Coolant Heater - techwebasto

1 Coolant Heater DBW DBW Operating Instructions Installation Instructions Contents1. General Legal Provisions .. Meaning of Warning, Caution and 1022. Operating your Webasto DBW Switching Switching Engine Preheating .. Engine and Sleeper 2023. Technical Technical Enclosure Heater Dimensions .. 3044. General Installation Mounting the Heater .. Exhaust Pipe Connection .. Combustion Air Supply .. Plumbing the General Information .. Select Your Sleeper and Engine Block Heating .. Contents Engine Fuel General Description .. Fuel Supply and Return .. Fuel Filter .. Wiring General Information .. Power Connection to Timer and Switch Connections .. Sleeper Fan Wiring .. Wiring Diagram .. Initial 426 IDBW 2010 Contents5. Maintenance of the Annual 5016.

2 Basic Trouble General Heater Test Unit Test Procedures .. 602 IIContentsDBW DescriptionWebasto DBW 2010 The Webasto DBW 2010 is designed to be used on any diesel vehicle including: trucks, buses,construction, off-road and military equipment, generators and independent heating Coolant heaters for the following block preheatingof liquid cooled engines to ensure reliable starting in cold weather andto reduce cold start wear and emissions (white smoke). and engine blockheating with the engine off. The Heater will increase the driverscomfort in cold weather, cut down on unnecessary idling and reduce engine and transmissionwear, as well as, air and noise heatingwith the engine running. The Heater will boost the heating system in cold weatherwhen an engine is running at light loads, even at high speeds or idling. The heat rejection ofmodern diesel engines to the Coolant , especially in buses, is often no longer adequate to heatthe vehicle s 20101 Introduction1 Electronic control unit2 Motor3 Electronic ignition coil4 Clutch5 Combustion air fan6 Solenoid valve7 Electrode holder8 Outlet water pipe9 Inlet water pipe10 Ignition electrodes11 Fuel nozzle12 Overheat fuse13 Control thermostat14 Overheat limiter15 Heat exchanger16 Exhaust pipe17 Combustion air swirler18 Combustion tube19 Flame detection photocell20 Fuel pump21 Fuel pipes22 Combustion air intake23 Reduction gear24 Nozzle preheat cartridge25 Preheat thermostat26 Bleed heating- The Heater can be used in independent heating systems to protect valuablecargo (produce, beverages, paint) from Boat installation should only be performed by a Webasto authorized marine dealer.

3 It isthe dealers responsibility that the installation complies with all applicable Coast Guard of Warning, Caution and Note1021 IntroductionDBW 2010 WARNINGThis heading is used tohighlight that non-compliance withinstructions or proceduresmay cause injuries orlethal accidents heading is used tohighlight that non-compliance withinstructions or proceduresmay cause damage heading is used tohighlight and drawspecific attention installation must be performed in accordance with the manufacturer s deviations from this instructions are only permitted with the written approval fromWebasto Thermosystems is the dealers responsibility to approve installations not performed by Webasto not complying with the installation instructions release Webasto Thermosystems any product installations must be approved by Webasto Thermosystems your Webasto DBW 2010 Before switching the Webasto on, set vehicle heating system to the heat position and open any shut off valves.

4 Depending on the type ofcontrol installed in the dashboard of the vehicle, the Webasto can beoperated by the following OnUsing a timer:Using a switch:TimerSwitchUpon actuation of the instant heat button the operationindicator on the timer lights the switch is used for switching ON the Webasto, theoperation indicator integrated in the switch is Heater motor and Coolant circulating pump begin to run. Afterapproximately 10-25 seconds the solenoid valve opens and fuel issprayed into the combustion chamber. At the same time, the electronicignition coil produces high voltage (8000 V) and the mixture of fuel andair in the combustion chamber is ignited by a spark produced at the tipof the ignition electrodes. The flame is detected by the photo resistor,then the electronic ignition coil stops producing high voltage andcombustion continues by itself (spark on electrodes is only required toignite the flame).

5 At this point the Heater is working and produces Webasto will cycle on and off until:1. The Webasto is switched Time has elapsed on the The vehicle battery voltage drops below ( ).4. The Webasto runs out of A fault lock out occurs, indicated by the operating indicator lightbeing off during the cool down cycle ( overheat).201 DBW 20102 Operating your Webasto DBW 2010 WARNINGDue to the danger of poi-soning and asphyxiation theheater must not be oper-ated in enclosed spacessuch as garages or work-shops without adequate ex-haust Heater must beswitched OFF while refu-eling and at fueling not operate any We-basto Heater in an areawhere toxic or explosivematerials or fumes may Heater is being switchedon while the engine is warmonly the circulating pumpwill run, Coolant tempera-ture must fall below 140 F.(60 C.) before OffWhen heating is no longer required, switch the Webasto Heater solenoid valve interrupts the fuel supply, combustion stops andthe indicator light turns off.

