Webasto Diesel Cooker x100 Service Manual

Diesel Cooker x100

Service Manual

08-05-2008

Webasto Diesel Cooker X 100

1. General

1.1 Contents and purpose 101

1.2 Use of the cooker 101

1.3 Additional documentation 101

1.4 Safety notes and legal issues 101

1.5 Suggestions for improvements and changes 101

2. Function description

2.1 System description 201

2.2 Main components 202

2.3 Operating scheme 207

3. Technical Data 301

Table of Contents

4. Failure detection

4.1 Trouble shooting chart 402

4.2 General failures 403

4.3 Failure blink codes 406

5. Updating and repair

5.1 Updating 501

5.2 Test program 503

5.3 Burner 504

5.4 Glow plug 506

5.5 Heat exchanger and glass panel 507

5.6 Pump Boost 508

6. Electrical connections 601

7. Maintenance and service

7.1 Basic maintenance 701

7.2 Control unit settings 703

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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, the general accident prevention regulations
and current works safety instructions are applicable.

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: [phone]
Fax: [phone]

You are also invited to fill out our online questionnaire

concerning our technical documentation and web

site at: www.techwebasto.com

Webasto Diesel Cooker X100 is tested by SGS, test
spesification standard EN 1:1998 + EN 60335-2­6:2003

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.

101

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. Gentler heat is available on the
oblong extension. The heating power is adjustable.

a

Main cooking area

Mounting piece

Fuel pump

Overheat thermostat

Burner chamber

Hot plate indication lamp Additional cooking area

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.

Exhaust gas tube
Combustion air fan

Temperature sensor

Fuel needle

Glow plug

Control unit

Ventilat ion box

201

Cooling fan

Cable lead-through

Fuel hose lead-through

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
indicator lamp
(red)

Power switch

Power
indication
lamp

Combustion
indication
lamp

High altitude switch

Start Stop

⇓

1

Yellow

0

1

Red

0

Start-up 2.5-4 min

Cooking

Power
adjustment

High altitude
indication lamp
(orange)

⇓

0,25 s0,25 s 0,25 s 0,25 s

Run down phase about 5 min

Signal lights of operating panel during normal operation

202

Webasto Diesel Cooker X 100 2 Functions description

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.

Combustion air fan

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. During the follow­ing second, the motor receives an initial impulse of 7
V from which the voltage is decreased to the mini­mum 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. Af ter the st art-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. > min.).

Heat exchanger

The heat generated 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.

Glow plug

During the first second of ignition the glow plug
receives quick pulses, with which you can make
sure it is working properly . During the 2
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.

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The principle of operation of the ignition voltage

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second,

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Heat exchanger

203

Webasto Diesel Cooker X 100 2 Functions description

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.

Hot plate indication lamp

An orange 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 %) 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.

Control panel

Wires for control
panel

Thermo element

Electrical connections for the control unit

204

Webasto Diesel Cooker X 100 2 Functions description

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. See also
installation manual : Exhaust system.

Í

Í

205

Webasto Diesel Cooker X 100 2 Functions description

Burner

Through pipe for
the temperature
sensor (T4)

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

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.)

Burner’s bottom mat spring

The bottom mat spring for the burner ensures that the
bottom mat stays on the bottom of the burner prevent­ing the glow plug from going under the bottom mat.

Bottom mat of the burner, Ø 85 mm

(Delivered together with the bottom mat spring.)

Base of the burner

Removing deposits:

Mechanically 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 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 Stop

Power
indication
lamp

1

Yellow

0

⇓

⇓

Combustion
indication
lamp

1

Red

0

Start-up 2.5-4 min

Signal lights of operating panel during normal operation

Cooking

0,25 s0,25 s 0,25 s 0,25 s

Run down phase about 5 min

207

Webasto Diesel Cooker X 100 2 Functions description

Main switch

Glow Plug

Combustion air
fan

Cooling fan

Fuel pump

Temperature
sensor (T4)

12 V

off

on

off

max

min

max

min

max

min

Rise: 30%
10 mV

0

30 sec.

4 min. 50 sec.

4 min. 50 sec.

