Diesel Cooker x100 Service Manual
Contents
1. Bn dun 2 uonisod pay90 ueym sayselj 1460 uonisod NO eui 01 YMS y t 1490 eui NOILISOd 134907 NI N3HM S3HSV 13 LH9IT o BuyyyAue Op saop ano s 941 402 Webasto Diesel Cooker X 100 4 2 General failures 4 Failure detection Cooker does not respond at all Cooker does not start Note After two failed start attempts the cooker is in lock up state Removing Lock Up 1 Turn the cooker ON lock up LED is blinking 2 Unplug the main cable blinking goes OFF 3 Plug in the main cable yellow LED blinks couple of times 4 When yellow LED goes OFF turn cooker OFF Is operating voltage under 10 7 VDC Measure the voltage from control unit s voltage connector A Yes Check the control unit control panel and control panel cable B No See how to repair Pump Check the main cable connections and the main switch Check fuses on main cable and on control unit Check the battery voltage Battery voltage must be over 10 7 VDC Pump does not get get pulses Red LED does not blink on control board Check the control unit Check the pump wires wiring and over heat protector s condition Pump get s the pulses but pump piston does not move A small ticking sound can be heard when the piston moves Check the pump Sometimes a small tapp on pump s side help s to relase the pi2. WHITE GREEN li Tw GLOW PLUG HOT PLATE INDIC ACK BLACK i ON FAN Electrical connections for the control unit 602 Webasto Diese Cooker 100 7 Maintenance and service 7 1 Basic maintenance The cooker shall be serviced every two years by an authorized service center In case of intensive use replace the fuel filter once a year Consider the following before taking measure ments You can begin to take verifying measurements only after the device has heated up thoroughly i e approximately 10 min after ignition The battery voltage must be at 12 14 V while taking measurements A battery or stabilized direct current supply should be used for supplying power A battery charger or rectifier can not be used because the device will not function properly with them A dish should be set on the left hand burner when the stove has been on at full power for a period of 15 minutes Otherwise the stove will over heat and obtaining normal measurements will be impossible The suction height from the top of the measuring glass to the bottom of the device must be 30 60 cm or more accurately the same suction height as in the actual installation Maintenance procedure 1 Clean the burner Open the burner according the instructions in 3 4
3. Burning fan s voltage U Max 9 5 see parameter file Min 5 5V see parameter file Longest permissible length of the 1 9 m straight downwards 1 2 m combustion hose 28 mm and 60 mm CO of the combustion calculated Max 6 7 Min 4 5 Temperature of the combustion T Max 265 C 509 F Min 135 C 275 F Combustion s carbon monoxide content lt 20 ppm lt 100 Combustion s soot index Max 0 Min 0 Air coefficient of the combustion Max 2 5 3 4 Combustion s oxygen contect O Max 11 5 13 0 Min 14 0 15 5 96 Webasto Diesel Cooker X 100 4 Failure detection 4 Failure detection This section describes how to identify and remedy faults on the Webasto Diesel Cooker X 100 If a fault occurs an error code will be output via the LED s of the operating panel CAUTION Troubleshooting work demands precise knowledge of the structure and theory of operation of the various components and must be carried out by trained personnel only CAUTION The troubleshooting guide is restricted to the localisation of defective components The following potential sources of malfunctions should always be checked so that they can then be excluded as the cause of the particular fault Corrosion on plugs Loose plug contacts Poor crimp contacts on plugs Corroded cables and fuses Corroded battery terminals If you wish to check individual components the electr
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5. Jlebasto Feel the drive Diesel Cooker x100 Service Manual Zn 08 05 2008 Webasto Diesel Cooker X 100 1 General 1 1 Contents and purpose 1 2 Use of the cooker 1 3 Additional documentation 1 4 Safety notes and legal issues 1 5 Suggestions for improvements and changes 2 Function description 2 1 System description 2 2 Main components 2 3 Operating scheme 3 Technical Data 4 Failure detection 4 1 Trouble shooting chart 4 2 General failures 4 3 Failure blink codes 5 Updating and repair 5 1 Updating 5 2 Test program 5 3 Burner 5 4 Glow plug 5 5 Heat exchanger and glass panel 5 6 Pump Boost 6 Electrical connections 7 Maintenance and service 7 1 Basic maintenance 7 2 Control unit settings Table of Contents 101 101 101 101 101 201 202 207 301 402 403 406 501 503 504 506 507 508 601 701 703 Webasto Diesel Cooker X 100 1 General 1 1 Contents and purpose This workshop manual is designed to assist trained personnel with repairing the Webasto Diesel Cooker X 100 1 2 Use of the cooker The Webasto Diesel Cooker is designed for use in motorcaravans It is not designed for use in boats 1 3 Additional documentation This workshop manual contains all the information and instructions required for repairing the Webasto Diesel Cooker X 100 If necessary the operating installation instructions may also be used 1 4 Safety notes and legal issues In principle
6. LED light During normal use incorrect device parameters should not occur in the device s memory because the XP Link terminal programme does not allow users to enter incorrect parameters into the device s memory Test phase When the thermostat pin pair S1 is closed the yellow LED light flashes according to the potentiometer setting during the test phase In this case when the potentiometer is at the minimum the LED light flashes on and off for a duration of 0 5 seconds When the potentiometer is at the maximum the LED light flashes on and off for a duration of 0 05 seconds The LED light flashes on and off for a duration of 0 5 seconds when S1 is open 407 Webasto Diesel Cooker X 100 Red LED Burning indicator and after cooling In the heating phase when the burning indicator has turned on during glowing or ignition the red LED light will illuminate at that point and remain illuminated continously The LED light will react without any delay if the burning indicator shuts off The actual malfunction that caused the burning indicator to shut off will be locked 5 seconds after the burning indicator fails to work During after cooling the LED light will begin to uniformly flash once the burning indication limit has been broken The LED will flash on and off for a duration of 0 25 seconds After cooling lasts for approximately five minutes Flashing due to over heating During the heating phase when the alarm i
