Webasto Diesel Cooker x100 User manual

Diesel Cooker x100
Service Manual
08-05-2008

Webasto Diesel Cooker X 100 Table of Contents
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
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
You are also invited to fill out our online questionnaire
instructions required for repairing the Webasto Diesel
concerning our technical documentation and web
Cooker X 100. If necessary the operating / installation
site at: www.techwebasto.com
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.
Webasto Diesel Cooker X100 is tested by SGS, test
spesification standard EN 1:1998 + EN 60335-2-
6:2003
Failure to follow the installation instructions and the
notes contained therein will lead to all liability being
refused by Webasto
The same applies if repairs are carried out
incorrectly or with the use of parts other than
genuine spare parts. You must read the operating
manual before starting the
heater for the first time.
1.5 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]
101

Webasto Diesel Cooker X 100 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
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.
Fuel pump
Ventilation box Cooling fan Fuel hose lead-through
Cable lead-through
Exhaust gas tube
Combustion air fan
Temperature sensor
Burner chamber Glow plug
Fuel needle
Mounting piece
Control unit
Overheat thermostat
Main cooking area Hot plate indication lamp Additional cooking area
201
2 Functions description

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.
Combustion
indicator lamp
(red)
High altitude switch
High altitude
indication lamp
(orange)
Power
adjustment
Power switch
Power indication lamp (yellow)
Yellow
Red
0
0
1
1
0,25 s0,25 s 0,25 s 0,25 s
Power
indication
lamp
Combustion
indication
lamp Run down phase about 5 min
Signal lights of operating panel during normal operation
Start Stop
⇓⇓
Start-up 2.5-4 min Cooking
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.
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 2nd second,
voltage increases with a pulse ratio of 25 %.After 5
seconds, the pulse ratio increases to 70 %; and
after 15 seconds, the voltage increases to 100 %.
Programmed ignition monitoring will begin 15
seconds after start-up, before which there is only
mechanical protection.
Combustion air fan
The voltage range of the burning fan may be altered
between 4.8 V and 10.7 V by changing the param-
eters; the adjustment range of the parameters is
4,000 mV – 11,000 mV. Check the voltage in the last
parameter file. During the first second of start-up the
control unit tests the fan’s motor. During the follow-
ing second, the motor receives an initial impulse of 7
V from which the voltage is decreased to the mini-
mum set forth in the parameters. The voltage will be
increased linearly towards the maximum during the
start-up cycle; the maximum will be reached in
approximately 4 minutes and 50 seconds after the
start-up cycle ends. The power control does not
work during this time.After the start-up cycle, the
burning fan adjusts itself from maximum to minimum
and minimum to maximum at a rate of 5 % per
second (20 sec. max. > 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 itgives
off heat to the ceramic glass panel. The exhaust gas
then exits through the exhaust gas tube and is
ducted outside the vehicle through the stainless
steel exhaust tube.
Heat exchanger
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The principle of operation of the ignition voltage
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
risesover 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.
204
Electrical connections for the control unit
Wires for control
panel
Control panel
Thermo element

Webasto Diesel Cooker X 100 2 Functions description
Cooling system
Í
Í
205
The cooker is cooled down by a ventilation box located
under the cook top. On the front side of the ventilation
box is anaxial 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 meansthat fresh
air is also cooling down the exhaust gases. See also
installation manual : Exhaust system.