4 min. 50 sec.

The yellow LED light is ON

240 sec. (alterable parameter)

The red LED light is ON

Burning indicator limit

20 sec.

The red LED light is
flashing

on

After-cooling

off

5 min.

T able illustrating the device´s priciple of operation

208

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 (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 de­signed for 12 V. The components overheat thermo­stat 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

Webasto Diesel Cooker X 100 3 Technical Data

THE DEVICE´S FUNCTION TECHNICAL VALUES

Dimensions

Weight

Size of replacement air aperture

466 x 316 x 205 mm

~ 8 kg

100 cm²

(minimum area)
Heating capacity

(calculated)

Max.
adjustment range

0.9 ... 1.9 kW

Fuel Diesel

Longest permissible length of fuel hose

8 m
Highest permissible rise of fuel hose
(without adjusting the pump)

Fuel consumption

Pump´s pulse intervals, 1/f

pump

Max
Min

Max
Min

1.5 m

190 ml/h (0.16 kg/h)

90 ml/h (0.07 kg/h)

1.45 sec. (see parameter file)

3.00 sec. (see parameter file)

Nominal operating voltage 12 V DC

Functioning voltage range 10.7 ... 15 V

Currency consumption 0.3 A , upon ignition 8 A

Glowing time 240 sec. (see parameter file)

Burning fan´s voltage, U

fan

Longest permissible length of the
combustion hose

CO

of the combustion (calculated)

2

Temperature of the combustion, T

Combustion´s carbon monoxide content,

CO

Combustion´s soot index

Air coefficient of the combustion

Combustion´s oxygen contect, O

2

Max
Min

Max
Min

Max
Min

Max
Min

Max
Min

Max
Min

Max
Min

~ 9.5 V (see parameter file)

~ 5.5 V (see parameter file)

1.9 m, straight downwards 1.2 m

(ø 28 mm and ø 60 mm)

6 ... 7 %

4 ... 5 %

~ 265° C (509° F)

~ 135° C (275° F)

< 20 ppm

< 100 ppm

0

0

~ 2.5

~ 3.4

1 1.5 ... 13.0 %

14.0 ... 15.5 %

302

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
electrical plug connectors on the control unit must
be disconnected. Conduct a function test in the
vehicle after correcting each fault.

401

Webasto Diesel Cooker X 100 4 Failure detection

4.1 Trouble shooting chart

(5)

(5)

the stove smokes.

Burning is irregular /

(2)(4)(5)

BURNER

sooty.

and cleaned.

The burner has become

The burner must be opened

BURNING FAN

(2)

too slowly.

rotate (light will flash

The burning fan does not

signifying defect), or it rotates

(4)

The stove suddenly

stops while running.

(3)

when starting up.

The stove smokes

(2)

tries).

start up (after two

The stove does not

plugs.

sufficient in size.

Check the couplings.

sectional area (mm²) is

Make sure that the cross-

(2)(3)

GLOW PLUG

Check the control unit.

PUMP

The pump is not receiving

get hot enough).

enough voltage (it does not

The glow plug is not receiving

heating protector.

the condition of the over-

Check the pump´s wiring and

is not flashing.

electric impulses. The red

LED light on the control unit

but the pump´s piston is not

The pump receives impulses,

by tapping the side of the

Check the pump. (You can

try to move the pump´s piston

pump´s vibration and the

moving. (You can see the

movement of the piston in the

slight clicking sound it makes.

use original Wallas glow

Check the brand and type of

glow plug you are using. Only

change the pump).

pump a bit; if necessary,

Defective glow plug (light

The pump receives impulses

flashes signifying defect).

and the piston is moving, but

the fuel is not moving through

shape when it breaks.)

glow plug often changes

Make a visual check. (The

(5)

(2)

Check to see if the fuel

needle or filter is clogged.

the hose.

The connection of the suction

hose to the pump is not

OTHER REASON

Clean the fuel needle and

completely tight and the

Low-grade fuel. Change the fuel.

needed, tighten it.

burner. Change the filter.

pump is sucking in air.

Change the pump.

Check the coupling and, if

and is unable to take in fuel.

