303560C_DBW 2010 EA_degbfr.
1303560C_DBW 2010 EA_degbfr.book Page 1 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Inhaltsverzeichnis Sommaire 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . 1 Verwendung / Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Einbaubeispiel für DBW 2010 / 2016. . . . . . . . . . . . . . . . . . .
1303560C_DBW 2010 EA_degbfr.book Page 29 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 1 Statutory regulations governing installation Statutory regulations governing installation 1.1. Statutory regulations governing installation DBW 2010 / 2016 heaters have been type-tested and approved in accordance with EC Directives ECE-R 122 (heaters) and ECE-R 10 (EMC) with the following permit numbers: DBW 2010 EMV: E1 10R 03 1087 DBW 2016 EMV: E1 10R 03 1087 1.2.
1303560C_DBW 2010 EA_degbfr.book Page 30 Tuesday, March 5, 2013 9:05 AM Statutory regulations governing installation 5.3.2.5 Every reasonable precaution should be taken in positioning the heater to minimize the risk of injury and damage to personal property. 5.3.3 Fuel supply 5.3.3.1 The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage. 5.3.3.
1303560C_DBW 2010 EA_degbfr.book Page 31 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 2 Use / version Use / version 2.1. Use of the water heaters Webasto DBW 2010 / 2016 water heaters are used in connection with the vehicle’s own heating system 2.2. – to heat the passenger cabin, – to defrost the vehicle windows and – to preheat water-cooled engines.
1303560C_DBW 2010 EA_degbfr.book Page 32 Tuesday, March 5, 2013 9:05 AM Installation 3 Installation IMPORTANT: – The statutory regulations governing installation on pages 29 and 30 must be adhered to. – If the water heater is to be operated in a separately installed heating system, prior to installation an installation planning report must always be submitted to Webasto for approval. If this approval is not obtained, all warranty and liability claims will be void.
1303560C_DBW 2010 EA_degbfr.book Page 33 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Installation 8 1 5 2 3,4 6 8 6 Fig. 1: 1 2 3 4 5 6 7 8 Combustion air intake Exhaust outlet Fuel intake Fuel discharge Space required to remove the burner chamber Coolant intake Max.
1303560C_DBW 2010 EA_degbfr.book Page 34 Tuesday, March 5, 2013 9:05 AM Installation 3.2. To install DBW 2010 / 2016 heaters The heater may be secured either with four M8 screws or with four bolts and nuts (see Figure 3). Fig. 2: DBW 2010 / 2016 3.3. Model plate The model plate must be protected from damage and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used). Position Fig. 4: Fig.
1303560C_DBW 2010 EA_degbfr.book Page 35 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 4 Installation example for DBW 2010 / 2016 Installation example for DBW 2010 / 2016 Water heating circuit – wall heater and roof duct heating system 1 2 3 4 5 6 7 8 Wall heater with fan Heat exchanger at entry point Heater Circulating pump Roof heat exchanger Vehicle engine Driver’s position heating system Control element Forwards Backwards Fig.
1303560C_DBW 2010 EA_degbfr.book Page 36 Tuesday, March 5, 2013 9:05 AM To install the circulating pump 5 DBW 2010 / 2016 To install the circulating pump The circulating pump is installed as shown in Figure 7 (U 4810) and 9 (U 4840). Note the installation position. NOTE: The pump ports and connection lines from the water intake and water outlet must be flush (no stress). 5.1. U 4810 circulating pump Delivery rate (with water at 20 °C) Flow resistance (with the pump stopped) Fig.
1303560C_DBW 2010 EA_degbfr.book Page 37 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 5.2. To install the circulating pump U 4840 circulating pump bar 0,50 Delivery rate (with water/glycol 50/50 at +23 °C) 0,40 Δp 0,30 12/24V 0,20 0,10 2800 2450 2100 1750 1400 1050 700 350 0 0,00 l/h Q Fig. 8: Delivery rate U 4840 circulating pump Fig.
1303560C_DBW 2010 EA_degbfr.book Page 38 Tuesday, March 5, 2013 9:05 AM Connection to the vehicle cooling system 6 Connection to the vehicle cooling system The heater is connected to the vehicle cooling system as shown in Figures 1 and 5. The system must contain at least 10 litres of coolant. The water hoses supplied by Webasto must always be used. If you do not use these hoses, the hoses that you do use must comply with DIN 73411.
03560C_DBW 2010 EA_degbfr.book Page 39 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 7 Fuel supply Fuel supply The fuel is taken from the vehicle fuel tank or from a separate fuel tank. 7.1. Fuel lines Fuel lines are to be installed with a gradient wherever possible to prevent air inclusions. Connections within the line are to be secured with hose clips if no mechanical screw connectors are used. If fuel hoses are used, the hoses supplied by or available from Webasto must generally be used.
1303560C_DBW 2010 EA_degbfr.book Page 40 Tuesday, March 5, 2013 9:05 AM Fuel supply 7.1.1. Maximum dimensions of the fuel lines: – Internal diameter for intake and return line: 6 mm (other diameters to order). – Maximum line length for each intake and return line: 10 m – Maximum intake height: 2 m (we recommend the installation of a foot valve if the max. intake height is used) – Maximum supply pressure: 0.3 bar. 7.2.
