Webasto Thermo Test Version 2.07 06/2005 Operating instructions
Contents
1. Jebasto Feel the drive 9 The process runs automatically after you plug in the USB adapter Windows responds The installer is ready to install Webasto ThermoTestGB on your computer Neue Hardware gefunden A USB K Line Adapter Click Next to start the installation Wait until the matching drivers have been found Assistent fiir das Suchen neuer Hardware Willkommen Dieser Assistent installiert einen Treiber fur ein Gerat 7 Click Next to start the installation Select Language Please select the language that you would like to use during the installation Klicken Sie auf Weiter um den Yorgang fortzusetzen i Abbrechen lt Zur ck Deutsch 10 Click Next to continue the installation of the USB drivers cancel 8 Please wait the installation is not yet finished 8 General information installation Assistent f r das Suchen neuer Hardware E Hardwaretreiber installieren nn Ein Ger tetreiber ist ein Programm das das Ansprechen des Ger ts durch das I Betriebssystem erm glicht Der Assistent wird die Installation des Ger ts fertig stellen a USB K Line Adapter Geratetreiber sind Programme zum Steuer der Hardware F r das neue Ger t sind Treiberdateien erforderlich Klicken Sie auf weiter um diese Treiberdateien zu suchen und die Installation zu abzuschlieBen Wie m chten Sie vorgehen Alle bekannten2. Heater specific diagnosis Heater specific diagnosis 2 9 Menu Window The Window menu enables you to influence how open dialog boxes and view windows are displayed 2 9 1 Overlapping Select menu command Window Overlapping if you want open windows to be arranged overlapping each other 2 9 2 Side by side Select menu command Window Side by side if you want open windows to be of the same size and arranged next to each other without any overlap 2 9 3 Close all Select menu command Window Close all if you want to close all open windows 2 9 4 To select an open window Select the Select an open window menu command if you want to switch between windows that are open at the same time Menu Window 21 Menu Help 2 10 Menu Help 2 10 1 Help This menu displays help topics relating to this diagnostic software e To obtain help on the program and problems select menu command Help Help or click the button x From this window you can go to instructions that will give you a step by step guide to using Webasto Thermo Test 2002 or you can view various types of reference information e As soon as you have opened the help topic you can click the Contents button at any time to return to the contents window 2 10 2 Program information This displays the version of this diagnostic software e Select the Help Program information menu command or click the 2 button to obtain information on your WTT version e Click lt OK
3. Jebasto Feel the drive Webasto Thermo Test Operating instructions Version 2 07 06 2005 Table of contents Let 1 2 1 3 1 4 1 5 21 2 2 2 3 2 4 2 5 2 6 2 1 2 8 2 9 2 10 3 1 3 2 General information installation General System requirements Diagnostic capable units Installation on the hard disk Connections Heater specific diagnosis Test procedure Menu Diagnosis Menu View Menu Error memory Menu Print Menu Control depending on heater version Menu Calibration Menu Tools Menu Window Menu Help Service modules for components and accessories IPCU intelligent PWM control unit Telestart T100HTM Troubleshooting General oOoft 12 13 15 16 17 18 19 20 21 22 23 23 24 25 25 Thermo Test General information installation General 1 General information installation 1 1 General The Webasto heater diagnostic software is used for checking heaters with a diagnostic capability in all voltage versions with the help of a personal computer The PC diagnostic adapter and the type specific test adapter supplied with the software are required to connect the heater to the PC see figure The test adapters are identical as used in combination with the diagnostic computer Although the program has been tested successfully on many computers it is not impossible that it will not run properly on certain PCs In this case please let us know so that we c
4. Calibration 2 7 1 CO2 adjustment To carry out the calibration process select menu command Calibration CO adjustment or click the button NOTE This function is only available when the heater is in certain statuses Please also read the corresponding chapter in the workshop manual of the heater in question Menu Calibration 19 Menu Tools 2 8 Menu Tools NOTE If the diagnostic adapter is connected to the USB port it will be auto matically recognised by Windows No settings are required The Tools menu provides you with two menu commands to configure your computer 2 81 COM port e Open the COM port selection dialog box using menu command Tools COM port e Select the COM port COM1 or COM2 you want to use to connect to the external device e Click the lt OK gt button to confirm your selection CAUTION If the COM port you wish to use is not displayed this means that the port is being used by a different program In this case quit all your applications and restart Thermo Test 2 8 2 Startup Select menu command Tools Startup if you wish to restart the connec tion to the control unit automatically after an interrupt This is an advan tage if the operating voltage is disconnected frequently during the test The selection will be confirmed by a tick being placed next to the Startup menu command If you reselect the menu command or terminate the connection this selection will be cancelled 20
