EN
Operating instructions
BlueCool V-Series
1 About This Document
Special aspects are pointed out with the following symbols:
CAUTION
Particular danger of injuries or fatal accidents
ATTENTION
Particular danger of damage to components
FLAMMABLE
Particular danger of fire and explosion
ENVIRONMENTAL INFORMATION
Note on environmental protection
TECHNICAL INFORMATION
Reference to further sources of information
NOTE
Note on a special technical feature
2 Safety precautions
CAUTION
Moving parts!
Danger of injury, damage to air-conditioning system.
Only operate the air-conditioning system when installed.
CAUTION
Hot surfaces!
Danger of burns.
Do not touch the chiller unit during operation.
2
ATTENTION
Danger from escaping refrigerant!
If you perceive a hissing noise and mist, refrigerant may
escape and the air-conditioning system may be defective.
Please proceed as follows:
Ventilate and leave room, interrupt power supply and secure
against switching on again;
Go on deck;
Contact Webasto Service Centre or shipyard.
FLAMMABLE
Ignition of surrounding gases or highly flammable liquids
by sparking of the air-conditioning system!
Danger of fire and explosion of ship or of petrol station.
The air-conditioning systems must ALWAYS be switched off
during refuelling or while in a petrol station area.
ATTENTION
Defective operation or damage to the components of the airconditioning system and the ship.
Follow the installation instructions when installing electrical
wiring, sea water piping, cold water lines as well as when
installing the electrical box.
Please read this information carefully before you start up the system!
If you require additional information about special applications in the marine
sector or are unsure about an application option, please contact your authorised
Webasto Marine dealer or visit our website at the following internet address:
•
www.webasto.com or
•
www.webasto.us
3
3 Operation
1
2
345
6
7
8
9
Digital chiller control element
1
Display
2 Plus button for changing setpoint temperature
3 Minus button for changing setpoint temperature
4 Fan setting button for controlling fan speed
5 Function button for setting/programming
6 "On/Off" button
7 LED display for heating mode
8 LED display for automatically switching between operating modes
9 LED display for cooling mode
4
The BlueCool V-Series air-conditioning system is operated with the control
element that enables access to all functions for normal operation of the air conditioning system.
3.1 Directly connected air handlers
The central digital chiller control element not only controls the general operation of the chiller unit but can also directly control the air handlers located in the
saloon and/or in the cabin (where the main cabin temperature sensor is located).
This direct air handler control function is not available in all installations.
NOTE!
When an air handler is connected directly to the BlueCool V-Series
chiller it acts as the reference and governs whether the system is to
heat or cool in automatic mode.
The secondary air handlers can only be operated in the same operating mode
(heating or cooling) as the chiller unit as the unit can either only heat or cool at
any one time.
NOTE!
By using electrical heating elements in the secondary air handlers
individual cabins can be heated while the overall system operates in
cooling mode.
3.2 Operation
All fans connected directly to the chiller electrical box are started when the operating mode LED lights up. The fan control facility checks whether the cold water
circuit is at the required temperature. Example: In cooling mode at a set temperature of 21°C, the fan speed in automatic operation remains at level 1 until the
temperature in the cold water circuit is lower than 21°C. This prevents the fan
starting up too early if the temperature in the cold water circuit is unsuitable.
The digital chiller control element can completely shut down fan operation, e.g.
at night, while the other air handlers on the boat continue to operate. The fan
control is completely independent of compressor operation.
5
3.3 Switching on central chiller unit and air handlers
After connecting the voltage supply, first all LEDs and all segments of the numeric
display flash for a few seconds, then "INIT" briefly appears on the control element. The display “50H” or “60H” follows, depending on which power supply
the air-conditioning system is operated on, for example 230 V/50 Hz or
230 V/60Hz.
If the system was switched on before cutting off the voltage supply, the current
cabin temperature in the reference cabin will appear on the control element and
the system will start up automatically in the set operating mode. Otherwise the
control panel will go dark and the air-conditioning system will assume standby
mode.
•
Switch on the system by pressing the "On/Off"
button (6).
Depending on the requested operating mode, either the LED indicator for heating
mode (7) or the LED indicator for cooling mode (9) lights up to show the active
mode. The LED indicator for automatically switching between operating modes
(8) shows whether switchover takes place automatically. Automatic switch-over
is dependent on the set temperature and the cabin temperature measured by the
cabin temperature sensor.
After a further 10seconds the 4/2-way reversing valve (that allows the air-conditioning system to operate as a chiller unit (cooling) or as a heat pump (heating))
opens to equalise pressure in the refrigerant circuit. After another 10seconds the
sea water pump starts up followed by the compressor. This is followed by normal
operation.
