Webasto BBW 46, DBW 46 Installation Instructions

Page 1
Water Heaters Installation Instructions
BBW 46 DBW 46
Be sure to read these Operating Instructions prior to putting the heater into operation.
9/1998
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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
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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.
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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
Page 5
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
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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
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BBW 46 / DBW 46

Connection to the Vehicle’s Cooling System

The heater is to be connected to the vehicle’s cooling sys­tem in accordance with Figs 3, 4, 5 and 6. A minimum of 4 litres of coolant must be maintained in the cooling circuit.
2
1
7
Fig 5: Integration into Engine/Water
Circuit “Inline Integration”
1
7
Fig 6: Integration into Engine/Water
Circuit “Thermostat Integration”
Legend of Figs. 5 and 6: 1 Expansion tank 2 Thermostat 3 Vehicle engine 4 Circulating pump 5 Heating device 6 Heat exchanger of heater 7 Radiator 8 Thermostat 9 Non-return valve
3
2
3
4
5
6
9
4
5
8
6
The integration of the heater into the cooling circuit is to be performed in the flow line of the vehicle’s heat exchanger.
As a rule, the water hoses supplied by Webasto with the heater should be used. If this is not the case, the hoses must comply with DIN 73411 requirements as a minimum. The hoses are to be routed without any kinks and – to
ensure proper venting – in an upward pitch, if possible. Hose connections must be secured against slipping off by means of hose clamps.
NOTE:
When securing the hose clamps to the heater, be sure to fit them between the bead (thicker part) of the hose and the heater. The hose clamps must be tightened to a torque of 2.0 +
0.5 Nm.
Before the heater is started up for the first time, or after the coolant has been replaced, it must be ensured that the cooling system is properly bled. Heater and piping should be installed in such a way that static bleeding of the sys­tem is ensured.
During heating operation, inadequate bleeding may lead to a malfunction due to overheating.

Re-Positioning of Circulating Pump

The circulating pump may be integrated into the water cir­cuit either by installation at the location provided on the heater or at a heater-remote location. It is important that the correct direction of flow through the heater be observed (water outlet at top / water inlet at bottom) as otherwise malfunctions will occur!

Connection to the Fuel System

Fuel system integration without non-return valve in the tank
The heater’s fuel supply circuit must be integrated in the re­turn line as shown in Fig. 3.
Fuel system integration with non-return valve in the tank or fuel system integration in the case of single­line fuel supply
Tank extractor with 90°-elbow is to be installed in the tank fitting (Fig. 7)
5
8,5
Bild 7: Tankarmatur 90°
Lochbild
Bild 8: Webasto-Tankentnehmer
500
Mindestabstand 25 mm
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BBW 46 / DBW 46
l2
l
1
l2
l
1
l1 + l2 13 m l1 3 m l2 10 m
Fig 9: Fuel Supply

Fuel Supply

Details on the permissible pressure at the fuel extraction point are contained in the table below.
Permissible
fuel feed height H (m)
0.00 1.5
1.25 1.4
2.50 1.3
3.75 1.2
5.00 1.1
6.25 1.0
7.50 0.9
8.75 0.8
10.0 0 0.7
Permissible fuel suction
height S (m)
0.00 -0.15 -0.15
0.50 -0.11 -0.11
1.00 – -0.07
NOTE
A fuel flow line can usually be identified by the in-line fuel filter.
NOTE:
If the vehicle’s fuel system is equipped with a vapour sep­arator, fuel extraction is to take place upstream of same.
For fuel extraction from flow or return lines it is imperative
that the special Webasto fuel pick-up (see Fig. 10) be used.
at max. permissible
overpressure (bar ) in fuel
line
at max. permissible
underpressure (bar) in fuel
tank
petrol diesel
to engine
from tank
to metering pump
Fig 10: Webasto Fuel Pick-Up
The fuel pick-up is to be mounted so that any air or gas bubbles that may form are automatically discharged to­ward the tank (see Fig. 10).
Air or gas bubbles in the fuel line of the vehicle can form if there is a leak in the vehicle’s carburettor or fuel pump, or if the ambient temperature exceeds the evaporating tem­perature of the fuel.
Fuel should not be extracted in the vicinity of the engine since here gas bubbles are likely to form in the lines owing to the heat radiating from the engine, which may result in malfunctions of the combustion operation.
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BBW 46 / DBW 46
If the heater is installed in vehicles with petrol injection sys­tems it must therefore be determined whether whether the fuel pump is mounted inside or outside the tank. Where the fuel pump is located inside the tank, the fuel can only be drawn from the return pipe in which case it must be ensured that the return pipe extends almost to the bottom of the tank. If this is not the case, it is possible to extend the return pipe.
Where the fuel pump is mounted outside the tank, the con­nection to the fuel system can be accomplished between the fuel tank and the fuel pump.