7. Parameter files may be saved from the file or manually edited Ventilation Fan MAX mV 11000 Ventilation Fan MIN mV For choosing the PC s port 9500 E Import B bens From the control unit to the PC From the PC to the control unit Pump MAX ms Export Pump MIN ms TT Choose All 3000 a Close Glowing time s 240 Hours 00047 Checking this box enables you to choose all devices at one time Amount of operating hours Connected to XP v1 12 Figure 1 501 Signifies what programme version is being used on the control unit Webasto Diesel Cooker 100 1 Copy all files from the CD on to your computer s hard disk to the location of your choice 2 Install the PC cable into an available COM port You may need a USB COM adapter to install the cable if your laptop does not have a COM port Note Make sure you choose the right USB adapter 3 Connect the PC cable to the XPS card as illustrated in Figure 2 Note The coupler has 5 studs in use one stud has been soldered shut There is only one way you can connect the PC cable to the control unit 4 Connect the electrical and control panel wires to the control unit and turn the stove on 5 Start the programme by double clicking on the xplink exe file located on your computer s hard disk XPlink will open up as illustrated in Figure 1 see previous page 6 Choose the correct COM por
8. WP lamp i Combustion indication Red 9 0 255 0255 0255 0255 lamp Start up 2 5 4 min Cooking Run down phase about 5 min Start Stop U Signal lights of operating panel during normal operation 202 Webasto Diesel Cooker 100 Fuel pump The fuel pump is a combined transport metering and shut off system for supplying fuel from the vehicle s tank to the cooker The adjustment range for the pump s pulsing is 0 5 sec 4 5 sec adjustment is linear Check the length of the pulsing in the last parameter file After turning the operating switch to the ON position the pump will be at a standstill for 30 seconds after which the pump s pulsing will begin to rise linearly towards the maximum setting it will reach the maximum 4 minutes and 50 seconds after the start up cycle ends The power adjustment will not work during start up cycle When you adjust the device from maximum to minimum the pump s impulse interval will immediately drop step by step to the value of the minimum pulse interval 0 5 sec After this the pulse will excellerate until it reaches the normal pulse interval at the minimum output In other words if the pulse interval at the maximum is 1 second and at the minimum 3 seconds then the pulse interval will decrease immediately to 3 5 seconds when adjusting from maximum to minimum It will rise from that point in 20 seconds to 3 seconds Glow plug During the first second of ignition th
9. on to the circuit card Choose the device device parameters X1 by connecting the pair of studs together with jumpers It is extremely important that the jumpers are in the correct places so the devices work properly Make sure you always use the latest parameters See Figures for the correct places for the jumpers XP Link BER File Help DEVICE 17 Webasto Diesel Cooker X100 17 Device 17 zi Burning Fan mV Foa 9500 Burning Fan MIN mV Ex s9 Xi s BL 5500 I Ventilation Fan MAX mV 11000 Ventilation Fan MIN mV 9500 Import Pump MAX ms SOS Export Pump MIN ms TT Choose All 2090 E Close Glowing time s 240 Hours 00047 Connected to XP v1 12 The parameters in the Figures are Al xpd parameters 703 Webasto Diesel Cooker X 100 Page for notes Webasto Diesel Cooker X 100 Page for notes Webasto ProductN A Inc 15083 North Road Fenton MI 48430 Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 WWW Webasto US WWW techwebasto com Part no WA490060
10. the general accident prevention regulations and current works safety instructions are applicable Webasto Diesel Cooker X100 is tested by SGS test spesification standard EN 1 1998 EN 60335 2 6 2003 Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts You must read the operating manual before starting the heater for the first time 1 General 1 5 Suggestions for improvements and changes Complaints improvement suggestions or corrections relating to this workshop manual should be addressed to Webasto Product North America Inc Technical Documentation Group 15083 North Road Fenton MI 48430 Phone 800 555 4518 Fax 810 593 6001 You are also invited to fill out our online questionnaire concerning our technical documentation and web site at www techwebasto com 101 Webasto Diesel Cooker 100 2 Functions description Exhaust gas tube 2 1 System description The Webasto Diesel Cooker X 100 is a safe diesel cooker with no open flame The exhaust gases are led out of the vehicle through the exhaust gas tube which is inside the cooling air tube The steam from the exhaust gas will not stay in the vehicle to add humidity As the diesel fuel burns the released heat is transferred to the ceramic plate The ho
