Thermo Test 2002 Version 1.19

09/2002

Operating Instructions

PCTe_Inh.fm Seite I Mittwoch, September 25, 2002 11:12 AM

General

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osis Adapter

Thermo Test

1 General

The Webasto heater diagnosis is used to test the heaters with diagnosticcapabilities

• 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 5000regardless of their type of power supply voltage by means of a personalcomputer.

For connection of the heater to the PC the PC diagnosis adaptersupplied and the type--specific test adapter are required (see figure).The test adapters are identical as used in combination with thediagnosis computer.

Although the program has been successfully tested on manycomputers, there might be incompatibilities with certain PCs In suchcase we request your report on your experiences for possibleimprovement.

. . . . . . . . . . . . .

Fig. 1: PC Diagn

General Thermo Test

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Fig.

Fig.

Fig.

eaters BW 80 and DW 80

eaters Air Top Z/C Handel and Air Toprder No. 925 66A

eaters Air Top 3500/5000

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

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

4: Test Adapter for Heaters BBW 46 S and DBW 46 SLocally manufactured as required

Fig. 5: Test Adapter for HOrder No. 213 33A

Fig. 6: Test Adapter for H2000 Diagnosis, O

Fig. 7: Test Adapter for HOrder No. 925 55A

General

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pter for Heaters DW 230/300/350 and Thermo 230/RVI), Order No. 926 29A

ter for Heaters DW 230/300/350 and Thermo 230/Van Hool), Order No. 926 37A

est Adapter for Heaters DW 230/300/350 and30/300/350 (MBI/Cilaro), Order No. 662 65A

Thermo Test

Fig. 8: Test Adapter for Heaters DW 230/300/350 and Thermo 230/300/350, Order No. 208 65A

Fig. 9: Test Adapter for Heaters DW 230/300/350 and Thermo 230/300/350, Order No. 226 56A

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

Fig. 11: Test Ada300/350 (

Fig. 12: Test Adap300/350 (

Fig. 13: Fig. 13 TThermo 2

System Requirements Thermo Test

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2

– W– 3

i– h– o– C

System Requirements

indows 95/98/ME/NT/2000/XP1/2 inch, 1.44 MB floppy disk drive (for installation; alternative

nstallation possible by means of network or other media)ard disk with at least 3 MB free memoryne unused standard RS232C serial interfaceD ROM drive (installation CD in preparation)

Installation on Hard Disk

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Thermo Test

3 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.

Connections Thermo Test

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Connections

TIONmandatory to perform the steps in the following sequence!

onnect 9-pole data connector to an unused free serial interfaceCOM1 or COM2) port of the PC (may remain connected asequired).

TIONre connection to the heater ensure no voltage is present betweennds of PC and vehicle! Voltages in excess of 5V may damage bothnosis adapter and PC.

onnect the type specific test adapter with the 4-pole connector ofhe diagnosis adapter and the heater. The heater may be inperation.

Econnector cable to the heater should not be routed near the vehicleion system or powered electrical devices (e.g. electric drill).

f the green LED on the diagnosis adapter does not illuminate afteronnection to the heater, the heater must be switched on or the twoerminal clamps of the diagnosis adapter must be connected to theiring of the vehicle electrical system with the appropriate colouroding.

efore disconnecting the cables exit the diagnosis program. Noarticular sequence must be observed when disconnecting theables.

Test Procedure

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ct afterwards.

o 230..350:

of these units malfunctions on the diagnosis. The diagnosis program detects such malfunctionse problem by erasing the error memory (stored error

:

agnosis the heater enters a diagnosis mode with

andel:

RS condition the heater may be restarted only as

10 seconds (only applicable when connectedS circuit diagram).

Ending the Programis software "Webasto Thermo Test" double-click on

irectory you have created or on the file link on yourrectory "Start\Programs".

w "Webasto Thermo Test" will be opened.

use the mouse and click on the square on thewindow title bar. The square is marked with X.

Thermo Test

5 Test Procedure

NOTEFor performing a test function the heater must be switched on but notnecessarily in operation.

Heaters of the type Thermo 50 MAN/Handel need not be switched on fordiagnosis.

If the adapter is not connected or connected to the wrong interface orthe heater is not on or not properly connected, the status window willdisplay the message "Timeout". In this case troubleshoot for one of the causes mentioned.

After the connection has been successfully completed it will bemaintained.

NOTEThe equipment identification numbers are partially customeridentification numbers.