Fuel Lines

NOTE:
The hose clamps are to be tightened to a torque of 1.0 +
0.4 Nm. Any fuel that may have leaked is to be removed from the engine or heater prior to starting up the heater or engine.
Only steel, copper and plastic pipes made of plas­ticised, light-resistant and temperature-stabilised PA 11 or PA 12 (e.g. Mecanyl RWTL) in accordance with DIN 73378 may be used as fuel lines.
As in the majority of cases it is not possible to route the lines in a continuous upward pitch, the inside diameter must not exceed a given dimension. If the inside diameter is larger than 4 mm, air or gas bubbles accumulate which result in malfunctions if the lines sag or are routed in a downward pitch. If the diameters shown in Fig. 9 are used you can be sure that no unwanted bubbles will form.
The lines leading from the metering pump to the heater should not be routed in a downward pitch.
To prevent the fuel lines from sagging, freely suspended lines must be secured. Mounting should be performed in such a manner that the lines are protected against flying stones and thermal influence (exhaust pipe).

Connecting Two Pipes Using a Hose

The proper connection of fuel lines using a hose is shown in Fig. 11.
Check for leaks!
correct
clamp
wrong
bubble
Fig 11: Pipe/Hose Connection

Metering Pump

The metering pump is a combined fuel delivery, metering and shutoff system and is subject to certain installation criteria (see Figs. 8 and 11).
bubble
Fig 12: Metering Pump without Diaphragm Damper
Installation position and mounting

Installation Location

Prior to installing the metering pump make sure that the maximum pressure prevailing at the fuel extraction point is lower than the max. permissible value indicated in the table on page 6.
It is recommended that the metering pump be installed in a location which sufficiently cool. On no account must the permissible ambient temperature at any given operating
state be in excess of + 20°C. Metering pump and fuel lines must not be mounted within
the radiation range of hot vehicle parts. If necessary, a radi­ation protection is to be provided.
The preferred installation location is near the tank.

Installation and Mounting

The metering pump is to be attached by vibration-damping suspension. The installation position is restricted as shown in Fig. 12 in order to ensure proper self-ventilation of the system.
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BBW 46 / DBW 46

Combustion Air Supply

The combustion air required must be drawn in from the out­side of the vehicle.
The combustion air should be drawn in at a splash-water protected location.
The combustion air intake opening must be so located that the possibility of clogging due to contamination is remote. It must not point in the direction of travel.
The combustion air line can be so routed that it features sev-
eral bends (total of 270°, smallest bending radius 50 mm). The combustion air line can have a length of max. 1000 mm.
On no account should the combustion air be extracted from areas occupied by persons. If the heater is located in an enclosed installation casing, a ventilation opening of at least 3 cm2 is required.
Where the heater is installed in the vicinity of the vehicle tank in a common installation space, combustion air must be drawn in from the outside of the vehicle and the exhaust gas be discharged to the atmosphere. The lead-through openings must be splash-proof.

Exhaust Pipe

The exhaust pipe (inside diameter 22 mm) may have a length of up to 5m and may feature several bends (in total 720°, smallest bending radius 50 mm).
The exhaust silencer is preferably to be mounted in the vi­cinity of the heater. It must not be installed near the combustion air intake opening.
Operation of the BBW 46 / DBW 46 heater is also per­missible without silencer.
The discharge opening of the exhaust pipe must not point
in the direction of travel (see Fig. 14).
Fig 13: Exhaust silencer
Direction of flow (optional)
direction of discharge approximately vertical 90° ± 10°
Fig 14: Exhaust Pipe Discharge Opening
Installation Position
Rigid pipes made of unalloyed steel with a minimum wall thickness of 1.0 mm or flexible tubes of alloyed steel should be used as exhaust pipes.
NOTE:
Any condensation water that may have collected in the ex­haust pipe must be drained immediately. If necessary, it is permitted to drill a condensation water drain hole.

Electrical Connections

Control Unit/Heater Connection

The electrical connection of the heaters is to be performed in accordance with Fig. 16.
The connection of the digital timer should be carried out in accordance with the circuit diagram shown in Fig. 15.

Vehicle Fan

The activation of the vehicle fan is controlled by the vehicle fan relay, see circuit diagram shown in Fig. 16.

