Webasto Blue Cool Premium Installation And Operating Instructions

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Air Conditioning Installation and

Operating Instructions

Blue Cool Premium

Ident.-Nr.: 0903071A

EDITION DATED 21ST AUGUST 2006

CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 1

Webasto AG - Special Products & Markets Kraillinger Strasse 5, 82131 STOCKDORF, Germany

Tel. : +49(0) 89 8 57 94 543 Fax : +49(0) 89 8 57 94 753 Website : www.webasto.de

Webasto - Marine Air Conditioning

OVER-BOARD DISCHARGE

CHILLER UNIT

COOL CYCLE LED

COMPRESSOR RUN LED

SET-POINT MODIFICATION KEYS

BLOWER KEY

AUTO CYCLE SWITCHING LED

HEAT CYCLE LED

MAIN ON/OFF SWITCH

FUNCTION KEY / SECONDARY COMMANDS

CHILLED WATER AIR-CONDITIONING SYSTEMS

OPERATING AND INSTALLATION MANUAL

DIGITAL CABIN

CONTROL PANEL

FLEXIBLE AIR-DUCT

2ND AIR-HANDLER - VERTICAL

SLIM-LINE MODEL

TRANSITION BOX + SUPPLY AIR-GRILLE

RETURN AIR GRILLE

Tee JUNCTION TO 2ND AIRHANDLER

TUBULAR INSULATION AROUND CHILLED WATER CIRCUIT PIPING

CHILLER UNIT

ELECTRICAL CONTROL BOX

SEA-WATER PUMP

AIR-HANDLER COMPACT SERIES

CIRCULATION PUMP

CHILLER UNIT

DIGITAL CONTROL

PANEL

NEW ELECTRONICS - 2004 SERIES

ROOM TEMPERATURE OR SET-POINT TEMPERATURE OR SECONDARY FUNCTION READ-OUT

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 2

EDITION DATED 21ST AUGUST 2006

CHILLED WATER AIR-CONDITIONING SYSTEMS

OPERATING AND INSTALLATION MANUAL

CONTENTS

Page

1) General information ...................................................................................................

2) Digital Display <CHILLER CONTROL> ..................................................................

2.1 - Drawing Digital Display - Operation Guide........................................................

3) Central Blower Control ...............................................................................................

4) Visual Error Codes Digital Display ............................................................................

5) Cabin Blower Control .................................................................................................

5.1 - Wiring diagram - <CAB> 230V AC Cabin Control ..........................................

6) Programmable Functions Chiller Condensing Units ..................................................

6.1 - Digital Display - Programming access ...............................................................

7) Pratical Installation of Components - Guidelines .......................................................

7.1 - Installation Drawing - Sea Water Pump system .................................................

8) Chilled Water Circuit Installation ................................................................................

8.1 - Integration of Added Heat-Exchangers in Chilled Water Circuit .......................

Golden Rules - Chilled Water Piping Installation .......................................................

Filling and Purging of a Chilled Water Circuit ...........................................................

Examples of Chilled Water Circuit Piping Schematics ..............................................

8.6 - Example Chilled Water Circuit Piping - Small 20000 BTU Chiller ..................

8.7- Example Chilled Water Piping - WBCP24/D Stern Location - 4 Air-Handlers .

8.8 - Example - Catamaran - WBCP36/D - Central Location - 6 Air-Handlers .........

8.9 - Example - Motoryacht - WBCP72/D Twin - Aft location - 10 Air-handlers .....

8F - Air Ducts - Ventilation ..............................................................................................

9) Routine Checks/Trouble Shooting...............................................................................

11) Wiring diagrams .........................................................................................................

11.1 - Wiring diagram single compressor WBCP12/16/20/24/30 - 1 phase................

11.2 - Wiring diagram single/twin compressor - 1/3 phase .......................................

11.3 - Wiring diagram compressor 3/4 - single and 3 phase .....................................

11.4 - Power Supply Schematics - TWIN/CI Chillers - single phase 230V ..............

11.5 - Power Supply Schematics - TWIN/TRI (3) compr. Chillers - 1 phase 230V .

11.6 - Power Supply Schematics - TWIN/TRI (3) compr. Chillers - 3 phase 400V .

11.7 - Wiring Diagram automatic staging secondary AC loads ..................................

11.8 - Wiring Diagram - Running Capacitors - ECOFIT Blowers ............................

11.9 -

Wiring Diagram - Connection 3-Way valve (Lizhan/Zhongli) on TECC card

Webasto AG - Special Products & Markets Kraillinger Strasse 5, 82131 STOCKDORF, Germany

Tel. : +49(0) 89 8 57 94 543 Fax : +49(0) 89 8 57 94 753 Website : www.webasto.de

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6 7

9 9

11 11

12 12 13 14 15 15 15 16 17

20 21 22 23 24 24 25 26 26 26

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 3

As from May 2004 all WEBASTO air conditioning units are controlled by a Digital Display <CHILLER CONTROL> 2004 SERIES which gives access to all functions necessary for the normal operation of the unit and attached accessories (blowers, pumps, etc).

All WEBASTO air conditioning units are sea-water cooled by means of an AC seawater pump.

In order to start the system you only need to press the On/Off key on the digital display.

