Webasto BlueCool Classic Series Installation Instructions Manual Download Page 2

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Diagnosis and repair of malfunctioning, non-functioning or damaged Webasto air
conditioning systems requires special factory training, technical information, special tools and
special equipment.

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ALWAYS carefully follow Webasto installation instructions and heed all WARNINGS.

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Improper installation voids all warranties on this product.

Summary of Contents for BlueCool Classic Series

Page 1: ...Self Contained Marine Air Conditioning Systems Installation Instructions BlueCool Classic Series ...

Page 2: ...ed Webasto air conditioning systems requires special factory training technical information special tools and special equipment ALWAYS carefully follow Webasto installation instructions and heed all WARNINGS Improper installation voids all warranties on this product ...

Page 3: ...Cool Classic unit 15 4 2 Installation and Positioning of Seawater Pump 15 4 3 Air Ducting Ventilation 18 4 4 Standard Electrical Accessories 20 4 4 1 Location digital display panel and external temperature sensor 20 5 PROGRAMMING 21 5 1 Programming Access 21 5 2 Accessing Hidden Programming 22 5 3 Re initializing of Factory Default Settings 23 5 4 Blower Speed Setting Calibration 26 6 TROUBLESHOOT...

Page 4: ...rs starting from the date of installation however with a maximum of three 3 years after date of WAG GCS invoicing OEM installed equipment warranties begin with the first purchase of the vessel not from the date of installation All parts for the WAG GCS Blue Cool Products repaired replaced under Warranty are guaranteed to be free from defects for 90 days or the remainder of the original term of war...

Page 5: ... collected documented during repair pictures highly recommended Limited warranty is extended only to the original application and is not transferable Any intervention by a third person or company not specifically and previously authorized by Webasto to repair work will void all Webasto warranty and will not be reimbursed by Webasto 1 3 Owners Responsibilities 1 Perform Webasto recommended maintena...

Page 6: ...entions must be observed for the installation work 2 3 Safety and Important Information Symbols and their Meaning Warning This symbol is used to highlight that non compliance with instructions or procedures can result in serious injuries or death to personnel Caution This symbol is used to highlight that non compliance with instructions or procedures may cause damage to equipment Attention This sy...

Page 7: ...to marine dealer or Webasto Product International NL directly at 31 0 38 3371160 The Netherlands Webasto Product N A Inc directly at 1 800 555 4518 USA or 1 800 667 8900 Canada To find an authorized Webasto marine installation center near you please call International 31 0 38 3371160 USA 800 860 7866 toll free or visit our web site at www webasto com or www webasto us ATTENTION It is the installer...

Page 8: ...ntained air conditioning unit Figure 1 Typical Installation A Self contained Unit B Digital Control Panel C Return Air Grille D Flexible Air Duct E Transition Box F Supply Air Grille G Sea Water Inlet H Sea Water Strainer I Sea Water Pump J Closing Valve K Overboard Discharge L Water Hose M Electrical Control Box N Power Cable O Display Cable ...

Page 9: ...oil While passing through the evaporator the temperature of the air is lowered by approximately 15 C 59 F Heating Cycle option ATTENTION The heat cycle becomes inefficient when the outside water temperature drops below 6 C 43 F approx It is quite possible to produce heat with an air conditioning unit For this purpose the unit shall be equipped with a 4 way reversed cycle valve option During the he...

Page 10: ...0 seconds the display will indicate the cycle in which operation the unit will start i e COOL or HEAT The choice will depend upon the setpoint temperature and the air temperature as measured by the external air temperature sensor After a further delay of approx 50 seconds the compressor s will start up and the normal operation cycle will begin Figure 3 Digital Display 1 2 3 4 5 6 7 8 9 Cool Auto H...

Page 11: ...ppropriate LED to the left heat cool etc will come on after approx 15 seconds and compressor operation will start after approx 50 seconds The seawater circulation pump will come on approx 9 seconds before compressor startup Modification of setpoint temperature The setpoint temperature i e the temperature desired by the operator for blower operation can be modified as following 1 Press and hold one...

Page 12: ... coil temperature has moved back to within normal operating values This feature is completely transparent to the end user When this happens code tA11 can be seen in the display instead of evaporator coil temperature Press key to read out evaporator coil temperature or code tA11 Infrared Remote Control Infrared remote control can be obtained as an option This remote control is based on the standard...

Page 13: ...Display Panel has been code locked To access these functions see 5 1 Programming Access Cycle mode choice F 3 1 to 4 The following cycle modes can be chosen manually 1 cool cycle only 2 heat cycle only 3 automatic cycle switching with reversible compressor 4 automatic cycle switching without reversible compressor AC Voltage readout U232 232 Volts Example Manual on off Compressor 1 1C01 1C01 Compre...