11. Change the bottom mat if needed 2 Check the glow plug See malfunction and testing of the glow plug in 3 2 Change the glow plug if needed 3 Measure the fuel consumption The fuel pump functions with electric pulses created by an electronic pulse generator You can hear the pump running by the soft thumping sound it makes The more rapid the pulses shorter pulses are the more fuel the pump delivers The ratio between the pulse interval and the amount of fuel is constant The pump is adjusted to fixed volume at the factory therefore all pumps provide the same amount of fuel within the same pulse interval 7 Maintenance and service Later as the pump gets older it may raise the amount of fuel input by 5 10 Therefore you should always make a verifying measurement of the fuel input when servicing the device or changing the pump A Fuel input measurement 1 Turn on the device 2 Adjust the device to maximum 3 Figure out how much fuel is being consumed by measuring the fuel consumed during a period of 6 min using a 50 or 100 ml measuring cylinder When multiplying the result by 10 you ll get the value ml h If the fuel input differes from the nominal value see technical information adjust the input according adjustment instructions B Fuel input adjustment 1 Turn on the device 2 Adjust the device to maximum 3 About 5 minutes after start up measure the pumps i
12. EST BF 2 L 7 R37 10k TEST ur 5 LL21 8 8 ok SR 08 6 Connection diagram for maintenance coupler 503 5 Updating and repair Maintenance coupler Coupler for device selection V v v V V Vv AZ You can measure the following values from the J6 connector while the unit is running J6 1 Operating voltage J6 2 Quick pumping J6 3 Glow plug voltage J6 4 T4 voltage after amplifier J6 5 T3 voltage pulse J6 6 Pump pulse J6 7 Voltage for burning fan J6 8 Voltage for main fan J6 9 GND Webasto Diesel Cooker 100 5 3 Burner Through pipe for the temperature sensor T4 Installation hole for glow plug Installation hole and needle support for the fuel needle Complete burner cylinder Includes all parts you see in the picture 5 Updating and repair Thermal radiator for the burner Detaching the thermal radiator There are two locking plates on the inside of the burner s perforated cylinder which have been spot welded to the sides of the cylinder Prying one of the locking plates with a screw driver against the side of the cylinder for example should be enough to free the thermal radiator Pull the thermal radiator up to remove Installing the thermal radiator Push the thermal radiator inside the perforated cylinder until the locking p
13. See also installation manual Exhaust system 2 Functions description 205 Webasto Diesel Cooker 100 Burner Through pipe for the temperature sensor T4 Installation hole for glow plug Installation hole and needle support for the fuel needle Complete burner cylinder Includes all parts you see in the picture 2 Functions description Thermal radiator for the burner Detaching the thermal radiator There are two locking plates on the inside of the burner s perforated cylinder which have been spot welded to the sides of the cylinder Prying one of the locking plates with a screwdriver against the side of the cylinder for example should be enough to free the thermal radiator and pull it up Installing the thermal radiator Push the thermal radiator inside the perforated cylinder until the locking plates lock the thermal radiator in place Note The locking plates must be bent a bit crosswise before you can assemble the thermal radiator back in place This will ensure that the thermal radiator will stay in place during transport as well Burner cylinder Burner s bottom mat spring The bottom mat spring for the burner ensures that the bottom mat stays on the bottom of the burner prevent ing the glow plug from going under the bottom mat Er Bottom mat of the burner 85 mm Delivered together with the bottom mat spring ue Base of the burner Removing deposits M
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15. e incorrect device parameters should not occur in the device s memory because the XP Link terminal programme does not allow users to enter incorrect parameters into the device s memory Testing phase The red LED light will be on during the testing phase when the voltage measured on the T4 circuit exceeds the 5 mV threshold Correspondingly the LED will shut off when the measured value drops under 5 mV 408 Webasto Diesel Cooker 100 5 Updating and repair WARNING The cooker must not be operated in enclosed areas such as garages and workshops without an emissions extraction system 5 1 Updating There may be a maximum of 32 parameter files programmed on the control unit The parameters may be put on the control unit either one at a time or all together XPS software Download the programme onto your computer the name of the programme is xplink exe Hook a data transmission cable between the computer and control unit The length of the cable is 1 5 m and you hook it to the serial port If your computer does not have a serial port then the data transmission cable must be connected via an USB adapter XP Link lel Es File Help 17 Device 17 Burning Fan mV 5 Updating and repair Make sure you always use the latest parameters Make sure the USB adapter you use is compatible with your operat ing system For choosing the device 9500 Burning Fan MIN mV 5500
16. e glow plug receives quick pulses with which you can make sure it is working properly During the 2 second voltage increases with a pulse ratio of 25 After 5 seconds the pulse ratio increases to 70 and after 15 seconds the voltage increases to 100 Programmed ignition monitoring will begin 15 seconds after start up before which there is only mechanical protection 5 S S Sy Mr Oe Oo 9 Ly gt 4 A So X Sy 9 The principle of operation of ignition voltage 2 Functions description Combustion air fan The voltage range of the burning fan may be altered between 4 8 V and 10 7 V by changing the param eters the adjustment range of the parameters is 4 000 mV 11 000 mV Check the voltage in the last parameter file During the first second of start up the control unit tests the fan s motor During the follow ing second the motor receives an initial impulse of 7 V from which the voltage is decreased to the mini mum set forth in the parameters The voltage will be increased linearly towards the maximum during the start up cycle the maximum will be reached in approximately 4 minutes and 50 seconds after the start up cycle ends The power control does not work during this time After the start up cycle the burning fan adjusts itself from maximum to minimum and minimum to maximum at a rate of 5 per second 20 sec max gt min Heat exchanger The heat generat
