Self-Contained Marine Air
Conditioning Systems
Installation Instructions
BlueCool Classic Series
• Diagnosis and repair of malfunctioning, non-functioning or damaged 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.
Webasto BlueCool Classic Series Table of Contents
CONTENTS Page
1 LIMITED WARRANTY .............................................................................................................................. 4
1.1 Installation / Validation & Commissioning ................................................................................... 4
1.2 Limitations and Exclusions........................................................................................................... 5
1.3 Owners Responsibilities............................................................................................................... 5
2 FOREWORD ............................................................................................................................................. 6
2.1 General ...................................................................................................................................... 6
2.2 Scope and Purpose ..................................................................................................................... 6
2.3 Safety and Important Information Symbols and their Meaning.................................................... 6
2.4 IMPORTANT SAFETY INFORMATION ........................................................................................... 7
3 OVERVIEW............................................................................................................................................... 8
3.1 Typical Installation ...................................................................................................................... 8
3.2 Description and operation........................................................................................................... 9
3.2.1 Self-Contained Air Conditioning Unit.......................................................................... 9
3.2.2 Digital Display Panel.................................................................................................. 10
4 INSTALLATION ...................................................................................................................................... 15
4.1 Installation and Positioning of BlueCool 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 TROUBLESHOOTING ............................................................................................................................. 27
6.1 Routine Checks......................................................................................................................... 27
6.2 Troubleshooting ....................................................................................................................... 27
6.3 Visual Error Codes - Digital Display............................................................................................ 28
7 SCHEMATICS ......................................................................................................................................... 32
7.1 Wiring Diagram - BlueCool Classic TCC V3 ............................................................................. 32
7.2 Wiring Diagram - BlueCool Classic multiple unit, one pump .................................................... 33
7.3 Wiring Diagram - BlueCool Classic Pump WB200 .................................................................... 34
8 TECHNICAL DATA ................................................................................................................................ 35
9 CHOOSE THE RIGHT BLUECOOL .......................................................................................................... 36
10 THE RIGHT COOLING CAPACITY ......................................................................................................... 37
LIMITED WARRANTY Webasto BlueCool Classic Series
4
Webasto BlueCool Classic®Series AC Systems
1 LIMITED WARRANTY
The Webasto warranty policy is extended to cover Webasto Blue Cool products manufactured or
supplied by Webasto AG, Business Unit Global Comfort Solutions, hereafter WAG-GCS, and is subject
to qualifications indicated.
The complete warranty policy is not described here, but available at your local Webasto subsidiairy.
WAG-GCS warrants for the period set forth below that products are free from defects and with good
workmanship for their normal use and are only valid for all original components. The warranty shall
not constitute a guarantee, unless explicitly specified as such in writing. The warranty is for the endcustomer whereby it is administered and processed inside the WAG-GCS network of authorized
dealers.
Webasto Warranty does not guarantee neither any timing for the repair nor any location where the
repair should be performed. These two aspects will be the object of separate service agreements with
annual fees.
Under this warranty and in accordance with Webasto Global Service & Warranty principles an
authorised Webasto dealer or an authorised Webasto installer may have a statutory warranty claim
within and outside the supply chain or reimbursement claims for zero-kilometre defects, but solely in
accordance with the terms and conditions hereunder.
The quality and good operation of WAG-GCS Blue Cool Products are guaranteed by WAG-GCS for a
period of two (2) years, 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 warranty, whichever is longer.
While warranty is provided to the “end user”, it is to be administered and serviced through a Webasto
Authorized Dealer in accordance with the Webasto warranty policy.
To locate the nearest “Webasto Authorized Dealer” please call:
• International: Webasto Product International at +31-(0)38-3371160
• USA: Webasto Product North America at (800) 860-7866 (toll free),
or visit our web site at:
• www.webasto.com or
• www.webasto.us
While this warranty covers parts and labor, if the air conditioner was self installed by the end user or
someone other than a Webasto Authorized Dealer, the diagnosis and repair must be completed by a
Webasto Authorized Dealer in order to receive compensation under the terms of this warranty.
1.1 Installation / Validation & Commissioning
All Blue Cool Products have to be installed by authorized installers or this installation has to be
reviewed and approved by an authorized installer.
All installation/application releases should be commissioned and validated according to Marine
Commissioning & Validation (MCV) report and completely documented. In case of OEM installations
this applies only for the first released representative applications.
The complete commissioning and validating procedure is described in Webasto’s Blue Cool Inter
Company Warranty Manual.
