Webasto Thermo Test Operating Instructions

Version 2.14
 Thermo Test

1 General information/installation . . . . . . . . . . . . . . . . . . . . . 3
1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2. System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Diagnostic-capable units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. OE-applications with W-Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5. OE-applications with K-Line . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6. Installation on the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7. Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Heater-specific diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1. Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2. Menu: Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3. Menu: View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4. Menu: Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5. Menu: Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6. Menu: Control (depending on heater version) . . . . . . . . . . . . 26
2.7. Menu: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8. Menu: Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.9. Menu: Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.10. Menu: Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Service modules for components and accessories . . . . . . 31

3.1. IPCU intelligent PWM control unit . . . . . . . . . . . . . . . . . . . . . 31
3.2. IPMU Intelligent PWM Master Unit . . . . . . . . . . . . . . . . . . . . . 32
3.3. Telestart T100 HTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
General information/installation General

1 General information/installation

1.1. General
The Webasto heater diagnostic software is used for checking heaters with
a diagnostic capability in all voltage versions with the help of a personal
computer.
The PC diagnostic adapter and the type-specific test adapter supplied with
the software are required to connect the heater to the PC (see fig. 1 up to
14). The test adapters are identical as used in combination with the
diagnostic computer.
Although the program has been tested successfully on many computers, it
is not impossible that it will not run properly on certain PCs. In this case,
please let us know so that we can make improvements if necessary.

Fig. 1: Test adapter for Thermo 90 heaters, order no. 83661B

Fig. 2: Test adapter for Thermo 90 S/ST, Thermo Top Evo and
Thermo 50 MAN/trade heaters, order no. 92556B

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General General information/installation

Fig. 3: Test adapter for BBW 46 S and DBW 46 S heaters. Fig. 6: Test adapter for Air Top 3500/5000/ST and Air Top 2000 ST
You can make an appropriate adapter yourself if required. heaters, order no. 92555A

Fig. 4: Test adapter for BW 80 and DW 80 heaters, Fig. 7: Test adapter for DW 230/300/350 and Thermo 230/300/350
order no. 21333A heaters, order no. 20865A

Fig. 5: Test adapter for Thermo Top Z/C trade and Air Top 2000/S Fig. 8: Test adapter for DW 230/300/350 and Thermo 230/300/350
heaters, order no. 92566B heaters, order no. 22656A

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General information/installation General

Fig. 9: Test adapter for DW 230/300/350 and Thermo 230/300/350 Fig. 12: Test adapter for DW 230/300/350 and Thermo 230/300/350
heaters, order no. 88336A (MB/Citaro) heaters, order no. 66265A

Fig. 10: Test adapter for DW 230/300/350 and Thermo 230/300/350 Fig. 13: Test adapter for Thermo 230/300/350 Rail heaters,
(RVI) heaters, order no. 92629A order no. 9012265C

Fig. 11: Test adapter for DW 230/300/350 and Thermo 230/300/350 Fig. 14: Test adapter PC Diagnosis 1533 timer,
(Van Hool) heaters, order no. 92637A order no. 1301783A

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System requirements General information/installation

1.2. System requirements

– 500 MHz processor or higher depending on the requirements of the
operating system.

– Min. 256 MB of RAM depending on the requirements of the operating

system.

– Microsoft Windows XP SP2, Vista (32/64 Bit), 7 (32/64 Bit).

– 30 MB available space on the hard disk.

– A vacant COM port (RS232C) or a vacant USB port.

– Internet access (for software updates).

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General information/installation Diagnostic-capable units

1.3. Diagnostic-capable units

Heater selection for USB interface Heater selection for COM interface
NOTE
If the device is not listed in Select device, the heater must be a model with Diagnosis of the following units is only possible via serial port, the USB
W-Bus. W-Bus-capable heaters are grouped under the heading of W-Bus. interface cannot be used with these units: BBW 46S; DBW 46S
In this case use the W-Bus selection. The W-Bus selection contains a list of
various heaters that use the same diagnostic port. (See also chapter 1.4.,
"OE-applications with W-Bus", page 8)

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OE-applications with W-Bus General information/installation

1.4. OE-applications with W-Bus

PC-Diagnosis with W-Bus enables:
• overview of heaters’ parameters and components;
• display error list (in case errors occur);
• delete error memory;
• heater information;
• graphs of actual values of components;
• overview heaters’ operating data;
• component test;
• fuel prime;
• CO2 calibration;
• Protocol of the measured values;
• creation of a summary.
NOTE
Vehicle specific, W-Bus capable heaters have been summarised here.
At device selection, please select W-Bus.