17. e hot plate indication lamp lights on the lower edge of ceramic plate when the plate is hot The hot plate indication lamp will light up immediately after the start The lamp will remain on for 50 minutes 10 96 after the cooker has been turned off Control unit The control unit is the central component for ensuring the cooker s function and monitoring for proper cooker operation If a fault occurs an error code will be output in the LEDs of the operating panel by various flashing sequences In addition the heater s parameters and running hours can be checked using a personal computer Note You must be sure you have ESD protection while handling the control unit Static electricity can damage the control unit Thermo element BLACK mmm 5 HOT PLATE INDICATION LED BLUI Electrical connections for the control unit 204 Webasto Diesel Cooker 100 Cooling system The cooker is cooled down by a ventilation box located under the cook top On the front side of the ventilation box is an axial fan wich draws fresh air into the box Hot air is blown away from box through an outlet which is located on the bottom of the box The exhaust outlet is located inside the fresh air tube a coaxial hose This means that fresh air is also cooling down the exhaust gases
18. eater tolerances of 10 at an ambient temperature of 20 C 68 F and at the rated voltage and in rated conditions Electrical components The control unit combustion air fan cooling fan fuel pump glow plug and operating element are de signed for 12 V The components overheat thermo stat and temperature sensor are not designed for a specific voltage Fuel The diesel fuel specified by the manufacturer must be used It has to comply with the normal quality available on the market We know of no negative influences due to additives If you change to low temperature fuel the cooker must be operated for approx 15 minutes so that the fuel system is filled with the new fuel 301 3 Technical Data Webasto Diesel Cooker X 100 3 Technical Data 302 THE DEVICE S FUNCTION TECHNICAL VALUES Dimensions 466 x 316 x 205 mm Weight 8kg Size of replacement air aperture 100 cm minimum area Heating capacity Max 0 9 1 9 kW calculated adjustment range Fuel Diesel Longest permissible length of fuel hose 8m Highest permissible rise of fuel hose without adjusting the pump 1 5m Fuel consumption Max 190 ml h 0 16 kg h Min 90 ml h 0 07 kg h Pump s pulse intervals Lio Max 1 45 sec see parameter file Min 3 00 sec see parameter file Nominal operating voltage 12V DC Functioning voltage range 10 7 15V Currency consumption 0 3 A upon ignition Glowing time 240 sec see parameter file
19. echanically remove deposits by using a screwdriver for example Scrape all of the inner surfaces of the burner clean and replace the bottom mat of the burner 206 Webasto Diesel Cooker 100 2 Functions description 2 3 Operating scheme How the device works Turn the device on by turning the switch on the control panel to the ON position The yellow LED light next to the switch will illuminate signifying that the device is on If the yellow LED light flashes at intervals of one second then the device is not receiving enough voltage The under voltage limit is 10 7 V Start Power M indication lamp Combustion indication geo Vas ems 666 08s lamp Start up 2 5 4 min Cooking Run down phase about 5 min Signal lights of operating panel during normal operation 207 Webasto Diesel Cooker X 100 2 Functions description 12V Main switch is _ _ off Glow Plug 240 sec alterable parameter max Combustion air fan min 4 min 50 sec max Cooling fan min 4 min 50 sec max Fuel pump min 4 min 50 sec 20 sec 30 sec The red LED light is ON The red LED light is Temperature Rise 30 flashing sensor T4 mV Burning indicator limit on After cooling off Table illustrating the device s priciple of operation 208 Webasto Diesel Cooker X 100 3 Technical Data Except where limit values are specified the techni cal data listed in the table refer to the usual h
20. ed by the combustion process is transferred to the air transported by the combustion air blowers into the heat exchanger There it gives off heat to the ceramic glass panel The exhaust gas then exits through the exhaust gas tube and is ducted outside the vehicle through the stainless steel exhaust tube Heat exchanger 203 Webasto Diesel Cooker 100 Temperature sensors The T4 circuit measures the voltage of the heat sensor thermocouple and will light the red LED light if the voltage exceeds the limit 10 mV Ten seconds after start up the T4 will begin recognizing the voltage The burning detection limit is 10 mV and it will be raised 30 at the same pace as the voltage rises The burning detector s red LED light ignition indicator is 10 mV and its shut down indicator is 13 mV There is an 8 second delay from the time the burning detector shuts off until the pump shuts down The lock up detector will automatically reset from the burning detector The red LED light will indicate whether or not the burning detector is functioning See 2 2 Descriptions of flashing lights T3 is a overheat thermostat When the temperature rises over 150 C 302 F power is removed from the fuel pump and the unit goes into a cooling phase The thermostat will automatically return to the On position after the unit cools Control panel Wires for control panel 2 Functions description Hot plate indication lamp An orang
