Webato Startup Procedure

[richard5933]

We had a rather cool day today (mid-50s) so I thought it was time to test the Webasto to see if it would start. The instructions left by the previous owner consist of:

1- Pull switch to turn on.

2- Control fan speed with rotating knob.

3- Control temp with thermostat.

Not much to go on there. I pulled switch. The green light came on indicating something was going on. Only nothing really was.

Before digging in without knowledge, I thought I'd ask and see if someone could point me in the right direction.

The previous owner did leave me with a fuel filter and a replacement nozzle. Seems like he thought those would be needed. Beyond that I have no clue. I did find a manual in my stack of paperwork, but it was not much help either.

Richard

[Gary Hatt - Publisher BCM]

The best answer can be obtained from Lloyd DeGerald.  He travels the country to all of the RV shows and repairs these.  You can reach him by phone.  He is on EST most of the time.  Check out  his website.  http://lloyddegerald.com/blog-1/ or call him at 501 258 8426. Tell him Gary sent you.  I just checked his scheduile and he is home now in Paron, AR.

[Geoff]

The Webasto manual should have all the troubleshooting procedures.  Maybe it's a fuse.

--Geoff

[buswarrior]

Webasto is very generous with their manuals, all available online.

Extensive explanations, parts diagrams, trouble shooting.

A great unit, simply needs to be understood and maintained properly.

Skimp on anything, you pay the price in dysfunction.

Your system is more than just the "webasto" It sounds like there are all manner of other bits and pieces.

The Webasto is the coolant boiler that warms the liquid that circulates to your various other devices that distribute that heat.

happy coaching!
buswarrior

[sixtyseven]

There are several things that could be the culprit, so at this point you have 2 choices.  1. What Gary said, Call Lloyd.   2. What Geoff & BW said, study the manual & troubleshoot.  Then when you narrow it down to a particular part and or have a specific question that will make it easier to answer.   When you turn it on does the webasto unit itself make any noises ?   If so, what noise?     
. 

[OneLapper]

I have rebuilt several 2010's and learned an interesting bit about the bearings.  The fan shaft uses an ever popular 608Z bearing.  But, 608Z bearings come with MANY different types of lubricant inside of the them.  I rebuilt one with OEM bearings and had no issues.  I rebuilt another with 608Z bearings from online ($1 a piece) and it bench ran perfectly, but when it was COLD outside, the unit didn't run properly.  Turns out the grease in the bearings was too thick (combined with the cold fuel going through the fuel pump) and 2010's motor ran too slow for proper ignition.  Oil lubricated 608 bearings solved the issue, but they aren't $1 a piece.

They are amazing pieces of engineering and are usually under maintained, but when you go through and baseline an older unit, it'll run as well as any new unit.

Motor RPM is key.  Too little, and it'll never run right. The items that will bring down RPM; bad motor, bad or incorrect bearings, fuel pump.

[richard5933]

This question might be really a beginner's one, but I still can't figure out the fan for my Webasto.

The Webasto is connected to the bus's cooling system. The coolant runs through the same hoses/pipes as the OTR HVAC systm.

When I fire up the Webasto, am I expecting the bus's air circulating fan to turn on, or is there a separate fan that will run with just the Webasto? If there is a separate fan, then is there a separate air handling system (vents) or will the Webasto fan push air through the bus's vents?

I'm assuming that there is a separate fan for the Webasto, as otherwise my batteries could never power the fans for more than a short while.

Or...Maybe I should ask if it's even possible to heat the bus using the Webasto when not on shore power or running the generator?

Don't think I've found all the components to the Webasto system yet. Hoping to get a little help knowing what I'm looking for.

Still summer here in Wisconsin, but not for long. In just a few weeks the nights will start getting cool enough for heat and I'll be in hot water if I can't get the water to heat.

Thanks
Richard

[thomasinnv]

Usually a webasto installed in a bus IN FACTORY CONFIGURATION is installed to be used as a suplemental heat source, in addition to the engine heat. In cold climates the 4 stroke engine does not produce adequate heat to keep the cabin and its passengers warm enough so the manufacturers install a webasto or equivalent. There are no separate fans for the webasto, it simply introduces additional heat into the otr system, and utilizes the otr fans and ducting. Many, like myself, have re-engineered the system so that it can be used as a stand alone system and install small cabin heat exchangers with low power draw fans.