NOTE Fig. 15: Wire harness Diagnosis OEM order no. 9016761A
For PC-Diagnosis, a wire harness Diagnosis OEM (order no. 9016761A) is
required.

NOTE
Avoid switching on the heater via W-bus in auxiliary heating mode,
because at applications without circulation pump control it can lead to
overheating.

NOTE
At many OEM applications, the error memory can only be deleted via the
OEM interface.

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General information/installation OE-applications with W-Bus

Brand Model Heater Diagnosis via…

Audi A3, ABII TT-V PIN 2 of the control unit or via Telestart.Telestart is situated in the
trunk.
Audi A6, C6 TT-V PIN 2 of the control unit or via Telestart.
Telestart is situated in the trunk.
Audi A8, D3 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated near the C-pillar.
Audi A8, D3 TT-Z PIN 1 of the control unit.
Bentley Continental, Coupé GT TT-C PIN 1 of the control unit or via Telestart.
BMW 5 Series, E60 TT-C PIN 1 of the control unit.
BMW 7 Series, E60 TT-C PIN 1 of the control unit.
BMW 7 Series, E60 TT-Z PIN 1 of the control unit.
Jaguar S Type, X204 TT-V PIN 2 of the control unit.
Landrover Baby Range, L320 TT-V PIN 2 of the control unit or via Telestart.
Maybach Maybach, W240 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mazda 6, J56 TT-Z PIN 1 of the control unit.
Mazda MPV, J16 TT-Z PIN 1 of the control unit.
Mercedes C Class, W203 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes CL, C215 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes CLK, A209 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.

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OE-applications with W-Bus General information/installation

Brand Model Heater Diagnosis via…

Mercedes CLS, C209 TT-C PIN 1 of the control unit or via Telestart.
from 11/2004 Telestart is situated in the trunk.
Mercedes E Class, W211 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes G Class, G463 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes S Class, W220 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes S Class, W220 TT-Z PIN 1 of the control unit.
Mercedes SL, R230 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Mercedes Sport Coupé, CL203 TT-C PIN 1 of the control unit or via Telestart.
Telestart is situated in the trunk.
Porsche Cayenne, E1 TT-C PIN 1 of the control unit.
VW Caddy, PQ35 TT-V PIN 2 of the control unit or via Telestart.
starting week 22 2004
VW Golf V Plus, PQ35 TT-V PIN 2 of the control unit or via Telestart.
starting summer 2004 Connection with Telestart is very complex.
VW Golf V, PQ35 TT-V PIN 2 of the control unit or via Telestart.
Connection with Telestart is very complex.
VW Multivan, T5 TT-C PIN 1 of the control unit or via Telestart.
VW Multivan, T5 TT-Z PIN 1 of the control unit.
VW Passat, PQ46, TT-V PIN 2 of the control unit.
starting 11/2004

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General information/installation OE-applications with W-Bus

Brand Model Heater Diagnosis via…

VW Passat, PQ46, TT-V PIN 2 of the control unit or via Telestart.
starting 11/2004
VW Phaeton, D1 TT-C PIN 1 of the control unit or via Telestart.
VW Phaeton, D1 TT-Z PIN 1 of the control unit.
VW Touareg, Mac TT-C PIN 1 of the control unit or via Telestart.
VW Touareg, Mac TT-Z PIN 1 of the control unit.
VW Touran, PQ35 TT-V PIN 2 of the control unit.
VW Touran, PQ35 TT-V PIN 2 of the control unit or via Telestart.
Trade TT-Evo PIN 2 of the control unit.