Webasto BlueCool Classic Series LIMITED WARRANTY
5
1.2 Limitations and Exclusions
This warranty is limited to repair & replacement only. It does not cover:
• Damages incidental and or consequential to the failure of Webasto Blue Cool equipment
• Failure of the Blue Cool equipment due to normal wear, accident, misuse, abuse, lack of
reasonable and necessary maintenance, unauthorized installation or repair by the endcustomer, alterations, civil disturbance or act of God.
• Transportation damages. This should be claimed directly with the forwarding company.
• Repair costs due to failure of Blue Cool equipment due to negligence, improper installation or
non-respecting the installation guidelines (installer fault) will be funded by repair country to
repair dealer and charged to country of origin / original installer upon evidence 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 maintenance procedures as described in this document.
2) Proof of purchase is required for all units.
3) Ask the installer of your Webasto Blue Cool air conditioning system or your Webasto
subsidiary for a copy of a Validation Report. Always keep a copy of the report together with
the air conditioning installation.
THE WARRANTY DESCRIBED IN THIS POLICY SHALL BE IN LIEU OF ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty gives you specific rights and you may also have other rights which vary by State or
Province.
FOREWORD Webasto BlueCool Classic Series
6
2 FOREWORD
2.1 General
The air conditioning units covered in this manual can be used to cool marine vessel cabins and
cockpits.
Installation accessories can be found in our Marine Catalogue.
2.2 Scope and Purpose
These installation instructions are intended to support the installation of self-contained air
conditioners in marine vessels.
Acknowledged engineering conventions 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 symbol is used to highlight and draw specific attention to important information.
Flammable or Combustible
This symbol is used to highlight and draw specific attention to flammable or
combustible materials or risks.
Webasto BlueCool Classic Series FOREWORD
7
2.4 IMPORTANT SAFETY INFORMATION
Read Before Proceeding with Installation!
WARNING!
• ALWAYS switch air conditioning units off during refueling or when in a refueling area.
CAUTION!
• Location of wiring and control devices and installation of air ducting are important for proper
operation. Failure to comply with the installation instructions provided may result in poor operation
or damage to air conditioner and vessel components.
• For information concerning special marine applications or marine applications you are not sure of,
contact an authorized Webasto 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’s responsibility that the installation complies with all applicable local regulations. E.g. CE
directives, American Boat & Yacht Council, U.S. Coast Guard regulations and general Air Conditioning and
Refrigeration Industry (ARI) standards. Also, all relevant state and provincial licensing regulations if any, governing
the installation and use of auxiliary heating devices in watercraft must be observed.
OVERVIEW Webasto BlueCool Classic Series
8
3 OVERVIEW
3.1 Typical Installation
The illustration below shows a typical installation of a self-contained 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
Webasto BlueCool Classic Series OVERVIEW
9
3.2 Description and operation
3.2.1 Self-Contained Air Conditioning Unit
ATTENTION
All Webasto air conditioning units pump seawater around the condenser to aid in the cooling process.
Cooling Cycle
The compressor compresses the refrigerant gas which is then condensed to liquid as it passes through
the seawater cooled condenser. The liquid refrigerant is injected through a small nozzle and
evaporates. This evaporation process produces the refrigeration effect. The evaporation takes place in
a tubular finned coil (also called: evaporator coil). A blower forces the air through the evaporator coil.
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 heat cycle the condenser effectively
becomes the evaporator. It removes any available heat from the seawater and transfers it to the
refrigerant. The finned evaporator becomes the condenser and produces heat to approx. 45/50 °C
(113/122 °F).
Figure 2 Classic Unit
1
2
3
4
5
8
7
6
1 Evaporator Coil
2 Blower Exit
3 Condenser Exit
4 Blower Motor
5 Optional reversed Cycle Valve
(Cool / Heat)
6 Stainless Steel Drain Pan
7 Condenser Entry
8 Compressor
OVERVIEW Webasto BlueCool Classic Series
10
3.2.2 Digital Display Panel
All Webasto air conditioning units are controlled by a Digital Display <AIR CONTROL> which gives
access to all functions necessary for the normal operation of the unit and attached accessories
(blowers, pumps, etc.).
In order to start the system you only need to press the key on the digital display. From there on the
electronic control unit takes care of the progressive starting up of the air conditioning unit as well as
its normal functioning.
The digital display will show the present air temperature of the cabin in which the digital display is
situated or where the main temperature sensor is located (in case it is placed in a different room).
After a delay of approx. 20 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
345
6
7
8
9
Cool
Auto
Heat
1 Temperature or Function Readout
2 Set Point Modification Key
- Press to read setpoint temperature
- Hold to raise setpoint temperature.