1303560C_DBW 2010 EA_degbfr.book Page 41 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 8 Combustion air supply Combustion air supply Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt or snow and cannot suck in splashing water.
1303560C_DBW 2010 EA_degbfr.book Page 42 Tuesday, March 5, 2013 9:05 AM Exhaust pipe 9 Exhaust pipe The opening of the exhaust pipe must not point towards the front of the vehicle. The exhaust pipe opening must be located so that it cannot become clogged with snow and mud. Rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm or flexible piping of alloyed steel only must be used as the exhaust line.
1303560C_DBW 2010 EA_degbfr.book Page 43 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 10 Electrical connections Electrical connections 10.1. Heater connection IMPORTANT HIGH VOLTAGE: Danger of death. Disconnect the plug connection to the vehicle before you open the heater. The electrical connection of the heaters is made as shown in Figure 11 (DBW 2010) or Figure 12 (DBW 2016): System circuit for DBW 2010 / 2016 with SG 1553 control unit and switch.
1303560C_DBW 2010 EA_degbfr.book Page 44 Tuesday, March 5, 2013 9:05 AM Electrical connections Item A1 A2 4 5 Designation Heater Control unit Ignition spark generator Thermostat 7 8 Thermostat Thermostat 10 Ignition electrodes 61.
1303560C_DBW 2010 EA_degbfr.book Page 45 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white Electrical connections Cable cross-sections < 7.5 m 7.5 m–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 6.0 mm² Vehicle’s own cable Fig.
1303560C_DBW 2010 EA_degbfr.book Page 46 Tuesday, March 5, 2013 9:05 AM Electrical connections Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white DBW 2010 / 2016 Cable cross-sections < 7.5 m 7.5 m–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 6.0 mm² Vehicle’s own cable Fig.
1303560C_DBW 2010 EA_degbfr.book Page 47 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white Electrical connections Cable cross-sections < 7.5 m 7.5 m–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 6.0 mm² Vehicle’s own cable Fig.
1303560C_DBW 2010 EA_degbfr.book Page 48 Tuesday, March 5, 2013 9:05 AM Electrical connections Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white DBW 2010 / 2016 Cable cross-sections < 7.5 m 7.5 m–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 6.0 mm² Vehicle’s own cable Fig.
1303560C_DBW 2010 EA_degbfr.book Page 49 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Electrical connections X5 2 1 4 85 3 Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white 30 K6 86 87 Cable cross-sections < 7.5 m 7.5 m–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 6.0 mm² B5 R2 ws Vehicle’s own cable Fig.
1303560C_DBW 2010 EA_degbfr.book Page 50 Tuesday, March 5, 2013 9:05 AM Electrical connections DBW 2010 / 2016 Item 9 F2 F3 H1 H2 Cable colours bl br ge gn gr or rt sw vi ws NOTE Sample application in conjunction with circuit diagram Figures 11 – 13 blue brown yellow green grey orange red black violet white Cable cross-sections < 7.5 m 7.5 m–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.
1303560C_DBW 2010 EA_degbfr.book Page 51 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 11 Initial start-up Initial start-up NOTE: Refer to the safety instructions in the operating and maintenance instructions. The operating and maintenance instructions must be read through without fail before starting the heater. After you have installed the heater, bleed the water system and the fuel supply system carefully. Follow the instructions supplied by the vehicle manufacturer for this purpose.
1303560C_DBW 2010 EA_degbfr.book Page 52 Tuesday, March 5, 2013 9:05 AM Troubleshooting 12 Troubleshooting 12.1. Fault lock-out If it recognises one of the following fault features, the heater will conduct a fault lock-out. – If there is undervoltage, approx. 10 – 25 seconds after the voltage drops below the switching threshold. – If no combustion starts within approx.
1303560C_DBW 2010 EA_degbfr.book Page 53 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 13 Technical data Technical data Except where limit values are specified, these technical data refer to the usual heater tolerances of 10 % at an ambient temperature of +20 °C and at the rated voltage. 13.1. Fuel The diesel fuel specified by the manufacturer must be used (DIN EN 590). We know of no negative influences due to additives.
1303560C_DBW 2010 EA_degbfr.book Page 54 Tuesday, March 5, 2013 9:05 AM Technical data Heater ECE type permit number EMC: Heating system: Model Heating current Fuel Fuel consumption Rated voltage Operating voltage range Rated power consumption (without circulating pump) Max. ambient temperature during operation (Heater, control unit, circulating pump) Max. storage temperature (Heater, control unit, circulating pump) Max.
1303560C_DBW 2010 EA_degbfr.book Page 55 Tuesday, March 5, 2013 9:05 AM DBW 2010 / 2016 Circulating pump Delivery rate Rated voltage Operating voltage range Rated power consumption Dimensions (Tolerance 3 mm) Weight Technical data I/h VVW mm mm mm kg U 4810 1600 (against 0.15 bar) 12 or 24 10...14 or 20...28 25 Length 173 Width 94 Height 77 0.8 U 4840 1600 (against 0,1 bar) 12 or 24 9...15 or 16...
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