Webasto Diesel Cooker X 100 2 Functions description
206
Burner
Complete burner cylinder
(Includes all parts you see in the picture.)
Thermal radiator for the burner
Detaching the thermal radiator:
There are two locking plates on the inside of the
burner’s “perforated” cylinder which have been spot
welded to the sides of the cylinder. Prying one of the
locking plates with a screwdriver against the side of
the cylinder, for example, should be enough to free the
thermal radiator and pull it up.
Installing the thermal radiator:
Push the thermal radiator inside the “perforated”
cylinder until the locking plates lock the thermal
radiator in place.
Note! The locking plates must be bent a bit
crosswise before you can assemble the thermal
radiator back in place. This will ensure that the
thermal radiator will stay in place during transport
as well.
Burner cylinder
Burner’s bottom mat spring
The bottom mat spring for the burner ensures that the
bottom mat stays on the bottom of the burner prevent-
ing the glow plug from going under the bottom mat.
Bottom mat of the burner, Ø 85 mm
(Delivered together with the bottom mat spring.)
Base of the burner
Installation
hole for glow
plug
Through pipe for
the temperature
sensor (T4)
Installation hole
and needle
support for the
fuel needle
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.

Webasto Diesel Cooker X 100 2 Functions description
207
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.
Yellow
Red
0
0
1
1
0,25 s0,25 s 0,25 s 0,25 s
Power
indication
lamp
Combustion
indication
lamp Run down phase about 5 min
Signal lights of operating panel during normal operation
Start Stop
⇓⇓
Start-up 2.5-4 min Cooking

208
Webasto Diesel Cooker X 100 2 Functions description
Main switch
off
12 V
Glow Plug
Combustion air
fan
Cooling fan
Fuel pump
Temperature
sensor (T4)
off
on
min
max
max
min
max
min
After-cooling on
off
0
5 min.
The red LED light is
flashing
The yellow LED light is ON
240 sec. (alterable parameter)
4 min. 50 sec.
30 sec. 20 sec.
4 min. 50 sec.
4 min. 50 sec.
The red LED light is ON
Burning indicator limit
10 mV
Rise: 30%
Table illustrating the device´s priciple of operation

Webasto Diesel Cooker X 100 3 Technical Data
3 Technical Data
Except where limit values are specified, the techni-
cal 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 de-
signed for 12 V. The components overheat thermo-
stat and temperature sensor are not designed for a
specific voltage.
Fuel
The diesel fuel specified by the manufacturer must
be used. It has to comply with the normal quality
available on the market.
.
We know of no negative influences due to additives.
If you change to low-temperature fuel, the cooker
must be operated for approx. 15 minutes so that the
fuel system is filled with the new fuel.
301