The pump is worn out or dirty

Open the lead-through.

(5)

There is water in the fuel. Filter it or change the fuel.

The lead-through is closed.

(1)(2)

CONTROL UNIT

trap).

in the curves of the

combustion hose (water

Check to see if there is water

(4)

combustion hose.

There is water in the

(3)

Defective control unit.

Check the control unit.

Check the control unit´s

(4)

Add more fuel.

(5)

The stove is out of fuel or

reach the fuel in the tank.

the end of suction hose to

there is not enough fuel for

Change the control unit.

couplings.

jumper settings.

Check the control unit´s

POSITION

stops flashing).

Unlocking the lock:

(light flashes when in locked position).

turn the switch to the OFF position.

3. Plug the main electric cable cack in

2. Unplug the main electric cable (light
(the yellow LED will turn on for 1-3 sec.).

4. When the yellow LED light has shut of,

anything.

The stove does not do

1. Turn the switch to the ON position

LIGHT FLASHES WHEN IN LOCKED

(1)

Yes

switch.

(1)

Is the device receiving

No

currency ?

Under 10,7 V

the control panel´s cable.

Check the control panel and

Check to see if the electric

wires are connected properly;

check the couplings and main

control unit fuses.

Check the power supply and

Check the battery voltage.

The battery voltage must be

at least 10.7 V.

necessary.

battery and power supply

Check the condition of the

cables. Charge the battery, if

402

Webasto Diesel Cooker X 100 4 Failure detection

4.2 General failures

How to repairFailure symptom Possible reason

Cooker does not respond at all.

Cooker does not start.

Note: After two failed st art 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

Pump does not get get pulses.
Red LED does not blink on control board.

Pump get’s the pulses, but pump piston
does not move.
(A small ticking sound can be heard when
the piston moves)

Pump get’s pulses and piston moves, but
fuel does not move inside the fuel line.

Fuel line joint to the pump is loose and
pump get’s air.

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.

Check the control unit.

Check the pump wires / wiring and over
heat protector’s condition.

Check the pump.
(Sometimes a small tapp on pump’s side
help’s to relase the piston, if necessary
change the pump).

Check if the fuel needle or fuel filter is
blocked.

Check and tighten joint.

Pump is worn or dirty and can not pump
fuel.

Glow plug

Glow plug does not get sufficient voltage.
(Glow plug is not hot enough).

Glow plug is faulty.
(fault blinking).

403

Replace the pump.

Check that the main cable cross area
(mm²) is large enough. Check also all
connections.

Visual check, (often the plug changes
form when faulty).

Webasto Diesel Cooker X 100 4 Failure detection

Combustion air blower

Combustion air blower does not run.
(Fault blinking).

Control unit (PCB)

Measure blower’s voltage,
(compare to the parameter table).

Replace the combustion air blower.

Control unit faulty.

Replace the Control unit.

T emperature 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.

Water in fuel.

Exhaust lead through blocked. Remove blockage.

Water inside the exhaust pipe.

No fuel.

Change the fuel.

Change the fuel.

Remove the water. Make sure that there is
no water lock, (water in pipe bend’s).

Refill fuel tank.

Cooker is smoking during start­ing phase.

Glow plug voltage is too low, (glow plug is
not hot enough).

Glow plug faulty,
(fault blinking)

Water in fuel. Change the fuel.

Water inside the exhaust pipe. Remove the water. Make sure that there is

Check that the main cable cross area,
(mm²), is large enough. Check also all
cable connections and connectors.

Visual check, (often the plug changes form
when faulty)

no water lock, (water in pipe bend’s).

404

Webasto Diesel Cooker X 100 4 Failure detection

Cooker goes OFF by itself.

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.

Water in fuel.

Water inside the exhaust pipe.

Hard wind pressure on exhaust lead
through vent.

Cooker over heated. Check the free air flow around the cooker.

Check the battery condition and main
cable connections. Recharge the battery
if necessary.

Change the fuel.

Remove water. Make sure that there is
no water lock, (water in pipe bend’s).

Turn the vehicle so that the wind does not
hit directly the lead through vent.