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

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 bymeans of the timer or the telestart. Therefore first disconnect diagnosis

cable and re-conne

DW 230..350/Therm

When saving errorsinterface may occurand tries to rectify thdata will be lost!).

BBW46S/DBW46S

After starting the dirun-down.

Thermo 50 MAN/H

After release of a Tfollows:

• switch off heater• end diagnosis• wait at least for

according to TR

5.1. Starting andTo start the diagnosthe file in the sub-ddesktop or in the di

The program windo

To end the programextreme right of the

Menu: Diagnosis Thermo Test

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6

6.1.Opemenswit

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6.2.EndEndbutt

6.3.Youselefunc

for BBW 46 S/DBW 46 S.

ed with a short run-down which makes theosis mode). The test starts after a furtherter key or a mouse click on the OK button.nents test by a mouse click on the Cancelrmal operation, i.e. it possibly starts

/Handel:available in the OFF condition. The CO2-rmed in the combustion mode of operation

ow by selecting the menu item Diagnosis/ouse click on the switch button .

the component you want to test, e.g.

alue and operating time to enter theplied for the test run.launch the test of the component selected.terminate the test in progress.

ow by selecting the menu item Diagnosis/click on the switch button .

Menu: Diagnosis

Equipment Selection (start diagnosis )n the dialogue window for equipment selection by means of theu item Diagnosis/Equipment Selection or with a mouse click on thech button .

Ee equipment is not listed in the Equipment Selection or no ection can be established, go to the menu W-Bus.

1. Control Unit Selection and Diagnosis Startlick on the auto search button.he system performs an auto search by means of the equipment

dentification and then starts the diagnosis process.ark the appropriate control unit by a mouse click and then click theK button.he diagnosis process will be launched.ouble click on the appropriate control unit.he diagnosis process will be launched.

End Diagnosisthe diagnosis in progress by means of the menu item Diagnosis/Diagnosis, the function key F3 or with a mouse click on the switch

on .

Start Diagnosismay restart the diagnosis of a control unit identified before bycting the menu item Diagnosis/Start Diagnosis, by pressing thetion key F2 or with a click on the switch button .

6.4. Components Test

NOTEThis function is not available

Remark for Air Top 2000:Heating operation is terminattest functions available (diagnacknowledgement with the EnAfter termination of the compobutton the heater resumes nooperation.

Remark for Thermo 50 MANThe components test is onlyadjustment may only be perfounder full load.

Open the corresponding windComponents Test or with a m

• in the options panel markcombustion air fan.

• use the input fields rated v"optimum" values to be ap

• click on the start button to• click on the end button to

6.5. Line PrimingOpen the corresponding windLine Priming or with a mouse

Menu: Diagnosis

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Thermo Test

• in the priming time field enter the time in seconds to complete the linepriming.

• 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.

6.6. Save Test RecordSelect the menu item Diagnosis/Save Test Record to open the dialoguewindow report file.

• enter a possibly unambiguous file name in the file name field for thenew text file, e.g. report_of_011213.The file extension (.TXT) is added automatically or may be enteredas 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 RecordTo open an already existing diagnosis test record select the menu itemDiagnosis/Open Test Record to open the dialogue window report file.

• mark the file you want to review with a mouse click. The name of thefile marked is transferred into the file name field.

• mouse click on the open button or double click on the correspondingfile name to open the text file.

• the screen display show test record is opened.• mouse click on the OK button to close the display.

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

Menu: Display Thermo Test

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a graphic presentation on the evolution tolue.

displays to see diagnosis results byisplay/Trend Presentation or with a mouse

.se click on the square in the extreme right

gh an indication of problems that occurred

plays to see diagnosis results by selectinggnosis Trouble Log or with a mouse click

use click on the square in the extreme right

Menu: Display

rder to provide an overview on the diagnosis and tests you mayct different display modes:

Overview Windowdisplay provides an overview on the values during diagnosis. Thereindication of the operating voltage, the temperature and among

r values also of the equipment status.

pen the first of the five displays to see diagnosis results by selectinghe menu item Display/Overview Window or with a mouse click onhe switch button .or closing this display mouse click on the square in the extreme rightf the title bar.

Operating Datadisplay provides an overview on a range of parameters inbination with the values recorded and the units assigned.

pen the second of the five displays to see diagnosis results byelecting the menu item Display/Operating Data or with a mouselick on the switch button .or closing this display mouse click on the square in the extreme rightf the title bar.