3.4 Switching off system
The system can be switched off by pressing the "On/Off" button
(6). The
condition for this is that the user is in the start menu with the display of the cabin
temperature. On the programming level (temperature, fan), the "On/Off"
but-
ton (6) is used to confirm the setting and not to switch off the system.
6
3.5 Selecting cooling mode/heating mode
The system selects cooling or heating operating mode depending on the required
temperature. The prerequisite is that the system has been configured for automatic switch-over between cooling and heating. For information on configuring the
operating modes please contact your authorised Webasto Marine dealer.
3.6 Setting setpoint temperature
•
Set the setpoint temperature in accordance with your own preferences.
•
Press the Plus button
(2) or Minus button (3).
The setpoint temperature is displayed.
•
Press the Plus
button (2) or Minus button (3) to change the setpoint
temperature.
•
Confirm the entry by pressing the “On/Off” button
(6) or wait at least 5se-
conds so that the entered value is automatically adopted.
3.7 Standby mode
The control element will assume standby mode if no button is pressed for
5minutes. The corresponding operating mode LED will then flash discretely every
20seconds. Press any button to return to the normal display.
3.8 Activating Eco mode
With the Eco mode function it is possible to continuously operate the BlueCool
V-Series under modulating partial load, thus limiting the current consumption of
the system. This makes it possible to operate the system with a lower generator
output, parallel with other large electrical loads such as hot water boiler or with
weak on-shore power supply.
7
Press the function button to activate Eco mode. Press the plus or minus button repeatedly to select the maximum output level at which the system is to operate.
•
Switching on system
•
Press the
•
Eco 0 is shown
•
Press the
•
Press the
Confirm the entry by pressing the "On/Off"
Eco 0: 100% of rated output
Eco 1: 80% of rated output
Eco 2: 45% of rated output
function button (5) once
button (2) to change the setting to Eco 1 or Eco 2
button (1) to return to the Eco 0 setting
button (6).
Activated Eco mode is indicated by the display alternately showing Eco1 and Eco2
as well as the set temperature.
Eco mode is never exited automatically but requires operator intervention.
Check the Eco mode setting if you find that the cooling output of the BlueCool
V-Series is unsatisfactory.
Refer to Section 4 "Malfunctions" for further information on reduced cooling
output.
3.9 Set the fan speed
•
Switching on system.
•
Press the fan setting button
(4).
The current fan speed is displayed.
•
Press the Plus button
•
If the Plus
button (2) is pressed again when the highest speed has already
(2) or Minus button (3) to change the fan speed.
been selected, automatic fan mode is switched on and “b A” appears on the
control element. Pressing the Minus button
(3) exits the automatic fan
mode and returns to the manual mode.
Confirm the entry by pressing the “On/Off” button
(6) or wait at least 5 se-
conds so that the entered value is automatically adopted.
8
3.10 Access code
Further setting options for the BlueCool air-conditioning system are reserved for
the technician and require an access code.
4 Malfunctions
4.1 Troubleshooting
CAUTION
Troubleshooting only by professionals!
Troubleshooting requires comprehensive knowledge on the
design and operation of the individual components of the airconditioning system and may only be carried out by authorised
professionals trained by Webasto for this purpose.
If malfunctions occur, the system must be switched off.
4.2 Malfunctions that are displayed
The following malfunctions are displayed directly on the digital control element
as a code (e.g. A02). Each time one of these fault codes appears, the system is
stopped for approx. 60 seconds and then a restart is attempted. If a malfunction
occurs more often than 6 times consecutively within 30 minutes, the system is
completely shut down and the fault code is displayed continuously. No further
restarts are attempted and the user should have the fault rectified and then reset
the system by switching it off or by temporarily interrupting the voltage supply to
the system.
9
4.3 Fault and status codes
Fault
code
Display
Description Possible cause Correction
AAA Undervoltage Switch-off in case
of undervoltage.
Voltage supply below set undervoltage value for longer
than 5seconds. The
cause is probably
excessively long
power cable for the
on-shore connection, overloading
or an insuciently
high power generator output.
Use a on-shore power
connection with a more
stable voltage supply. Use
a shorter power cable for
the on-shore connection.
Switch off other electrical
loads. Please contact
your authorised Webasto
Marine dealer.
10
Fault
code
Display
A01
Description Possible cause Correction
Compressor
shut-down due
to low pressure
Wrong low pressure
sensor reading.
Please contact your authorised Webasto Marine
dealer.
