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Webasto DBW 2020 Manual

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DBW 2010
DBW 2020
DBW 300
Operating Instructions
Coolant Heaters
North American Headquarters
3333 John Conley Drive
Lapeer, MI 48446
Phone (810) 245-2400
Toll-free (800) HEATER-1
Fax (810) 664-7720
Canadian Operations
Toll-free (800) 667-8900
Website: www.webasto.com
Rev. 11/00 699540 (English)
I
WEBASTO DBW SERIES HEATERS
Introduction
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant Heater DBW 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Coolant Heaters DBW 2020 / 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Instructions
Operating your Webasto DBW Series Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation with 7-Day Digital Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setting the Digital Timer (Models 1529 & 1531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531) . . . . . . 14
Operation with 7-Day Electronic Timer Model CDN-1224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Timer Operation Modes (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONTENTS
II
WEBASTO DBW SERIES HEATERS CONTENTS
Dip Switch Programming (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Timer Operation (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance
Maintenance of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Basic Troubleshooting
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Malfunction Identification - DBW Series Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sequence of Events - DBW Series Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Heater Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
U 4810 and U 4846 Coolant Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
U 4814, U 4851 and U 4852 Coolant Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1
WEBASTO DBW SERIES HEATERS INTRODUCTION
Introduction
Important Information
• The heater must be installed according to the “Installation Instructions” and must be examined by an officially
recognized, Webasto authorized installation/ servicing facility.
• When the heater is installed in vehicles used for the transportation of dangerous or inflammable goods, or in
boats, the appropriate regulations must be observed.
• Webasto Thermosystems, Inc. does not recommend the installation and servicing of Webasto products by
untrained, unauthorized personnel or end-users.
• Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users will release
Webasto Thermosystems, Inc. and Webasto authorized distributors, dealers and personnel from responsibility for
damage to Webasto product or collateral property and personal injury.
• Any use, operation, installation, modification or application of the product not described in Webasto manuals, or
subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics
is misuse of the product.
• Failure to comply with all operation, installation, and servicing instructions is a misuse of Webasto product.
The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters
“Official Marks of Conformity.”
• In the vicinity of the coolant heater, a temperature of 185 °F (85 °C) must not be exceeded under any
circumstances (e.g. during body paint work). A violation of this temperature limit may cause permanent damage
to the electronics.
2
INTRODUCTIONWEBASTO DBW SERIES HEATERS
WARNING
Due to the danger of poisoning and suffocation, the heater must not be operated in enclosed areas, such as garages
or workshops, without an exhaust venting system, not even if the start-up is activated by the timer or remote start
device.
At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosions.
Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal grain deposits or similar
situations) the heater must be switched off to prevent explosions.
• When checking the coolant level, proceed in accordance with the vehicle manufacturer’s instructions.
• The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based
anti-freeze.
• The pressure setting of the coolant filler cap should be between 0.4 and 2 bar (6 p.s.i. and 28 p.s.i.).
• The coolant heater may only be operated within the specified operating voltage range designated by type.
• The coolant heater may only be operated with the specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene and
certain military spec. fuels).
• The operational state of the heater, i.e. an indication “On” or “Off”, must be clearly visible to the operator.
• If electrical welding is to be done on the vehicle, the main positive and negative feed cables should be
disconnected from the battery and securely connected to the chassis. This is necessary to protect the electronic
control unit from voltage surges.
3
WEBASTO DBW SERIES HEATERS INTRODUCTION
General Safety Regulations and Information
The general safety regulations for the prevention of accidents and relevant operating safety instructions must be
observed at all times. The specific safety regulations applicable to this manual are highlighted in the individual
chapters by Warnings, Cautions and Notes.
Meaning of Warnings, Cautions, and Notes
Warnings, Cautions and Notes in this manual have the following meaning:
NOTE:
This heading is used to highlight and draw specific attention to information.
CAUTION
This heading is used to highlight that non-compliance with instructions or procedures may cause damage to
equipment.
WARNING
This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal
accidents to personnel.