21. hort circuit or the routing for the main fan is completely broken The main fan should be tested in the ventilation stage as well Testing the power control the flashing speed of the yellow LED light only changes according to the potentiometer setting when the pin pair S1 is closed When S1 is open the speed of the flashing correlates to the minimum of the potentiometer regardless of the potentiometer s actual position Indication of a malfunction in the operating voltage A uniform flashing of the yellow LED light indicates if and when the battery voltage has decreased below 10 7 V The LED light is on for 0 25 seconds turns on and off alternatingly Third attempt to start the device After two unsuccessful attempts to start the device the third attempt will lock it In this case all LEDs will begin to flash at a quick pace The LEDs flash on and off for a duration of 0 125 seconds Incorrect device parameters If the device s parameters are not set within the permitted range of values at the point of start up then the device will not start However the attempt to start the device counts towards one start up All LEDs will begin to flash in a circulating pattern each LED light will be on for a duration of 0 125 seconds All LED lights shut off for a duration of 0 125 seconds between the time the first LED light shuts off and another LED turns on The LEDs circulate in the following order the yellow LED light and the red
22. ical plug connectors on the control unit must be disconnected Conduct a function test in the vehicle after correcting each fault 401 4 Failure detection Webasto Diesel Cooker X 100 4 1 Trouble shooting chart Xue y ut Jan ey yoes asoy uonons jo pue eur 40 any uBnoue jou s say 10 JAN Jo NO SI 5 YL ppy 9 g den N Y asoy uonsnquioo asoy uorsnquioo 991 jo S NI ay ul ay SI 21941 SI JI 225 01 9849 5 00 y BuiApubis USE jou seop ug eu 9 pue aq snw jeuing 841 Koos sey sewing y L 8 ey uado 4 amp si uBnoiu peo ay J s A f Y N r jan y eBueuo 10 y Jen y 51 6191 nA 4 9 Y 4 f ey 4 rog VERRA syeaig y ueym adeys seBueuo ueyo Ond 4 241 ensi IJEN 2 Qoajap saysey s nd 1461 sejem asn ET Buisn eje mojb ad pue putuq eu youd 1 sBui
23. lates lock the thermal radiator in place Note The locking plates must be bent a bit crosswise before you can assemble the thermal radiator back in place This will ensure that the thermal radiator will stay in place during transport as well Burner cylinder Burner s bottom mat spring The bottom mat spring for the burner ensures that the bottom mat stays on the bottom of the burner prevent ing the glow plug from going under the bottom mat y Bottom mat of the burner 85 mm Delivered together with the bottom mat spring s Base of the burner Removing deposits Mechanically remove deposits by using a screw driver for example Scrape all of the inner surfaces of the burner clean and replace the bottom mat of the burner 504 Webasto Diesel Cooker 100 5 Updating and repair Installing the fuel needle The direction of the slanted tip of the needle in the burner must be considered when installing the fuel needle o o 0 01 3 0 0 O 0070 The slant of the needle goes towards the upper edge of the burner 505 Webasto Diesel Cooker 100 5 4 Glow plug The glow plug consumes approximately 8 A of power during the glowing stage The length of the glowing phase is the time stated in the parameters The temperature of the glow plug rises extremely quickly As you can see from Fig 5 the tip of the plug reaches 850 C in twenty second s
24. n the burner or a defective burning fan A CO value that is too low indicates that the device is not getting enough fuel or there is too much combustion air See the nominal value in technical information If the value differes make the adjustment Combustion air adjustment Adjust the device to minimum and let it run at the minimum for 10 min to reach the opera tion temperature When the device has reached its minimum operation temperature measure the combustion and if needed adjust the minimum rotation speed of the burning fan to MIN with the trim a Turning the trim counter clockwise will decrease the rotation speed of the burning fan turning it clockwise will increase the rotation the adjustment range is approximately 5 b Measure the combustion again Adjust the device to the maximum and let it run for 10 min to reach the operation tem perature When the device has reached its maximum operation temperature measure the combustion and if needed adjust the maximum rotation speed of the burning fan with the ANGLE trim a Turning the trim counter clockwise will decrease the rotation speed of the burning fan turning it clockwise will increase the rotation the adjustment range is approxi mately 5 b Measure the combustion again 7 Maintenance and service 5 Soot test The soot test determines whether the combustion is pure You can perform the test with a A CO meter y
25. n u abe 6 Electrical connections Note You must be sure you have ESD protection while handling the control unit Static electricity can damage the control unit X1 Device selection e Xxx aan ooo e RO 0euuoo Id LX 9S IX eS IX 65 LX 85 LX ZS LX 11 Flame monitor switch T4 with jumper thermostat without jumper N L 2r z z replaced with the J9 1 J9 2 wire loop Buneay ieno er 10 99 01d EL p zr Je joa aa 5 ww 2 28 53 a5 BS Sd po eo 2 2 lt lt t 28 p m oO oe 410 1 T4 thermocouple thermostat green 410 2 T4 thermocouple thermostat white 413 4 Main fan 413 3 Main fan 413 2 Over heating protector for the blower lid 413 1 Over heating protector for the blower lid 1 Oy D J12 GND J8 3 Glow plug GND u J8 2 Glow plug voltage J8 1 Glow plug Outer connections of the control unit 601 Webasto Diesel Cooker 100 6 Electrical connections Note You must be sure you have ESD protection while handling the control unit Static electricity can damage the control unit Control panel Wires for control panel Thermo element lr BOTTOM COVER VENTILATION FAN