Measure the fuel consumption, adjust if
needed. Max 190 ml, Min 90 ml

Unstable combustion / cooker
smokes.

Burner is sooty. Clean the burner.

(see chapter burner)

Water in fuel. Change the fuel.

Bad fuel 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. Clean the burner.

(see chapter burner)

405

Webasto Diesel Cooker X 100 4 Failure detection

4.3 Failure blink codes

Signal lights in case of malfunctions.

Glow plug
problem

Combustion
air fan
problem

Cooling
air fan
problem

Under­voltage

Locking
after 2
unsuccessful
starts.

ON

Yellow

0.125 s 0.125 s 0.125 s

OFF

ON

Yellow

0.125 s 0.125 s 0.125 s

OFF

ON

Yellow

OFF

ON

Yellow

ON

Yellow

OFF

ON

Red

0.125 s 0.125 s 0.125 s 0.125 s ...

OFF

0.25 s 0.25 s 0.25 s

OFF

2 s 2 s

0.125 s 0.125 s 0.125 s 0.125 s

2 s 2 s

0.25 s ...

0.125 s0.125 s 0.125 s

0.125 s 0.125 s 0.125 s0.125 s 0.125 s 0.125 s

2 s2 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

Lights after
failure
signal

ON

OFF

ON

OFF

The red lamp begins blinking when failure signal has lasted for 5
minutes.

Red

0.25s 0.25s 0.25s 0.25s

Red

30s 30s0.125s 0.125s

406

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

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. Af ter 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 short 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.

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
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 .

T est 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.

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 .

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Webasto Diesel Cooker X 100 4 Failure detection

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. Af ter-cooling last s for approximately five
minutes.

Flashing due to over-heating

During the heating phase, when the alarm indicating
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 over­heating.

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 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.

T esting 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 .

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.

408

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. Hook a data­transmission 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.

Make sure you always use the latest
parameters.

Make sure the USB adapter you
use is compatible with your operat­ing system.

17: Device 17

9500

5500

11000

9500

1450

3000

240

Figure 1

For choosing the device
Parameter files may be saved

from the file or manually edited

For choosing the PC’s port

From the control unit to the PC
From the PC to the control unit

Checking this box enables you to
choose all devices at one time

Amount of operating hours

Signifies what programme
version is being used on

the control unit

501

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.

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 port (COM1 ...COM4,

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” > Open > AI.xpd (always use the last file

that was used)

8.

There are two ways to update a single device:

8.1

Y ou can update all parameters by clicking on “Choose
all”.
Click on “Export”
The parameters of all devices are updated at the
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

Y ou can also update the p arameters of just one
device. In this case,

DO NOT click on “Choose all”.
Next, choose the appropriate device from the pop­down menu.
“Device 17”.
Click on “Export”.
Loading may take 1 to 2 seconds.
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 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.

Y ou can use the new parameters immediately.

PC cord connector

PC connection on XPS card

Figure 2

502

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 / i n 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. 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, 1 1 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

“Maintenance”
coupler

Coupler for device
selection

You can measure the following values from the J6
connector while the unit is running:

Connection diagram for
maintenance coupler

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, Volt age for burning fan
J6-8, Volt age for main fan
J6-9, GND

503

Webasto Diesel Cooker X 100 5 Updating and repair

5.3 Burner

Through pipe for
the temperature
sensor (T4)

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 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

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.)

Burner’s bottom mat spring

The bottom mat spring for the burner ensures that the
bottom mat stays on the bottom of the burner prevent­ing the glow plug from going under the bottom mat.

Bottom mat of the burner, Ø 85 mm

(Delivered together with the bottom mat spring.)

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 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.

505

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 2

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.

nd

generation category.)

Þ

1.

T esting:

To see if resistance wire is broken, measure the
resistance between the + and – terminals with a
circuit analyzer. There will be no resist ance if the
plug is broken. The resistance between the
terminals 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 of the 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.

506

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 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 (Ø 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.

Adhesive

The adhesive used is Loctite
Store the adhesive in room temperature.

Figure 2:

®

5368.

