Thermo Test 2002 Version 1.

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Operating Instructions

09/2002

Thermo Test
1 General

General

The Webasto heater diagnosis is used to test the heaters with diagnostic capabilities Thermo Top (serial number 300.000 and up) Thermo Top T (serial number 300.000 and up) Thermo Top Z/C Thermo Top Z Mercedes Thermo Top C Mercedes Thermo Top Z/C Audi Thermo 50 MAN/Handel BBW 46S und DBW 46S BW 80 und DW 80 Thermo 90 Thermo 90 S DW 230, DW 300 und DW 350 Thermo 230, Thermo 300 and Thermo 350 Thermo 230, Thermo 300 and Thermo 350 (K-Bus) Air Top 2000 Diagnosis Air Top 3500 und Air Top 5000 regardless of their type of power supply voltage by means of a personal computer. For connection of the heater to the PC the PC diagnosis adapter supplied and the type-specific test adapter are required (see figure). The test adapters are identical as used in combination with the diagnosis computer. Although the program has been successfully tested on many computers, there might be incompatibilities with certain PCs In such case we request your report on your experiences for possible improvement. .............

Fig. 1:

PC Diagnosis Adapter

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General

Thermo Test

Fig. 2:

Test Adapter for Heaters Thermo 90 Order No. 836 61A

Fig. 5:

Test Adapter for Heaters BW 80 and DW 80 Order No. 213 33A

Fig. 3:

Test Adapter for Heaters Thermo 90 S and Thermo 50 MAN //Handel , Order No. 925 56A

Fig. 6:

Test Adapter for Heaters Air Top Z/C Handel and Air Top 2000 Diagnosis, Order No. 925 66A

Fig. 4:

Test Adapter for Heaters BBW 46 S and DBW 46 S Locally manufactured as required

Fig. 7:

Test Adapter for Heaters Air Top 3500/5000 Order No. 925 55A

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Thermo Test

General

Fig. 8:

Test Adapter for Heaters DW 230/300/350 and Thermo 230/ 300/350, Order No. 208 65A

Fig. 11: Test Adapter for Heaters DW 230/300/350 and Thermo 230/ 300/350 (RVI), Order No. 926 29A

Fig. 9:

Test Adapter for Heaters DW 230/300/350 and Thermo 230/ 300/350, Order No. 226 56A

Fig. 12: Test Adapter for Heaters DW 230/300/350 and Thermo 230/ 300/350 (Van Hool), Order No. 926 37A

Fig. 10: Test Adapter for Heaters DW 230/300/350 and Thermo 230/300/350, Order No. 88 3 36A

Fig. 13: Fig. 13 Test Adapter for Heaters DW 230/300/350 and Thermo 230/300/350 (MBI/Cilaro), Order No. 662 65A

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System Requirements
2 System Requirements

Thermo Test

Windows 95/98/ME/NT/2000/XP 3 1/2 inch, 1.44 MB floppy disk drive (for installation; alternative installation possible by means of network or other media) hard disk with at least 3 MB free memory one unused standard RS232C serial interface CD ROM drive (installation CD in preparation)

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Thermo Test
3 Installation on Hard Disk

Installation on Hard Disk

For installation of the Webasto PC heater diagnosis proceed as follows: insert installation disk in the relevant drive. create a new sub-directory in one of your computer directories , e.g. C:\Programs\Webasto\Thermo_Test. copy the exe-file from your floppy disk drive or a net drive into the new sub-directory. to facilitate the future access to this diagnosis program you may also create a link on your desktop to the exe-file or in your directory "Programs" accessible via the "Start" button in the task bar. For details how to do this refer to your operating system user manual.

It is planned to provide an installation program.

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Connections
4 Connections

Thermo Test

CAUTION It is mandatory to perform the steps in the following sequence! Connect 9-pole data connector to an unused free serial interface (COM1 or COM2) port of the PC (may remain connected as required). CAUTION Before connection to the heater ensure no voltage is present between grounds of PC and vehicle! Voltages in excess of 5V may damage both diagnosis adapter and PC. Connect the type specific test adapter with the 4-pole connector of the diagnosis adapter and the heater. The heater may be in operation. NOTE The connector cable to the heater should not be routed near the vehicle ignition system or powered electrical devices (e.g. electric drill). If the green LED on the diagnosis adapter does not illuminate after connection to the heater, the heater must be switched on or the two terminal clamps of the diagnosis adapter must be connected to the wiring of the vehicle electrical system with the appropriate colour coding. Before disconnecting the cables exit the diagnosis program. No particular sequence must be observed when disconnecting the cables.

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Thermo Test
5 Test Procedure
cable and re-connect afterwards. DW 230..350/Thermo 230..350:

Test Procedure

NOTE For performing a test function the heater must be switched on but not necessarily in operation. Heaters of the type Thermo 50 MAN/Handel need not be switched on for diagnosis. If the adapter is not connected or connected to the wrong interface or the heater is not on or not properly connected, the status window will display the message "Timeout". In this case troubleshoot for one of the causes mentioned.

