Description 2.1 Combustion Air Fan with Intake Muffler The combustion air fan delivers the air required for combustion through the intake muffler to the burner head. For combustion air control an adjustment screw is provided on the combustion air fan housing. 2.3 Burner Head with Combustion Pipe Within the burner head and combustion pipe the fuel is conditioned, ignited and burned. This process heats the coolant via the heat exchanger. Burner Head with Combustion Pipe 2.
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BBW 46 / DBW 46 2.5 2 General Description Flame Sensor 2.7 The flame sensor consists of a photo transistor protected by a pipe. After flame-up the pipe starts to glow so that the sensor signals "flame". The flame sensor monitors the flame condition throughout heater operation. Temperature Sensor The temperature sensor consists of an aluminium sleeve with an integral silicon PTC sensor. The flame sensor senses the coolant temperature in the heat exchanger of the heater as an electrical resistance.
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BBW 46 / DBW 46 3 Functional Description 3. Functional Description 3.1 Sequence of Operation The control units with order no. 230 04_ and 230 05_ have the glow cycling integrated with no influence on the sampling within the control unit. 3.1.2 Combustion Operation 3.1.1 Switch On Upon switch on positive control voltage is applied from the battery across F2 and terminal A5 to the electronics of the control unit. – operating indicator light H1 illuminates.
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BBW 46 / DBW 46 3 Functional Description NOTE The heater may also remain in part load, full load or control idle operation for longer periods after achieving a balance between generation and use of heat. Also the control sequences for full load/part load and part load/control idle may alternate dependent on the heat required (see functional diagram). 3.1.3 Switch Off 3.1.3.1 Heater is in Combustion Operation – After switch off the operation indicator (H1) extinguishes.
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BBW 46 / DBW 46 1a 2a 1 2 A B C D E F °C 3 Functional Description 4 3 6 5 8 7 8 6 10 9 2 11 *55 78 70 78 86 4 3 6 13 10 5 12 9 70 Fig.
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BBW 46 / DBW 46 4. 4 Technical Data Technical Data Electrical Components: Where no threshold values are specified technical data are understood to include standard tolerances for heater units of ± 10 % at an ambient temperature of +20 °C and at nominal voltage. Heater Control unit, motors for combustion air fan and circulation pump, glow plug, dosing pump, switch and timer are either 12 Volt or 24 Volt components.
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BBW 46 / DBW 46 5. Troubleshooting 5.1 General 5 Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components. The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunction: This section describes troubleshooting procedures for the heaters BBW 46 and DBW 46.
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BBW 46 / DBW 46 6 Functional Checkouts 6. Functional Checkouts 6.1 General 6.3.2 Flame Sensor Check This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. During electrical testing with a digital multimeter the flame sensor readings should be as follows: flame sensor "dark" approx. 12 V or 24 V flame sensor "bright" approx. 1 V. Heater On 12 V or 24 V after 14...
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BBW 46 / DBW 46 7. Circuit Diagrams 7.1 General 7 Circuit Diagrams Circuit diagram (Fig. 702) shows possible heater circuits for the heater BBW 46 and DBW 46. Fig. 701 presents the pin assignment.
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BBW 46 / DBW 46 7 Circuit Diagrams A M1 M2 B 5 2 6 3 C 2 1 4 1 2 1 (75) 15 30 61 W1 F4 X1 Y1 D 8 4 rt B1 E B2 R1 X1 F3 7 3 3 4 vi 4 5 br 5 6 rt 6 7 sw 7 8 ge 8 sw/rt 2 1 W1 2 1 2 3 6 4 1 7 8 S3 B3 rt/bl 5 2 12V 24V Y W1 R2 F3 S2 A1 M M2 9 10 X2 ge ws 7 1 R1 M M1 B1 B2 31 Wire Colours Wire Gauges < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 2.5 mm2 4.0 mm2 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.
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BBW 46 / DBW 46 8. Servicing 8.1 General 8 Servicing 8.4 Heater Test Run The heater must not be operated, not even with the timer, in enclosed areas like garages or workshops not provided with exhaust ventilation facilities. This section describes the servicing procedures allowed on the heater when installed. 8.5 8.
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BBW 46 / DBW 46 8 Servicing 8.6 Visual Inspections and Installation Regulations After replacing the coolant ensure that the cooling system is bled thoroughly. The heater and hoses must be installed so that a static venting is guaranteed. 8.6.1 Connection to the Vehicle Cooling System Insufficient venting may cause malfunctions during operation by overheating. The installation location of the heater should be as low as possible to ensure self-venting of the heater and circulation pump.