Webasto Diesel Cooker X 100 3 Technical Data
Fuel Diesel
Fuel consumption Max
Min 190 ml/h (0.16 kg/h) 90 ml/h (0.07 kg/h)
Nominal operating voltage 12 V DC
Functioning voltage range 10.7 ... 15 V
Currency consumption 0.3A, upon ignition 8A
Glowing time 240 sec. (see parameter file)
Dimensions
Weight
Temperature of the combustion, T
Max
Min
~ 265° C(509° F)
~ 135° C(275° F)
0
0
Combustion´s carbon monoxide content,
CO Max
Min
< 20 ppm
< 100 ppm
Combustion´s soot index
Max
Min
Air coefficient of the combustion
Max
Min
~ 2.5
~ 3.4
Combustion´s oxygen contect, O2Max
Min 11.5 ... 13.0 % 14.0 ... 15.5 %
CO2of the combustion (calculated)
Max
Min
6 ... 7 %
4 ... 5 %
Burning fan´s voltage, Ufan Max
Min ~9.5 V (see parameter file)
~5.5 V (see parameter file)
Pump´s pulse intervals, 1/fpump Max
Min 1.45 sec. (see parameter file) 3.00 sec. (see parameter file)
Longest permissible length of the
combustion hose 1.9 m, straight downwards 1.2 m (ø 28 mm and ø 60 mm)
466 x 316 x 205 mm
~8 kg
Longest permissible length of fuel hose
Highest permissible rise of fuel hose
(without adjusting the pump)
8 m
Size of replacement air aperture
(minimum area) 100 cm²
Heatingcapacity
(calculated) Max.
adjustment range 0.9 ... 1.9 kW
THE DEVICE´S FUNCTION TECHNICALVALUES
1.5 m
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
CONTROL UNIT
BURNING FAN
GLOW PLUG
PUMP
The stove does not
start up (after two
tries).
(2)
The stove does not do
anything.
(1)
Check to see if the electric
wires are connected properly;
check the couplings and main
switch.
Check the power supply and
control unit fuses.
Check the battery voltage.
The battery voltage must be
at least 10.7 V.
Check the control unit.
Is the device receiving
currency ?
Check the control panel and
the control panel´s cable.
No
The pump is not receiving
electric impulses. The red
LED light on the control unit
is not flashing.
The pump receives impulses,
but the pump´s piston is not
moving. (You can see the
movement of the piston in the
pump´s vibration and the
slight clicking sound it makes.
Check the pump´s wiring and
the condition of the over-
heating protector.
Check the pump. (You can
try to move the pump´s piston
by tapping the side of the
pump a bit; if necessary,
change the pump).
The pump receives impulses and the piston is moving, but
the fuel is not moving through
the hose. Check to see if the fuel
needle or filter is clogged.
Check the coupling and, if
needed, tighten it.
Change the pump.
The connection of the suction
hose to the pump is not
completely tight and the
pump is sucking in air.
The pump is worn out or dirty
and is unable to take in fuel.
OTHER REASON
The glow plug is not receiving
enough voltage (it does not
get hot enough).
Defective glow plug (light
flashes signifying defect).
Make a visual check. (The
glow plug often changes
shape when it breaks.)
Make sure that the cross-
sectional area (mm²) is
sufficient in size.
Low-grade fuel. Change the fuel.
Check the couplings.
There is water in the fuel. Filter it or change the fuel.
Check the control unit.
Change the control unit.
The burning fan does not
rotate (light will flash
signifying defect), or it rotates
too slowly.
The lead-through is closed.
There is water in the
combustion hose.
The stove is out of fuel or
there is not enough fuel for
the end of suction hose to
reach the fuel in the tank.
Open the lead-through.
Check to see if there is water
in the curves of the
combustion hose (water
trap).
Add more fuel.
The stove smokes
when starting up.
(3)
The stove suddenly
stops while running.
(4)
Burning is irregular /
the stove smokes.
(5)
Yes
Clean the fuel needle and
burner. Change the filter.
BURNER
The burner has become
sooty.
The burner must be opened
and cleaned.
Check the control unit´s
jumper settings.
Check the control unit´s
couplings.
(2)
(2)
(2)(3)
(3)
Check the condition of the
battery and power supply
cables. Charge the battery, if
necessary.
(4)
(2)(4)(5)
(4)
(5)
(5)
(5)
Check the brand and type of
glow plug you are using. Only
use original Wallas glow
plugs.
(5)
Under 10,7 V
Defective control unit.
(1)(2)
LIGHT FLASHES WHEN IN LOCKED
POSITION
Unlocking the lock:
1. Turn the switch to the ON position
(light flashes when in locked position).
2. Unplug the main electric cable (light
stops flashing).
3. Plug the main electric cable cack in
(the yellow LED will turn on for 1-3 sec.).
4. When the yellow LED light has shut of,
turn the switch to the OFF position.
(1)
4.1 Trouble shooting chart
402

Webasto Diesel Cooker X 100 4 Failure detection
403
4.2 General failures
Cooker does not respond at all. Check the main cable connections
and the main switch.
Check fuses on main cable and on
control unit.
Cooker does not start.
Note:After two failed start attempts
the cooker is in lock-up state !
Check the battery voltage.
Battery voltage must be over 10,7 VDC.
Pump
Is operating voltage under 10.7 VDC ?
(Measure the voltage from control unit’s
voltage connector).
How to repairFailure symptom Possible reason
Pump does not get get pulses.
Red LED does not blink on control board. Check the control unit.
Pump get’s the pulses, but pump piston
does not move.
(A small ticking sound can be heard when
the piston moves)
Check the pump.
(Sometimes a small tapp on pump’s side
help’s to relase the piston, if necessary
change the pump).
Check the pump wires / wiring and over
heat protector’s condition.
A) Yes.
Check the control unit, control
panel and control panel cable.
B) No. See how to repair.
Glow plug
Glow plug is faulty.
(fault blinking). Visual check, (often the plug changes form when faulty).
Glow plug does not get sufficient voltage.
(Glow plug is not hot enough). Check that the main cable cross area (mm²) is large enough. Check also all
connections.
Pump get’s pulses and piston moves, but
fuel does not move inside the fuel line. Check if the fuel needle or fuel filter is
blocked.
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. Fuel line joint to the pump is loose and
pump get’s air. Check and tighten joint.
Pump is worn or dirty and can not pump
fuel. Replace the pump.