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OE-applications with K-Line General information/installation

1.5. OE-applications with K-Line

Vehicle specific, K-Line capable heaters have been summarised here. At NOTE
device selection, please select the device specified in the column “device Avoid switching on the heater via K-line in auxiliary heating mode, because
selection” of the table below. at applications without circulation pump control it can lead to overheating.
NOTE
For PC-Diagnosis, a wire harness Diagnosis OEM (order no. 9016761A) is NOTE
required. See fig. 15. At many OEM applications, the error memory can only be deleted via the
OEM tester.

Brand Model Heater Device selection Diagnosis via…

Alfa Romeo 166, 936 TT-Z TT-Z Fiat Vehicle diagnosis plug (adapter required), or directly at PIN 2 of the
control unit.
BMW X5, E53 TT-C TT-Z/C BMW PIN 2 of the control unit.
BMW X5, E53 TT-Z TT-Z BMW PIN 2 of the control unit.
Chrysler Voyager, RG Minivan TT-Z TT-Z PIN 2 of the control unit.
Citroën Berlingo, M59 TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Citroën C5, X4 TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Citroën C8, V TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Citroën Xsara Picasso, N68 TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Fiat Ducato, 244 TT-C TT-Z/C Fiat Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Fiat Ducato, 244 TT-Z TT-Z Fiat Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Fiat Multipla, 186 TT-C TT-Z/C Fiat Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Fiat Stilo, 192 TT-C TT-Z/C Fiat Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Fiat Ulysse, V TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.

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General information/installation OE-applications with K-Line

Brand Model Heater Device selection Diagnosis via…

Hyundai Trajet, F0 TT-Z TT-Z PSA Vehicle diagnosis plug (below steering column) or directly at PIN 2 of
the control unit.
Kia Sorento, BL TT-Z TT-Z PSA Vehicle diagnosis plug (front fuse box) or directly at PIN 2 of the
control unit.
Lancia Thesis, 841 TT-C TT-Z/C Fiat Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Landrover Discovery, L25 TT-Z TT-Z BMW PIN 2 of the control unit.
Landrover Range Rover, L30 TT-C TT-Z/C BMW PIN 2 of the control unit.
Landrover Range Rover, L30 TT-Z TT-Z BMW PIN 2 of the control unit.
MG Rover 75, R40 TT-C TT-Z/C BMW PIN 2 of the control unit.
MG Rover 75, R40 TT-Z TT-Z BMW PIN 2 of the control unit.
Peugeot 807, V TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Peugeot Jumper, U64 TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.
Peugeot Partner, M49 TT-Z TT-Z PSA Vehicle diagnosis plug or directly at PIN 2 of the control unit.

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Installation on the hard disk General information/installation

1.6. Installation on the hard disk

NOTE Please note
Webasto does not accept liability for any data loss on your computer. If you are working in a network and require administrator rights for the
Therefore, we recommend you back up your hard disk. installation then please log on using the corresponding user name and
password.
If you already have older versions of the software installed on your
computer, they must be uninstalled before the new installation. Windows responds:

1.6.1. Download from the Internet and installation

The latest version of the program is available from our dealer area under
http://dealers.webasto.com.
If you do not have access, please contact the regional manager responsible
for your area or your Webasto dealer.
Download:
• Click the download link on the Internet.
• Select save file and save the file in a suitable folder on your hard drive.
Installation (new installation or update): 1. Select the required language and confirm your selection with “OK”.|

• Close all Windows programs.

• Open Explorer and go to the folder in which you saved the file from the
Internet.
• Double click this file.
• The Windows Set-up Manager will then guide you through the
installation.

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General information/installation Installation on the hard disk
Webasto Thermo Test software. If you wish to change the specified
path (C:\Program Files\WebastoThermoTest\), click “Browse” and
select a different folder.

Please note
Please note that if you select your own path, any folders with the same
name on the hard disk will be overwritten.

4. Confirm the settings with “Next”.

2. Click “Next” to continue.

5. The installation is completed.

Close the window with "Close"

Connect the USB adapter to a vacant USB connection on your computer.

3. At this point, you are asked in which folder you want to install the

15
Installation on the hard disk General information/installation
6. After connecting the USB adapter the following message will be
displayed:

8. Click "Install the software automatically (Recommended)" and

confirm with “Next”.

