Shillas X100 Diesel Cooker Instruction Manual

X100 Diesel Cooker

SDhiiellsaeslDCieosoekl eCroxok1e0r0
Installation Instructions
08-05-2008

SWheibllaasstDoiDesieesl eCloCookoekrer X100 Index
1. Legal notices 2. Overview and function 3. Installation 4. Fuel supply 5. Electrical connections 6. Exhaust system 7. Initial start-up 8. Technical details

Page 2 3 4 11 13 14 15 16

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SWheibllaasstDoiDesieesl eCloCookoekrer X100 1. Legal notices
IImmpprrooppeerr iinnssttaallllaattiioonn oorr rreeppaaiirr ooff aa WSheibllaasstoDiDeiseesleCl oCookoekrecracnancacuasuese fire or the leakage of deadly carbon monoxide leading to serious injury or death. TToo irnesptaailrl tahnedSrhepillaairDthieeseWl eCboaosktoerDyioeusenleCeodotkoehr ayvoeu need to have tchoemapplpetreodpraiaWteetbeacshtnoictraalindioncgucmoeunrtsaetiaonnd, shpaevceiathl teoaoplspraonpdrisapteecial eteqcuhipnmicaelndt.ocumentation, special tools and special equipment. NNEEVVEERR ttrryy ttoo iinnssttaallll oorr rreeppaaiirr tthhee WSheibllaasstoDiDesieesleCl oCookoekreirf iyfoyuoudohanvoet hnaovt ecothmepnleetceedsasaWryebteacshtonitcraalinsiknigllscoanudrsyeo, uyoduodnoont ohtahveavteecthhneical ndeocceusmseanrytatteiocnh,ntiocaollsskainllds eaqnudipyomuendtoanvoatilhaabvlee ttoecehnnsiucrael that you dcoancucmomenptlaettieonth, etoionlsstaalnladtieoqnuaipnmd erenpt aaivrawilaobrkleptroopenersluyr.e that you can complete the installation and repair work properly. AALLWWAAYYSSccaarreeffuullllyyffoolllloowwWSehbilalasstoininstsatlalalltaitoionnaannddrereppaairirininsstrturucctitoionnss and note all WARNINGS. Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel. Install the Webasto Diesel Cooker only to road vehicles, not to boats. Use the Webasto Diesel Cooker only for cooking. It is not a heater.
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SWheibllaasstDoiDesieesl eCloCookoekrer X100 2. Overview and function
2.1 Overview
Figure 1:

2.2 Function
The WSheilblaasstDoieDsiesl eCloCookoekrer iXs1a00saisfeadsieasfe ldcieosoeklecr ooker 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 heat power is steplessly adjustable.

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.

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SWheibllaasstCooDoikeesrel Cooker X100 3. Installation

3.1 Cooker location
When installing a cooker it should be noted that it has to be dismounted for servicing. It is advisable to make the connections in such a way that the device can be easily disconnected for servicing.
There must be at least 20 mm between the cooker and any vertical surface. See figure 2. Make sure that inflammable materials like curtains cannot touch the ceramic plate.
An authorized Webasto
service center has to take care of the installation.
3.1.1 Location of pipes, hoses and wires
The power cords and fuel hoses must be protected in places where they are exposed to mechanical damage due to, for example, sharp objects or heat.
Materials which come into contact with parts of the cooker or the coaxial exhaust tube have to resist temperatures of 80 °C.

Figure 2:

Do not install the cooker in an area where there may be petrol fumes risk of explosion.
The cooker, exhaust gas tube and all other metal parts must be insulated from the vehicle metal chassis so that in case of an electrical malfunction the voltage is not transferred from the chassis to the cooker or vice versa.