Page 14: ...ired setpoint temperature has been reached un interrupted blower operation regardless of thermostatic compressor control The choice between these two functioning modes can be programmed directly by the end user The digital control is initially programmed by the manufacturer in second i e un interrupted blower operation Blower control can be manual with 5 different speed levels or automatic in this...

Page 15: ... a way that the unit can be removed for future service if need be Do not remove any covers caps or fittings that may expose any wiring or refrigerant Only remove these items when you are ready to complete the installation or for service purposes Removal of any covers may result in damage to the electrical components Removal of the caps or fittings may result in refrigerant loss 4 2 Installation an...

Page 16: ...installation take care to re align them to ensure proper air flow 4 Air ducts Flexible air ducts need to be of good quality with sufficiently strong steel or plastic reinforcement Do not restrict air flow by bending the air ducts too tightly or by accidental local deformation Do not install air ducts of excessive lengths 2 5 m the pressure loss and consequent reduction of air flow will seriously d...

Page 17: ...ONS CLAM SHELL TYPE THRU HULL FITTING WITH SLOTS DIRECTED TOWARDS BOW TO OBTAIN POSITIVE PRESSURE IN SUCTION LINE SEA WATER STRAINER CENTRIFUGAL NON SELFPRIMING PUMPS SITUATED MINIMUM 25 CMS BELOW WATERLINE WATER LINE TO OVER BOARD OUTLET APPROX 10 CM ABOVE WATER LINE INSTALLATION OF BLEEDER ADVISABLE SUCTION GENTLY UPWARDS TO FACILITATE PRIMING ...

Page 18: ... friction For very short lengths non insulated ducts may be used Over greater lengths it is advisable to use insulted type ducts to avoid condensation on the outside of the air ducts Table 2 Air Duct Requirements BLUECOOL CLASSIC MODEL SUPPLY AIR GRILL MODEL SECTION RETURN AIR GRILL MODEL SECTION DUCT DIAM 1 8 m 6 ft DUCT Length DUCT DIAM 1 8 m 6 ft DUCT Length 5 000 BTU 1 x 8x4 150 cm 1 x 12x5 32...

Page 19: ...hat the depth of the transition box is an important factor to allow dispersion of the air flow The table see Figure 7 gives the necessary information as to the minimum dimensions advisable for such transition boxes Figure 7 Transition Box Information 5 Return Grill Offset It is best to avoid placing a return air grill directly opposite the finned coil surface of an air handler This will inevitably...

Page 20: ...xternal temperature sensor shall be a good representation of the ambient temperature Do NOT place the digital display panel and the external temperature sensor close to a supply air grill Place them in a position free from outside influences i e direct sunlight heaters stoves lights radiation from compressors etc We recommend to place the external temperature sensor in the return air flow i e back...

Page 21: ... will appear Air blower or chilled water pump Premium only will start Depending on controller setting unit will start in cooling or heating mode In case error codes appear see trouble shooting OFF Push 1x unit and display will automatically shut off when running MEMO NENO Push 1x to memorise new settings during programming RETURN Push 1x display will return to room temperature when programming FUN...

Page 22: ...tal display 2 Press and keys simultaneously for approx 3 seconds until the word CODE is visible on the display 1 3 Press and hold the key until 64 appears on the display 1 and then press the key Now you are in the deep programming mode 4 You see to the left of the display window a single number code indicating the programming line presently valid and to the right the programming value 5 To go to t...

Page 23: ...en 2 and 18 C 36 and 64 F Code 2 45 C 113 F Higher setpoint temperature of the deicing procedure in relation to the evap coil temperature when in heat cycle to avoid HP cut outs Gives the cut out point of the compressor s when functioning in heat cycle Setpoint temperature Adjustment range between 30 and 50 C 86 and 122 F Code 3 38 C 100 F Lower setpoint temperature of coil temperature cut in when...

Page 24: ...egulated for standard 115V 230V seawater pump For the use of the WEBASTO WB200 self priming variable speed pump this code should be set to 1 In that case the AC outlet is pulse hashed to enable variable pump speed Code d 12 V Lower adjustment ceiling DC output for special self priming pump Can be adjusted to higher ceiling 18V see also Code E hereafter Code E 18 V Higher adjustment ceiling DC outp...

Page 25: ...ge levels Do not lower factory settings Code 1 00 Infrared remote control 00 Infrared remote control disabled in this mode no interference is possible with other Infrared commands 01 Infrared remote control active Code 2 01 Blower type Centrifugal or Crossflow 01 all blower models Code 3 01 Blower Settings 01 Uninterrupted blower operation regardless of the thermostatic control 00 Thermostatic con...

Page 26: ...west speed No 1 and go back again to speed No 5 if not satisfied When all speeds are programmed according to need validate by pushing key MEMO will be displayed briefly Code b 64 Access code for programming mode Note If the system is locked and the access code cannot be found you can access the programming line by using the factory code number 64 00 No access code required 01 to 99 access code num...