Sent from my SM-G920T using Tapatalk

[Geoff]

We had a rather cool day today (mid-50s) so I thought it was time to test the Webasto to see if it would start. The instructions left by the previous owner consist of:

1- Pull switch to turn on.

2- Control fan speed with rotating knob.

3- Control temp with thermostat.

Not much to go on there. I pulled switch. The green light came on indicating something was going on. Only nothing really was.

Before digging in without knowledge, I thought I'd ask and see if someone could point me in the right direction.

The previous owner did leave me with a fuel filter and a replacement nozzle. Seems like he thought those would be needed. Beyond that I have no clue. I did find a manual in my stack of paperwork, but it was not much help either.

Richard

Okay, here is how a Webasto works:
1) There is an on-off switch to start the Webasto.  The unit should start whining and if everything is okay the burner will start in less than 30 seconds.  This circulates the coolant while it heats up to say 160f.  It normally would pre heat your engine and the heater lines going through the bus.
2) The fan switch is to draw the heat out from the interior heater boxes and warm the inside.
3) The thermostat controls#2 but the Webasto continues to run and turns the burner on and off to maintain 160f in the coolant regardless of #2.

If the green light comes on and the Webasto does not start the Webasto is not getting electrical power.  Get the downloadable instruction manual and check for power at the Webasto fuses.  Then get back to us.

--Geoff

[richard5933]

Thanks.

I'll be getting into the bowels of the bus this week and will see what I find. I've got the manual now and will see what things look like. I'm going to assume that there is a low current fan somewhere, because I've found a rotating switch near the Webasto start switch labeled 'fan'. From the looks of the switch there is no way it's large enough to control anything but a low current fan. Now to find it...

[Gary Hatt - Publisher BCM]

For anything Aqua-Hot, Hydro-Hot, or Webasto related, call Lloyd DeGerald as he is the authority on these systems.  He is very knowledgeable and can send you any part you may need. He travels the country attending different RV related events and services these units. For his schedule, check out his website http://lloyddegerald.com/blog-1/

501-258-8426

lloyd.degerald@gmail.com

[richard5933]

I made the executive decision today to throw in the towel on the Webasto and sent the unit to Lloyd for him to evaluate and repair. I could spend countless hours looking for a $5 part that went bad and end up replacing parts unnecessarily. While I enjoy being able to fix things in house, sometimes it's just time to call in the A team.

Now if only I could send the OTR heat system to someone to troubleshoot...

Richard

[richard5933]

I got the Webasto back from Lloyd and reinstalled. Seems my thermostat is bad, as if I jump it the Webasto motor will start and the burner will now light. Circulating pump doesn't work though, so I can only run the burner for a minute or two.

Questions about the circulating pump for those experts out there...

Right now, the circulating pump is plugged into the 'A' spot on the control box. There are two leads, brown ground and a black positive. Weird thing is that the wires have 12 volts going to them at all times. According to Lloyd, the 'B' connected should have power to the red lead at all times and to the yellow lead when the switch is on and the thermostat is calling for heat.

Seems strange that the pump is always on. I can easily wire a master power on/off switch to control power to the Webasto so that when in the 'off' position there is no power to anything.

Big question now is whether the circulating pump should be running at all times the Webasto system is turned on, or should it only run when the thermostat calls for heat? I'm of two minds on this. For power consumption savings I'd like the pump to only run when needed to bring hot water to the heater core to make heat in the cabin. But, if the circulating pump turns off prematurely the Webasto will not be able to cool itself down after firing or if there is a high-heat situation in the heat exchanger. Ideally I'd want the circulating pump to stay on for a few minutes after the burner shuts down so that the system has a change to cool a tad.

Any thoughts?

Richard

[buswarrior]

Webasto needs coolant circulation, or you risk blowing the overheat fuses, and then you are back into the poop.

A system would have 2 layers of control, the coolant circulation, and the temperature of the coolant being circulated.

2 pumps, one that takes care of the webasto, and one that circulates your heated reservoir to the heat exchangers in the coach.

An electric hot water tank has been used by busnuts as that reservoir, webasto circulates in and out of it to heat it, second pump pulls hot coolant out to heta the interior, and the electric element is available for use when a power pole is available, and no stink needed to stay warm when it is only cool, and not cold.

Good stuff doesn't come simple?

happy coaching!
buswarrior

[opus]

Webasto needs coolant circulation, or you risk blowing the overheat fuses, and then you are back into the poop.

And lighter in the wallet!