5. Treiber f r das Ger t in einer Liste anzeigen und den entsprechenden Treiber selbst auswahlen lt Zur ck Abbrechen 11 Select Search for a suitable driver for the device and confirm your selection with Next Assistent f r das Suchen neuer Hardware Suche nach Treiberdateien Geben Sie an wo nach den Treiberdateien gesucht werden soll Nach Treiberdateien f r folgende Ger te suchen op USB K Line Adapter Der Assistent sucht in der Treiberdatenbank und auf den angegebenen Laufwerken nach passenden Treibern Klicken Sie auf weiter um die Suche zu starten Wenn der Suchvorgang auf einer Diskette oder einem CD ROM Laufwerk ausgef hrt wird legen Sie zuvor den Datentr ger ein Andere Quelle angeben T Microsoft Windows Update lt Zur ck Abbrechen 12 Select CD ROM drives from the other sources and click Next to confirm Installation on the hard disk Wait until the matching drivers have been found Assistent f r das Suchen neuer Hardware Treiberdateien Suchergebnisse en Die Suche nach den Treiberdateien f r das Ger t ist beendet I F r folgendes Ger t wurde ein Treiber gefunden oy USB 7 K Line Adapter Es wurde ein Treiber fur das Ger t gefunden Klicken Sie auf weiter um diesen Treiber zu installieren a d wusb inf Abbrechen lt Zur ck 13 Windows has found the suitable drivers Click Next to ins
6. into the protocol file name box for the new text file e g protocol_dated_011213 The file extension TXT is added automatically or may be entered as part of the file name e g Test_011214 txt e Enter the recording interval the default is 10 seconds NOTE When you have finished the diagnosis end the measurement recording 2 2 9 To end measurement recording e The lt OK gt button starts the recording e Use the Diagnosis Measurement recording menu command to end measurement recording Heater specific diagnosis 2 3 Menu View You can select between different views in order to see different displays and data about the heaters 2 3 1 Overview window This view gives you an overview on the values during the diagnosis In addition to the operating voltage temperature etc the device status is also shown e Use the View Overview window menu command or click the Fl button to open the Overview window 2 3 2 Operating data The operating data view gives you an overview of a number of parame ters in addition to the values that have been found and the units for them e Use the View Operating data menu command or click the button to open the Operating data 2 3 3 Control unit information The device information view contains a list of all the information and values relating to the connected device e Use the View Control unit information menu command or click the IE button to open the Control unit informatio
7. priming the line in seconds in the priming time box The default is 30 seconds e Click the lt Start priming gt button to start the line priming process e Click the lt Stop priming gt button to cancel your entry or to stop the line priming prematurely NOTE The priming process cannot be stopped on some heaters 2 2 6 To save the data summary Select menu command Diagnosis Save summary to open the report file dialog box The summary shows operating data and control unit information 14 Heater specific diagnosis e Enter as clear a file name as possible in the file name box for the new text file e g report_dated_011213 The file extension TXT is added automatically or may be entered as part of the file name e g Test_011214 txt e Click the lt Save gt button to save the summary of the diagnostic data 2 2 7 To open the data summary To open an existing summary of diagnostic data open the report file dialog box using menu command Diagnosis Open summary e Mark the file you want to review by clicking it The name of the marked file will be transferred into the file name box e Click the lt Open gt button or double click the file name to open the text file e The Display summary view will be opened e Click the lt OK gt button to close the view 2 2 8 Start test record Use the Diagnosis Start measurement recording menu command to open the Protocol file dialog box e Enter as clear a name as possible
