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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 Ve-
hicles for Road Traffic) the following regulations are primar-
ily 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 Certifica-
tions” 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 ac-
cordance with these Installation Instructions. The installa-
tion 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 de-
sign certification  stating the following:
- vehicle manufacturer
- vehicle type and
vehicle identification number.

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 up-
ward, 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 ex-
haust 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 addi-
tional 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 re-
main unaffected by torsional stresses in the vehicle, en-
gine 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-

orating fuel can neither collect nor be ignited by hot compo-
nents or electrical equipment.

The heater must not be installed in spaces occupied by
persons.

The operating state of the heater 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 ap-
proved type will lead to the revocation of the General De-
sign Certification of the heater and thus the General Opera-
ting Permit of the entire vehicle. The same applies to im-
properly performed repairs or those where other than ge-
nuine 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 independently of the vehicle’s
engine and are connected to the cooling system, the fuel
system and the electrical system of the vehicle.

BBW 46 / DBW 46

Содержание BBW 46

Страница 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 ...

Страница 2: ...BW 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 BBW 46 DBW 46 I ...

Страница 3: ...side 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 ex haust 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 mu...

Страница 4: ...ct splashwater area of the wheels Type Plate The type plate must be located at a place where it is pro tected against damage and where it can be easily viewed once the heater has been installed or else a type plate du plicate is to be used The years not applicable must be removed from the type plate Mount The heater mount must be fitted to the vehicle body or the intermediate support by means of a...

Страница 5: ...er 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 15 Digital timer 16 Fuel extractor 17 Fuel metering pump 18 Exhaust silencer 19 Circulating pump B...

Страница 6: ...hicle 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 heating 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 pum...

Страница 7: ...ng of the sys tem 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 cir cuit 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 ou...

Страница 8: ...For fuel extraction from flow or return lines it is imperative that the special Webasto fuel pick up see Fig 10 be used The fuel pick up is to be mounted so that any air or gas bubbles that may form are automatically discharged to ward 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 tempe...

Страница 9: ...es 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...

Страница 10: ...adius 50 mm The exhaust silencer is preferably to be mounted in the vi cinity of the heater It must not be installed near the combustion air intake opening Operation of the BBW 46 DBW 46 heater is also per missible without silencer The discharge opening of the exhaust pipe must not point in the direction of travel see Fig 14 Rigid pipes made of unalloyed steel with a minimum wall thickness of 1 0 ...

Страница 11: ...way for tuning and thus allocating a second transmitter 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...

Страница 12: ...ling in the ve hicle 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 dissolv ing cleaner e g methylated spirits Peel off protective film from antenna and glue antenna in place NOTE Do neither shorten nor sharply bend antenna cable Route antenna cable ...

Страница 13: ... rt bl bl bl br br or or rt rt rt vi vi gn gn gn rt bl rt 87a 85 86 87 30 30 E1 E2 31 31 gn ws rt sw rt ws sw br br rt sw br br br 87a 87b 87 3 4 1 5 2 6 ϑ ϑ 1 9 7 8 8 7 6 4 5 4 1 6 3 1 2 3 12 2 2 11 1 1 2 2 10 5 Y A F4 F2 F1 F3 K6 R2 24V 12V A2 A4 S3 B3 W1 W1 W1 W1 M3 S2 S1 R1 A1 M1 X1 X1 X1 M2 B1 B2 X2 E K7 Fig 16 Automatic control circuit BBW 46 DBW 46 12V digital timer and Telestart T6 legend ...

Страница 14: ...tal 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 circulating pump for separate activation V3 Diode in pos A2 V108 Transistor in pos A2 W1 Cable harness X1 Connector 12 pole X2 Connecto...

Страница 15: ...inguished during operation fuel is de livered 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 occur ring over a ...

Страница 16: ...rising burner Heat output full load part load 4 6 kW 2 3 kW Fuel petrol diesel Fuel consumption full load part load 0 63 l h 0 23 l h 0 58 l h 0 29 l h 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 full load part load 44 W 33 W Max permissible ambient temperature Heater operation storage Control ...

Страница 17: ... 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 BBW 46 DBW 46 15 ...

Страница 18: ......

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