From there on the electronic control unit takes care of the progressive starting up of the air conditioning components as well as it normal functioning.

The digital display will show the present room temperature of the cabin in which the digital display is situated or where the main temperature sensor is located (in case the optional secondary temperature sensor is used).

The WEBASTO <CHILLER CONTROL> digital display allows access to information and controls at three distinct levels :

Immediate Access - Level 1 :

1) Room temperature read-out 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-users entered set-point temperature.

- Heat cycle only operation.

3) 2 set-point keys give immediate access to the thermostatic set-points for blowercontrol (“Sun” and “Snow” key). These keys are also used to alter programming values - see here-after chapter 6.

Press and hold one of the set-point selector keys and wait until the new desired set-point temperature is obtained. Release the setpoint key.

The display will memorize the value and return to normal room temperature read-out after approx. 5 seconds.

Secondary commands and info Level 2 :

The F/Blower 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 chilled water temperature read-out, etc.

See hereafter drawing 2.1 for complete list.

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.

An access code can be enforced to avoid accidental modification of programming values.

See Chapter 6 - Page 9.

Start-up delay :

After pushing the On/Off 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 adequate LED to the left (heat, cool , etc) will come on after approx. 15 seconds and compressor operation will start after approx. 50 seconds.

The chilled water circulation pump will come on immediately after system initialization.

New features - 2004 Series :

As from June 2004 all WEBASTO air conditioning units are controlled by a new Digital Display <AIR CONTROL> 2004 SERIES

2.1 - <CHILLER CONTROL> DIGITAL DISPLAY - OPERATING GUIDELINES

BASIC COMMANDS :

1 - Press to turn on - press again to turn off. 2 - Press to read set-point temperature - hold to raise

set-point temperature.

3 - Press to read set-point temperature - hold to lower

set-point temperature. 4 - Led indicating system working in cool cycle 5 - Led indicating automatic reversed cycle mode is operative 6 - Led indicating system working in heat cycle 7 - Function/Blower Key - immediate access to :

- chilled water temperature read-out ....................

- manual choice of operating cycle (cool only, .....

heat only, etc)

- AC voltage read-out ...........................................

- manual compressor selection On/Off 1 to 4.

- start-up priority compressors 1 to 4....................

- time delay between compressor start-up.............

- individual thermostatic advance compressors ....

- automatic dehumidification cycle during absence

- display time of secondary functions accessible by F/Blower key

8 - Dedicated Blower speed key ................................

9 - Access to hidden programming functions - see

Chapter 6 - page 9

NB - System stops while displaying 3 lettres <AAA> : safety cut-out because of persistent low voltage. To restart make sure voltage level is raised above 195V AC

1 - GENERAL INFORMATION - CHILLER AIR CONDITIONING SYSTEMS

9 -

Push Both Keys Simultaneously

after Display Extinction.

H13.2

F 3

U230 1C01

etc

P123

etc

L 9

1L0.0

etc

d 0

t 1

b A

*Default Values

EDITION DATED 21ST AUGUST 2006

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 4

EDITION DATED 21ST AUGUST 2006

which gives access to all functions necessary for the normal operation of the unit and attached accessories (blowers, pumps, etc).

2004 Series Electronic Controls are easily recognized by their special remobale bezels.

The new 2004 displays are backwards compatibel with the older TCC electronic controller cards. In that case however the dedicated Blower key is not operational.

Continued features - 2000 Series :

A) 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.

B) Calibrate all blower speed settings

in real time mode. It is now possible to calibrate all speed settings (1 to 5) before actually putting the system into service.

To do so enter programming mode with setpoint at 15° C.; proceed to line <6> = speed 5 (max). (see chapter 6 - page 9) The blower will start to function as soon as you access code <6>.

Alter the value to the right of code <6> and the blower speed will immediately change in real time. When satisfied go to following line <7> = speed 4 and do the same.

Proceed until lowest speed N° 1 and go back again to speed N° 5 if not satisfied.

When all speeds are programmed according to need, validate by pushing on/off key (<memo> will be displayed briefly).

Attention : Never program speeds so low that the blower is in danger of stopping or will not re-start at that setting. This will inevitably entail motorwindings burn-out and will not be covered by the WEBASTO warranty.

C) Infra-Red Remote Control :

Infra-red remote control can be purchased 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 appli-

ances.

Generaly, it is therefore advisable to avoid locating a WEBASTO <AIR CONTROL> display next to other appliances using infrared control units.

D) ACCESS CODE :

The end-user can deny access to all program settings by introducing an access code (see page 10 - code ). Blower speed and setpoints always remain accessible.

Once an access code is activated, the digital display will show <Code> if the end-user tries to access other functions then blower speed or set-point temperature. To gain full access push the sun key to reach the code value as programmed and push the F key again to gain access to full program settings.

3 - CENTRAL BLOWER CONTROL

The central <CHILLER CONTROL> digital display which controls general operation of the condensing unit(s) can also directly control the blower(s) of the saloon/cabin where the main temperature sensor is located.

This direct blower control is optional and not all installations use this facility to control a part of the ship’s blowers.