When saving errors of these units malfunctions on the diagnosis interface may occur. The diagnosis program detects such malfunctions and tries to rectify the problem by erasing the error memory (stored error data will be lost!). BBW46S/DBW46S: After starting the diagnosis the heater enters a diagnosis mode with run-down. Thermo 50 MAN/Handel: After release of a TRS condition the heater may be restarted only as follows: switch off heater end diagnosis wait at least for 10 seconds (only applicable when connected according to TRS circuit diagram).

After the connection has been successfully completed it will be maintained. NOTE The equipment identification numbers are partially customer identification numbers.

The programme monitors the connection to the heater and identifies disconnects. Irregular disconnects (e.g. pulling a plug during the test run) will display the message "Timeout" in the status window.

5.1. Starting and Ending the Program To start the diagnosis software "Webasto Thermo Test" double-click on the file in the sub-directory you have created or on the file link on your desktop or in the directory "Start\Programs". The program window "Webasto Thermo Test" will be opened. To end the program use the mouse and click on the square on the extreme right of the window title bar. The square is marked with X.

Remarks on the various types of heaters: Thermo Top/Thermo Top T: The function "Start diagnosis" will start the heater. Thermo Top Z/C: If the diagnosis cable is connected, the heater cannot be started by means of the timer or the telestart. Therefore first disconnect diagnosis

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Menu: Diagnosis
6 Menu: Diagnosis
6.4. Components Test

Thermo Test

6.1. Equipment Selection (start diagnosis) Open the dialogue window for equipment selection by means of the menu item Diagnosis/Equipment Selection or with a mouse click on the switch button .

NOTE This function is not available for BBW 46 S/DBW 46 S. Remark for Air Top 2000: Heating operation is terminated with a short run-down which makes the test functions available (diagnosis mode). The test starts after a further acknowledgement with the Enter key or a mouse click on the OK button. After termination of the components test by a mouse click on the Cancel button the heater resumes normal operation, i.e. it possibly starts operation. Remark for Thermo 50 MAN/Handel: The components test is only available in the OFF condition. The CO2adjustment may only be performed in the combustion mode of operation under full load. Open the corresponding window by selecting the menu item Diagnosis/ Components Test or with a mouse click on the switch button . in the options panel mark the component you want to test, e.g. combustion air fan. use the input fields rated value and operating time to enter the "optimum" values to be applied for the test run. click on the start button to launch the test of the component selected. click on the end button to terminate the test in progress.

NOTE If the equipment is not listed in the Equipment Selection or no connection can be established, go to the menu W-Bus. 6.1.1. Control Unit Selection and Diagnosis Start click on the auto search button. The system performs an auto search by means of the equipment identification and then starts the diagnosis process. mark the appropriate control unit by a mouse click and then click the OK button. The diagnosis process will be launched. double click on the appropriate control unit. The diagnosis process will be launched. 6.2. End Diagnosis End the diagnosis in progress by means of the menu item Diagnosis/ End Diagnosis, the function key F3 or with a mouse click on the switch button . 6.3. Start Diagnosis You may restart the diagnosis of a control unit identified before by selecting the menu item Diagnosis/Start Diagnosis, by pressing the function key F2 or with a click on the switch button .

6.5. Line Priming Open the corresponding window by selecting the menu item Diagnosis/ Line Priming or with a mouse click on the switch button .

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Thermo Test
in the priming time field enter the time in seconds to complete the line priming. click on the start button to launch the line priming process. click on the cancel button to cancel your time input or to stop the line priming in progress.

Menu: Diagnosis

6.6. Save Test Record Select the menu item Diagnosis/Save Test Record to open the dialogue window report file. enter a possibly unambiguous file name in the file name field for the new text file, e.g. report_of_011213. The file extension (.TXT) is added automatically or may be entered as part of the file name, e.g. Test_011214.txt. click on the save button to store the diagnosis test record.

6.7. Open Test Record To open an already existing diagnosis test record select the menu item Diagnosis/Open Test Record to open the dialogue window report file. mark the file you want to review with a mouse click. The name of the file marked is transferred into the file name field. mouse click on the open button or double click on the corresponding file name to open the text file. the screen display show test record is opened. mouse click on the OK button to close the display.

NOTE To copy text into other programs mark the text to be copied with the left mouse button pressed and subsequently press the keys STRG+C. The marked text is then stored in the intermediate store to be copied into other programs by using the keys STRG+V.

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Menu: Display
7 Menu: Display

Thermo Test

In order to provide an overview on the diagnosis and tests you may select different display modes: 7.1. Overview Window This display provides an overview on the values during diagnosis. There is an indication of the operating voltage, the temperature and among other values also of the equipment status. open the first of the five displays to see diagnosis results by selecting the menu item Display/Overview Window or with a mouse click on the switch button . for closing this display mouse click on the square in the extreme right of the title bar.

7.4. Trend Presentation This display provides you with a graphic presentation on the evolution to be expected for a specific value. open the fourth of the five displays to see diagnosis results by selecting the menu item Display/Trend Presentation or with a mouse click on the switch button . for closing this display mouse click on the square in the extreme right of the title bar.