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SWheibllaasstDoiDesieesl eCloCookoekrer X100

3.2 Installation example

Figure 3:
1. Cooker
22.. OMpaeinractoinngnepcatnioenl plug 33.. OCopoekratotipngcopnatnroelllecrords 44.. PFuoewlepricckaubplepsipe 55.. F15ueAl pmuaminp fuse 66.. BMaatitnerfuysmeain switch 77.. FFuueell hhoossee 88.. FFuueell pfiultmerp holder 99..FT-upeilefciletefror fuel to vehicles 1r0e.tuErnxhlianuest gas tube 1110.. CEoxohlainugstagiratusbtueb6e0mm 11. Cooling air tube

2 3

1

1

6

4
10

8 11

10

7

9

9 7

6 5

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SWheibllaasstDoiDesieesl eCloCookoekrer X100
3.3 Replacement air
The cooker needs air for combustion and cooling. There must be sufficient air circulation in the whole vehicle at all times. The place and method of installation must be selected in such a way that the cooker always gets enough replacement air.
There is a cooling fan in the front plate of the ventilation box. There must be at least 200 cm2 replacement air opening near the cooling fan in the installation space.
Figure 4 A:

There must be at least a 200 cm2 opening for replacement air in the space where the cooker is installed. The air inlets and outlets must never be covered.
The ventilation box is an important part of the cooker. Never install the cooker without the ventilation box.

270mm

440mm

Front edge of cooker

3.4 Installation opening
Saw an installation opening of 29705 x 4402 mm as shownn in figure 4. Do not cut it larger because ceramic plate could be damaged otherwise. Make sure that the cooker is resting with the metal frame on the tabletop.
Note space requirements for ventilation box. The whole ventilation box has to fit into the installation space.

Figure 4B: 315mm

440mm 465mm

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270mm

SWheibllaasstDoiDesieesl eCloCookoekrer X100

3.5 Mounting the

cooker
Figure 5:

Figure 5:

FFaigsuteren6th: e front plate to the
ventilation box with only a feiPnwlsatc4ael.l2athtxioe1nc3oomopkemenrinsincgrtaehnweds. Faigttaucreh 6th:e mounting pieces to the nuts at the ends of the PcloaockeetrhuescinogotkheerMin6thxe12 ianmmotstramotaBculh)slnacatttirhcineoecgwnomsrpod.oipeiCnuecghnneotitinoopngsogtehsapeitntiheidoecnes(A totatbhleetnouptsthaictktnheesesn. ds of the cooker using the M6 x 12

mm screws. Choose the

mounting piece position (A Figure 6:

or B) according to the

tabletop thickness.

A

B

Figguurree77::

Theenn tighhtteenn thhee mmoouunnttiinngg

pieces against tthheettaabblleewwitithh

M66 x 300 mmmmssccrreewwss..UUsseeththee

lockkiinngg nnuuttss((MM66))aanndd

Figure 7:

prootteeccttiioonnppluluggssøø66mmmm. .

Protection plug

Figguurree88::

PlLeoacskeingNnoutet :-

BCeofnonreectotnhneefcutienlghothse tfuoethl heose to the fuel pump, bleed the diesel fuel in the fuel line before the

fueell puummppbayndeitherpporwesesrurising thMeofuunetinl gtasnckrewwith a small amount of air-pressure to push the fuel tcharboulegthotthheefcuoeul lpinlien,gthbieshwinilldsave you having to re-start the cooktop many times to push the fuel

tthhreocuogohkfeorr.best results fuel pump should be within 4 ft of diesel cooktop

Figure 8:

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SWheibllaasstDoiDesieesl eCloCookoekrer X100 4 Fuel supply
The fuel must not be taken from the fuel hose going to the engine. The maximum allowed pressure for cooker fuel hose is 2 bar.

The fuel couplings must be properly tightened to prevent any air leaks into the hose. Air will cause malfunction of the unit.
Always check that the coupling surfaces of the fuel hose and the fuel hose itself are clean before tightening them.

4.1 Fuel line
The maximum length of the fuel hose is 8 m. The fuel hose shall always be cut to suitable length for each installation.
The fuel hose must always be equipped with a filter. The fuel filter shall be installed inside the vehicle to prevent freezing in winter. Use a place where it can be easily checked and replaced if necessary.
4.2 Fuel feed
The fuel tank must always be situated below the cooker. The delivery lift of the fuel pump should be less than 1.5 m.
If the delivery height of the fuel pump is above 1.5 m, the fuel feeding needs to be checked and adjusted if necessary. The fuel feeding must also be checked whenever a fuel system part, such as the pump or electronics card, has been replaced.
Fuel feed adjustment must be carried out by an authorized service provider.