8. trade heater does not need to be switched on during the diagnosis After a TRS condition has been triggered the heater may only be restarted as follows e Switch off the heater e To exit the diagnosis e Wait atleast 10s Heater specific diagnosis 2 2 Menu Diagnosis 2 2 1 Select device Start diagnosis Open the dialog box to select the control unit using the menu command Diagnosis Select device or by clicking the button E Unit Application Thermo Top V All existing applications Thermo Top C Z DC C Class W203 and W203Mopf after 09 04 DC E Class W211 DC S Class W220 and W220Mopf after 09 02 DC SL Class R230 DC CLK Class W209 Porsche Cayenne AUDI A8 D3 VW Phaeton D1 VW T5 VW Touareg MAC BMW 7 Series E65 Mazda 6 Mazda MPV both U222 AT2000ST All AT3500ST All Thermo 90ST All GBW 300 All Menu Diagnosis Heater selection for USB interface 2 2 1 1 To select the control unit and start the diagnostic process e Click the lt Auto search gt button The system performs an automatic search using the device identifier and then starts the diagnostic process or e Mark the appropriate control unit by clicking it and then click the lt OK gt button The diagnostic process will be started or e Double click the relevant control unit The diagnostic process will be started 2 2 2 To exit the diagnosis End the current diagnosis using the menu command
9. Diagnosis End diagnosis function key F3 or by clicking the button 2 2 2 3 To restart the diagnosis You can restart the diagnosis of the control unit you have specified earlier by selecting the menu command Diagnosis Start diagnosis pressing function key F2 or clicking the button 2 2 2 4 Component test Open the dialog box of the same name using the menu command Diagnosis Component test or by clicking the button fa e Mark the components that you wish to test in the options box for example the combustion air fan e Click the lt Start gt button to start the test on the selected component e Click the lt Stop all gt button to terminate the current test 13 Menu Diagnosis NOTE This function is not available for BBW 46 S DBW 46 S Note on Air Top 2000 Heating mode is terminated with a short slow down time after which the test functions are available diagnostic mode The test starts after a further acknowledgement by pressing the Enter key or clicking the OK button After the component test has been ended by clicking the Cancel button the heater will resume normal control mode Note on Thermo 50 MAN trade The component test is only available when the heater is OFF The CO adjustment may only be carried out in combustion mode with the heater in full power 2 2 5 Line priming Open the dialog box of the same name using the menu command Diagnosis Prime line or by clicking the button l e Enter the time for
10. E NT4 2000 XP or newer versions COMCTL32 DLL Version 4 70 or newer Can be downloaded from the Microsoft Internet download area http www microsoft com 3 MB available space on the hard disk A vacant COM port RS232C or a vacant USB port Optional Internet access for software updates NOTE The USB port cannot be used for PC diagnosis with Windows 95 and Windows NT because these operating systems do not support USB ports General information installation General information installation 1 3 Diagnostic capable units Device selection _____ x Please notice The following list describe diagnostic protocols not heating devices For new generation heating devices please select the W Bus Webasto Bus location Thermo Top C E after market P C Z MB DC Thermo 230 300 350 SG1572 K Line Thermo Top C Z PSA It is a USB Adapter currently in use Please notice Not all heating devices are at present available over USB In case that the device is not in the list please plug in the adapter to the COM port Cancel Fr automatic search Heater selection for USB interface NOTE If the device is not listed in Select device the heater must be a model with W Bus W Bus capable heaters are grouped under the heading of W Bus In this case use the W Bus selection The W Bus selection contains a list of various heaters that use the same diagnostic port see also point 1 Diagnostic capable units Ste
11. HTM 3 2 1 Programming the system level DialogBox Telestart T100 HTM Comfort level 1 Comfort level 2 Comfort level 3 Comfort level 4 System level 0 20min 30min 40min 50min System level 1 20min 35min 50min 65min System level 2 20min 40min 60min 80min System level 3 20min 45min 70min 90min Read system level Info Service modules for components and accessories Comfort level 5 60min 80min 100min 120min Heating Time Management HTM in the Telestart receiver calculates the heating duration depending on the prevailing temperature and the comfort level C1 to C5 selected using the hand held transmitter Comfort level We recommend comfort level 2 3 as the basic setting However the user can adapt the comfort level according to his or her individual require ments using the HTM transmitter The specialist workshop can select a higher system level in advance to adapt the system in accordance with specific requirements System level The system level setting is used for the default setting depending on the corresponding vehicle type This setting can only be made by the Webasto specialist workshop or an installation partner using the diagnostic software 24 We recommend the following typical default settings for the system level S1 For small cars and saloons S2 For off roaders estate cars SUVs and in general for vehicles with a spacious interior S3 S4 Only in regions with very cold outdo