Blowers in the wheel-house for instance, where the <CHILLER CONTROL> display is located, can be directly controlled by the TECC card. The <FAN> outlet of the TECC controller card offers manual speed settings and thermostatic control in the same manner as the individual cabin controls.

This central blower control is therefore quite distinct from the secondary Cabin Control systems where the <AIR CONTROL> digital display only operates the blower(s) of the cabin where the display is situated without any direct link to the main condensing unit.

Any blowers directly connected to the TECC controller card will be activated after the cycle LED comes on. However blowers will only become active if the chilled water temperature is compatible with the enteredsetpoint.

If blower operation cannot be activated the error code <bA11> will flash briefly and then remain visible when accessing blower control through F/Blower key. (See also here-after list of error codes).

Blower operation will only start after a compatibility check with the temperature of the

chilled water circuit.

Example : in <Cool> mode with a set-point temperature of 21° C., blower operation will only start after the temperature of the water circuit has reached 20° C or less. This avoids start-up of blower operation with a non compatible water circuit temperature.

For these TECC cards it is possible to altogether stop blower operation by choosing the option <0> after manual blower speed <1>.

This allows to altogether stop blower operation by the main controller card during the night for example while still continuing to operate the chiller unit for the rest of the ship’s air-handlers.

With the <CHILLER CONTROL>, blower control is completely distinct from compressor operation :

1) Blower control will continue even if compressor operation is thermostatically stopped.

2) Compressor operation will continue even if the blower is thermostatically stopped.

It is not possible however to operate the blowers in a different cycle from compressor operation ; for instance : compressors running in cool cycle and blowers in heat cycle. In that case compressor operation will have priority and blower-operation will be stopped (error code <bA11>).

4. SECONDARY COMMANDS :

The F/Blower key gives immediate access to commands and displays necessary for day to day operation. When pushing the F/Blower key you will see to the left a code which indicates the type of display or command and to the right the present value.

In order of appearance here-after an explanation of these commands/displays :

a) Blower speed control :

(0,1,2,3,4,5) This command preceeded by the letter b (blower) allows the following settings : A = automatic blower speed adjusted to tem-

perature differential. 0 = blower stop 1 to 5 = manual Speed Control Speed control is in real time mode i.e. changes are effected immediately without any validation procedure.

Warning :

All following func-

tions need validation before a new

value is accepted.

Validation is obtained by pushing the F/Blower key again and by going to the next function line.

Then final validation will occur automatically when the display goes back to room temperature read-out or final validation can be forced by pushing the On/Off key briefly while still in F mode.

Validation is witnessed by the brief

display of the message <memo>.

b) Read out of chilled water temperature :

<H10.2> (10.2 ° C) - for example.

c) Cycle mode choice : <F 3> (1 to 5) The following cycle modes can be choosen manually : 1 = cool cycle only 2 = heat cycle only 3 = automatic cycle switching with reversible compressor 4 = automatic cycle switching without reversible compressor 5 = heat cycle only without reversible compressor

d) AC Voltage read-out : < U232>

(232 Volts)

e) Manual on/off Compressor 1 : <1C01>

<1C01> = Compressor 1 on <1C00> = Compressor 1 off

f) Manual on/off Compressor 2 : <2C01>

<2C01> = on <2C00> = off

Idem for compressors 3 and 4 - <3C01> and <4C01>.

g) Start-up Priority Compressors 1 to 4 :

<P123> = 1,2,3,4 ; <P341>=3,4,1,2

= automatic priority rotation; when

in this priority mode, the starting order will be changed at every

restart after a thermostatic cut-out.

h) Time delay between compressor start-up :

<L 9> (9 seconds) - programmable

from 1 and 9 seconds.

i) Individual thermostatic advance compres-

sors 1 to 4. In relation to the general chilled

water temperature set-point, it is possible to

differenciate the cut-out temperature for

each compressor.

Factory default setting : <1L0.0> etc

<2L1.2> means compressor 2 will cut out

1.2° before the general set-point value. So

for a general value of 4°, compressor 2 will

cut out at 4 + 1.2 = 5.2 °.

Same is possible for the other compressors.

j) Automatic dehumidification while absent.

factory default setting : <d 0> 0 = non active 1 = 1 cycle per 24H 2 = 2 cycles per 24H etc

k) Display time of secondary functions (F/

Blower key) by periods of 20 seconds. <t 1> (factory default setting) = display time 20 seconds.

4. VISUAL ERROR CODES DIGITAL DISPLAY

The following malfunctions will be displayed directly on the digital display by a code and will be followed by a system halt (except for <bA11> - see hereafter).

Whenever any of these codes appear the system is stopped for approx. 60 seconds and then a re-start is attempted.

If for more than 30 minutes the same malfunction occurs, the system will be stopped completely and the error-code will become steady.

No more re-starts will be attempted and the user will have to re-set the system by pushing the On/Off key or by temporarily cutting off the AC supply to the system.

List of error-codes and nature of malfunction :

Code <AAA> :

Persistent low voltage (voltage below 195V) for more than 5 seconds - (see also hereafter

- Trouble-Shooting - Page 19).

Code A01 to A08 :

Pressure safety cut-out of compressors 1 to 4. The HP(High Pressure) and BP(Low Pressure) safety switches are directly controlled by the micro-processor inclusing the time-delays for re-start, etc.