4.3 Fuel connection
Cut Mecanyl lines without burr and do not crush them. Do not cut them with sidecutting pliers.
A rubber hose suitable to diesel must be used with all fuel connections.
4.3.1 Fuel extractor Figure 17.
The fuel can be taken from the vehicle fuel tank or from a separate tank with fuel extractor.

Figure 17: A) Fuel pickup from the plastic tank via tank fitting. The fitting must be made from metal.
B) Fuel pickup from the plastic tank via tank drain screw.

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SWheibllaasstDoiDesieesl eCloCookoekrer X100

F4u.3e.l2SRueptpulryn- line

Figure 18: 1. T-piece, 2. Rubber hose ø 5 mm, 3. Hose clamp ø 10 mm,

Pinlesatasellantoiotenthe diesel fuel dosing4p.uRmubpbiesr thoorsuenøp8amrrmallferol mwiethngtihnee grertouurnndlinoer, 5c.hHaossseiscloafmthpeøv1e2hicle

iuFspigiwtutaorredfas1c.8eT.hseligphutlmy pupwwilal rndotaot paenrianmtcelmiinf.eit

of is

not more mounte4d

than 15 degrees, vertically

with

the

pressure

side

facing

The fuel hose can be FfipunuieseeltclaleiplnlietepodectswohnesitnhheeonWcugtlodeinrbbseae’psslpteroreaoTsttuee-rcnetendsufrroemthaenyyamreebcuhtat nciocnanl deactmedagtoe,1pwrehveennct oannnyebcutibnbglefusefloprmipiensg.with the

line.

5

4.3.3 Fuel filter The filter can be installed to

4
5 3

a ø 5 mm fuel hose. Ensure

that the hoses are clear

before installation. There

2

must not be any dirt between

the pump and the filter in

particular, because it will damage the pump.

3 Fuel hose to cooker

Install the filter inside the

vehicle.

Figure 19:

1. Filter, 2. Rubber hose ø 5 mm, 3. Hose clamp ø 10 mm.

3 2

3

Fuel flow

1

3

2 3

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SWheibllaasstDoiDesieesl eCloCookoekrer X100 5 Electrical connections

5.1 Connections of device
The device operates on 12 V DC. Attach the red wire of the power cord to the plus pole of the battery and the black wire to the minus pole.
5.2 Cable Diameter
In order to minimise voltage losses we recommend you make the power cord as short and with as few couplings as possible.
The cross-sectional area of the cable depends on the length of the power cable. See table 1. The maximum cable length is 10 m.
The fast coupling of the cooker is for 4 mm2 cable. If cables >4 mm2 are needed, the cable connection should be made as close to the cooker as possible (maximum distance 1m).
Tabel 1:
Total length of electrical cable (m)

Figure 20: 1. Main fuse, 2. Main switch, 3. Device quick coupling.

3

21

5.3 Battery main switch
A main switch must be installed to the plus wire of the device. Always cut the power from the main switch when the device is not used for a long time.
Cross-section of cable (mm²)

5.4 Main fuse
A main fuse must be installed in the red plus wire near the battery. See figure 20.
5.5 Voltage
The power consumption of the device is the highest when the glow plug is on during start-up, and so are the voltage losses. During glowing, the voltage must be at least 10.7 V, measured at the quick coupling of the device. See figure 20. If the voltage is below that, starting may fail.

0 – 4

4

4 – 6

6

6 – 10

10

Never cut the power from the device before the run down phase has been completed.