26. ndicating over heating has locked as the result of a 5 second over heating situation the red LED light will uniformly flash The LED will flash on and off for a duration of 0 25 seconds The LED light will shut off 5 minutes after the start of the flashing due to over heating Flashing light after the flashing due to a malfunction When the flashing light due to intial test malfunctions as presented in the Initial testing section has lasted 5 minutes the yellow LED light will shut off and the red LED will begin to flash at intervals of 30 seconds Each flash during the 30 seconds lasts 0 125 seconds Third attempt to start the device After two unsuccessful attempts to start the device the third attempt will lock it In this case all LEDs will begin to flash at a quick pace The LEDs flash on and off for a duration of 0 125 seconds 4 Failure detection Incorrect device parameters If the device s parameters are not set within the permitted range of values at the point of start up then the device will not start However the attempt to start the device counts towards one start up All LEDs will begin to flash in a circulating pattern each LED light will be on for a duration of 0 125 seconds All LED lights shut off for a duration of 0 125 seconds between the time the first LED light shuts off and another LED turns on The LEDs circulate in the following order the yellow LED light and the red LED light During normal us
27. nput at maximum and adjust it to the correct value using the PUMP trim which is on the card the adjustment range is approximately 5 a Turning the trim counter clockwise will decrease the yield turning the trim clockwise will increase it b Measure the fuel input again C Malfunction of the pump Malfunctions in the pump may be caused by dirt build up in the valves or a damaged valve disc Even a small particle may prohibit the pressure gradient needed for pumping from forming especially when starting the device for the first time when the pump does not contain fuel In this case you can decrease the pumping pressure gradient by putting the suction end of the fuel hose in a bottle containing fuel for example Then raise the bottle to the same level of the heater or above it Change the pump if needed 701 Webasto Diese Cooker 100 4 Analyze the O and CO An O analysis reveals more quickly the reason for impure burning The O analysis should be performed with a meter intended for the purpose Combustion meters have an oxygen cell which measures the O value The device numerically changes the value to the CO value which is used universally in service shops There are differences in calculation formats a more precise test result can be achieved using the O value ACO value that is too high indicates an excess in fuel input not enough combustion air an air gap i
28. of an undamaged plug is approximately 1 ohm In case of a short circuit measuring the resistance will not uncover the malfunction because there is a 1 ohm resistance in the wires of the circuit analyzer alone In this case you can hook the glow plug up to a 12 V power supply remember the fuse and monitor the heating of the tip ofthe glow plug The tip should turn red within 20 seconds if the glow plug is working as it should Protect your eyes and be exremely careful when connecting the glow plug to the power supply A defective glow plug may spatter melted metal through the shell Webasto Diesel Cooker X 100 5 5 Heat exchanger and glass panel Changing the glass In the event you need to change a broken glass range or if you need to reach the structures underneath the glass range i e you must break the range Detaching the glass Cut the weld adhesive between the range and the profile with a sharp knife while at the same time prying it with a screw driver or similar tool Gluing the glass Clean the old adhesive and grease off the profiles well and dry the surfaces Spread the adhesive in an even strip 4 mm in the niche of the front back and side profile Go around the entire device according to Figures 1 and 3 Press the range carefully in place such that the adhesive does not squeeze from between the range and profile When gluing the range take note of the way the spring of the banjo located under the
29. ou can compare the result to the nominal value in technical information Soot test pump Instructions to use of soot test pump Place the test pump s suction hose into the combustion pipe hose and take a sample by slowly and fully pumping the pump 10 times The result must be 0 with the exception of the first 5 6 minutes after start up when a small amount of soot can be accepted In an burner that functions properly the formation of soot stops when glowing stops If the device becomes sooty the fuel input may be too much or not enough the combustion air input has been adjusted incorrectly or there is an air gap in the channels for the combustion air input or some other reason See the Troubleshooting chart The combustion air input can be analyzed and adjusted according the instructions in check point 4 6 In case the basic maintenance does not help If the device runs unbalanced or becomes sooty despite the correct fuel and air values then the malfunction could be caused by the following sooty burner air gap in the burner system wrong kind of fuel combustion channels are clogged or they have water in them If the device has any other fault or acts unusual way check the sourse of malfunction from the trouble shooting chart 5 0 702 Webasto Diese Cooker 100 7 Maintenance and service 7 2 Control unit settings The parameters for several different devices have been programmed
30. pump will pump another 300 times The PB will stop imme diately if you open the pins If you want to start the PB again turn the switch to the 0 position gt 1sec The PB works when the operating voltage is more than 11 V and the over heating protector T3 is not on The PB function may only be used in situations where the device is completely cold or if the fuel hose is empty J5 5 Updating and repair Pump Boost pins 1 and 2 J6 25 ks SI 54 508 Webasto Diesel Cooker 100 6 Electrical connections J5 1 heating ON J5 2 ventilation ON J5 3 12 VDC J5 4 power control J5 5 power control J5 6 yellow LED light J5 7 green LED light J5 8 red LED light J14 1 vuoristokytkin J14 2 vuoristokytkin J14 3 12 VDC J14 4 GND J9 1 Room thermostat _ J9 2 GND amp 2 J9 3 Burning indicator 3 J9 4 Timer ON 9 5 12 V J9 6 GND 510 Mountain switch Mountain setting with jumper S1 Room thermostat Follows power control with jumper S1 does not normally have a jumper it has been J6 Test pin header ccccccccc mors E abeljon ue ure JOA EL G dund d ni d abe ape as Bui abeyo