12. an make improvements if necessary General General information installation Fig 1 Test adapter for Thermo 90 heaters Fig 4 Test adapter for BW 80 and DW 80 heaters order no 836 61B order no 213 33A Fig 2 Test adapter for Thermo 90 S ST and Thermo 50 MAN Fig 5 Test adapter for Thermo Top Z C trade and Air Top 2000 S trade heaters order no 925 56A heaters order no 925 66B Fig 3 Test adapter for BBW 46 S and DBW 46 S heaters Fig 6 Test adapter for Air Top 3500 5000 ST and Air Top 2000 ST You can make an appropriate adapter yourself if required heaters order no 925 55A General information installation General 7 Fig 7 Test adapter for DW 230 300 350 and Thermo 230 300 350 Fig 10 Test adapter for DW 230 300 350 and Thermo 230 300 350 heaters order no 208 65A RVI heaters order no 926 29A Fig 8 Test adapter for DW 230 300 350 and Thermo 230 300 350 Fig 11 heaters order no 226 56A Fig 9 Test adapter for DW 230 300 350 and Thermo 230 300 350 Fig 12 Test adapter for DW 230 300 350 and Thermo 230 300 350 heaters order no 883 36A MBI Citaro heaters order no 662 65A System requirements 1 2 System requirements Webasto Thermo Test 2002 will not run under Windows 3 1 with Win32s IBM compatible PC 486 or higher depending on the requirements of the operating system Min 8 MB of RAM depending on the requirements of the operating system Microsoft Windows 98 M
13. e installation will start automatically If the program does not autorun select Start gt Run Click Browse and then select Setup exe on the installation CD and click OK Alternatively select the CD drive containing the installation CD using Explorer In the main directory click Setup exe The Windows Setup Manager will then guide you through the installation General information installation 1 4 1 1 WTT 2002 software installation NOTE In this example installation under Windows 2000 has been selected The installation under other Microsoft operating systems such as Windows 98 ME or XP is identical Please note If you are working in a network and require administrator rights for the installation then please log on using the corresponding user name and password 1 Perform the steps listed in 3 1 Windows responds Sprache Language deutsch english frangele espanol Galana flemiect nederland gE neka russki 2 Select the required language and confirm your selection with OK General information installation Installation on the hard disk 3 Wait for the installation preparation to finish The Setup program responds i WebastoThermoTestGB ji WebastoThermoTestGB Welcome to the WebastoThermoTestGB Se Wizard Webasto Feel the driwe The installer will install Webasto ThermoT estGB to the following folder The WTT installer will lead you throu
14. emain connected if necessary Connect the 9 pin plug or USB plug to the diagnostic adapter NOTE The system must be switched manually between COM1 and COM2 if the PC has more than one serial port There is no need to switch between the COM and USB ports manually The USB port to which the hardware is connected will be recognised automatically This applies even if there is more than one USB port Both COM and USB connections are not allowed to be used atthe same time CAUTION To avoid potential differences the vehicle must not be connected to a charger during the diagnostic procedure CAUTION Before connecting to the heater ensure that there is no voltage between the earths of the PC and the vehicle Voltages in excess of 5 V may damage both the diagnostic adapter and the PC First connect the adapter to the positive pole and then to the earth to ensure this Connect the type specific test adapter to the 4 pole connector of the diagnostic adapter and the heater The heater may be switched on Connections NOTE The connection cable to the heater is not allowed to be routed near the vehicle ignition system or activated electrical devices e g electric drill Exit the diagnostic program before disconnecting the cables No particular sequence must be observed for disconnecting the cables 11 Test procedure 2 Heater specific diagnosis 2 1 Test procedure NOTE The heater must be connected to the vehicle
15. gh the installation of WebastoThermoTestGB i A S P p To install in this folder click Next To install to a different folder enter it below or click Browse Eolder C Program Files WebastoThermoTestGB Browse Disk Cost All rights of the producer and of the owner of the work reproduced reserved Unauhtorized copying Install WebastoThermoTestGB for yourself or for anyone who uses this computer hiring or lending prohibited C Justme Cancel 4 This is information about the copyright and industrial rights of this 5 software If you agree with these clauses click Next to continue om m en At this point you are asked in which folder you want to install the Webasto Thermo Test software If you wish to change the specified path C Program Files WebastoThermofTest click Browse and select a different folder You are then asked whether the program should be installed for all users of this computer or only for the current user Please note Please note that if you select your own path any folders with the same name on the hard disk will be overwritten If you select the Current User option the program is only installed for the current user 6 Confirm the settings with Next Installation on the hard disk General information installation iif WebastoThermoTestGB Connect the USB adapter to a vacant USB connection on your computer Confirm Installation