Page 27: ...e delay of 1 minute approx 3 The compressor will start but no seawater circulation can be observed Check sea cock to seawater pump Check seawater strainer Check if pump rotates If the pump does not turn with the compressor working check power supply from the main control unit box to the pump 4 Compressor and pump work but no correct operation in either cool or heat cycle Check for proper air venti...

Page 28: ...y the micro processor including the time delays for restart etc See note Standard TCC controller cards have only 1 outlet for 1 single compressor However the embedded micro processor program can operate up to 4 SC units from 1 single controller card This special controller card can be obtained on special request but is not standard delivery ATTENTION Models SC5 to 12 do not have a low pressure saf...

Page 29: ...en short circuit Check sensor and wiring Replace sensor on Schrader if necessary COOLING MODE Insufficient seawater cooling Blocked seawater strainer or not primed Check discharge water volume V 8 l min or 30 000 BTU V 18 l min Clean strainer and bleed sea water circuit HEATING MODE Insufficient air flow Check air flow ΔT evaporator in out minimum 4K A03 to A08 Not used for BlueCool Classic units ...

Page 30: ...l controller cable and connections Replace defective cable panel or controller card n a No output on printboard Defective fuse or open short circuit on specific circuit Repair or replace fuse open short circuit or replace printboard Printboard damaged by high voltage Replace printboard Broken electronic relay TRIAC Replace defective TRIAC or printboard operation of TRIAC can easily be tested with ...

Page 31: ...ocked refrigerant circuit Drier capillary or expansion valve To be determined by a refrigerant specialist Technical Memo available Bad compressor To be determined by a refrigerant specialist n a Pumps running continuously When additional relays are used to operate pumps a small leaking current from the printboard may operate the relay continuously Remove R56 C24 and or R57 C27 from the printboard ...

Page 32: ...witch board Pressure switches LP only for 16 000 BTU and more Run capacitor Start capacitor only for 16 000 BTU and more Capacitor and resistor pump Display External air temp sensor Evaporator temp sensor comp fan valve pump Capacitor and resistor pump In case a relay is used the controller should be without related capacitor and resistor Cable colours bl br ge gn gr rt sw vi ws blue brown yellow ...

Page 33: ...tiple unit one pump IMPORTANT The TCC controller card of each unit should be without capacitor and resistor at the related output Remove if necessary Common seawater pump TCC pump outlet unit 1 115 230V AC switch board TCC pump outlet unit 2 TCC pump outlet unit 3 TCC pump outlet unit 4 ...

Page 34: ...assic Pump WB200 bl br IMPORTANT For proper operation TCC controller settings at setpoint 29 C line c must be set at 01 Seawater pump TCC pump outlet Cable colours bl br blue brown Display comp fan valve pump External air temp sensor Evaporator temp sensor FUSE VOLTAGE SETTING ...

Page 35: ...00 500 ø condenser water connection mm 16 16 16 16 16 Dimensions LxDxH mm 424x285x278 444x285x278 434x285x301 459x382x312 467x451x315 ø air outlet mm 100 100 100 100 125 Suggested breaker A 8 10 10 12 16 Model SC16 SC20 SC24 SC30 Performance BTU kW 16 000 4 7 20 000 5 8 24 000 7 30 000 8 8 Voltage 230V 115V 50 60Hz 60Hz 230V 50 60Hz 230V 50 60Hz 230V 50 60Hz Power consumption start A 5 5 12 6 5 14...

Page 36: ...oning system with a 20 000 BTU h cooling performance 20 000 BTU Step 5 Depending on the demands you can decide on a BlueCool Classic or Premium with a cooling capacity of 20 000 BTU h SC20 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 5 000 3 750 6 250 10 000 7 500 12 500 15 000 11 250 18 750 20 000 15 000 25 000 25 000 18 750 31 250 30 000 22 500 37 500 35 000 26 250 43 7...

Page 37: ...commended that the condenser is increased in size Category 1 Volume of the rooms m3 region portlights only cabin s all below deck 400 BTU m3 normal cold hot Category 2 Volume of the rooms m3 region average glass area cabins partly below deck 500 BTU m3 normal cold hot Category 3 Volume of the rooms m3 region glass area above average saloon above deck 600 BTU m3 normal cold hot Category 4 Volume of...

Page 38: ...THE RIGHT COOLING CAPACITY Webasto BlueCool Classic Series 38 ...

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Page 40: ... Constructieweg 47 NL 8263 BC Kampen The Netherlands Phone 31 0 38 337 11 37 Fax 31 0 38 332 51 81 E mail info nl webasto com Internet www webasto com http dealers webasto com Webasto Product N A Inc 15083 North Road Fenton MI 48430 Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 Internet www webasto us www techwebasto com ...

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