4
INTRODUCTIONWEBASTO DBW SERIES HEATERS
WEBASTO DBW SERIES HEATERS DESCRIPTION
General Description
1 Electronic control unit
2 Motor
3 Electronic ignition coil
4 Coupler
5 Combustion air fan
6 Fuel solenoid valve
7 Electrode holder
8 Coolant outlet
9 Coolant inlet
10 Ignition electrodes
11 Fuel nozzle
12 Overheat fuse (white wires)
13 Control thermostat
14 Temperature limiter
15 Heat exchangers
16 Combustion chamber
17 Combustion air swirler
18 Exhaust pipe
19 Flame detector
20 Fuel pump
21 Fuel supply/ return pipes
22 Combustion air adjusting shutter
23 Fuel pump drive gearing
24 Nozzle pre-heater
25 Preheat thermostat (blue & green wires)
26 Air bleed screw
Fig. 1: Major Components of the DBW 2010 Coolant Heater
5
12345
23
6
25
7
24
81011 12
13
14
9
26
22 21 20 19 18 17 16 15
Coolant Heater DBW 2010
DESCRIPTIONWEBASTO DBW SERIES HEATERS
6
1 Electronic control unit
2 Motor
3 Electronic ignition coil
4 Coupler
5 Combustion air fan
6 Fuel solenoid valve
7 Electrode holder
8 Coolant inlet
9 Ignition electrodes
10 Fuel nozzle
11 Overheat fuse (white wires)
12 Control thermostat
13 Temperature limiter
14 Coolant outlet
15 Heat exchangers
16 Combustion chamber
17 Combustion air swirler
18 Exhaust pipe
19 Flame detector
20 Fuel pump
21 Fuel supply/ return pipes
22 Combustion air adjusting shutter
Fig. 2: Major Components of the DBW 2020 / 300 Coolant Heaters
1 2 3 4 5 6 7 8 10 11 12 13 149
22 21 20 19 18 17 16 15
Coolant Heaters DBW 2020 / 300
OPERATING INSTRUCTIONS
Operating Instructions
Operating your Webasto DBW Series Heater
WARNING
Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces
such as garages and workshops without adequate exhaust extraction.
WARNING
Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations.
WARNING
Due to the risk of explosion, the heater must never be operated in areas where explosive materials, fumes or dusts
may be present.
7
WEBASTO DBW SERIES HEATERS
28
BASIC TROUBLESHOOTINGWEBASTO DBW SERIES HEATERS
Malfunctions
The DBW Series of coolant heaters are designed with automatic, self-monitoring systems that will shut the heater off
in the event of a problem.
The heater will switch itself off automatically if combustion does not start after the heater has been switched on, or if
the flame goes out, or if the heater overheats. The operation indicator light will go out to signify a problem.
The following steps can be taken to determine and correct obvious problems.
If the operation indicator light does not come on at the same time as the heater is switched on, check and, if
necessary, replace fuse (F2). If the operation indicator light comes on when the heater is switched on, but goes out
after about 30 seconds, check and, if necessary, replace fuse (F3).
If overheating has occurred, locate and correct the problem. On the DBW 2010 Arctic, DBW 2020 and DBW 300
series heaters, it may be necessary to replace the overheat melt fuse located under the thermostat cover on top of
the heater. The fuse can be identified by the two white wires protruding from its top. The fuse is screwed hand tight
into a dry well plug. Do not over tighten the fuse when replacing. On all other DBW 2010 heaters not equipped with
an overheat fuse, simply correct the cause of overheating and allow the heater to cool down.
If a lock-out condition occurs due to a malfunction, this condition can be cleared and the control unit reset by
switching the heater off and switching it back on again. If the heater goes to lock-out once again after correcting all
obvious problems, consult your nearest Webasto Service Station.
NOTE:
In most heater models, the fuses referred to in the above paragraph can be located on the back wall of the heater
enclosure or are tray. Some models may also utilize a 30 amp. main fuse at the battery connection.
… 31 …


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