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BBW 46 / DBW 46 8 Servicing Wiring harness Vehicle fuel line Heater fuel line Exhaust line Water circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Radiator Coolant thermostat Water pump Vehicle engine with standard outfit Water heater Battery Fuse holder Control unit Relay (for vehicle air fan) Control valve of vehicle heating system Heat exchanger of vehicle heating system Air fan of vehicle heating system Switch for air fan of vehicle heating system Fusebox in vehicle Timer Fuel tapping Dosing p
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BBW 46 / DBW 46 8 Servicing Wiring harness Vehicle fuel line Heater fuel line Exhaust line Water circuit 1 2 3 4 5 5A 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Radiator Coolant thermostat Water pump Vehicle engine with standard outfit Water heater Check valve Battery Fuse holder Control unit Relay (for vehicle air fan) Control valve of vehicle heating system Heat exchanger of vehicle heating system Air fan of vehicle heating system Switch for air fan of vehicle heating system Fusebox in vehicle Timer Fue
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BBW 46 / DBW 46 8 Servicing 8.6.2 Connection to Vehicle Fuel System In vehicles with carburettor or fuel injection including a return line the heater fuel system integration must be in the return line. Carburettor engines without return line must have the heater integrated in the fuel system's fuel supply line between fuel tank and vehicle fuel pump. A fuel supply line can normally be identified by its fuel filter. The following table lists the pressures permitted at the fuel tapping location.
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BBW 46 / DBW 46 8 Servicing Air or gas bubbles may build up in the vehicle fuel line in case the carburettor or the fuel pump is leaking or if ambient temperatures exceed the fuel evaporation temperature. Plastic Tank The fuel tap should not be located near the engine, as gas bubbles may build up due to the heat radiated by the engine resulting in malfunctions of combustion operation.
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BBW 46 / DBW 46 8 Servicing 8.6.3.2 Installation and Attachment The dosing pump is to be attached with anti-vibration mounts. The installation location is limited according to Fig. 808 to ensure sufficient self-venting capability. correct hose clamp 8.6.4 Fuel Filter wrong bubble bubble If there is the probability of contaminated fuel only the Webasto filter, order no. 487 171, may be used. Installation possibly vertical up to horizontal the most (observe direction of flow). 8.6.
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BBW 46 / DBW 46 8 Servicing 8.7.1 Removal and Installation of Heater 8.7.1.1 Removal 1. Disconnect vehicle battery. 2. Remove top cover (see 9.2.1). WARNING Allow coolant to cool down sufficiently to prevent skin burns. Also depressurise cooling system and refit cap afterwards. 10° 10° Direction of exhaust flow nearly 90° ± 10° Fig. 809 Installation Arrangement of Exhaust Pipe Outlet Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.
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8 Servicing 8.7.3 Replacement of Temperature Limiter or Temperature Fuse BBW 46 / DBW 46 8.7.6 Replacement of Flame Sensor NOTE The replacement procedure for the flame sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.5. NOTE The replacement procedure for the temperature limiter is identical with the heater installed or removed. Perform replacement in accordance with 9.2.2 or 9.2.3 as applicable. 8.7.
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BBW 46 / DBW 46 8 Servicing 8.8 First Operation After heater installation the coolant circuit and the fuel supply system must be thoroughly bled observing manufacturer's instructions. During the test run of the air heater all coolant and fuel line connections are to be checked for no leakage and tight fit. The coolant line connections (20 - 27 mm Ø) are to be re-tightened with a torque of 2.0 + 0.5 Nm.
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BBW 46 / DBW 46 9. Repair 9.1 General 9 Repair NOTE Prior to glow plug installation apply high temperature grease Copaslip or copper paste to thread. This section describes the repairs that may be performed on the heater BBW 46/DBW 46 when removed. Any further disassembly will void the warranty. For re-assembly only components of the original spare part kits are to be used. 9.1.
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BBW 46 / DBW 46 9 Repair 9.1.2.1 Replacement of Temperature Fuse against Temperature Limiter with Reset 5 General Several reasons (e.g. unfavourable installation location, wrong manual control during operation) favour the premature response of the temperature fuse. Therefore we recommend the replacement of the temperature fuse (1) against a temperature limiter with a reset facility (2). This component may be ordered with order no. 14865A.
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BBW 46 / DBW 46 9 Repair 9.2.1.2 Making Electrical Connections 3. Press electrical cables into grommet as shown in figure. Slide grommet with cables into top cover. 1. Making electrical connection of round connector: Insert connector pins into connector lower part of connector. Connector pins must not be interchanged. Press lower part of connector into upper part until locked. 4. Slide top cover into rear locking wedge first, push against direction of arrow and then press into forward locking wedge.
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BBW 46 / DBW 46 9 Repair 9.2.2 Replacement of Temperature Limiter NOTE The temperature limiter is installed only on heaters from June 1988 and up or starting from serial number 71771 (BBW 46) and 38177 (DBW 46) or after performing the modification (see 9.1.2.1). 9.2.2.1 Removal 1. Remove heater (see 8.7.1.1) 2. Break electrical connections (see 9.2.1.1).