7. Click "No, not this time" and"Next", to proceed with the USB driver
installation.

9. Click “Finish” to complete installation of the USB drivers successfully.

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General information/installation Connection

1.7. Connection
CAUTION – Connect the type-specific test adapter to the 4-pole connector of the
The work MUST be completed in the following sequence! diagnostic adapter and the heater. The heater may be switched on.
ATTENTION
– Connect the 9-pin plug or the USB plug (both cables are supplied) to a
Contact with moving parts of the vehicle (e.g. ventilator) can lead to
vacant serial port (COM1 or COM2) or a vacant USB port on the PC (the damages.
plug can remain connected if necessary).
– Connect the 9-pin plug or USB plug to the diagnostic adapter.
ATTENTION
NOTE Risk of tripping over the supply line or data line of the adapter.
The system must be switched manually between COM1 and COM2 (if the
PC has more than one serial port). There is no need to switch between the WARNING
COM and USB ports manually. The USB port to which the hardware is Don’t let the heater run without exhaustion.
connected will be recognised automatically. This applies even if there is
more than one USB port.Both COM and USB connections are not allowed ATTENTION
to be used at the same time. Don’t open the body of the heater because of risk of injuries and loss of
warranty.
ATTENTION
To avoid potential differences the vehicle must not be connected to a NOTE
charger during the diagnostic procedure. The connection cable to the heater is not allowed to be routed near the
vehicle ignition system or activated electrical devices (e.g. electric drill).
ATTENTION
Before connecting to the heater ensure that there is no voltage between – Exit the diagnostic program before disconnecting the cables.
the earths of the PC and the vehicle. Voltages in excess of 5 V may damage No particular sequence must be observed for disconnecting the cables.
both the diagnostic adapter and the PC. First connect the adapter to the
positive pole and then to the earth to ensure this.

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Test procedure Heater-specific diagnosis

2 Heater-specific diagnosis

2.1. Test procedure

NOTE Thermo Top 98:
The heater must be connected to the vehicle’s electrical system but not When using USB diagnosis adapter ID 9008487B, test adapter ID 92566B
necessarily operating to execute a test function. is required.
If the adapter is not connected or connected to the wrong port or the When using USB diagnosis adapter ID 9008487D via a RS232 (COM) port,
heater is not on or not properly connected, an error message will be test adapter ID 92566B is also required.
displayed. In this case check the above causes.
When using USB diagnosis adapter ID 9008487D via a USB port, an
additional test adapter is not required.
The program monitors the connection to the heater and identifies
disconnects. Irregular disconnects (e.g. pulling a plug during the test) will DW 230..350/Thermo 230..350:
result in the message “Timeout” being displayed in the status window. The diagnostic port may suffer malfunctions when errors from this unit are
saved. The diagnostic program detects these malfunctions and will rectify
Specific notes on the various types of heaters: the problem by deleting the error memory (saved error data will be lost).

Thermo Top Z/C: The pump pressure test is not possible.

If the diagnostic cable is connected, the heater (depending on the version) Thermo 50 MAN/trade:
cannot be started using the timer or the Telestart. In this case first The Thermo 50 MAN/trade heater does not need to be switched on during
disconnect the diagnostic cable, start the heater and then reconnect the the diagnosis.
diagnostic cable.
After a TRS condition has been triggered, the heater may only be restarted
BBW46S/DBW46S: as follows:
After the diagnosis has been started the heater enters a diagnostic mode
• Switch off the heater
with a run-down.
• exit the diagnosis
Thermo Top P: • Wait at least 10 s.
The UP (circulating pump) button is not permanently activated during
diagnosis; instead, it flashes at various frequencies depending on the
operating status of the circulating pump.