6 The Combustion air fan and the waterpump remain on for another 2-3 minutes (after run cycle) purging thecombustion chamber of any Preheating1. Set the timer 30 min. to 1 hr. before you want to start engine. Theheater will start up at set time. (See timer operating instructions.)Or switch the toggle switch or instant on switch on your timer inthe vehicle dash to ON . The Heater will start When time is elapsed on your timer or engine preheat is no longerrequired, switch the Webasto Heater OFF . The DBW 2010 will gothrough the after-run and Sleeper Heating1. Switch the toggle switch (or the instant on button of the timer) inthe vehicle dash to ON . The Heater will start up if coolanttemperature is below 140 F. (60 C.). Above this temperature onlythe water pump will Turn ignition key to accessory position to power up your sleeper orswitch on Webasto Set the thermostat in the sleeper to desired temperature.

7 Switchsleeper fan to low position. The fan will cycle ON and OFF andmaintain selected sleepers with continuous fan operation a Webasto Thermostatand auxiliary bunk heat exchanger is heat exchanger kit 12V part # When engine and sleeper heating is no longer required, switch theWebasto OFF . The DBW 2010 will go through the after-run your Webasto DBW 2010 DBW 2010 NOTER estarting the Webastoduring the after-run periodis sleepers where theblower is cycled On andOff by the fan operationwill run down the vehiclebatteries with most factoryinstalled off unnecessaryequipment, radio,position lights, DataThe following data is subject to the normal tolerance for heaters, if notolerance is specified. This is approximately +/-10% in an ambient of20 C at nominal 2010 DesignCoolant Heater with high pressure nozzleHeat Output BTU/hr (kW)45,000 ( )FuelDiesel #1, Diesel #2 and ArcticFuel Consumption l/hr (gal/hr) ( )Rated Voltage (V)12 or 24 Operating Voltage (V)10 - 14 or 20 - 28 Power Consumption w/o Water pump (W) 60 Permissible Ambient Temperatureduring Operation C ( F)-40.

8 +60 (-40 .. +140)Storage Temperature C ( F)+85 max. (185 max.)Min. Capacity of Cooling System l (gal) 10 ( )Permissible Operating Pressure ofCoolant bar (psi)0,4-2(06-29)CO in Exhaust Gas ppm32CO in Exhaust Gas % by + in Exhaust Gas ppm70HC in Exhaust Gas ppm<5 Emission Bacharach1 Dimension ofLHeaterWmm (inch)H584 (23)205 ( )228 (9)Dimension ofLEnclosure Box and Tray MountWmm (inch)H610 (24)254 (10)300 ( )Weight with Enclosure Box kg (lb)29,5 (65)Weight on Tray kg (lb)21,3 (47)Weight of Heater incl. Control Unit kg (lb) 15(33)301 DBW 20103 Technical DataWater pumpU4846 ( magnetic drive )Flow Rate l/hr (gal/min)1650 (7) against 0,15 barRated Voltage (V)12 or 24 Power Consumption (W)28 DimensionsLmm (inch)WH128 ( )94 ( )82 ( )Weight kg (lb) ( )Hose connection mm (inch)20 ( ) DimensionsFoot print Enclosure box and tray mount kit3023 Technical DataDBW 2010 Enclosure box dimensionsTray mount dimensions303 DBW 20103 Technical DataWater pump mounting position3043 Technical DataDBW InformationWebasto will take you step by step through the installation process toensure successful operation for years to come.

9 The installation mustbe performed in accordance with the installation instructions providedin this LocationInstallation Locations1. Behind cab or On left/right side of the In an existing enclosure (tool box) on the Webasto should be installed as low as possible in the coolingsystem to assure static bleeding of the Heater and the Box Mounting angle401 DBW 20104 InstallationNOTE:This manual does notcover all possibleinstallations. For specialapplications use thismanual as a generalguideline only. Contact anauthorized Webasto dealeror WebastoThermosystems directly not install Heater insidethe circulating pump is notself the Heater is installed in an existing enclosure box other than theWebasto enclosure the installation template (enclosed) must be usedand adequate ventilation [4 in (20 cm )] must be the HeaterA. Enclosure box frame rail mounting1. Remove the enclosure Mark frame rail (522 mm, 20,55") and drill 2 holes ( 1/2") oneach Bolt angle brackets to frame rail (Webasto part # )4.

10 Bolt enclosure box to angle box mountingB. Tray Kit mounting in existing enclosure on vehicle, tool-box, battery Ensure that the enclosure is big enough to accommodate theheater. Use supplied installation The installation housing must be provided with adequate ventilation[4 in (20 cm )].3. Lay supplied installation template in enclosure box. Mark themounting hole location and exhaust Drill 4 mounting holes (9 mm) and Exhaust hole 70 mm (2,75").5. Bolt tray in enclosure 2010 WARNINGE xhaust pipes must be sorouted that the possibilityof exhaust fumes enteringthe vehicle is Heater must not beinstalled in either the driver scompartment or in the pas-senger area flexible exhausttubing # not weld anglebrackets to the mount Pipe Connection1. Insert supplied exhaust pipe to Heater and fasten exhaust clamp2. The discharge opening of the exhaust pipe must not point in thedirection of travel, and so located that any clogging caused bysnow or mud is not to be exhaust pipe 1 1/2" (38 mm) can have a length up to 16 (5 m)and may have several bends (totaling 270 ).