31. quality Change the fuel Water inside the exhaust pipe Remove the water Make sure that there is no water lock water in pipe bend s Wrong fuel consumption Measure the fuel consumption adjust if needed Max 190 ml Min 90 ml Check the fuel needle and the filter Burner is sooty 405 Clean the burner see chapter burner Webasto Diesel Cooker 100 4 Failure detection 4 3 Failure blink codes Signal lights in case of malfunctions Glow plug problem OFF 0 1255 25 0 1255 25 0 1255 Combustion air fan p ellow problem OFF 0 125 5 0 125 s 0 1255 25 0 1255 0 1255 0 1255 25 Cooling x air fan Yellow 0 125 50 125 s 0 125 5 0 1255 0 125 5 25 0 125 5 0 125 5 0 125 5 0 1255 0 1255 25 problem id Under votage ww LJ LJ LT OFF 0 255 0 255 0 255 0 255 Lockin oN ae2 wa ELT unsuccessful LT LT LT LT LT LT starts OFF 0 125 5 0 125 s 0 125 s 0 125 s Opening the locking 1 Switch the power ON lock blinking 2 Disconnect the main power cord blinking stops 3 Reconnect the main power cord the yellow LED lights up for 1 3 seconds 4 When the yellow LED has gone out switch the power OFF Overheat d OFF 0 25s 0 255 0 255 0 255 Lights after IN failure Red signal OFF 0 125s 30s 0 125s 30s The red lamp begins blinking when failure signal has lasted for 5 minutes 406 Webasto Diesel Cooke
32. r Make sure that there is no water lock water in pipe bend s No fuel Glow plug voltage is too low glow plug is not hot enough Refill fuel tank Check that the main cable cross area mm is large enough Check also all cable connections and connectors Glow plug faulty fault blinking Visual check often the plug changes form when faulty Water in fuel Change the fuel Water inside the exhaust pipe 404 Remove the water Make sure that there is no water lock water in pipe bend s Webasto Diesel Cooker X 100 Cooker goes OFF by itself Unstable combustion cooker smokes No fuel 4 Failure detection Check and add fuel if necessary Check the fuel pump s operation Battery voltage too low must be more than 10 7 VDC Check the battery condition and main cable connections Recharge the battery if necessary Water in fuel Change the fuel Water inside the exhaust pipe Remove water Make sure that there is no water lock water in pipe bend s Hard wind pressure on exhaust lead through vent Turn the vehicle so that the wind does not hit directly the lead through vent Cooker over heated Check the free air flow around the cooker Measure the fuel consumption adjust if needed Max 190 ml Min 90 ml Burner is sooty Water in fuel Clean the burner see chapter burner Change the fuel Bad fuel
33. r X 100 4 Failure detection Descriptions of the flashing LED lights beginning from XPS v 1 2 Leds on the control panel Yellow LED If the device does not shut off in the heating phase after the initial testing due to a defect then the start up will continue and the yellow LED light will illuminate and remain on continuously Initial testing One quick flash of the yellow LED indicates that there is a malfunction in the glow plug The LED light will be on for 0 125 seconds and off for two seconds after which it will repeat the sequence The glow plug defect may be due to a short circuit or complete breakage Two quick consecutive flashes of the yellow LED light indicate a malfunction in the burning fan In this case the LED is on for 0 125 seconds at first then it is off for 0 125 seconds and then on again for another 0 125 seconds After the second flash the LED is off for two seconds before it makes a new double flash The malfunction is either due to a short circuit or the routing for the burning fan is completely broken Three quick consecutive flashes of the yellow LED light indicate a malfunction in the main fan other names include rotary fan ventilation fan or cooling fan Each flash lasts 0 125 seconds and the time between two consecutive flashes is also 0 125 seconds After the third flash the LED light is off for two seconds before it makes a new triple flash The main fan s malfunction is either due to a s
34. range depresses The spring must depress along with the range such that the edges of the range have evenly settled against the profiles Place something heavy on the range that distributes evenly over the entire range for the entire time it takes for the range to dry Concentrated weight on a certain area of the range will cause it to warp You have six minute s time to apply the adhesive before it starts drying It will be completely dry after 24 hours Adhesive strip Front and back profile Side profile Figure 1 5 Updating and repair Figure 2 Adhesive The adhesive used is Loctite 5368 Store the adhesive in room temperature Location of the adhesive in the profiles and adhesive cleat The strip of adhesive is approximately 4 mm thick and goes around the entire device in the place illustrated in the Figure 1 Adhesive strip Figure 3 507 Webasto Diesel Cooker 100 5 6 Pump Boost The Pump Boost PB function has been designed to facilitate filling the fuel hoses during installation and maintenance Connect the PB by turning the maintenance per son s switch to the vent position and connecting the J6 pins 1 and 2 of the maintenance coupling The pump will click once and by holding the pins together for at least two seconds the PB will work There is no vent position on the control panels of stoves The integrator stops the PB after the pump has pumped 300 times by opening the studs the
35. s immediately PC cord connector PC connection on XPS card ols Figure 2 Webasto Diesel Cooker 100 5 2 Test program A device named Test The test device assists the maintenance person when investigating the condition of the control unit e g directly from the maintenance coupler J6 The test device is a device in the device parameter selection X1 Device 1 You can get to Device 1 by detaching all jumpers from the pin pairs 52 56 The test device assists the maintenance person when investigating the condition of the control unit e g directly from the maintenance coupler J6 The following values have been programmed as the test device 7 V for the main fan s motor 7 V for the burning fan s motor Glow on normally and stays on 11 V 4 clicks from the pump T4 voltage 5 mV Burning indicator LED light turns on T4 voltage decreases 5 mV Burning indicator LED light shuts off Flashing of the yellow LED 1 Hz when the potentiometer is at the minimum Flashing of the yellow LED 10 Hz when the potentiometer is at the maximum If you do not get these values the control unit is defective Measurements from the control unit TESTIPIIKKIRINA 6 1 TEST_PB J6 2 TEST_RG p m R33 10k TEST ANA T4 2 8 4 10 R34 TEST T3 J6 5 10k TEST_P J amp 6 10k R38 T
36. ston if necessary change the pump Pump get s pulses and piston moves but fuel does not move inside the fuel line Check if the fuel needle or fuel filter is blocked Fuel line joint to the pump is loose and pump get s air Check and tighten joint Pump is worn or dirty and can not pump fuel Replace the pump Glow plug Glow plug does not get sufficient voltage Glow plug is not hot enough Check that the main cable cross area mm is large enough Check also all connections Glow plug is faulty fault blinking 403 Visual check often the plug changes form when faulty Webasto Diesel Cooker X 100 Cooker is smoking during start ing phase Combustion air blower 4 Failure detection Combustion air blower does not run Fault blinking Measure blower s voltage compare to the parameter table Replace the combustion air blower Control unit PCB Control unit faulty Replace the Control unit Temperature sensor T4 Temperature sensor voltage does not rise during start up Measure the voltage approx 5 minutes after the start up voltage must be over 13mV sensor wires attached to the board Check the temperature sensor Other cause Bad fuel quality Change the fuel Water in fuel Change the fuel Exhaust lead through blocked Remove blockage Water inside the exhaust pipe Remove the wate
37. t depending on your computer s settings When you have succeeded in getting the correct COM port to work the control unit s amount of operating hours and programme version will be displayed on the Xplink operating system Figure 1 7 Click File gt Open gt Al xpd always use the last file that was used 502 5 Updating and repair 8 There are two ways to update a single device 8 1 You can update all parameters by clicking on Choose all Click on Export The parameters of all devices are updated at same time this takes just a few moments When the parameter update has succeeded the text file transfer ok will appear on the screen after a few seconds If the data transfer has been unsuccessful the operating sustem will display an error message on the screen 8 2 You can also update the parameters of just one device In this case DO NOT click on Choose all Next choose the appropriate device from the pop down menu Device 17 Click on Export Loading may take 1 to 2 seconds When the parameter update has succeeded the text transfer ok will appear on the screen after a few seconds If the data transfer has been unsuccessful the operating system will display an error message on the screen 9 When the parameter update has been successful detach the PC cable from the control unit 10 You can use the new parameter
38. time The glow plug we have used is in the 2 generation category Malfunction The glow plug may experience a malfunction as a result of thermal overload In this case the resistance wire will either break or short circuit with the shell of the glow plug Installation If you are only going to change the glow plug make sure you are careful in connecting the wire The largest permissible tightening torque for the mounting is 5 Nm When connecting the mounting nut you must hold on to the bottom nut 1 to keep the inner parts of the glow plug from becoming damaged ms Z 4 a 506 5 Updating and repair Steady state temperature I 1170 BERU SR sheathed heater plug 3rd generation Quick start sheathed heater plug 2nd generation F 150 100 Standard sheathed heater plug ist generation Ignition temperature sd Sl u um m Emm e ee 2 7 9 nm Black curves Current strength Glow tube temperature C Preheating current o 10 20 30 40 50 60 70 Preheating time 5 Fig 5 Temperature development of the various sheathed heater plug generations Testing To see if resistance wire is broken measure the resistance between the and terminals with a circuit analyzer There will be no resistance if the plug is broken The resistance between the terminals
39. ttest area is on the round plate Gentler heat is available on the oblong extension The heating power is adjustable Main cooking area Fuel pump _ Overheat thermostat Burner chamber Hot plate indication lamp 2 Functions description Additional cooking area Operating panel Operating panel cables Main switch Main fuse Power cables I Fuel filter Fuel connection Cooling air tube with T piece A cooling fan in the ventilation box ensures that the temperature in the mounting space will not rise too high The warm air is led out through the cooling air tube The cooker is ideally suited for cooking and heating of all kinds of food The cooker is made entirely of stainless materials Additional cooking area Cable lead through Cooling en Fuel hose lead through 201 Webasto Diesel Cooker X 100 2 Functions description 2 2 Main components Operating panel The cooker starts to heat up automatically when the power button is switched to ON position The yellow indicator lamp lights up as soon as the cooker is switched on The red combustion lamp will light up when the combustion is stabilized in the burner about 2 5 4 minutes after the start up Power indication lamp yellow Combustion Power switch Power adjustment High altitude indication lamp orange a High altitude switch Power i indication
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