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Heater-specific diagnosis Menu: Diagnosis

2.2. Menu: Diagnosis

2.2.1. Select device (Start diagnosis) NOTE

Open the dialogue box to select the control unit using the Diagnosis / If the device is not listed in Select device, the heater must be a model with
Select device menu command or by clicking the button . W-Bus. W-Bus-capable heaters are grouped under the heading of W-Bus.
In this case use the W-Bus selection. The W-Bus selection contains a list of
various heaters that use the same diagnostic port
Unit Applications with W-Bus (see also chapter 1.4., "OE-applications with W-Bus", page 8).
Thermo Top V All existing applications
2.2.1.1. Selecting the control unit and start the diagnostic process:
Thermo Top C/Z DC C Class (W203 and W203 Facelift starting 09/04), • Click the <Auto Search> button.
DC E Class (W211), The system performs an automatic search using the device identifier
DC S Class (W220 and W220 Facelift starting 09/02), and then starts the diagnostic process.
DC SL Class (R230), or
DC CLK Class (W209), • Mark the appropriate control unit by clicking it and then click the <OK>
Porsche Cayenne, button.
AUDI A8 (D3), The diagnostic process will be started.
VW Phaeton (D1), or
VW T5, • Double click the relevant control unit. The diagnostic process will be
VW Touareg (MAC), started.
BMW 7 Series (E65),
Mazda 6, 2.2.2. Exit the diagnosis
Mazda MPV (both U222) End the current diagnosis using the Diagnosis / End diagnoses menu
command, F3 function key or by clicking the button.
AT2000ST all
2.2.3. Restarting the diagnosis
AT3500ST all You can restart the diagnosis of the control unit you have specified earlier
Thermo 90ST all by selecting the Diagnosis/ Start diagnosis menu command, pressing the
F2 function key or clicking the button.
GBW 300 all

Thermo Top Evo all

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Menu: Diagnosis Heater-specific diagnosis
2.2.4. Component test NOTE
Open the dialogue box of the same name using the Diagnosis / The priming process cannot be stopped on some heaters.
Component test… menu command or by clicking the button.
• Mark the components that you wish to test in the options box, for 2.2.6. Fuel pump test
Measuring the fuel discharge flow to the heaters Thermo Top Z, E, C, P
example the combustion air fan.
trade with PC-Diagnosis "Webasto Thermo Test".
• Click the <Start> button to start the test on the selected component.
• Click the <Stop all> button to terminate the current test.
CAUTION
Perform the following steps when testing the fuel pump (measuring
NOTE
discharge flow):
This function is not available for BBW 46 S/DBW 46 S.

1. Loosen the fuel line at the heater and put it into a suitable metering
Note on Air Top 2000:
box (range 30 ml).
Heating mode is terminated with a short slowdown time, after which the
test functions are available (diagnostic mode). The test starts after a further 2. Make all necessary connections for Webasto Thermo Test.
acknowledgement by pressing the Enter key or clicking the OK button.
After the component test has been ended by clicking the Cancel button, 3. Select heater: Thermo Top C, E trade, C/Z MB/DC.
the heater will resume normal control mode.
4. Open display Overview.

Note on Thermo 50 MAN/trade: 5. Select menu Fuel pump test.

The component test is only available when the heater is OFF. CO2
6. Start measurement.
adjustment may only be carried out in combustion mode with the heater
in full load. 7. During the filling check the fuel pump frequency (5.263 Hz) displayed
in the overview.
2.2.5. Line priming
Open the dialogue box of the same name using the Diagnosis / Prime 8. Wait 60 s.
line… menu command or by clicking the button.
• Enter the time for priming the line in seconds in the priming time box.
The default is 30 seconds.
• Click the <Start priming> button, to start the line priming process.
• Click the <Stop priming> button to cancel your entry or to stop the line
priming prematurely.

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Heater-specific diagnosis Menu: Diagnosis
Analysis Smoking and any kind of open fire is prohibited.
1. Compare the fuel quantity in the metering box with the set point
Fuels can contain solvent-similar substances. Avoid skin and eye contacts.
value of 20 ml (+/- 2 ml).
Wear protective gloves. Change and clean protective clothing frequently.
2. When there are deviations from the set point value, disconnect the Don’t bring fuel in contact with clothes. If case fuel comes in contact with
fuel pump from the vehicle’s fuel tank. clothes, change clothes immediately.