Control Unit Informationdisplay provides a list with all Information and values for the

ipment connected.

pen the third of the five displays to see diagnosis results byelecting the menu item Display/Control Unit Information or with aouse click on the switch button .

or closing this display mouse click on the square in the extreme rightf the title bar.

7.4. Trend PresentationThis display provides you withbe expected for a specific va

• open the fourth of the fiveselecting the menu item Dclick on the switch button

• for closing this display mouof the title bar.

7.5. Diagnosis Trouble LoThis display provides you witduring diagnosis.

• open the last of the five disthe menu item Display/Diaon the switch button .

• for closing this display moof the title bar.

Menu: Error Memory

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Thermo Test

8 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 switchbutton .

• his overview presents in listed form all errors stored in the control unitin combination with the values recorded at the time of the error. Forunambiguous differentiation each error is listed separately.

• when clicking on a particular error an explanation on the particularerror will be given.

• to close the show error list window mouse click on the square at theextreme right of the title bar The square is marked with X.

8.2. Erase Error MemoryIn you want to erase all previously recorded errors select the menu itemError Memory/Erase Error Memory, press the function key F5 or click onthe switch button .

NOTEBe aware that after erase error memory all previously recorded errorswill no longer be available. Print out the errors before if required (seefunction Print).

Menu: Print Thermo Test

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9.1.Seleor c

Menu: Print

Print Test Recordct the menu item Print/Print Test Record, press the function key F12

lick on the switch button to get a test record printout.

Menu: Control

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Thermo Test

10 Menu: Control

10.1. OffSelect the menu item Control/Off, press the function key F4 or click onthe switch button for switching the heater off.

10.2. OnSelect the menu item Control/On or click on the switch button forswitching the heater on.

10.3. Stationary HeatingSelect the menu item Control/Stationary Heating or click on the switchbutton for switching the stationary heating on.

10.4. Auxiliary HeatingSelect the menu item Control/Auxiliary Heating or click on the switchbutton for switching the auxiliary heating on.

10.5. VentilationSelect the menu item Control/Ventilation or click on the switch buttonfor switching the ventilation on.

10.6. Boost OperationSelect the menu item Control/Boost Operation for operating the heaterin the boost mode (full load operation).

10.7. Circulation PumpSelect the menu item Control/Circulation Pump for switching thecirculation pump on.

NOTENot all of the control commands are applicable to all heaters.

Menu: Calibration Thermo Test

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11

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Menu: Calibration

ct the menu item Calibration/CO 2-Adjustment or click on the switchon to perform calibration.

Menu: Extras

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Thermo Test

12 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. AutostartSelect the menu item Extras/Autostart for an automatic start of theconnection to the control unit.

The selection is confirmed by a tick placed next to the menu itemAutostart.

A reselection of this menu item deselects Autostart.

Menu: Window Thermo Test

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13.3The

13.4Selewind

Menu: Window

mands in the menu Window allow you to influence the arrangementpen dialogue and display windows.

. Overlappingct the menu item Window/Overlapping if you want open windows torranged overlapping and staggered.

. Side-by-Sidect the menu item Window/Side-by-Side if you want open windows tof the same size and arranged next to each other without anylap.

. Arrange Symbolsmenu item Window/Arrange Symbols is not yet available.

. Close Allct the menu item Window/Close AlI if you want close all openows at the same time.

Menu: Help

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Thermo Test

14 Menu: Help

14.1. Program InformationThe Help menu at this time provides you only with information concerningthe development status of this software:

• select the menu item Help/Program Information or click on the switchbutton to get information on the current development status of thesoftware.

• click on the switch button OK to close the program informationwindow.

Troubleshooting Thermo Test

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Troubleshooting

r selecting a test function the error message "Timeout" is displayed.

heck if the diagnosis adapter is connected to the selected serialnterface of the PC and that the heater is properly connected.nsure that the heater is switched on and is supplied with power.

s a connection to ground present (except across diagnosis line)etween PC and vehicle? If true: immediately disconnect diagnosis

ine and remove interfering connection to prevent damage to adapternd PC.ontrol unit may be defective (check prior to replacement).ossibly an attempt has been made to diagnose a control unit notentioned above.wrong connector on the control unit has been used for the

iagnosis line.

nostic data display sometimes is incomplete and communication isuently interrupted.

s a connection to ground present (except across diagnosis line)etween PC and vehicle? If true: immediately disconnect diagnosis

ine and remove interfering connection to prevent damage to adapternd PC.