Feel the drive Service manual Webasto Diesel Cooker X 100 11/2005
Webasto Diesel Cooker X 100 Table of Contents 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 101 101 101 101 101 2. Function description 2.1 System description 2.2 Main components 2.3 Operating scheme 3. Technical Data 201 202 207 301 4. Failure detection 4.1 Trouble shooting chart 4.2 General failures 4.3 Failure blink codes 402 403 406 5. Updating and repair 5.1 Updating 5.
Webasto Diesel Cooker X 100 1 General 1.5 Suggestions for improvements and changes 1 General 1.1 Contents and purpose Complaints, improvement suggestions or corrections relating to this workshop manual should be addressed to This workshop manual is designed to assist trained personnel with repairing the Webasto Diesel Cooker X 100. Webasto AG BU: Global Comfort Solutions Dept. B5.6.2 Kraillinger Str. 5 D-82131 Stockdorf Phone: +49 (89) / 8 57 94 - 6 34 PC-Fax: +49 (89) / 8 57 94 - 3 97 1.
Webasto Diesel Cooker X 100 2 Functions description 2 Functions description 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 hottest area is on the round plate.
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.
Webasto Diesel Cooker X 100 2 Functions description Fuel pump Combustion air fan The fuel pump is a combined transport, metering and shut-off system for supplying fuel from the vehicle’s tank to the cooker. The voltage range of the burning fan may be altered between 4.8 V and 10.7 V by changing the parameters; 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.
Webasto Diesel Cooker X 100 2 Functions description Temperature sensors Hot plate indication lamp 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.
Webasto Diesel Cooker X 100 2 Functions description Cooling system Í In order to cool down the cooker underneaht of the cooker is assembled a ventilation box. On the frontside of the box is a axial fan wich is blowing fresh air into box. Hot air is blown away from box through outlet which is located on the bottom of the box. The exhaust outlet is located inside the fresh air tube (= a coaxial hose). This will mean that fresh air is also cooling down the exhaust gases.
Webasto Diesel Cooker X 100 Burner 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 screw driver against the side of the cylinder, for example, should be enough to free the thermal radiator and pull it up.
Webasto Diesel Cooker X 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 indication lamp 1 Stop ⇓ ⇓ Yellow 0 Combustion Red indication lamp Start-up 2.
Webasto Diesel Cooker X 100 2 Functions description 12 V The yellow LED light is ON Main switch off on 240 sec. (alterable parameter) Glow Plug off 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. Temperature sensor (T4) The red LED light is ON Rise: 30% 10 mV 0 The red LED light is flashing Burning indicator limit on 5 min.
Webasto Diesel Cooker X 100 3 Technical Data 3 Technical Data Except where limit values are specified, the technical data listed in the table refer to the usual heater tolerances of ±10% at an ambient temperature of +20 °C 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 designed for 12 V.
Webasto Diesel Cooker X 100 THE DEVICE´S 3 Technical Data FUNCTION TECHNICAL VALUES Dimensions 466 x 316 x 205 mm Weight ~ 8 kg Size of replacement air aperture (minimum area) 100 cm² Heating capacity (calculated) Max. adjustment range 0.9 ... 1.9 kW Fuel Diesel Longest permissible length of fuel hose Highest permissible rise of fuel hose (without adjusting the pump) 8m 1.5 m Fuel consumption Max Min 190 ml/h 90 ml/h (0.16 kg/h) (0.07 kg/h) Pump´s pulse intervals, 1/fpump Max Min 1.
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.
Under 10,7 V 402 Yes Check the condition of the battery and power supply cables. Charge the battery, if necessary. Check the battery voltage. The battery voltage must be at least 10.7 V. Check the power supply and control unit fuses. Check to see if the electric wires are connected properly; check the couplings and main switch. Check the control panel and the control panel´s cable. No Is the device receiving currency ? (1) The stove does not start up (after two tries).