CAUTION Do not inhale fuel. Inhalation of fuel can cause physical damage.
Remove fuel tank cap, relief pressure, close fuel tank. Collect fuel that runs
out in a suitable container and respectively close fuel line with an
Don’t spill fuel. When spilling fuel, bind immediately with appropriate
appropriate tool.Connect the suction side to an unpressurised container bonding agents and dispose environment-friendly. Make sure that no fuel
and lead the pressure side with a short line directly to the metering box.
is spilled in the soil!
Then, repeat the measurement.
In particular avoid fire, open light and sparks in the circumference of 20
3. In case of the same deviation, the fuel pump may be defect.
meters around the workspace.
Otherwise, search and remedy the failure at the fuel extraction (e.g.
too high or too low pressure) or fuel line (e.g. kinked or blocked). 2.2.7. Save summary
Use the Diagnosis / Save summary... menu command to open the report
file dialogue box.
The summary shows operating data and control unit information. For
additional information, see chapter 2.3.2., "Operating data", page 23 and
chapter 2.3.3., "Control unit information", page 23.

CAUTION • Enter a file name as clear as possible in the file name box for the new
When starting the fuel pump test, fuel is pumped! text file, e.g. report_dated_011213. The file extension (.TXT) s added
automatically or may be entered as part of the file name, e.g.
Consider the relevant rules for safety and for the prevention of accidents Test_011214.txt.
prescribed by the professional associations, the legislator, other generally • Click the <Save> button to save the summary of the diagnostic data..
recognised, safety-relevant rules and rules according to industrial
medicine, as well as the legal environmental protection amendments!

21
Menu: Diagnosis Heater-specific diagnosis
2.2.8. Open summary
To open an existing summary of diagnostic data, open the report file
dialogue box using the Diagnosis / Open summary... menu command.
• Mark the file you want to review by clicking it. The name of the marked
file will be transferred into the file name box.
• Click the <Open> button or double click the file name to open the text
file.
• The Display summary view will be opened.
• Click the <OK> button to close the view.

2.2.9. Start test record

Use the Diagnosis / Start measurement recording... menu command to
open the Protocol file dialogue box.
• Enter a clear name as possible into the protocol file name box for the
new text file, e.g. protocol_dated_011213. The file extension (.TXT) s
added automatically or may be entered as part of the file name, e.g.
Test_011214.txt.
• Enter the recording interval (the default is 10 seconds).
NOTE
When you have finished the diagnosis, end the measurement recording.

2.2.10. Ending the measurement recording

• The <OK> button starts the recording.
• Use the Diagnosis / measurement recording menu to end measurement
recording.

22
Heater-specific diagnosis Menu: View

2.3. Menu: View

You can select between different views in order to see different displays • Use the View / Trend graphic... menu command or click the button
and data about the heaters: to open the trend graphic.

2.3.1. Overview window 2.3.5. Protocol display

This view gives you an overview on the values during the diagnosis. In This protocol display view lists all the statuses of the heater during the
addition to the operating voltage, temperature, etc. the device status is diagnosis.
also shown.
• Open the last of the five views of the diagnostic results using View /
• Use the View / Overview window... menu command or click the Protocol display... menu command or by clicking the button .
button to open the overview window. • To close this view click the square at the far right of the window title
bar.
2.3.2. Operating data
The operating data view gives you an overview of a number of parameters
in addition to the values that have been found and the units for them.
• Use the View / operating data... menu command or click the button
to open the operating data.

2.3.3. Control unit information

The device information view contains a list of all the information and values
relating to the connected device.
• Use the View / control unit information... menu command or click the
button to open the control unit information.

2.3.4. Trend graphic

The graphical trend view shows the sequence of the heater values over
time in a diagram. Right-clicking the display with the mouse displays a
shortcut menu for the displayed values. You can show or hide the
individual values by clicking here. The same thing applies to the displays in
chapter 2.3.5., "Protocol display", page 23.

23
Menu: Error memory Heater-specific diagnosis

2.4. Menu: Error memory

2.4.1. Display error lists

• Use the Error memory / display error list... menu command or click the
button to open the Error display window.
• This view displays a list of all the errors saved in the control unit
together with the values that occurred during the error. Each error is
listed separately to distinguish clearly between them.
• If you click an error, an explanation of that error will be displayed.

2.4.2. Clear fault memory

To delete all the entries in the error memory select Fault memory / clear
fault memory…, the F5 function key, or by clicking the button.
NOTE
Please note that after they have been deleted, the error values can no
longer be reviewed. If necessary you should print out the error values
before you delete them (see chapter 2.5., "Menu: Print", page 25).

24
Heater-specific diagnosis Menu: Print

2.5. Menu: Print

2.5.1. Print report

To print a summary select the Print / Report menu command, the F12
function key, or by clicking the button.

25
Menu: Control (depending on heater version) Heater-specific diagnosis

2.6. Menu: Control (depending on heater version)

2.6.1. Off
To switch off the heater select the Control / Heater off menu command,
the F4 function key, or by clicking the button.

2.6.2. On
To switch on the heater select the Control / Heater on menu command or
click the button.

2.6.3. Parking heating

If you wish to use parking heating mode select the Control / parking
heating mode or click the button.

2.6.4. Auxiliary heating

If you wish to use auxiliary heating mode select the Control / auxiliary
heating mode or click the button.

2.6.5. Ventilation
If you wish to use ventilation mode select the Control / ventilation mode
or click the button.

2.6.6. Boost mode

If you wish to use boost mode select the Control / Boost mode menu
command.

2.6.7. Circulating pump

To switch on the circulation pump select the Control / circulating pump
menu command.

NOTE
Not all of the control commands are available for all of the heaters.

26
Heater-specific diagnosis Menu: Calibration

2.7. Menu: Calibration

2.7.1. CO2 adjustment

To carry out the calibration process select the Calibration / CO2 adjustment
or by clicking the button.
NOTE
This function is only available when the heater is in certain statuses.
Please also read the corresponding chapter in the workshop manual of the
heater in question!

27
Menu: Tools Heater-specific diagnosis

2.8. Menu: Tools

NOTE
If the diagnostic adapter is connected to the USB port, it will be
automatically recognised by Windows. No settings are required.

The Tools menu provides you with two menu commands to configure your
computer:

2.8.1. COM port

• Open the COM port selection dialogue box using the Tools / COM port
menu command.
• Select the COM port (COM1 or COM2) you want to use to connect to
the external device.
• Click the <OK> button to confirm your selection.
CAUTION
If the COM port you wish to use is not displayed, this means that the port
is being used by a different program. In this case quit all your applications
and restart Thermo Test.

2.8.2. Start-up
Select the Tools / Startup menu command if you wish to restart the
connection to the control unit automatically after an interrupt. This is an
advantage if the operating voltage is disconnected frequently during the
test.
The selection will be confirmed by a tick being placed next to the Startup
menu command.
If you reselect the menu command or terminate the connection, this
selection will be cancelled.

28
Heater-specific diagnosis Menu: Window

2.9. Menu: Window

The Window menu enables you to influence how open dialogue boxes and
view windows are displayed:

2.9.1. Overlapping
Select the Window / overlapping menu command if you want open
windows to be arranged overlapping each other.

2.9.2. Side-by-side
Select the Window / Side-by-side menu command if you want open
windows to be of the same size and arranged next to each other without
any overlap.

2.9.3. Close all

Select the Window / Close all menu command if you want to close all open
windows.

2.9.4. Select an open window

Select the Select an open window menu command if you want to switch
between windows that are open at the same time.

29
Menu: Help Heater-specific diagnosis

2.10. Menu: Help

2.10.1. Help
This menu displays help topics relating to this diagnostic software.
• To obtain help on the program and problems, select the Help / Help
menu command or click the button . From this window you can go
to instructions that will give you a step by step guide to using Webasto
Thermo Test 2002 or you can view various types of reference
information.
• As soon as you have opened the help topic you can click the Contents
button at any time to return to the contents window.

2.10.2. Program information

This displays the version of this diagnostic software:
• To obtain information on your WTT version select the Help / Program
information... or click on the button.
• Click <OK> to close the program information window.

30
Service modules for components and accessories IPCU intelligent PWM control unit

3 Service modules for components and accessories

3.1. IPCU intelligent PWM control unit

3.1.1. IPCU programming The button “Set selected parameters” sets the predefined parameter for
the selected vehicle module under “IPCU programming”. The parameter
values can also be changed individually.
Programming the selected parameters is not carried out until the "Program
IPCU" button is pressed.
NOTE:
When selecting user-defined parameters, make sure they are suitable for
the requirements of the fan motor. Incorrect parameters can lead to a
malfunction or damage to the fan motor when the module is operating.

This dialogue box is used for programming an electrical system, referred to

as IPCU module for short, for controlling vehicle fan motors.
The current settings of the IPCU module are continuously read out and
displayed under “Current IPCU settings”.
A list of vehicle modules can be found in “Vehicle-specific parameters”.

31
IPMU Intelligent PWM Master Unit Service modules for components and accessories

3.2. IPMU Intelligent PWM Master Unit

3.2.1. Reading out vehicle specific parameters via IPMU In case the correct vehicle specific parameters for programming the IPCU
module are unknown, these can be read out via a IPMU module and special
measuring equipment.After the IPMU module is connected to the USB
Diagnostics Adapter and to the vehicle with measuring equipment, reading
out can be started with the this dialogue box.
To do this, click on “Start measurement”.
Following a successful measurement, the following message appears:
PWM VALUES SUCCESSFULLY MEASURED.
To program and IPCU with these values, select the IPCU from the control
unit selection list without ending the Webasto Thermo Test 2002 program
beforehand. The measured values are then automatically transferred in the
"Program IPCU" window of the IPCU dialogue box. Programming the
measured values is not carried out until the "Program IPCU" button is
pressed.

NOTE:
The function "High Side active" or "Low Side active" cannot be
determined with the IPMU. After a successful measurement, the function
is always shown as "High Side active". Should it not be possible to control
the fan after programming the IPCU, the function must be changed to
"Low Side active".

NOTE:
The IPMU and the necessary measuring equipment can be purchased
under order no. 9016656A.

32
Service modules for components and accessories Telestart T100 HTM

3.3. Telestart T100 HTM

3.3.1. Programming the system level

Heating Time Management (HTM) in the Telestart receiver calculates the We recommend the following typical default settings for the system level:
heating duration depending on the prevailing temperature and the S0: For small cars and saloons
comfort level (C1 to C5) selected using the hand-held transmitter. S1: For off-roaders, estate cars, SUVs and in general for vehicles with a
Comfort level spacious interior
S2 / S3: Only in regions with very cold outdoor temperatures or if the
We recommend comfort level 2/3 as the basic setting. However, the user customer has special requirements.
can adapt the comfort level according to his or her individual requirements
using the HTM transmitter. The specialist workshop can select a higher Altering the system levels makes it possible to adapt the heating duration
to the given features of a particular vehicle heating system.
system level in advance to adapt the system in accordance with specific
requirements. The maximum heating duration (below -20 °C) is specified for each system
level in the dialogue box. The minimum heating duration (above +10 °C)
System level
is always 10 minutes.
The system level setting is used for the default setting depending on the
The heating duration between these two temperature values varies with an
corresponding vehicle type. This setting can only be made by the Webasto
approximately linear progression.
specialist workshop or an installation partner using the diagnostic
software.

33
General Troubleshooting

4 Troubleshooting

4.1. General
When you select a test function, an error message is displayed.
• Check if the diagnostic adapter is connected to the selected serial port
or the USB port on the PC and that heater is properly connected.
• Check whether the heater is switched on and is receiving power.
• Is there an earth connection (apart from via the diagnostic cable)
between the PC and the vehicle? If so immediately disconnect the
diagnostic cable and disconnect the relevant connection to prevent
damage to the adapter and PC.
• The control unit may be defective (check with a different unit before
replacing it).
• A control unit that has no diagnostic capability may have been selected.
• An incorrect connection on the control unit has been used for the
diagnostic cable.
• If you are using an RS232 (COM) port:If another program (e.g. keypad
or mouse) is accessing the port, this application must be closed.

34
Troubleshooting General

35
General Troubleshooting

36
 Ident no. 2005101C_EN • 07/12 • Errors and omissions excepted • © Webasto Thermo & Comfort SE, 2012
Webasto Thermo & Comfort SE
Postfach 1410
82199 Gilching
Germany

Visitors' address:
Friedrichshafener Str. 9
82205 Gilching
Germany

Internet: www.webasto.com

The telephone number of each country can be found in the

Webasto service center leaflet or the website of the respective
Webasto representative of your country.