Water Heaters Installation Instructions
BBW 46
DBW 46
Be sure to read these Operating Instructions
prior to putting the heater into operation.
9/1998
BBW 46 / DBW 46
Table of Contents
Page
Installation Instructions 1
Legal Provisions 1
Installation Location 2
Installation Example
BBW 46 / DBW 46 3
Connection to the Cooling System 5
Re-Positioning of Circulating Pump 5
Fuel Circuit Connection 5
Combustion Air Supply 8
Exhaust Gas Pipe 8
Electrical Connections 8
Allocation of Telestart T60 9
Installation of Telestart Receiver 9
Circuit Diagrams 12
Initial Start-Up 13
Technical Data 14
Version 15
I
Installation Instructions
Legal Provisions for Installation
For testing the heater in accordance with Section 19, 20 or
21 StVZO (German Regulations Authorising the Use of Vehicles for Road Traffic) the following regulations are primarily to be observed (Section 22 a StVZO):
NOTE:
These provisions are binding within the scope of the
StVZO and should also be observed in countries
where no special locally applicable regulations are in
effect!
Within the scope of the StVZO ”General Design Certifications” have been granted by the Federal Office for Motor
Traffic for the BBW 46 and DBW 46 water heaters with the
following design approval numbers:
~S 185 for heaters BBW 46 - petrol
~S 186 for heaters DBW 46 - diesel
The installation of the heaters must be performed in accordance with these Installation Instructions. The installation must be checked
a) upon the homologation of the vehicles
in accordance with Section 20 StVZO
b) upon any individual test
in accordance with Section 21 StVZO, or
c) upon any examination
in accordance with Section 19 StVZO by a
registered expert or examiner for motor traffic, an
expert for automotive vehicles, or any other
authorised official, in accordance with Paragraph
7.4 a of Appendix VIII to the StVZO,
and in the case of item c) the proper installation must be
certified on the approval certificate contained on the design certification stating the following:
- vehicle manufacturer
- vehicle type and
vehicle identification numb er.
The effectiveness of the design certification is dependent
on this certificate. The approval certification is to be kept in
the vehicle.
The year of initial operation must be durably marked by the
installer on the type plate of the heater by removing the
years that are not applicable.
Extracting the combustion air from the interior of the
vehicle is not permissible.
The discharge opening of the exhaust pipe should point upward, sideways, or in the case that the exhaust pipes are
routed on the underside of the bottom of the vehicle, it
must be positioned near the lateral or rear edge of the
driver’s cab or vehicle.
Exhaust pipes must be routed so that the possibility of exhaust fumes entering the interior of the vehicle is remote.
The functioning of any parts of the vehicle essential for its
operation must not be impaired.
The openings of the combustion air inlet and exhaust gas
outlet pipes must be so designed that a spherical object of
16 mm dia. cannot be introduced.
Electric lines, switchgear and controlgear of the heater
must be so arranged in the vehicle that their functioning
cannot be impaired under normal operating conditions.
For the routing of fuel lines and the installation of additional fuel tanks, Sections 45 and 46 StVZO are to be
adhered to. The most important excerpts therefrom are as
follows:
Fuel lines must be designed in such a way that they remain unaffected by torsional stresses in the vehicle, engine movement, and the like. They must be protected
against mechanical damage. All parts of the fuel system
must be protected against heat which would impair their
operation, and must be located such that dripping or evap-
BBW 46 / DBW 46
orating fuel can neither collect nor be ignited by hot components or electrical equipment.
The heater must not be installed in spaces occupied by
persons.
The operating state of the heate r at any given time – at
least an indication as to whether it is “on” or “off” - must be
easily recognisable.
The installation of components which are not of an approved type will lead to the revocation of the General Design Certification of the heater and thus the General Operating Permit of the entire vehicle. The same applies to improperly performed repairs or those where other than genuine replacement parts have been used.
Use of the Water Heater
The BBW 46 / DBW 46 water heaters, in conjunction with
the vehicle’s heating system, are used for
- heating the passenger compartment,
- defrosting the vehicle’s windows,
- preheating water-cooled engines.
The water heaters operate ind epen dent ly of the vehicle’s
engine and are connected to the cooling system, the fuel
system and the electrical system of the vehicl e.
1
BBW 46 / DBW 46
Installation Location
Preferably, the heater should be installed in the engine
compartment in the splash-water protected area of the
front fenders or at the splash wall.
The heater should be installed at a level as low as possible
so as to ensure automatic venting of the heater and the circulating pump. . This is of special importance since the circulating pump is not of the self-priming type.
CAUTION:
The openings of the water connecting pipe sockets must
never, not any installation position, point downward.
CAUTION:
The heater must not be installed :
- in the immediate vicinity of or above hot vehicle parts
- in the direct splashwater area of the wheels
Fig 1: Installation Positions
Type Plate
The type plate must be located at a place where it is protected against damage and where it can be easily viewed
once the heater has been installed (or else, a type plate duplicate is to be used).
The years not applicable must be removed from the type
plate.
2
1
6
4
5
Fig 2: Installation Drawing BBW 46 / DBW 46
Mount
The heater mount must be fitted to the vehicle body or the
intermediate support by means of at least four M6 screws.
It is required that washers and lock washers be used.
2
3
1 Fuel inlet
2 Water outlet
3Water inlet
4 Exhaust gas outlet
5 Heater mount
6 Combustion air inlet
In the case of level body surfaces, the washers must have
a minimum diameter of 22 mm.
Do not use sheet metal screws for attaching the mount.
4
2
Cable harness
Fuel line
Heater fuel line
Exhaust gas line
Water circuit
Fig 3: Installa tion example of BBW 46 / DBW 46 heating device in a passenger car (inline integration)
1 Radiator
2 Cooling water thermostat
3 Water pump (of vehicle engine)
4 Vehicle engine with standard equipment
5 Water heater
6 Battery
7 Fuse holder
8 Control unit
9 Relay (for vehicle fan)
10 Regulating valve of vehicle heating
11 Heat exchanger of vehicle heating
12 Vehicle heating fan
13 Switch for vehicle heating fan
14 Fuse bank in vehicle
BBW 46 / DBW 46
15 Digital timer
16 Fuel extractor
17 Fuel metering pump
18 Exhaust silencer
19 Circulating pump
3
BBW 46 / DBW 46
Cable harness
Fuel line
Heater fuel line
Exhaust gas line
Water circuit
Fig 4: Installation example of BBW 46 / DBW 46 heating device in a passenger car (thermostat integration)
1 Radiator
2 Cooling water thermostat
3 Water pump(of vehicle engine)
4 Vehicle engine with standard equipment
5 Water heater
5A Non-return valve
6 Battery
7 Fuse holder
8 Control unit
9 Relay (for vehicle fan)
10 Regulating valve for vehicle heating
11 Heat exchanger, vehicle heat ing
12 Vehicle heating fan
13 Switch for vehicle heating fan
14 Fuse bank in vehicle
15 Digital timer
16 Fuel pick-up
17 Fuel metering pump
18 Exhaust silencer
19 Circulating pump
20 Thermostat
4
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