7.5. Diagnosis Trouble Log This display provides you with an indication of problems that occurred during diagnosis. open the last of the five displays to see diagnosis results by selecting the menu item Display/Diagnosis Trouble Log or with a mouse click on the switch button . for closing this display mouse click on the square in the extreme right of the title bar.

7.2. Operating Data This display provides an overview on a range of parameters in combination with the values recorded and the units assigned. open the second of the five displays to see diagnosis results by selecting the menu item Display/Operating Data or with a mouse click on the switch button . for closing this display mouse click on the square in the extreme right of the title bar.

7.3. Control Unit Information This display provides a list with all Information and values for the equipment connected. open the third of the five displays to see diagnosis results by selecting the menu item Display/Control Unit Information or with a mouse click on the switch button . for closing this display mouse click on the square in the extreme right of the title bar.

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Thermo Test
8 Menu: Error Memory

Menu: Error Memory

8.1. Show Error List open the show error list window by selecting the menu item Error Memory /Show Error List or with a mouse click on the switch button . his overview presents in listed form all errors stored in the control unit in combination with the values recorded at the time of the error. For unambiguous differentiation each error is listed separately. when clicking on a particular error an explanation on the particular error will be given. to close the show error list window mouse click on the square at the extreme right of the title bar The square is marked with X. 8.2. Erase Error Memory In you want to erase all previously recorded errors select the menu item Error Memory/Erase Error Memory, press the function key F5 or click on the switch button . NOTE Be aware that after erase error memory all previously recorded errors will no longer be available. Print out the errors before if required (see function Print).

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Menu: Print
9 Menu: Print

Thermo Test

9.1. Print Test Record Select the menu item Print/Print Test Record, press the function key F12 or click on the switch button to get a test record printout.

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Thermo Test
10 Menu: Control

Menu: Control

10.1. Off Select the menu item Control/Off, press the function key F4 or click on the switch button for switching the heater off. 10.2. On Select the menu item Control/On or click on the switch button switching the heater on.

for

10.3. Stationary Heating Select the menu item Control/Stationary Heating or click on the switch button for switching the stationary heating on. 10.4. Auxiliary Heating Select the menu item Control/Auxiliary Heating or click on the switch button for switching the auxiliary heating on. 10.5. Ventilation Select the menu item Control/Ventilation or click on the switch button for switching the ventilation on. 10.6. Boost Operation Select the menu item Control/Boost Operation for operating the heater in the boost mode (full load operation). 10.7. Circulation Pump Select the menu item Control/Circulation Pump for switching the circulation pump on. NOTE Not all of the control commands are applicable to all heaters.

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Menu: Calibration
11 Menu: Calibration

Thermo Test

Select the menu item Calibration/CO 2-Adjustment or click on the switch button to perform calibration.

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Thermo Test
12 Menu: Extras

Menu: Extras

This menu provides you with two commands for computer configuration. 12.1. COM-Port open the COM port selection window by means of the menu item Extras/COM Port. select the COM interface (COM1 or COM2) you want to use for communication with external equipment. click on the OK button to acknowledge the selection. 12.2. Autostart Select the menu item Extras/Autostart for an automatic start of the connection to the control unit. The selection is confirmed by a tick placed next to the menu item Autostart. A reselection of this menu item deselects Autostart.

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Menu: Window
13 Menu: Window

Thermo Test

Commands in the menu Window allow you to influence the arrangement of open dialogue and display windows. 13.1. Overlapping Select the menu item Window/Overlapping if you want open windows to be arranged overlapping and staggered. 13.2. Side-by-Side Select the menu item Window/Side-by-Side if you want open windows to be of the same size and arranged next to each other without any overlap. 13.3. Arrange Symbols The menu item Window/Arrange Symbols is not yet available. 13.4. Close All Select the menu item Window/Close AlI if you want close all open windows at the same time.

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Thermo Test
14 Menu: Help

Menu: Help

14.1. Program Information The Help menu at this time provides you only with information concerning the development status of this software: select the menu item Help/Program Information or click on the switch button to get information on the current development status of the software. click on the switch button OK to close the program information window.

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Troubleshooting
15 Troubleshooting

Thermo Test

After selecting a test function the error message "Timeout" is displayed. Check if the diagnosis adapter is connected to the selected serial interface of the PC and that the heater is properly connected. Ensure that the heater is switched on and is supplied with power. Is a connection to ground present (except across diagnosis line) between PC and vehicle? If true: immediately disconnect diagnosis line and remove interfering connection to prevent damage to adapter and PC. Control unit may be defective (check prior to replacement). Possibly an attempt has been made to diagnose a control unit not mentioned above. A wrong connector on the control unit has been used for the diagnosis line.

Diagnostic data display sometimes is incomplete and communication is frequently interrupted. Is a connection to ground present (except across diagnosis line) between PC and vehicle? If true: immediately disconnect diagnosis line and remove interfering connection to prevent damage to adapter and PC.

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