COOLING MODE:
Cold water flow
rate too low.
HEATING MODE:
-Sea water flow
rate insucient or
sea water too cold
(Temperature below
6 °C).
-Sea water strainer
blocked or no
intake.
Refrigerant shortage.
Check operation of the
cold water pump. If fitted,
open shut-off cock valves.
Please contact your authorised Webasto Marine
dealer.
Remove blockage at sea
water inlet. Check/clean
sea water strainer and
bleed sea water circuit.
Please contact your authorised Webasto Marine
dealer.
11
Fault
code
Display
A02
Description Possible cause Correction
Compressor
1 shut-down
due to high
pressure
A09 Cabin temper-
ature sensor
malfunction
A10 Malfunction
- cold water
temperature
Pressure switch
defective or power
circuit interruption/
short circuit or
wrong high pressure sensor reading.
COOLING MODE:
insucient sea
water cooling. Sea
water strainer soiled
or no intake.
HEATING MODE:
Cold water flow
rate too low.
Cabin temperature
sensor defective,
break/short-circuit
in electrical circuit,
cabin temperature
sensor not connected.
Water temperature
sensor defective or
break/short-circuit
in electrical circuit.
Please contact your authorised Webasto Marine
dealer.
Remove blockage at sea
water inlet. The minimum
flow rates must be complied with. Clean sea water
strainer and bleed sea
water circuit.
Check operation of the
cold water pump. If fitted,
open shut-off cock valves.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
12
Fault
code
Display
Description Possible cause Correction
A15 The flow switch
identifies
insucient cold
water flow 5
seconds after
the cooling
water pump is
switched on.
Cold water circuit
is blocked or wire
break at flow switch
when parameter FL
<FLno>.
Please contact your authorised Webasto Marine
dealer.
A20 Maximum
pressure level
reached.
Incorrect pressure
sensor measurement.
COOLING MODE:
-Insucient sea
water cooling.
-Sea water strainer
soiled or no flow.
-Sea water pump
defective.
-Refrigerant circuit
blocked.
Please contact your authorised Webasto Marine
dealer.
Remove blockage at sea
water inlet. The minimum
flow rates must be complied with. Clean sea water
strainer and bleed sea water circuit. Operate unit for
5 minutes in heating mode
(if possible) then switch to
cooling mode and check
whether the fault occurs
again. Please contact
your authorised Webasto
Marine dealer.
13
Fault
code
Display
Description Possible cause Correction
A20 Maximum
pressure level
reached.
HEATING MODE:
-Cold water pump
defective.
-Plate heat exchanger or cold water
circuit blocked.
-Refrigerant circuit
blocked.
Remove blockage at sea
water inlet. The minimum
flow rates must be complied with. Clean sea water
strainer and bleed sea
water circuit. Operate the
unit for 5 minutes in cooling mode (if possible) then
switch to heating mode
and check whether the
fault occurs again. Please
contact your authorised
Webasto Marine dealer.
A21 Excess current
at inverter.
Excess current
caused by undervoltage. Insucient
voltage supply.
Cause is probably
excessively long
cable, overloading
or an insuciently
high power generator output.
Improve voltage supply or
activate ECO mode.
14
Fault
code
Display
Description Possible cause Correction
A22 Excess tem-
perature at
inverter.
Ambient temperature too high or
insucient cooling.
Check whether the air
vents in the electronics box
are blocked. Remove dust
deposits from the heat
sink. The max. ambient
temperature must not
exceed 60 °C.
A23 Excess
temperature,
compressor.
Incorrect temperature measurement.
15
Fault
code
Display
Description Possible cause Correction
A23 Excess
temperature,
compressor.
COOLING MODE:
-Insucient sea
water cooling.
-Sea water strainer
soiled or no flow.
-Sea water pump
defective.
-Refrigerant circuit
blocked.
Remove blockage at sea
water inlet. The minimum
flow rates must be complied with. Clean sea water
strainer and bleed sea water circuit. Operate unit for
5 minutes in heating mode
(if possible) then switch to
cooling mode and check
whether the fault occurs
again. Please contact
your authorised Webasto
Marine dealer.
HEATING MODE:
-Cold water pump
defective.
-Plate heat exchanger or cold water
circuit blocked.
-Refrigerant circuit
blocked.
Check sea water flow rate
at sea water outlet. The
minimum flow rate must
be maintained. Clean sea
water strainer and bleed
sea water circuit. Operate
the unit for 5 minutes in
cooling mode (if possible)
then switch to heating
mode and check whether
the fault occurs again.
Please contact your authorised Webasto Marine
dealer.