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BBW 46 / DBW 46 9.2.2.2 Installation 1. Apply Copaslip (Ident. No. 105898) to thread of temperature limiter (2, Fig. 902) and manually screw into heat exchanger (9). 2. Using a fork wrench tighten temperature limiter (2) with a third of a turn. Maximum torque 1.5 Nm. 3. Fit protective cap (1). 4. Make electrical connections (see 9.2.1.2). 5. Install heater (see 8.7.1.2). 9 Repair 3. Unscrew temperature sensor (8, Fig. 902) and remove together with O-ring (7). 4.
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BBW 46 / DBW 46 9 Repair 9.2.6.1 Removal 9.2.6.2 Installation 1. 2. 3. 4. 5. Remove heater (see 8.7.1.1). Break electrical connections (see 9.2.1.1). Open clamping ring (3, Fig. 903). Remove circulation pump (2) and gasket (1). Perform procedures on components after disassembly (refer to 9.1.1). 1. Remove deposits form water inlet of heat exchanger. 2. Apply Copaslip (Ident. No. 105898) to new gasket (1) and locate on connector pipe. 3.
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BBW 46 / DBW 46 9 Repair 9.2.7 Replacement of Combustion Air Fan 9.2.7.2 Installation 9.2.7.1 Removal 1. Locate combustion air fan (1, Fig. 904) for assembly and slide onto air intake muffler (5) and burner head (7). 2. Screw hexagon socket head cap screws (6) into burner head and torque to 4.5 Nm. 3. Tighten hose clamp (4) on air intake muffler (5). 4. Make electrical connections (see 9.2.1.2). 5. Secure cable with cable tie (2). 6. Install heater (see 8.7.1.2). 7.
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BBW 46 / DBW 46 9 Repair 9.2.8 Replacement of Glow Plug 9.2.8.2 Installation 9.2.8.1 Removal NOTE Observe remarks on glow plug replacement (see 9.1.1.3). 1. 2. 3. 4. 5. Remove heater (see 8.7.1.1). Break electrical connections (see 9.2.1.1). Pull wiring harness (2, Fig. 905) from glow plug (1). Unscrew glow plug (1) from burner head (3). Perform procedures on components after disassembly (refer to 9.1.1). 1. Apply Copaslip (Ident. No. 105898) or copper paste to thread of glow plug. 2.
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BBW 46 / DBW 46 9 Repair 9.2.9.2 Installation 9.2.9 Replacement of Burner Head with Combustion Pipe 9.2.9.1 Removal 1. 2. 3. 4. 5. 6. 7. Remove heater (see 8.7.1.1). Break electrical connections (see 9.2.1.1). Remove combustion air fan (see 9.2.7.1). Remove glow plug (see 9.2.8.1). Remove flame sensor (see 9.2.5.1). Remove V-clamp (2, Fig. 906). Engage two screw drivers in recess (4) and lever off burner head (1) and remove. 8. Perform procedures on components after disassembly (refer to 9.1.1).
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BBW 46 / DBW 46 9 Repair 9.2.10 Disassembly of Heat Exchanger 9.2.10.2 Assembly 9.2.10.1 Removal 1. Apply Copaslip (Ident. No. 105898) to mating surfaces between heating pipe (1, Fig. 907) and heat exchanger (4). 2. Fit new O-ring (2), slide heating pipe (1) into heat exchanger (4) and locate for assembly. 3. Install burner head with combustion pipe (see 9.2.9.2). 4. Install temperature sensor (see 9.2.4.2). 5. Install temperature limiter or temperature fuse as applicable (see 9.2.2.2 or 9.2.3.2). 6.
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BBW 46 / DBW 46 9 Repair 9.2.11 Replacement of Felt Disk in Burner Head 9.2.11.1 Removal 1. Remove heater (see 8.7.1.1). 2. Press clamping spring (6, Fig. 908) from locking pegs (9) using screw driver. 3. Engage two screw drivers in recesses (7) and lever off cover (1). 4. Discard O-ring (2) and gasket (8). 5. Remove felt disk (3) and ring (4) from burner head (5) and discard. 6. Check burner head for felt deposits and contamination and remove as required. 7. Clean glow plug orifice (10), diameter 2.5 mm.
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BBW 46 / DBW 46 9 Repair Ring must not touch glow plug to prevent short circuit During installation on burner head ensure tension spring During installation onsafely on engages firmly and burner lockinghead pegsensure to prevent clamping danger ofspring fires engages firmly and safely on locking pegs to prevent danger of fires Groove must engage Holes covered Groove must engage Ensure ring seats flush in accordance with dimensions shown.
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BBW 46 / DBW 46 10. 10 Packaging, Storage and Shipping Packaging, Storage and Shipping 10.1 General The heater or its components shipped to Webasto Thermosysteme GmbH for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and storage. CAUTION When shipping a complete heater assembly it must be drained completely. No fuel or coolant is allowed to escape during packaging or shipping. Dummy plugs must be fitted to the coolant line connections.