Webasto Diesel Cooker X 100 4 Failure detection
404
Bad fuel quality.
Combustion air blower
Combustion air blower does not run.
(Fault blinking). Measure blower’s voltage,
(compare to the parameter table).
Control unit (PCB)
Replace the combustion air blower.
Control unit faulty.
Temperature sensor T4
Temperature sensor voltage does not rise
during start up. Measure the voltage approx. 5 minutes
after the start up, voltage must be over
13mV, (sensor wires attached to the board).
Check the temperature sensor.
Replace the Control unit.
Other cause
Water in fuel.
Water inside the exhaust pipe.
Change the fuel.
Remove the water. Make sure that there is
no water lock, (water in pipe bend’s).
No fuel.
Change the fuel.
Exhaust lead through blocked. Remove blockage.
Refill fuel tank.
Cooker is smoking during start-
ing phase. Glow plug voltage is too low, (glow plug is
not hot enough). Check that the main cable cross area, (mm²), is large enough. Check also all
cable connections and connectors.
Glow plug faulty,
(fault blinking) Visual check, (often the plug changes form when faulty)
Water in fuel. Change the fuel.
Water inside the exhaust pipe. Remove the water. Make sure that there is
no water lock, (water in pipe bend’s).

Webasto Diesel Cooker X 100 4 Failure detection
405
Battery voltage too low, must be more
than 10.7 VDC.
Cooker goes OFF by itself.
Hard wind pressure on exhaust lead
through vent.
Check the battery condition and main
cable connections. Recharge the battery
if necessary.
Turn the vehicle so that the wind does not
hit directly the lead through vent.
No fuel. Check and add fuel if necessary.
Burner is sooty. Clean the burner.
(see chapter burner)
Cooker over heated. Check the free air flow around the cooker.
Measure the fuel consumption, adjust if
needed. Max 190 ml, Min 90 ml
Unstable combustion / cooker
smokes.
Wrong fuel consumption. Measure the fuel consumption, adjust if
needed. Max 190 ml, Min 90 ml
Burner is sooty. Clean the burner.
(see chapter burner)
Check the fuel pump’s operation.
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).
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.)
Check the fuel needle and the filter.

Webasto Diesel Cooker X 100 4 Failure detection
406
4.3 Failure blink codes
Yellow
Yellow
Yellow
0.125 s 0.125 s 0.125 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
0.125 s 0.125 s 0.125 s
2 s 2 s
2 s2 s
2 s 2 s
0.25 s 0.25 s 0.25 s 0.25 s ...
OFF
OFF
OFF
OFF
ON
ON
ON
ON
Glow plug
problem
Combustion
air fan
problem
Cooling
air fan
problem
Under-
voltage
Yellow
Yellow
Red
Red
Red 30s 30s0.125s 0.125s
0.25s 0.25s 0.25s 0.25s
0.125 s 0.125 s 0.125 s 0.125 s ...
OFF
OFF
OFF
OFF
ON
ON
ON
ON
Locking
after 2
unsuccessful
starts.
Overheat
Lights after
failure
signal
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.
The red lamp begins blinking when failure signal has lasted for 5
minutes.
Signal lights in case of malfunctions.
0.125 s 0.125 s 0.125 s 0.125 s