Error codes displayed and probable nature of anomaly.

<A01> : BP (low pressure) cut-out - com-

pressor 1 - probable causes :

- interrupted or insufficient waterflow in chiller circuit

- sea-water circulation deficient when running in heat cycle mode

- insufficient refrigerant charging level

- abnormal sea-water temperature conditions in heat cycle (sea-water temperatures under 6° C. approx.)

- first start-up in heat cycle with very low chilled water circuit tem-

peratures (below 8° C approx.).

<A02> : HP (high pressure) cut-out - com-

pressor 1 - probable causes :

- insufficient or non-existent seawater cooling - check sea-water pump.

- insufficient or interrupted water flow in chiller circuit when operating in heat cycle.

- too much refrigerant in system call a specialist

- abnormal sea water temperature conditions in heat cycle (sea-water temperatures above 20° C approx.)

<A03> : BP cut-out - compressor 2 - for

probable causes see <A01>

<A04> : HP cut-out - compressor 2 - for

probable causes see <A02>

<A05> to <A08> - same as above for compressors 3 and 4 (if present).

If any of these error codes appear too frequently and no appropriate action can be taken with the available means on board, it is necessary to call a specialist.

Do not insist with manual re-starts in such cases as this may cause major damage to the principal components (compressors, pumps, etc).

<A09> - absent or defective external air sen-

sor.

<A10> - absent or defective chilled water

sensor.

<bA11> - blower operation from TECC card

impossible because of non-compatible water temperature versus pro-

grammed set-point. This is the only error code which will not result in a complete system halt.

<CA11> - all compressors are disactivated by soft - through F/Blower key : <1C00>, <2C00>, etc.

To reactivate re-program as follows : <1C01>, <2C01>, etc

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 5

EDITION DATED 21ST AUGUST 2006

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 6

EDITION DATED 21ST AUGUST 2006

Individual cabins controlled by WEBASTO Digital Cabin Controls are completely independent from the central condensing unit i.e. there is no direct electrical or electronic link between the cabin control unit and the central TECC controller.

The chilled water temperature sensor allows the Cabin Control to ascertain which cycle (heat or cool) is presently valid.

A Cabin Control can be operated entirely independently from the main condensing unit i.e. :

- it can be switched off or turned on at any

time by the end-user

- the end-user can set any temperature set-

point as long as it is compatible with

the general operation mode valid (heat or

cool)

- blower operation can be individually con-

trolled and programmed

2) Flashing of Error Code <bA11> :

If the user programs a set-point temperature incompatible with the general water circuit temperature as presently available (for example : set-point requested : 20° C for a room temperature of 25° C and a water-circuit temperature of 35° C) = Cool cycle requested with the chilled water circuit obviously working in heat cycle.

Blower operation will be stopped and error code <bA11> will blink for approx. 10 seconds. After that the error code will still be visible when accessing blower control by the F key. The error code will disappear and normal blower operation will resume as soon as the water circuit temperature drops below 20° C.

Direct read-out of water-circuit temper-

ature at air-handler entry :

All Cabin Controls allow the user to immediately visualize the water-circuit temperature at the entry of the cabin’s air-handler. (push F/Blower key - see also drawing here-above).

This feature allows the user to ascertain that water-circulation is normal through the airhandler without abnormal differences as compared with the condensing unit water exit. (Normally temperature rise between condensing unit exit and air-handler entry should not exceed approx. 4° C.) Before getting worried however, the first thing to check is the proper attachment of the cabin control water temperature sensor to the air-handler entry and its proper insulation from outside interference.

5A - DIGTAL CABIN CONTROL TYPE CAB - 230V - 2000 SERIES

This is the most common type of digital cabin control and includes :

- digital display <AIR CONTROL>

- CAB - 230V controller card in plastic box

- 4 ml display cable

- 2.5 ml chilled water temperature cable

- 4 ml air temperature sensor (optional)

The digital display <AIR CONTROL> includes an air temp. sensor housed behind the 2 small openings on the front panel. It is sometimes necessary however to use the optional external air-sensor if for instance the digital display is subject to direct heat induction (sun-rays, instruments from behind, etc)

All CAB controls include an outlet for solenoid water valve control on the entry of the air-handler. Solenoid valve control are an optional extra :

Danfoss/Lizhan 3-way solenoid valve systems, where the water-flow is completely halted when set-point temperature is reached and the flow returned directly to the returnline through a nozzle.

When using 3-way valves it is possible to adopt continuous blower operation.

See page 7 - drawing N° 5.1 for full schematics.

Secondary Commands - <F> key :

The <F> key gives immediate access to commands and displays necessary for day to day operation. When pushing the F key you will see to the left a code which indicates the type of display or command and to the right the present value.

In order of appearance here-after an explanation of these commands/displays :

a) Blower speed control :

(0,1,2,3,4,5) This function is also accessible directly through the dedicated Blower key.

