Webasto BlueCool Premium DBW 2010 - Chiller Installation Manual CAUTION – 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.
Table of Contents Contents 3 Page Foreword 4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety and Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. We encourage our customers to write to us with their comments or criticisms concerning this manual or product. Thank you for your participation.
Foreword 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. All Webasto BlueCool (WBC) products are 110 or 220 volt components that are only allowed to be installed, connected and maintained by trained and duly certified personnel.
Foreword Symbol Identification The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures.
Foreword 7 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.
Foreword Packaged Components www.webasto.us Category Description Qty. Intake and Exhaust TUBE FLEX SS 38MM X 5M 1 THRU HULL FITTING 38MM 1 INSULATION TAPE 25FT 1 Manuals / Warranty INSTALL / OPERATION MANUAL P/N 5001077A 1 Heater Parts DBW 2010 MARINE ON TRAY 1 Parts Bag Mounting MOUNTING BRACKET KIT 1 Webasto Product N.A., Inc. www.techwebasto.
Installation 9 2. Installation General Information IMPORTANT • The DBW 2010 must be installed outside the passenger cabin. • The following temperature ranges apply to some components: • ABS pipe system (G. Fischer) and fittings from -40°F - 140°F (-40°C to +60°C). Use a pipe system designed for temperatures up to 248°F (120 °C), e.g. Hep2O made by Hepworth.
Installation 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 automatically. Fig. 5 DBW 2010 Mounting Angle Restrictions Mounting the Heater Step by Step: 1. Ensure that the enclosure is big enough to accommodate the heater. Use supplied installation template. 2. The installation housing must be provided with adequate ventilation [4 in² (20 cm²)]. 3.
Installation 11 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. Sea water filter 3. Webasto Blue Cool Premium Unit 110 / 220 volts 5. 3-way valve 6. Intermediate storage tank (optional) 7. Water heater – DBW 2010 126°F (52 °C) 8. Webasto BlueCool Air Handler 110 / 220 volts 10.
Installation Electrically actuated 3-way valve: Electrically actuated 3-way valves of the relevant sizes are used in chiller systems with up to 36,000 BTU. The selection is made according to the diameter of the pipe used. • 3-way valve 5/8" incl. fitting • 3-way valve 3/4" incl. fitting • 3-way valve 1" incl. fitting The hoses must be installed without kinks and (to ensure perfect bleeding) rising if possible. Hose connections must be supported by hose clips to prevent them slipping.
Installation 13 Fuel System The fuel is drawn from the vessels fuel tank through a fuel standpipe. This stand pipe can be utilized on vessels with a spare threaded port, or if no threaded port is available, a 1" hole can be drilled into the tank and the universal tank boss installed. Keep the fuel standpipe 2" from the bottom of the fuel tank. Fuel Supply The fuel can be used from the vessels fuel tank or from a separate fuel tank.
Installation Connection to Fuel Source The fuel can be taken from the vessels fuel tank or a separate tank Only use a tank connector if the fuel tank is made from metal Fig. 9 Fuel Standpipe Note: Use supplied hose clamps to secure connections. CAUTION Fuel lines must be secured every 12” and kept away from hot exhaust and moving parts. Since the lines cannot be routed with a constant rising gradient, the internal diameter must not exceed a certain size.
Installation 15 Combustion Air Supply WARNING Asphyxiation risk! The combustion air required for the heater may only be drawn in from the outside or from spaces that are not occupied by persons e.g. ventilated foredeck box or ventilated *engine compartment (Diesel only). The combustion air intake line (internal diameter at least 3.2” (80 mm) may be 1 1/2” (0.5 m) to 16 1/2” (5 m) long with several bends totalling 360°. The minimum bending radius is 1 3/4” (45 mm).
Installation Heater Exhaust Route the flexible exhaust 1.5” (38mm) in such a way that the heat cannot affect adjacent heat sensitive materials, plastic piping, electric cables and sails etc. Make sure to use the glass / silicon protective insulating sleeve supplied in the kit to ensure surrounding objects are protected. If additional protection is required, it is recommended to over-sleeve with an additional layer of insulation (available from your local Webasto marine dealer).