When gluing the range, take note of the way the
spring of the banjo, located under the 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

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

Front and back
profile

Figure 1:

Side profile

Figure 3:

507

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.
The integrator stops the PB after the pump has
pumped 300 times; by opening the studs, the pump
will pump another 300 times. The PB will stop imme­diately if you open the pins. If you want to start the
PB again, turn the switch to the 0 position (> 1sec.).
The PB works when the operating volt age is more
than 1 1 V and the over-heating protector T3 is not on.

Pump Boost
pins 1 and 2

The PB function may only be
used in situations where the
device is completely “cold” or if
the fuel hose is empty.

508

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.

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
J9-3, Burning indicator
J9-4, Timer “ON”
J9-5, + 12 V
J9-6, GND

S10, Mountain switch

Mountain setting (with jumper)

S1, Room thermostat

Follows power control (with jumper)

S1 does not normally have a jumper; it has been
replaced with the J9-1 / J9-2 wire loop.

J6, Test pin header

J6-9, GND

J6-8, Main fan voltage

J6-7, Burning fan voltage

J6-6, Pump impulse

J6-5, T3 voltage (pulse)

J6-4, T4 voltage

J6-3, Glow plug voltage

J6-2, Speed pumping

J2-2, Pump

J2-1, Pump

J2-3, T3 over-heating protector

X1, Device selection

X1 - S6

X1 - S5

X1 - S4

X1 - S3

X1, PC connec.

J6-1, Operating voltage

X1 - S9

X1 - S8

J4-1, Burning fan +

J2-4, T3 over-heating protector

X1 - S2

X1 - S7

J4-2, Burning fan -

J1-2, Operating voltage -

J1-1, Operating voltage +

S11, Flame monitor switch,

T4 (with jumper),
thermostat (without jumper)

J10-1, T4 thermocouple / thermostat - (green)
J10-2, T4 thermocouple / thermostat - (white)
J13-4, Main fan +

J13-3, Main fan -
J13-2, Over-heating protector(for the blower lid)
J13-1, Over-heating protector(for the blower lid)

J12, GND

J8-3, Glow plug GND
J8-2, Glow plug voltage
J8-1, Glow plug +

Outer connections of the control unit

601

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.

Control panel

Wires for control
panel

Thermo element

Electrical connections for the control unit

602

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 center.

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. A battery or stabilized direct­current 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 lef t-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.

Later, as the pump get s 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

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.

maximum.

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.
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.

B Fuel input adjustment

1. Turn on the device.

2. Adjust the device to maximum.

3. About 5 minutes after start-up, measure the

pump’s input at maximum and adjust it to the
correct value using the
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 build­up 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.

“PUMP” trim, which is on

701

Webasto Diese Cooker X 100 7 Maintenance and service

4. Analyze the O2 and CO

2

An O2analysis reveals more quickly the reason for
impure burning. The O

analysis should be performed

2

with a meter intended for the purpose.
Combustion meters have an oxygen cell, which

measures the O2 value. The device numerically
changes the value to the CO2value, which is used
universally in service shops. There are differences in
calculation formats; a more precise test result can be
achieved using the O2 value.

value that is too high indicates an excess in

A CO

2

fuel input, not enough combustion air, an air gap in
the burner, or a defective burning fan. A CO

value

2

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
A Adjust the device to minimum and let it run at

the minimum for 10 min to reach the opera­tion 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.

5. Soot test

The soot test determines whether the combustion is
pure.
You can perform the test with a

A CO-meter (you can compare the result to the

nominal value in technical information)

B 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.

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.

B 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.

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 trouble­shooting chart 5.0

702

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.

DEVICE 17: Webasto Diesel Cooker X100

17: Device 17

9500

5500

11000

9500

1450

3000

240

The parameters in the Figures are AI.xpd
parameters.

703

Webasto Diesel Cooker X 100 Page for notes

Webasto Diesel Cooker X 100 Page for notes

Webasto Product N.A., Inc.

15083 North Road

Fenton, MI 48430

Technical Assistance Hotline

USA: [phone]

Canada: [phone]

WWW.Webasto. US

WWW.techwebasto.com

Part no.: WA490060