3 Set Point Modification Key
- Press to read setpoint temperature
- Hold to lower setpoint temperature.
4 Dedicated Blower Speed Key
5 Set-Up / Programming Key
- Allows access to secondary functions and
programming
6 On/Off Key
- Press to turn on
- Press again to turn off.
7 Led indicating system working in heat mode
8 Led indicating automatic cycle-switching is
active
9 Led indicating system working in cool mode
Webasto BlueCool Classic Series OVERVIEW
11
Digital Display
The WEBASTO Digital Display gives access to information and controls at three distinct levels:
Immediate Access - Level 1
1. Room temperature readout in the main 4 LED display window
2. 3 small LED’s to the left indicating the operating cycle presently active: cool cycle only operation;
automatic cycle (switching governed by the end user’s entered setpoint temperature); heat cycle
only operation.
3. 2 setpoint keys give immediate access to the thermostatic setpoints for blower control ( and
keys). These keys are also used to alter programming values.
Secondary commands and info -Level 2
The key gives immediate access to a number of secondary commands which need to be accessed
frequently for day to day operation. First access is to the blower speed control, then evaporator
temperature readout, etc.
Programming Commands - Level 3
A number of programming commands that do not need to be accessed for day-to-day operation are
hidden and require a special procedure to enable access and modification (See 5.1: "Programming
Access"). An access code can be enforced to avoid accidental modification of programming values.
Startup delay
After pushing the key the LED’s will display <On> while initializing the system. Push again to stop
operation; the display will briefly show <Off> before extinction. The appropriate 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 of the setpoint selector keys ( or ) and wait until the new desired
setpoint temperature is obtained.
2. Press key to memorize.
The display will return to normal room temperature readout after approx. 5 seconds. Non-volatile
memory keeps last settings.
Special Features
Dedicated Blower speed key
The digital display provides for a dedicated blower speed key which allows you to cycle through
the speed settings. The key is only used for programming and setting purposes.
Self-priming pumps
WEBASTO Marine has developed a variable flow ultra-silent self-priming pump system. This will
automatically adjust its flow rate to the real required capacity, i.e. during a hot sunny afternoon the
pump will run at full speed, during the night it will slow down to minimum speed. This system is
referenced: WEBASTO WB200; it is basically a DC pump with a special control unit between the TCC
controller card and the pump allowing to adjust the pump speed as needed. The use of standard
115V/230VAC pumps is still possible without any restriction. Installation of WB200 pumps can be
above the waterline to 250 mm approx.
Flow rate varies between 6 and 12 L/min. approx.
OVERVIEW Webasto BlueCool Classic Series
12
Automatic blank/sleep mode programmable time delay
Factory default:15 minutes. While in blank/sleep mode the cycle LED flashes discretely every
20 seconds. To go back to normal operation push any key.
Calibrate all blower speed settings in real time mode
It is possible to calibrate all speed settings (1 to 5) before actually putting the system into service (See
5.4: "Blower Speed Setting Calibration").
CAUTION!
Never program speeds so low that the blower is in danger of stopping or will not restart at that
setting. This will inevitably entail motor winding burnout and will not be covered by the WEBASTO
warranty.
Automatic Deicing Control
During intermediate seasons (spring, autumn) when moderate temperature conditions prevail, there is
a definite risk of icing the evaporator coil in cool mode and pressure safety cut-outs in heat mode. To
allow maximum blower speed variation and still function within a normal operating window, the TCC
card is equipped with a second temperature sensor which reads the exact evaporator coil temperature.
Whenever coil temperature approaches the danger zone, blower speed is increased to half speed; if
that is not sufficient the micro-processor will stop compressor operation for pre-determined intervals
and will resume normal operation when 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
protocols also used by TV and other appliances. Although the WEBASTO controls have been chosen so
as to avoid interference with most TV models, the end user should be aware that in certain cases
interference may occur with TV sets or other appliances.
In general, it is therefore advisable to avoid locating a WEBASTO control panel next to other
appliances using infrared control units.
Access Code
The end user can deny access to all program settings by introducing an access code (see 5.1:
"Programming Access" - code <b>). Blower speed and setpoints always remain accessible. Once an
access code is validated, the digital panel will show <CODE> if the end user tries to access functions
other than blower speed or setpoint. To gain full access push the key to reach the code value as
programmed and push the key again to gain access to full program settings.
Secondary Commands
The key gives immediate access to settings and displays necessary for day-to-day operation. When
pushing the key you will see a code which indicates the setting or the present value.
The following is a list of commands / displays In order of appearance:
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