This command preceeded by the letter b (blower) allows the following settings : A = automatic blower speed adjusted to tem-

perature differential. 0 = blower stop 1 to 5 = Manual Speed Control

Speed control is in real time mode i.e. changes are effective immediately without any validation procedure.

b) Read out of chilled water temp. :

5 - DIGITAL CABIN BLOWER CONTROL - GENERAL PRINCIPLES

BASIC COMMANDS :

1 - Press to turn on - press again to turn off. 2 - Press to read set-point temperature - hold to raise

set-point temperature.

3 - Press to read set-point temperature - hold to lower

set-point temperature. 4 - Led indicating system working in cool mode 5 - Led indicating manual blower speed control is active 6 - Led indicating system working in heat mode 7 - Function/Blower Key - immediate access to :

- chilled water temperature read-out .......................

- automatic dehumidification cycle during absence

- display time secondary functions accessible by F/Blower key

8 - blower speed control .............................................

9 - Access to hidden programming functions - see page 7.

H13.2

d 0

t 2

* Default Values

9 -

Push Both Keys Simultaneously after Display Extinction

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 7

EDITION DATED 21ST AUGUST 2006

<h10.2> (10.2 ° C) - example.

c) Control of external heat-source.

<F 1> = normal auto-reverse cycle (cool/heat) without external heat source. <F 2> = autoreverse cycle operation with external heat assistance. In that case the oulet connectors <HEAT> on the Cabin controller card are activated together with the <VALVE> oultlet when heat cycle is selected. This external heat source can be an AC heating element or any other source such as ceramic heaters etc <F 3> = heat operation with external heat source only. Inthat case the <VALVE> outlet on the controller card is not activated and only the <HEAT> connectors are operational.

c) Automatic dehumidification

while absent. Factory default setting : <d 0> 0 = non active 1 = 1 cycle per 24H 2 = 2 cycles per 24H etc

d) display time of secondary functions

(F/Blower key) by periods of 20 seconds. Factory default setting : <t 1> = display time 20 seconds

Special features - 2000/2004 Series :

See beginning page 4.

Continued features - 2000 Series :

A) Automatic blank/sleep mode - programmable time delay. Factory default : 15 min-

utes. While in blank/sleep mode the cycle LED flashes discretely every 20 seconds. To go back to normal operation push any key.

B) Real time modification of all blower speed settings.

It is now possible to alter all speed settings (1 to 5) before actually putting the system into service. To do so entrer programming mode with set-point at 15° C.; proceed to line<6> = speed 5 (max).

Alter value and blower speed will immediately change in real time. When satisfied go to following line <7> = speed 4 and do the same.

Proceed until lowest speed N° 1 and go back again to speed N° 5 if not satisfied.

When all speeds are programmed according to need, validate by pushing on/off key (<memo> will be displayed briefly).

Attention : Never program speeds so low that the blower is in danger of stopping or will not re-start at that setting. This will inevitably entail motor-windings burn-out and will not be covered by WEBASTO warranty.

Programming of the CAB - 230V controller cards :

To access hidden programming functions

raise set-point temperature to 29° or lower to 15° and push On/Off key. Then push both set-point keys simultaneously for approx. 3 seconds and you will enter programming mode as explained here-after.

Validation is obtained by pushing the F/Blower key and by going to the next programming line.

Programming codes available by raising the set-point to 29° C :

Code <4> : Calibration of chilled water temp Code <5> : time delay in minutes before the

display goes into sleep mode.

Code <7> : Calibration of room temperature

read-out.

Code : Program version

Programming codes available when lowering the set-point to 15° C : Code <1> - factory setting : 0 - infra-red remote control : 0 = infra-red remote control disabled 1 = infra-red remote control active Code <2> : Blower type : Centrifugal or

Cross-Flow. Factory default : 1 0 = centrifugal blowers only 1 = centrifugal + cross-flow

Code <3> : continuous blower operation = 1

thermostatic blower control = 0

Code <4> : integrated air-sensor = 1

external air-sensor = 0

Code <5> : display in Celsius or Fahrenheit

default value = 0 0 = Celsius read-out 1 = Fahrenheit read-out

Code <6> : calibration speed N° 5 (max)

3 x 1 mm²

BROWN

BLACK

BLUE

Chilled Water sensor to be fixed on chilled water entry of Air-handler

5.1 - ELECTRICAL AND OTHER CONNECTIONS - CABv3 - 230V - DIGITAL CABIN CONTROL

3 4

230V BOAT SUPPLY

RELAY

24 14 NO

21 11 COM

22 12 NC

A2 A1

AIRHANDLER BLOWER

LIZHAN / ZHONGLI

3-WAY VALVE

12A

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 8

EDITION DATED 21ST AUGUST 2006

Code <7> : idem speed N° 4 Code <8> : idem speed N° 3 Code <9> : idem speed N° 2 Code <A> : idem speed N° 1 Code <c> : duration heat cycle dehumidifi-

cation mode in minutes.

Code <d> : duration cool cycle dehumidifi-

cation mode in minutes.

5D - MTH - MECHANICAL THERMOSTAT

The MTH thermostat has a knob control for setting the desired set-point temperature and a selector to switch between summer and winter operation. See here-after the electrical schematics of MTH installation.

5E - MTH2 - MECHANICAL THERMOSTAT + 3 SPEED CONTROL

The MTH2 mechanical thermostat incorporates a 3 position selector which can be linked to a simple 3 speed blower control system. See here-after (Photo 5.6) for the components included in this system. The assembly is delivered with a multi-conductor plug to

avoid cabling errors.

