Webasto DBW 2010 Bedienungsanleitung

– 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.

– NEVER attempt to install or repair a Webasto heating or cooling system unless you

have successfully completed the factory training course and have the technical skills,

technical information, tools and equipment required to properly complete the

necessary procedures.

– ALWAYS carefully follow Webasto installation and repair instructions and heed all

WARNINGS.

– Webasto rejects any liability for problems and damage caused by the system being

installed by untrained personnel.

CAUTION

Webasto BlueCool Premium

DBW 2010 - Chiller

Installation Manual

Table of Contents

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Contents Page

Foreword 4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety and Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Heater Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Heater Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation 9

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation Site / Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hose Connections to Chiller Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Heater Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Information about Air Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Circuit Diagrams 22

Initial Start-up 24

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Technical Data 25

Troubleshooting 26

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Heater Test Unit 440.280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Foreword

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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 towrite to us with their comments or criticisms concerning this manual or product. Thank you

for your participation.

Please write to us at:

Webasto Product North America, Inc.

Technical Documentation Group

15083 North Road

Fenton MI 48430

You are also invited to fill out our online questionnaire concerning our technical documentation and web site at:

www.techwebasto.com

If you have immediate questions concerning this manual, the installation procedures within or the product itself, please call

our technical support team at: (800) 860-7866 or send a fax to: (810) 593-6001

Scope and Purpose

This manual is intended to provide the information necessary to ensure proper installation and operation of the DBW 2010

in conjunction with the BlueCool Premium System. Improper installation can result in unsatisfactory performance and/or

premature failure of these units. BEFORE proceeding, please read this manual completely. In the interest of product

improvement, specifications and design are subject to change without prior notice.

Foreword

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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. The electrical power supply must be permanently disconnected before

any work is started on the systems.

The year in which the heater is used for the first time must be permanently recorded on the heater’s factory plate by deleting

the inapplicable year figures.

The heater must not be operated:

• In filling stations

• In places where explosive vapors or dust may build up (e.g. near fuel, coal, wood, or dust).

• In enclosed rooms (e.g. winter storage facilities)

The heater must not:

• Be exposed to temperatures of more than 248°F (120 °C) (storage temperature), otherwise the electronics may

suffer permanent damage.

The heater must:

• Be operated with the fuel specified on the factory plate.

• Be switched off if considerable quantities of smoke is generated, in case of unusual combustion noises or if you

smell fuel. Switch it off by removing the fuse. The heater must not be restarted until the unit has been checked by

personnel duly trained by Webasto.

• Be operated for 10 minutes at least once a month. The heater must be inspected by a specialist at the beginning of

the heating season or earlier.

Foreword

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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.

Indicates an imminently hazardous situation which, if not avoided,

WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

MAY result in minor or moderate injury or property damage.

It may also be used to alert against unsafe practices.

These symbols are used to alert the installer to important or useful information about proper

installation of the equipment.

Heater Description

DANGER

WARNING

CAUTION

Fig. 1 Heater Description of DBW 2010

1 Electronic control unit

2 Motor

3 Electronic ignition coil

4 Coupler

5 Combustion air fan

6 Solenoid valve

7 Electrode holder

8 Outlet water pipe (1 in. OD.)

9 Inlet water pipe (1 in. OD.)

10 Ignition electrodes

11 Fuel nozzle

12 Overheat fuse

13 Control thermostat

14 Overheat limiter

15 Heat exchanger

16 Exhaust pipe

17 Combustion air swirler

18 Combustion tube

19 Flame detection photocell

20 Fuel pump (single line, no return)

21 Fuel connection pipe (JIC #4)

22 Combustion air intake

23 Reduction gearing

24 Nozzle preheat cartridge

25 Preheat thermostat

26 Bleed screw

Foreword

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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

Foreword

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Packaged Components

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

Installation

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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.

• Radial blower on the heat exchanger (arranged on inlet side) up to 131°F (55 °C)

• For this reason, a DBW 2010 with a specialized control unit must be used. The heater has a pre-programmed

nominal temperature of 126°F (52 °C).

• DBW 2010 Heater – 12 volt diesel

• If the volume of water in the circuit is too small less than 2.5gal. (10 liters), the heating system may shut down

prematurely. To avoid this, a storage tank should be installed ahead of the heater.

• The heater is incorporated into the water circuit of the air conditioning unit by means of an additional, electrical 3-

way valve. Activation is controlled by the TECC card within the Webasto Blue Cool Premium (WBCP) air conditioning

unit.

• The heater is powered by 12 volt battery voltage. The heater is activated by the electronic control unit via a 12 volt

signal wire. The Webasto BlueCool Premium Air Conditioning Unit functions with 110 or 220 volts.

• The circulation pump (P1) operates continuously when the system is switched on. This means there is no need for

the circulating pump on the heater. As a result, it is integrated directly at the heater inlet. A cool down cycle is

assured from program version 413 of the TECC card onwards.

• The DBW 2010 offers excellent heat capacity to an air handler power up to 31,000 BTU.

• If an external heater is incorporated into a Webasto Blue Cool Premium System with an electrically operated 3-way

valve, function F 04:“Automatic with External Heater” or function F 05 “Heat Cycle Only with External

Heater” must be preset on the Chiller Control and the operating element must be blocked by a code.

• When connecting the heater, it is essential that the correct terminal is selected for the nominal temperature.

NOTE: If the vessels manufacturer has issued separate instructions, they must be followed.

Installation

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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 auto-

matically.

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. Lay supplied installation template in enclosure box. Mark the mounting hole location and exhaust location.

4. Drill 4 mounting holes (9 mm) and Exhaust hole 70 mm (2.75").

5. Bolt tray in enclosure box.

Fig. 5 DBW 2010 Mounting Angle Restrictions

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