Connection of Telestart Receiver T60

The connection of Telestart receiver T60 is to be carried out as shown in Fig. 16.
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BBW 46 / DBW 46
Tuning of Teles ta rt T6 0 Han dhe ld Tr ansm it ter a nd Re­ceiv er
NOTE:
Each receiver can be allocated 2 handheld transmitters.
- Place batteries in battery compartment.
- Pull antenna out of transmitter approx. 5 cm.
25
15
A
1
A
A
Wait 10 seconds
-
Interrupt voltage supply for at least 10 seconds by re­moving the 15A flat fuse (blue).
NOTE:
If the Telestart receiver is retrofitted, fuse F2, 1A (black) has to be removed.
25
15
A
1
A
A
Wait 5 seconds
- Briefly press the ”Start” button.
Start
Operation indicator on transmitter is flashing.
Wait 15 seconds
- Briefly press the ”Off” button.
Off
Operation indicator on transmitter no longer flashes.
- Tuning is finished. If any specified time period is exceeded or fallen short of,
tuning will not be successful and the procedure is to be re­peated from the beginning. Proceed in the same way for tuning and thus allocating a second transmitter.
Off

Retrofitting the T60 Telestart Receiver

NOTE:
The BBW 46 / DBW 46 water heaters can be retrofitted with the T60 Telestart remote control.
The retrofit kit T60 consists of the following parts:
- Transmitter T60 with 2 alkaline LR1 1.5V batteries
- Standard antenna T6
- Receiver T6
- Mounting hardware (bag) comprising 2 sheet metal screws 1 receptacle housing 1 tab connector housing 3 push-on receptacles
The installation may only be performed by authorised We­basto service centres.
CAUTION:
The receiver must be installed in the interior of the vehicle. It is not permitted to extend the cable harness (approx . 70 cm long) provided on the receiver.
- Determine suitable installation location for receiver T6 in
the interior of the vehicle, in the vicinity of the digital timer.
- Mount receiver using the sheet-metal screws (containe d
in the kit).
- Immediately after reinstalling the flat fuse press the ”Off” button.
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BBW 46 / DBW 46

Installation of Antenna

NOTE:
Preferably, the antenna should be installed in the interior of the vehicle, at the top in the centre of the windshield or rear window. If installed at different location s, the range is likely to be diminished.
For an optimal reception, a distance of 2 ± 0.5 cm from the windshield edge is to be maintained (Fig. 15). The cable should be routed upward, beneath the panelling in the ve­hicle roof and then directed to the right or left to the chassis member.
NOTE:
In the case of lack of space, the antenna may be installed up to 15 cm off-centre.
- Clean windshield or rear window using grease-dissolv­ing cleaner (e.g. methylated spirit s).
- Peel off protective film from antenna and glue antenna in place.
Antenna
2 ± 0.5 cm
Fig 15: Installation of Antenna
NOTE:
Do neither shorten nor sharply bend antenna cable.
- Route antenna cable to receiver.
- Establish plug connection at receiver and tighten con­nector hand-tight.
- Secure antenna cable using cable ties.
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BBW 46 / DBW 46
B1B2EX1F3
R1
AB C D
M1
M2
(75) 15
30
61
X1Y1
K7
X2Y2
87
1
7 8
9
87a87b
22
bl/ge gr
33 44
vi
55
br
66
rt
7
sw
8
ge
P
rt
30
E1
sw
A4
31
Fig 16: Automatic control circuit BBW 46 / DBW 46, 12V digital timer and Telestart T6 (legend see page 12)
E2
31
br
5
6
4
3
2
1
F4 F2 F1
W1
B3
rt/bl
87
87a
86
K6
85
30
sw
S1
br
M3
S2
2
2
1
1
W1
rt
W1
34
sw/rt
rt
gn/ws
57
68
1
2
A
3 4
1
5 2
6
S3
W1
ws/sw br
br br
br
bl
M
X1
bl
A1
2
341
6 8 10 12 57911
br ge
X1 X1
A2
221111
bl
br
16
5
24V
Y
4
M1
rt
rtrtvi vi
R1
B1 B2
312312
sw sw
br
br
bl ge/rt
M
ϑ
F3
M
M2
R2
10
ws ws
or or
gn gn
gn
ϑ
X2
12V
2
ge
197887645
2
br
ge ge
E
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BBW 46 / DBW 46
Wire Cross-Sections
< 7.5 m 7.5 - 15 m
2
0.5 mm
2
0.75 mm
2
1.5 mm
2
2.5 mm
2
4.0 mm
0.75 mm
1.5 mm
2.5 mm
4.0 mm
6.0 mm
Wire Colours
bl
blue
br
2 2 2 2 2
brown
ge
yellow
gn
green
gr
grey
or
orange
rt
red
sw
black
vi
violet
ws
white
Pos. Designation Remarks
A1 Heater BBW 46 / DBW 46 A2 Electroni c control uni t SG 1560 A4 Telestart receiver T 6 B1 Flame detector B2 Temperatur e sensor B3 Room thermostat for vehicle fan on/off E Glow plug F1 Fuse 16A motor vehicle fuse DIN 72581 F2 Fuse 8A motor vehicle fuse DIN 72581 F3 Temperature fuse F4 Fuse 16A motor vehicle fuse DIN 72581 K6 Relay for vehicle fan K7 Relay for Telestart receiver M1 Motor combustion air fan M2 Motor circulating pump M3 Motor vehicle fan P Timer, digital for presetting operating time R1 Resistor for part-load operation R2 Resistor only required for 12-volt glow plugs in a 24-volt heater S1 Switch for vehicle fan S1 or S2 depending on vehicle S2 Switch for vehicle fan S1 or S2 depending on vehicle S3 Switch for circulati ng pump for separate activation V3 Diode (in pos. A2) V108 Transistor (in pos. A2) W1 Cab le harnes s X1 Connector 12-pole X2 Connector 2-pole X4 Connector 1-pole Y Metering pump
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BBW 46 / DBW 46