16
Fault
code
Display
Description Possible cause Correction
A24 High pressure
sensor faulty.
Pressure sensor
defective or power
circuit interruption/
short circuit.
Please contact your authorised Webasto Marine
dealer.
A25 Low pressure
sensor
faulty.
A26 Compressor
temperature
sensor defective.
A27 Fault in inverter
data communication.
Pressure sensor
defective or power
circuit interruption/
short circuit.
Compressor
temperature sensor
defective or break/
short-circuit in
electrical circuit.
No data communication between
inverter and PCB.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
17
Fault
code
Display
Description Possible cause Correction
A28 Compressor
operation outside operating
range.
Incorrect pressure
sensor measurement.
COOLING MODE:
-Insucient sea
water cooling.
-Sea water strainer
soiled or no flow.
-Sea water pump
defective.
-Refrigerant circuit
blocked.
Please contact your authorised Webasto Marine
dealer.
Remove blockage at sea
water inlet. The minimum
flow rates must be complied with. Clean sea water
strainer and bleed sea
water circuit. Operate the
unit for 5 minutes in heating mode (if possible) then
switch to cooling mode
and check whether the
fault occurs again. Please
contact your authorised
Webasto Marine dealer.
18
Fault
code
Display
Description Possible cause Correction
A28 Compressor
operation outside operating
range.
A30 Inverter
temperature
exceeded.
A31 Inverter excess
current.
HEATING MODE:
-Cold water pump
defective.
-Plate heat exchanger or cold water
circuit blocked.
-Refrigerant circuit
blocked.
The permissible
temperature in the
inverter housing is
exceeded.
-Current too high
due to sudden
increases in load
-Short-circuit in
motor connection
cable
-Incorrect parameter
settings.
Check sea water flow rate
at sea water outlet. The
minimum flow rate must
be maintained. Clean sea
water strainer and bleed
sea water circuit. Operate
the unit for 5 minutes in
cooling mode (if possible)
then switch to heating
mode and check whether
the fault occurs again.
Please contact your authorised Webasto Marine
dealer.
-Check whether the air vents
in the electronics box are
blocked.
-Remove dust deposits from
the heat sink.
-If possible, reduce the max.
ambient temperature to
below 60 °C.
Please contact your authorised Webasto Marine
dealer.
19
Fault
code
Display
Description Possible cause Correction
A33 Earth fault
found.
Earth current too
high.
Please contact your authorised Webasto Marine
dealer.
A34 HW excess
current.
-Current too high
due to sudden
increases in load
-Short-circuit in compressor connection
cable
-Incorrect inverter
parameter settings.
A35 DC bus fault. No input voltage at
power supply.
A36 Undervoltage
“power factor
Insucient voltage
supply
correction”.
A37 Undervoltage. Undervoltage due
to low supply
voltage or defective
inverter.
A38 Incorrect speed
(at high loads).
Incorrect parameters or load too
high.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
20
Fault
code
Display
Description Possible cause Correction
A39 Compressor
switched off
when the
input is not bypassed/open.
Cable not connected
Function of external
relay, 24V voltage
not applied.
Please contact your authorised Webasto Marine
dealer.
A40 Compressor
overload.
Maximum permissible current was
exceeded within
the defined time
window.
A41 Overvoltage. The DC voltage of
the intermediate
circuit has exceeded
the maximum permissible value as the
result of excessively
long delay or overvoltage peaks in the
supply voltage
A42 Inverter tem-
perature too
low.
A43 Compressor
excess temperature.
Temperature in
inverter below
permissible level.
The measured PTC
thermistor temperature corresponds to
a resistance >2600
ohm.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
21
Fault
code
Display
Description Possible cause Correction
A44 Inverter fault
IGBT.
Internal fault. Please contact your au-
thorised Webasto Marine
dealer.
A45 CPU fault. Data loss in mem-
ory.
A46 Parameter
reset.
Parameters were
reset automatically
to factory setting:
User-specific
parameter setting
corrupted.
A47 Data communi-
cation fault.
A48 Inverter ther-
Data reception
faulty.
Internal fault. Please contact your au-
mistor fault.
A49 Automatic
adjustment
Incorrect parameters.
faulty.
A50 Internal fan
Internal fault. Please contact your au-
fault.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
thorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
thorised Webasto Marine
dealer.
22
Fault
code
Display
Description Possible cause Correction
A51 Module fault. Excess current C1,
C2:
Connections
short-circuited
A53 Module fault
Internal fault. Please contact your au“Safe Torque
Off”. No contact between
"Safe Torque
Off" connection and
PCB.
A54 Module fault
Internal fault. Please contact your au“Safe Torque
Off”.
n/a No LED indica-
tion on PCB.
Fuse faulty or break/
short-circuit in this
electrical circuit.
n/a Compressor
not running.
Please contact your authorised Webasto Marine
dealer.
thorised Webasto Marine
dealer.
thorised Webasto Marine
dealer.
Please contact your authorised Webasto Marine
dealer.
The system starts up on
reaching a defined cold
water temperature. Cut-in
temperature:
4°... 8°C (Cooling mode)
41°... 45°C (Heating
mode)
23
Fault
code
Display
Description Possible cause Correction
n/a Sea water
pump(s) start
up directly after
the control is
switched on.
n/a Compressor
keeps cutting in
and out.
n/a No or insu-
cient cooling
or heating
capacity.
n/a Incorrect
cabin/ambient
temperature or
water temperature displayed.
Wiring of pump
1 (sea water) and
pump 2 (cold wa-
Please contact your authorised Webasto Marine
dealer.
ter) interchanged.
Too little cold water. Please contact your au-
thorised Webasto Marine
dealer.
Poor air or water
flow, soiled or circu-
lation blocked.
Refrigerant short-
age.
Oil lock.
Secure adequate air or
water flow.
(see A01 and/or A02).
Please contact your authorised Webasto Marine
dealer.
Refrigerant circuit
blocked. (Filter or
expansion valve).
Compressor fault.
Temperature
sensor positioned
incorrectly, subject
to interference
or display values
falsified.
Check whether the sensor
is subject to direct fault
sources such as direct
sunlight or devices radiating heat. Please contact
your authorised Webasto
Marine dealer.
24
Fault
code
Display
Description Possible cause Correction
CA11 Compressor(s)
programmed in the
control setting not
active.
Please contact your authorised Webasto Marine
dealer.
INIT Initialisation
procedure
or system
blocked.
Electrical wiring de-
fective, interruption
in power circuit/
short circuit.
Please contact your authorised Webasto Marine
dealer.
4.4 Malfunctions not displayed on control element
1. After switching on, the system does not react. Check the power supply, the
supply line circuit breakers, etc.
2. The compressor starts up, however no sea water exits from the sea water
outlet. If the sea water pump is running:
• Check whether the shut-off valves are opened.
• Check whether the sea water strainer is clogged.
• There could be air in the pump head causing the pump to malfunction.
Bleed the air out of the sea water line, e.g. with a bleeder valve downstream
of the pump.
If the sea water pump is not running:
• Check the power supply to the sea water pump.
• The pump rotor may be blocked by dirt. If possible and accessible, using a
tool turn the pump rotor from the motor side until it moves freely.
25
3. The compressor and the sea water pump are running, but neither the heating
mode nor the cooling mode function satisfactorily. Check whether Eco mode is
activated and the compressor output is therefore reduced.
• Check whether the cold water pump is running. If necessary, check the
power supply to the pump. Check whether the shut-off valves in the cold
water circuit are opened.
• Allow the fan to run in the automatic fan mode.
• Check the air ducts of the air handlers.
• If the sea water flow rate is too low, the sea water in the condenser can
freeze in heating mode, blocking and damaging the system.
• Check the voltage level. Do not operate the system continually with insucient voltage (under 195 V).
• Heating mode takes a long time to start up. This is normal when the sea
water is very cold. When the temperature of the sea water drops below approx. 6 °C, the heating eciency decreases and the air-conditioning system
takes a long time before producing the expected heat. Run air-conditioning
system in heating mode for about 60minutes to remove a possible oil
blockage in the refrigerant circuit.
• If the performance of the system is still unsatisfactory after checking all of
the above points, you should have the refrigerant fill level checked.
• An incorrect cabin temperature is displayed. Cabin temperature sensor
positioned incorrectly, fault sources are present or display values are falsified.
Check whether the cabin temperature sensor is subject to direct fault sources, like direct sunlight or devices radiating heat. Calibrate sensor or replace
defective sensor. Have corrected by a specialist workshop.
26
27
In multilingual versions the German language is binding.
The telephone number of each country can be found in the Webasto
service center leaflet or the website of the respective Webasto representative of your country.
Webasto Thermo & Comfort SE
Postfach 1410
82199 Gilching
Germany
Visiting Address:
Friedrichshafener Str. 9
82205 Gilching
Germany
www.webasto.com
Ident No. WBCL010825A • 12/14 • Errors and omissions excepted • Printed in Turkey• © Webasto Thermo & Comfort SE, 2014
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