Webasto Diesel Cooker X 100 4 Failure detection 4.2 General failures Failure symptom Cooker does not respond at all. Possible reason Operating voltage is 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. Cooker does not start. Note: After two failed start attempt the cooker is in lock-up state ! How to repair Check the main cable connections and the main switch.
Webasto Diesel Cooker X 100 4 Failure detection Combustion air blower 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).
Webasto Diesel Cooker X 100 Cooker goes OFF by itself. 4 Failure detection No fuel. 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.
Webasto Diesel Cooker X 100 4 Failure detection 4.3 Failure blink codes Signal lights in case of malfunctions. ON Glow plug problem Combustion air fan problem Cooling air fan problem Undervoltage Yellow OFF 0.125 s 2s 0.125 s 2s 0.125 s ON Yellow OFF 0.125 s 0.125 s 0.125 s 2s 0.125 s 0.125 s 0.125 s 2s ON Yellow OFF 0.125 s 0.125 s 0.125 s 0.125 s 0.125 s 2s 0.125 s 0.125 s 0.125 s 0.125 s 0.125 s ON Yellow OFF Locking after 2 unsuccessful starts. 0.25 s 0.25 s 0.25 s 0.
Webasto Diesel Cooker X 100 4 Failure detection Descriptions of the flashing LED lights beginning from XPS v 1.2. Leds on the control panel Third attempt to start the device Yellow LED 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.
Webasto Diesel Cooker X 100 4 Failure detection Red LED Burning indicator and after-cooling Incorrect device parameters 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.
Webasto Diesel Cooker X 100 5 Updating and repair 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.
Webasto Diesel Cooker X 100 5 Updating and repair 1. Copy all files from the CD on to your computer’s hard disk to the location of your choice. 8. There are two ways to update a single device: 2. Install the PC cable in to 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.
Webasto Diesel Cooker X 100 5 Updating and repair 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 (S2 – S6). The test device assists the maintenance person when investigating the condition of the control unit, e.g.
Webasto Diesel Cooker X 100 5.3 Burner 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 and pull it up.
Webasto Diesel Cooker X 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. The slant of the needle goes towards the upper edge of the burner.
Webasto Diesel Cooker X 100 5 Updating and repair 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 time. (The glow plug we have used is in the 2nd generation category.) Malfunction: The glow plug may experience a malfunction as a result of thermal overload.
Webasto Diesel Cooker X 100 5 Updating and repair 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, for example.
Webasto Diesel Cooker X 100 5 Updating and repair 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 person’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.
Webasto Diesel Cooker X 100 6 Electrical connections 6 Electrical connections Note! You must be sure you have ESD protection while handling the control unit. Static electricity can damage the control unit. J6, Test pin header X1 - S2 X1 - S3 X1 - S4 X1 - S5 X1 - S6 X1 - S7 X1, PC connec.
Webasto Diesel Cooker X 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.
Webasto Diese Cooker X 100 7 Maintenance and service 7 Maintenance and service 7.1 Basic maintenance The cooker shall be serviced every two years by an authorized service centre. In case of intensive use, replace the fuel filter once a year. Consider the following before taking measurements: - 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.
Webasto Diese Cooker X 100 7 Maintenance and service 4. Analyze the O2 and CO2 5. Soot test An O2 analysis reveals more quickly the reason for impure burning. The O2 analysis should be performed with a meter intended for the purpose. The soot test determines whether the combustion is pure. You can perform the test with a Combustion meters have an oxygen cell, which measures the O2 value. The device numerically changes the value to the CO2 value, which is used universally in service shops.
Webasto Diese Cooker X 100 7 Maintenance and service 7.2 Control unit settings The parameters for several different devices have been programmed 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.
Webasto Diesel Cooker X 100 Page for notes
Webasto AG Postfach 80 D-82131 Stockdorf http://www.webasto.de Subject to modification Part no.