Initial Operation

NOTE:
The safety information contained in the Operating Instruc­tions have to be adhered to!
After the heater has been installed, the water circuit and the fuel supply system are to be thoroughly bled. Follow the directions of the vehicle manufacturer.
Perform a test run of the heater thereby checking all water and fuel connections for leakage and security. Should the heater fail during operation, troubleshooting activities are to be carried out.

Malfunctions

Fault Lock-Out Due to Malfunctions of the Heater
If no flame forms fuel is delivered for max. 180 sec­onds.
If the flame is extinguished during operation, fuel is de­livered for max. 90 seconds.
In the event of overheating fuel supply is immediately
stopped.
CAUTION:
No visual indication occurs in the case of overheating.
Fault Lock-Out Due to Undervoltage
In the case of an undervoltage of 9.5 ± 0. V (in the case of 12-volt heaters) or 19 ± 1 V (in the case of 24-volt heaters), measured at the input of the control unit, occur­ring over a period of 20 seconds, the heater will shut down in its fault lock-out mode and an after-run period will follow.

Interlock Deactivation

- Eliminate cause of malfunction
- Resetting is performed by switching the heater off and
back on again (the ’off’ period has to last for at least 1 sec).
- In the case of overheating, the temperature fuse has to be replaced or the temperature limiter to be reset.
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BBW 46 / DBW 46

Technical Data

Unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient tempera-
ture of +20°C and at the rated voltage.
Fuel for BBW 46 (Petrol):
The type of fuel specified by the vehicle manufacturer is suitable as fuel for the heater.
Fuel for DBW 46 (Diesel):
The diesel fuel specified by the vehicle manufacturer is suitable as fuel for the heater. When changi ng to cold-re­sistant fuels, the heater must be operated for about 15 minutes to ensure that the fuel line and fuel pump are also filled with the new fuel. Any negative effect caused by additives is not known.
Heater Operating
Mark of approval Type water heater with vaporising burner Heat output full load
Fuel petrol diesel Fuel consumption full load
Rated voltage 12 or 24 volts Operating voltage range 10 ... 14 volts or 20 ... 28 volts Rated power consumption without
circulating pump (without vehicle fan) Max. permissible ambient temperature:
Heater: - operation Control unit: - operation Metering pump: - operation
Max. allowable working pressure (heat carrier) 0.4 ... 2.0 bar Filling capacity of heat exchanger 0.25 l Min. amount to be maintained in the circuit 4.00 l Volume flow of circulating pump against 0.1 bar 950 l/h CO2 content in exhaust gas (perm. funct. range) 10 ... 10.5 % by vol. Dimensions of heater length 277 mm
Weight incl. control unit and circulating pump 3.9 kg
- storage
- storage
- storage
Mode
part load
part load
full load part load
BBW 46 DBW 46
S 185
~
0.63 l/h
0.23 l/h
4.6 kW
2.3 kW
44 W 33 W
-40° ... + 80°C
-40° ... +100°C
-40° ... + 75°C
-40° ... + 85°C
-40° ... + 20°C
-40° ... + 85°C
width 148 mm
height 197 mm
S 186
~
0.58 l/h
0.29 l/h
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BBW 46 / DBW 46

Version

Type DBW 46 Supplementary Heater Water heater for ”diesel” fuel
Type BBW 46 Supplementary Heater Water heater for ”petrol” fuel
The BBW 46 / DBW 46 water heaters are designed for 12-volt or 24-volt operation.
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