5F - PLANA (Vimar) 3 speed Thermostats

Based on the modular Plana series by Vimar with the same features as 5E.

MTH - MECHANICAL THERMOSTAT - CABIN BLOWER CONTROL

SUMMER/WINTER SELECTOR

SET-POINT ADJUSTMENT KNOB

Heat/Cool Selector

On/Off Switch

3 Speed

Selector

WEBASTO PREWIRED RJ45 CABLE

WEBASTO 3 SPEED Controller Card

5.6 - WIRING DIAGRAM - MTH BELUX THERMOSTAT + 3 SPEED BLOWER CONTROL

PLANA (VIMAR) MECHANICAL THERMOSTAT + 3 SPEED BLOWER CONTROL

Thermostat Knob

Blower Speed Knob (0 + 3)

Heat/Cool Selector + On/Off Selector

Display Cable 4.5 ml

3 Speed Controller

230V BOAT SUPPLY

12A

24 14 NO

21 11 COM

22 12 NC

A2 A1

LIZHAN / ZHONGLI

3-WAY VALVE

AIRHANDLER BLOWER

C NC NO N L

ELECTRONIC VIMAR/PLANA THERMOSTAT

RELAY

WIRING DIAGRAM - PLANA THERMOSTAT + 3 SPEED CONTROL

Brown

Black

Blue

Black

Brown

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 9

EDITION DATED 21ST AUGUST 2006

To access the programmable parameters of the TECC electronic controller proceed as following :

Raise set-point temperature to the max. i.e. 29° Centigrade. Then turn off system by pressing the <On/Off> key.

Press simultaneously the 2 set-point keys for aprox. 3 seconds until you see to the left of

the digital display a single number code indicating the programming line presently valid and to the right a single ou double read-out indicating the present programming value. To go to the next programming line (left single number), press <F> key.

If you modify the programming value (to the right of the display), you need to validate the changes made by pressing the <F> key and go to the next programming line. This step will validate and memorize the changes made.

Here-after the explanations regarding the available programmable functions :

1° Functions accessible by raising the setpoint to 29° C. :

Code <0> - factory setting : +4° Celsius -

lower set-point temperature of the chilled water circuit when in cool cycle. This value gives the compressor cut-out point when in cool cycle. Adjustment range : between 0°C and +15°C.

Code <1> - factory setting : +7° Celsius higher set-point temperature of the chilled water circuit when in cool cycle. This value

gives the re-start point of the compressor(s) after a thermostatic interruption (in cool cycle). Adjustment range : between 2°C and +18°C. Code <2> - factory setting : 40° C. higher set-point temperature of the chilled water circuit when in heat cycle. This value gives the cut-out point of the compressor(s) when functioning in heat cycle. Set-point temperature adjustable between 30° and 55° C.

Code <3> -factory setting : 37° C. - lower set-point temperature of the chiller water cir-

cuit when in heat cycle. This value gives the re-start point of the compressor(s) after a thermostatic interruption (in heat cycle). Set-point temperature adjustable between 27° and 52° C.

Code <4> - pre-programmed value : 0 - calibration of the chilled water circuit temperature - possible adjustment between -9° and +9° C.

Code <5> - factory setting : 15 - time delay in minutes before the digital display goes into blank/sleep mode. Cycle LED flashes discretely to indicate system is operational.

Code <6> - factory setting : 1 - first start up delay in seconds after connecting AC supply. Adjustable between 1 and 20 seconds.

Code <7> - factory setting : 0 - calibration of room temperature read-out. Correction between +9 and -9° C.

Code <8> - pre-programmed value : 0. Factory calibration of AC voltage 50 Hz as displayed on the digital panel when accessing the secondary commands - F/Blower key. Correction between -20 and +20 Volt.

Code <9> - pre-programmed value : 0 Functioning principle of staging relay : Value 0 : the relay functions as a staging relay (see also page 25) Value 1 : the relay functions as the outlet control for a soleniod valve system for the airhandlers directly controlled by the main TECC controller. Value 2 : the relay functions as a witness for a system halt and general alarm (A01, A02, A09, etc) :

- contacts closed between C2 and R2 or contacts open between C2 and T2 = no alarm

- contacts open between C2 and R2 or contacts closed between C2 and T2 : general alarm and system halt. Value 3 : cycle indication

- contacts closed between C2 and T2 = heat cycle

- contacts closed between C2 and R2 = cool cycle

System Halt : contacts closed between C2 and R2.

Code <A> - pre-programmed value : -10. Factory calibration of AC voltage 60 Hz as displayed on the digital panel when accessing the secondary commands - F/Blower key. Correction between -30 and +20 Volt

Code - Program version

Re-intializing the factory default settings :

It is possible to force the program to re-initialize all program values to factory default settings by the following procedure : When reading the line as above (through the 29° set-point), push the <sun> key until the program version starts to flash. Keep the <sun> key pushed down until the display shows <init>.

6 - PROGRAMMABLE FUNCTIONS - CHILLER CONTROL

PROGRAMMING MODE :

To enter programming mode : raise or lower set-point to 29 or 15° C. Turn off system by pressing <Power> key - 14.