16. gt to close the program information window 22 Heater specific diagnosis Service modules for components and accessories IPCU intelligent PWM control unit 3 Service modules for components and accessories 3 1 IPCU intelligent PWM control unit 3 1 1 IPCU programming The button Set selected parameters sets the predefined parameter for the selected vehicle module under IPCU programming IPCU DialogBox a Be Dix The parameter values can also be changed individually Programming of the selected parameters is only performed using the button IPCU programming ecu NOTE I ep J When selecting user defined parameters make sure they are suitable o for the requirements of the fan motor Incorrect parameters can lead to ee IE ER Programmen Fahrzeugspeaifische Parameter a malfunction or damage to the fan motor when the module is operating DutyCycle DuyCycle BE I Frequenz Hz Frequenz o ah Spannung y Ausgew hlte Parameter setzen Funktion S Funktion x Beenden This dialog box is used for programming an electrical system referred to as IPCU module for short for controlling vehicle fan motors Timeout The current settings of the IPCU module are continuously read out and displayed under Current IPCU settings A list of vehicle modules can be found in Vehicle specific parameters 23 Telestart TIOOHTM 3 2 Telestart TIOO
17. n 2 3 4 Trend graphic The graphical trend view shows the sequence of the heater values over time in a diagram Right clicking the display with the mouse displays a shortcut menu for the displayed values You can show or hide the individual values by clicking here The same thing applies to the displays in point 7 5 Protocol display e Usethe View Trend graphic menu command or click the z button to open the Trend graphic Menu View 2 3 5 Protocol display This protocol display view lists all the statuses of the heater during the diagnosis e Open the last of the five views of the diagnostic results using menu command View Protocol display or by clicking the button Ej e To close this view click the square at the far right of the window title bar 15 Menu Error memory 2 4 Menu Error memory 2 4 1 To display the error list e Open the error display window using menu command Error memory Display error list or by clicking the button e This view displays a list of all the errors saved in the control unit together with the values that occurred during the error Each error is listed separately to distinguish clearly between them e If you click an error an explanation of that error will be displayed 2 4 2 To delete the error memory To delete all the entries in the error memory select menu command Error memory Delete error memory function key F5 or click the button H NOTE Please note that after the
18. or temperatures or if the customer has special requirements Altering the system levels makes it possible to adapt the heating duration to the given features of a particular vehicle heating system The maximum heating duration below 20 C is specified for each system level in the dialog box The minimum heating duration above 10 C is always 10 minutes The heating duration between these two temperature values varies with an approximately linear progression Troubleshooting 4 Troubleshooting 4 1 General When you select a test function an error message is displayed Check if the diagnostic adapter is connected to the selected serial port or the USB port on the PC and that heater is properly connected Check whether the heater is switched on and is receiving power Is there an earth connection apart from via the diagnostic cable between the PC and the vehicle If so immediately disconnect the diagnostic cable and disconnect the relevant connection to prevent damage to the adapter and PC The control unit may be defective check with a different unit before replacing it A control unit that has no diagnostic capability may have been selected An incorrect connection on the control unit has been used for the diagnostic cable If you are using an RS232 COM port If another program e g keypad or mouse is accessing the port this application must be closed General 25