Installation 17 WARNING 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 • use condensation water drain • if desired, use an optional gas tight exhaust muffler to reduce interior noise CAUTION • DO NOT fit the skin fitting below the water line.
Installation Electrical System General Information Electrical connections are to be carried out in accordance with the circuit diagrams contained in this installation manual. When installing the electrical system make sure that the components are installed in protected, dry areas to prevent corrosion. If vessel only has one battery, we recommend a second battery be installed for the operation of the heater. To avoid having to charge the battery too often, its capacity should not be too small.
Installation 19 Deep Programming Mode: Numbering below in ** represent reference numbers in Fig 12. 14 Setting Code 2: 10. Programming Code 2: With unit on, lower temperature set-point to 59° F (15° C). 11. Turn the system off by pressing the - *14*. 12. Simultaneously press the and buttons - *11*. 13. Now in deep programming mode, hit the button twice. The number 2 will be displayed *15* on the left along with the current value code to the right *16*. e.g.
Installation 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.
Installation 21 Information about Air Guidance Inlets and outlets: In principle, the air guidance in the ship is designed for air conditioning operation. This means the air is extracted at floor level and blown out at ceiling level. By nature, cool air subsides so this arrangement provides a natural circulation of air. In heating mode, this circulation is weaker and, theoretically, the air is only circulated by the blower.
Circuit Diagrams 3. Circuit Diagrams Circuit diagram legend for the DBW 2010 6. Temperature coding (temperature at water outlet): Refer to following circuit diagram legend for further information. 7. Vessel Fuse 8. Vessel Blower Switch Cable cross-sections < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 0.75 mm2 1.0 mm2 1.0 mm2 1.5 mm2 1.5 mm2 2.5 mm2 2.5 mm2 4.0 mm2 4.0 mm2 6.
BATTERY NEGATIVE BATTERY POSITIVE (12 / 24V) TO T1 OF TECC CHILLER UNIT NOT USED NOT USED X4 BROWN BROWN H J BROWN WHITE BROWN G BROWN RED RED F E RED RED RED A C GREEN RED B BLACK F1 F2 F3 F4 RED/YELLOW RED/BLACK GREEN BLACK X1 X1 30 87 HR X2 85 86 S2 K1 BROWN GREEN t B6 B2 B5 B4 B3 B1 A2 C5 M2 BROWN TO C1 OF TECC CHILLER UNIT RED RED YELLOW BROWN BLUE A t 6 M 5 4 3 C1 C7 C4 2 B 1 C2 2 1 1 BROWN t S3 S4 4 5 6 5 3 4 C3 8 L1 2 1
Initial Start-up 4. Initial Start-up General After you have installed the heater, bleed the water system and the fuel supply system carefully. Conduct a trial of the heater to check all the water and fuel connections for leaks and to ensure that they are secure. If the heater suffers a fault during operation, the fault must be located and remedied.
Technical Data 25 5. Technical Data The following data is subject to the normal tolerance for heaters, if no tolerance is specified. This is approximately +/-10% in an ambient of 20 °C at nominal voltage. Heater DBW 2010 Design Coolant heater with high pressure nozzle Heat output BTU/hr. (kW) 45,000 (13.1) Fuel Diesel #1, Diesel #2 and Arctic Fuel Consumption l/hr. (gal/hr.) 1.5 (0.
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.
Troubleshooting 27 Test Procedures Setup - Remove connector blocks from heater control unit, inspect for loose wires, corrosion and proper wire connections. - Plug control unit connector blocks into tester. - Put heater switch/timer to “ON” and turn vessel heater valve to “FULL” mode (if equipped). - Proceed to component test procedures. WARNING Do not attempt to test or run heater with burner head open. Ensure burner head is properly closed and secured in place.
Troubleshooting Manual test run of heater - Turn WATER PUMP switch (4) “ON” - Turn MOTOR switch (5) “ON” - Push and hold FUEL SOLENOID VALVE button (7) “ON” (start fuel flow to combustion chamber) - Push and hold IGNITION SPARK COIL button (6) “ON” (starts electrodes sparking) until combustion has taken place.
Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.
Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.
Notes www.webasto.us Webasto Product N.A., Inc. www.techwebasto.
Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 Org. 10/2005 Rev. N/A P/N: 5001077A www.webasto.us www.techwebasto.