Press simultaneously keys <11>. The display will show to the left <15>, the number code of the current programming line and to the right <16> the present value.

To validate and memorize modified parameters press the <F> key (12) and proceed to the following programming line.

6.1 - DIGITAL DISPLAY <CHILLER CONTROL> - PROGRAMMING ACCESS

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 10

EDITION DATED 21ST AUGUST 2006

Leave programming mode by pushing <On/Off> key - you are now back to the factory default settings.

2° Functions accessible when lowering the set-point temperature to 15° C :

Code <0> - pre-programmed value :195 low AC voltage cut-out value. Time delay is 5 seconds approx. i.e. the low voltage situation will have to persist during more than 5 seconds before cut-out occurs.

After a cut-out the electronic controller resets and will start a new cycle. So a renewed attempt to start the compressor will occur after approx. 90 seconds.

During low-voltage cut-out the display panel will show the 3 letters <AAA>.

Programming of a cut-out level below 195 V is done at the entire risk of the operator. It should be noted that almost all compressor manufacturers decline all responsibility for defects resulting from operating the compressors below 195V AC.

Code <1> - factory setting : 0 - infra-red remote control : 0 = infra-red remote control disabled 1 = infra-red remote control active

Code <2> - factory setting : 0 - choice of small relay setting indicating cool/heat cycle operation or alarm status. 0 = cycle indication :

- contacts closed between C1 and T1 = heat cycle

- contacts closed between C1 and R1 = cool cycle

System Halt : contacts closed between C1 and R1.

1 = alarm status : the relay functions as a witness for a system halt and general alarm (A01, A02, A09, etc) :

- contacts closed between C1 and R1 or contacts open between C1 and T1 = no alarm

- contacts open between C1 and R1 or contacts closed between C1 and T1 : general alarm and system halt.

Code <3> - pre-programmed value : 0 basic choice of blower control : 0 - thermostatic control of blower operation i.e. blower operation will be interrupted thermostatically when reaching the appropriate set-point. 1 - un-interrupted blower operation regardless of the thermostatic control.

Code <4> - factory setting : 0 - Choice between integrated air sensor and external air sensor :

1 - air sensor integrated in digital display 0 - external air sensor

Code <5> - Display in Celsius or Fahrenheit

default value = 0 0 = display in Celsius 1 = display in Fahrenheit

Code <6> : modification speed N° 5 (max) Code <7> : idem speed N° 4 Code <8> : idem speed N° 3 Code <9> : idem speed N° 2 Code <A> : idem speed N° 1

Code - factory setting : 0 - access code

value for programming mode. 0 = no access code required 1 to 99 = access code activated

In case you can’t remember your access code you can gain access to the concerned programming line by typing in the factory access code : 64

Code <c> - factory setting : 1 - duration in minutes of heat cycle operation under the dehumidifying procedure.

Code <d> - factory setting : 1 - duration in minutes of cool cycle operation under the dehumidifying procedure.

DIPSWITCHES :

The TECC controller card has a dipswitch arrangement which should be set and maintained according to the following settings :

1) TECC controller for compressors 1 and 2 only, without the secondary card for compressors 3 and 4 :

2) TECC controller for 3 or 4 compressors, with secondary card for compr. 3 and 4 :

Warning :

if dipswitches are not set

according to the above configurations i.e. according to the number of compressors effectively on line, the TECC controller card may behave in an unpredictable manner :

- the initialisation <init> can not be completed - card remains blocked on start-up.

- HP/BP alarms for non-existing compressors.

Etc.

OPEN

ATT. DIPSWITCH SETTINGS

BLACK = PUSHED DOWN

1234

OPEN

ATT. DIPSWITCH SETTINGS

BLACK = PUSHED DOWN

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 11

EDITION DATED 21ST AUGUST 2006

) SEA WATER COOLING

Install the pump/strainer assembly in such a manner that a natural gentle upwards slope exists from the sea-cock to the pump itself. See also drawing hereafter - ref. 7.1

It is strongly recommended to install an airbleeder system immediately at the discharge outlet of the pump. The advice is especially valid for pumps CLD125/250/350/1000/ 1500 and 2000. The CLD2500 and higher generally will not require a bleeder system to

ensure proper operation.

For ALL boats it is strongly recommended to install a water-scoop at the entry of the seacock and directed towards the bow of the boat so that at speed positive pressure builds up in the supply line to the sea-water pump.

Sea-water cooling exits :

Provide for a separate sea-water exit for each air-conditioning unit installed even if only one pump provides cooling for all units.

Introduce shut-off valves for each unit if 1 pump provides cooling for more than 1 airconditioning unit.

This will allow easy priming of the circuit and also calibration of the sea-water flow for each air-conditioning unit in case of imbalance in the water tubing lengths.

7B) AIR-HANDLER COILS :

The finned coils of the evaporators and/or air-handlers are fragile. When during installation the fins of these coils are damaged, take care to re-align the fins in order not to impair proper air-flow.

Return air should be filtered to avoid accumulation of dust on the coil fins.