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SWheibllaasstDoiDesieesl eCloCookoekrer X100 6 Exhaust system

6.1 Exhaust outlet
Air must always be able to flow free past the exhaust gas outlet. Try to install the outlet in such a way that wind can blow past it. The outlet must not be placed in a corner or a confined area when wind pressure may disturb the operation of the device.
6.2 Exhaust installation
Make a ø 65 mm leadthrough to the floor for exhaust gas and cooling air tubes. Lead both tubes through the hole. Let the cooling air tube stick out min. 10 mm below the vehicles floor. Seal the floor lead-through and cooling air tube with heat resistance silicone. Fasten the exhaust gas tube under the vehicle. Also fix the coaxial hose to the furniture and the floor of the vehicle. Exhaust gas and cooling air tubes must always run downwards to avoid water traps. The minimum bending radius for the exhaust tube is 50 mm.

Figure 21:

Exhaust gas is hot. Always make sure that there is no inflammable material within 200 mm after the exhaust outlet.
Coaxial tube radiates heat. Beware of the hot surface of the tube during use.

The end of the exhaust gas tube shall point downwards with a tolerance of ±10°. Make sure that the exhaust outlet ends at the side of the vehicle opposite from the passanger entry door. Also ensure that exhaust gas is blown away from underneath the vehicle.

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SWheibllaasstDoiDesieesl eCloCookoekrer X100

I7nsItnaliltaitaiolns&tausret-oufpcontrol switch
Remove the adjustment heat control knob to expose the screw mounting hole.

The cooker starts to heat up If the fuel line does not fill up

automaOticpaellryatwiohne&n tfhaeult light power switch is turned to ON
position. TheOyne/OlloffwBuinttdoincator lamp lights up as soon as

during tw.Toossttaarrttsth,ethSehicllaosodkieesrel heater simply turn the heat control

will lock kitnsoeblftoanthde bdeostihrerdetdemperature & push the start button.

and

yelloIlefwdthlleiiggdhhitetwsseilbll scetogaoriktntfoltaposhshinoguilnddhicaavteinagnay

fault occur then the red problem with the cooktop

blink. The amount of flashes given by the led indicate the problem as

the cooker is swHitecahtecdoonntr.ol knob

listed below in the fault table-

The red combustion lamp

Unlocking the diesel cooker:

will light up when a proper combustion has stabilized in the burner, which is 2.5-4 minutes after the start-up.
The cooker will not necessarily start the first try after installation when the fuel hose is empty. Then the red combustion light starts to blink about 4.5 minutes after the start-up.

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.

Turn the power switch to OFF position. The device cannot be restarted until both indicator lamps have gone out (run down phase).
Once the indicator lamps have gone out, restart the stove. The red combustion lamp will light up about 2.5-4 minutes after the start-up,

5. Start cooker normally.
Turn the power switch to OFF position to shut down the stove after test use. The red combustion lamp will keep blinking for about 5 minutes while the cooker is cooling.

when the combustion is

normal.

The cooker locks itself after two unsuccessful starts. PwInlfieloltahtgsteoerydinnetoovtotiescfteaaaufrwttleitilrtlc3mnoodfoaterisel1ettadhirnatad,ntietcetvawmetinipcotetnshwontoiouthgsfouhtauetrlthteceethgcfeunceokl ihnfuagsetlrheeetaccctahhueesdectohooefktphtuoemp p, do problem.

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SWheibllaasstDoiDesieesl eCloCookoekrer X100 8 Technical details

TTaabbllee 22:: TTeecchhnniiccaall ddeettaaiillssooffSWhiellbaassDtoieDseiel sCeoloCkoeroker X100.

Fuel

Diesel oil

Operating voltage Fuel consumption Heating capacity

12 V DC 0.09 – 0.19 l/h (0.074 – 0.156 kg/h) 00..99 — 21..29 kkWW

Power consumption

0.3 A, at ignition 8 A.

Dimensions
Weight
Minimum area of the cooling air inlet
Maximum permitted length of the exhaust hose
Maximum permitted length of the fuel hose

WW 456355 xx DD331453xxHH191590mmmm HHeeiigghhtt ddeeppeennddssoonntatbalbelteotpopthtihckicnkenss Approx. 8 kg 200 cm2
1.9 m, straight downwards 1.2 m (ø 28 mm and ø 60 mm)
8 m (ø 5/2 mm)

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