19. s electrical system but not necessarily operating to execute a test function If the adapter is not connected or connected to the wrong port or the heater is not on or not properly connected an error message will be displayed In this case check the above causes The program monitors the connection to the heater and identifies disconnects Irregular disconnects e g pulling a plug during the test will result in the message Timeout being displayed in the status window Specific notes on the various types of heaters Thermo Top Z C If the diagnostic cable is connected the heater depending on the version cannot be started using the timer or the Telestart In this case first disconnect the diagnostic cable start the heater and then reconnect the diagnostic cable BBW46S DBWA6S After the diagnosis has been started the heater enters a diagnostic mode with a run down Thermo Top P The UP circulating pump button is not permanently activated during diagnosis instead it flashes at various frequencies depending on the operating status of the circulating pump 12 Heater specific diagnosis DW 230 350 Thermo 230 350 The diagnostic port may suffer malfunctions when errors from this unit are saved The diagnostic program detects these malfunctions and will rectify the problem by deleting the error memory saved error data will be lost The pump pressure test is not possible Thermo 50 MAN trade The Thermo 50 MAN
20. tall the driver Installation on the hard disk Assistent f r das Suchen neuer Hardware Fertigstellen des Assistenten USB K Line Adapter Die Software fur das Gerat wurde installiert Klicken Sie auf Fertig stellen um den Vorgang abzuschlie en Abbrechen 14 Click Finish to complete installation of the USB drivers successfully 15 Restart the computer to complete the installation 10 General information installation 1 4 2 Download from the Internet and installation The latest version of the program is available from our dealer area under www webasto de If you do not have access please contact the regional manager responsible for your area or your Webasto dealer Download e Click the download link on the Internet e Select save file and save the file in a suitable folder on your hard drive Installation new installation or update e Close all Windows programs e Open Explorer and go to the folder in which you saved the file from the Internet e Double click this file e The Windows Setup Manager will then guide you through the installation See Installation chapter 1 4 1 page 6 General information installation 1 5 Connections CAUTION The work MUST be completed in the following sequence Connect the 9 pin plug or the USB plug both cables are supplied to a vacant serial port COM1 or COM2 or a vacant USB port on the PC the plug can r
21. uerger teauswahl R5232 SCHNITTSTELLE Bitte beachten Sie dass die nachfolgende Liste keine Heizger te sondern Diagnoseprotokolle beschreibt Heizger te neuerer Gereration sind z T im W Bus Webasto Bus zusammengefa t Thermo Top C E Handel P C Z MB DC Thermo Top 98 473500 5000 Thermo 905 Thermo 230 300 350 SG1572 K Line Thermo Top BMW DW 230 300 350 E1 Thermo 230 300 350 E2 DEW BBW 465 IPCU Intelligente PwM Steuereinheit Telestart Abbrechen automatische Suche Heater selection for COM interface Diagnosis of the following units is only possible via serial port the USB interface cannot be used with these units Thermo 50 Thermo 90 Thermo 230 Thermo 300 Thermo 350 not with SG1572 K line BBW 46S BW 80 DBW 46S DW 80 DW 230 DW 300 DW 350 Installation on the hard disk 1 4 Installation on the hard disk NOTE Webasto does not accept liability for any data loss on your computer Therefore we recommend you back up your hard disk If you already have older versions of the software installed on your computer they must be uninstalled before the new installation 1 4 1 Installation using the installation CD To install the Webasto PC heater diagnostic software proceed as follows Webasto recommends using the automatic installation program 1 Close all Windows programs 2 Deactivate the virus scanner 3 Insert the installation CD in the appropriate drive 4 Th
22. y have been deleted the error values can no longer be reviewed If necessary you should print out the error values before you delete them see the Print function chapter 2 5 16 Heater specific diagnosis Heater specific diagnosis 2 5 Menu Print 2 5 1 To print the summary To print a summary select menu point Print Summary function key F12 or click the button Ej Menu Print 17 Menu Control depending on heater version 2 6 Menu Control depending on heater version 2 6 1 Off To switch off the heater select menu command Control Off function key F4 or click the button Sj 2 6 2 On To switch on the heater select menu command Control On or click the button 2 6 3 Auxiliary heating If you wish to use auxiliary heating mode select menu command Control Auxiliary heating or click the button 2 6 4 Additional heating If you wish to use additional heating mode select menu command Control Additional heating or click the button gt l 2 6 5 Ventilation If you wish to use ventilation mode select menu command Control Ventilation or click the button Fl 2 6 6 Boost mode If you wish to use boost mode select menu command Control Boost mode 2 6 7 Circulating pump To switch on the circulation pump select men command Control Circulation pump NOTE Not all of the control commands are available for all of the heaters 18 Heater specific diagnosis Heater specific diagnosis 2 7 Menu
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