This can be obtained by 2 means :

a) Install WEBASTO supplied return air grilles which include a filter element behind the grilles.

b) Install a filtering element just in front of the return air coil surface. Such filter material can be also obtained from WEBASTO Marine.

7C) 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 ml); the pressure loss and consequent reduction of air-flow will seriously diminish the efficiency of the installation.

If long ducts are an absolute necessity, try to use rigid PVC piping of equal diameter and the associated elbows, etc.

PVC piping because of its smooth interior induces far less friction then standard steel wire re-inforced flexible ducting.

TO OVER-BOARD OUTLET APPROX. 10 CMS ABOVE WATER-LINE

INSTALLATION OF BLEEDER ADVISABLE

PUMPS SITUATED

AT LEAST 25 CMS BELOW WATER-LINE

SEA-WATER STRAINER

SUCTION GENTLY UPWARDS TO FACILITATE PRIMING

CLAM-SHELL TYPE THRU-HULL FITTING WITH SLOTS DIRECTED TOWARDS BOW TO OBTAIN POSITIVE PRESSURE IN SECTION LINE

NB - ALL PIPING AS SHORT AS POSSIBLE WITHOUT

KINKS NOR SYPHONS

WATER-LINE

7.1 - INSTALLATION OF SEAWATER COOLING PUMP AND PIPING

7 - PRACTICAL INSTALLATION OF COMPONENTS - GUIDELINES

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 12

EDITION DATED 21ST AUGUST 2006

8A) PRESSURIZED/NON PRESSURIZED SYSTEMS :

Chilled water circuit can be static non-pressurized or pressurized with membrane type expansion-tanks.

If the system adopted is static, the expansion tank should be the highest point of the circuit while taking into consideration the possible heeling angle under sail.

Expansion tanks should always be connected to the suction side of the circulation pump.

8B) FREE FLOW VERSUS SOLENOID VALVE CONTROL :

The water-circuit can be free-flow where the water-flow is continuous through all air-handlers and thermostatic control for each airhandler is obtained by stopping blower operation.

In this case it is advisable to introduce manual ball-valves on each of the air-handler entries so as to enable balancing out of the water-flow if necessary.

In case of a solenoid valve system where each air-handler is equipped with a electrical solenoid valve controlled by the WEBASTO

Cabin Control, it is not necessary to provide for other entry valves.

8C) WATER CIRCUIT TEMPERATURE SENSORS :

To obtain a satisfactorily working system it is of utmost importance that the water-circuit temperature sensors are correctly placed accordingly to WEBASTO specifications.

In order to exclude any erroneous temperature pick-up, WEBASTO provides specific locations on its condensing units.

These points are short tubular housings which cross the chilled water outlets at the following locations :

Single Evaporator Chiller Units :

Exit temperature sensor : the water-circuit exit on each evaporator is provided with a tubular transverse housing where this temperature sensor should be placed.

Twin Evaporator Chiller Units (TWIN/CI):

For TWIN-CI modules with 2 compressors on 1 tray and independent evaporators, the chilled water sensor is attached to the Tee junction where the 2 exit pipes of the evapo-

rator meet. The sensor should be properly insulated against external infuence. All TWIN-CI units delivered by WEBASTO come with the sensor already fixed in the proper location.

8H) ADDED HEAT-EXCHANGERS

The TECC controller card allows to add heat-exchangers in the chilled water circuit which can be of all nature :

1) Water/Water exchanger to use the 85/90° C hot water circulation from a fuel heater

2) Electrical calorifiers

3) Engine heat

Etc

Here-after (Drawing N° 8.1) an example of a Water/Water exchanger specially adapted for Webasto fuel heaters .

8 - CHILLED WATER SYSTEM INSTALLATION

ONNECT TO <VALVE> OUTLETS

N TECC CONTROLLER CARD

SPECIAL MARINE 3-WAY VALVE ASSEMBLY

75/85˚ C WATER FROM FUEL HEATER

RETURN LINE TO FUEL HEATER

RETURN TO FUEL HEATER

MARINE EXCHAN

GER

REF. WBCL005080 OR WBCL005081

CHILLED WATER CIRCUIT OUT

CHILLED WATER CIRCUIT IN DIRECTLY FROM CHIILER PUMP

DIRECTLY FROM CHIILER PUMP

2 POLE ELECTRICAL WIRE

8.1 - SCHEMATICS - INSTALLATION AND CONNECTION OF WEBASTO HEAT EXCHANGER

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 13

EDITION DATED 21ST AUGUST 2006

8E - CHILLED WATER PIPING AND ACCESSORIES

Chilled water piping can be in rigid plastic tubing and/or flexible reinforced hoses.

Internal dimensions of tubing should be in conformity with piping drawing as supplied by WEBASTO.

PAY SPECIAL ATTENTION TO :

1) ELBOWS

Only use large radius elbows and not short

radius. Short radius elbows entail a flowrate loss of approx. 2.5% per elbow. A succession of 8 short radius elbows will therefore result in total flow-rate reduction of 100% x0.975x0.975x0.975x0.975 etc =

81.66%.

Large radius elbows only result in a flowrate loss of approx. 0.5%.

If no large radius elbows can be found use 2 successive 45° elbows instead.

Webasto Blue Cool Premium Installation And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual