Webasto Compact Cooler 4E, Compact Cooler 5, Compact Cooler 5 Lite, Compact Cooler 8 Operating Instructions
Compact Cooler 4E / 5 / 5 Lite / 8
Aufdach-Klimaanlage
Roof-Top Air-Conditioning System
Climatisation sur toiture
Impianto climatizzatore da tetto
Climatizador de sobretecho
Bedienungsanweisung
Operating Instructions
Notice d'utilisation
Istruzioni per l'uso
Instrucciones de funcionamiento
Compact Cooler 4E / 5 / 5 Lite / 8
Contents
1 Maintenance and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Operating and control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Switching on /
Switching off 16
3.3 Fan power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4 Temperature setting with temperature controller, without heating (option) . . . . . . . . . . . . . . . . . . . . . . . .16
3.5 Temperature setting with temperature controller, with heating (option Compact Cooler 8) . . . . . . . . . . . . 16
3.6 Fresh air ventilation flap (option Compact Cooler 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Heating (option Compact Cooler 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Faults in the air-conditioning / heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Faults in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.3 Faults in the heating circuit (option Compact Cooler 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.4 Faults on the compressor drive unit (Compact Cooler 4E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7 Warranty Claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
II
Compact Cooler 4E / 5 / 5 Lite / 8
1 Maintenance and safety instructions
Please read these instructions carefully prior to commissioning and keep them for future reference.
Please read the following information and carry out maintenance work at regular intervals.
System Component Maintenance Work Frequency
Refrigerant system
Hoses
Connections
Refrigerant filling
Condensed-water drain
Electrical system
Inspect connections for firm seating, condition and
damage
Conduct a leak test using a leak detector
Check refrigerant quantity at sight glass
Check that opening is clear and clean if necessary
Check electrical connections and plug connectors for
proper condition and firm seating
monthly every 6
months
X
X
X
X
annually
X
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Compact Cooler 4E / 5 / 5 Lite / 8
CAUTION
If the heating option is installed (Compact
Cooler 8): Coolant level can only be
checked when the Webasto heating / airconditioning system Compact Cooler 8 is
switched off. I.e. the 2/3-position switch
must be in the neutral position.
1. The system must be installed in
accordance with the installation
instructions.
2. Installing the air-conditioning system
increases the height of the vehicle. Please
note the heights specified in the vehicle
papers and ensure registration if necessary.
3. If faults develop in the refrigerant circuit,
the system must be tested and repaired by
an authorised service centre. Under no
circumstances may refrigerant be vented
into the open air (see § 8 CFC-Halon
Prohibition Directive dated 06.05.1991).
4. Installation, maintenance, repair and all
work on the refrigerant circuit may only be
carried out by specialist personnel in an
authorised service centre. This work may
only be carried out with the engine at a
standstill and the power supply switched
off. The battery must be disconnected
before starting any work on the electrical
wiring.
5. Wear protective clothing and safety
goggles when handling refrigerant.
6. Regardless of how long the system is in
use, it is also possible to experience
refrigerant loss despite the line connections
being absolutely sealed. However, if
relatively large quantities of refrigerant are
lost over short periods of time, you may
assume that there is a leak in the system.
7. Only the materials, special tools and
accessories listed in the installation
instructions may be used for maintenance
work on the air-conditioning circuit.
8. As is the case with all parts of a vehicle,
the air-conditioning system is continuously
subjected to loading. To guarantee that the
system operates correctly and to prevent
any damage to the parts, the maintenance
work must be carried out at regular
intervals.
9. The proper treatment of the system and
a record of all maintenance work are
necessary for the acceptance of any
warranty claims involving damage to parts
that require regular maintenance.
10. Irrespective of the schedule in the
installation instructions, all the device
fasteners and the connections on the
refrigerant lines must be checked for firm
seating within the first four weeks of using
the roof-top system for the first time.
12
Compact Cooler 4E / 5 / 5 Lite / 8
11. Even if the air-conditioning unit is not in
use, individual components may be subject
to wear due to the normal ageing process
or the stresses or strains generated by
driving the vehicle. The appropriate checks
listed in the maintenance and service chart
in the installation instructions must
therefore be carried out regardless of the
system operating time.
12. The receiver-drier must be replaced at
least every twelve months. When working
on the refrigerant system, the receiver-drier
must always be replaced (not necessary for
Compact Cooler 5 Lite).
13. During extended shut-down periods,
the air-conditioning system must be
operated at least once a month for a period
of approx. 15 minutes to prevent the shaft
seals on the refrigerant compressor from
becoming drying out or any moving parts
from seizing due to oil resinification.
Requirement: Minimum outside
temperature > 5 °C e.g within a heated
factory building.
14. Always ensure that the amount of oil in
the air-conditioning unit complies with the
details in the installation instructions.
15. The plate fins of the condenser,
evaporator or heat exchanger should be
cleaned with compressed air directed
against the normal direction of air flow if
contamination is slight. If the soiling is
severe or the unit has greasy deposits, first
clean it using soap suds or a suitable
cleaning solution (must be compatible with
copper or aluminium) and then use
compressed air or a water jet.
Caution: Beware of damage due to an
excessively strong jet of air or water.
16. When the vehicle is cleaned with a
direct jet of water or in a car wash, the fresh
air ventilation flap must be closed. Note the
overall height of the vehicle including rooftop air-conditioning system
17. Failure to observe the installation
instructions and the information it contains
will lead to Webasto being released from
any and all liability. The same applies to
repairs performed improperly or using parts
other than genuine spare parts.
18. The fresh air ventilation flap (option for
Compact Cooler 8) should remain closed in
winter.
19. When filling the heating circuit with
coolant (water / glycol), care must be taken
to bleed the circuit via the bleed valve of the
system. Further replenishment of the
heating circuit is only permitted with the
engine running.
20. Only operate the air-conditioning
system when the housing and lines are not
damaged.
13
Compact Cooler 4E / 5 / 5 Lite / 8
2 General information
Only start the air-conditioning system when
the vehicle engine is running as the vehicle
battery will be discharged if the engine is at
rest.
If the electrical connection of the airconditioning system is such that the fans
can be activated when the engine is
switched off, they will not cool the cab.
Operating the system with the engine
switched off results in the air in the interior
of the vehicle being circulated.
Attention, battery discharging!
The air-conditioning system is only operable
when it is filled with the quantity of
refrigerant and refrigerating machine oil
specified in the installation instructions.
Without temperature controller, the
temperature of the air-conditioning system
is controlled by the anti-ice thermostat
installed in the system. This thermostat
switches the compressor off once the
evaporator reaches a temperature when ice
is likely to form. The evaporator (radial) and
condenser fans (axial) continue to run. On
the Compact Cooler 5 Lite, only the
evaporator fan continues to run. When the
temperature rises above the trigger point of
the anti-ice thermostat, the compressor
cuts in again.
If the temperature controller is installed
(optional), any desired cabin temperature
can be set between 10 and 30 °C. The
compressor is switched off when the set
temperature is reached. The evaporator
(radial) and condenser fans (axial) continue
to run. On the Compact Cooler 5 Lite, only
the evaporator fan continues to run. The
passenger compartment temperature
increases again and switches on the
compressor again when the switching
temperature is reached.
To quickly cool and dehumidify the interior
of the vehicle after it has been parked for a
lengthy period of time in a high ambient
temperature and sunny conditions, we
recommend that you initially operate the
fan at speed 3 in the recirculating air mode.
After the interior temperature has reached
a pleasant level the fan can be turned down
to speed 2 or 1 depending on the ambient
temperature.
If the vehicle is greatly heated up by
exposure to direct sunlight, it is
recommended that the doors and windows
be opened for ventilation before switching
on the air-conditioning system.
The Compact Cooler 4E electric airconditioning system can be operated either
when the engine is running or when the
ignition is switched on. For operation with
the ignition switched on, the system is
equipped with a battery-discharge
protection circuit. If the electrical system
voltage falls below 20 V for longer than
10 seconds or if the electric motor suffers
an overload (> 80 A/sec), the system will cut
out automatically. It can be restarted by
being switched on again.
Your service centre will be happy to answer
questions regarding installation.
14
Compact Cooler 4E / 5 / 5 Lite / 8
3 Operation
The system is operated via the ON / OFF
switch in combination with the 3-position
switch for the required fan power. Both
switches have no indication of their switch
position. The optional temperature
controller permits selection of the required
temperature.
As an option the integral fresh air valve can
be actuated using the OPEN / CLOSE switch.
When it is open the control light in the
switch (Compact Cooler 8) will be lit.
If the roof-top air-conditioning system
Compact Cooler 8 has been installed with
optional heating, the heating will be
switched on via a combined heating / airconditioning switch. The two-position ON /
OFF switch for the air-conditioning system
(top right) will then be replaced by the
combined heating / air-conditioning switch
(bottom right).
3.1 Operating and control elements
Response to new temperature
controller settings is
delayed.
!
Temperature
controller (optional)
Rotary control for
setting the cabin
temperature
Temperature
controller is replaced
if the optional
heating is installed
(Compact Cooler 8)
Red = HEATING
Blue = COOLING
Temperature is not controlled
when the switch is set to 0
ON / OFF switch airconditioning system
(replaced by heating / airconditioning switch (see
below) when optional heating
is installed))
3 position switch
Fan power
2-position switch
(optional, Compact Cooler 8 only)
Fresh air ventilation flap
OPEN / CLOSED with indicator for
OPEN position
3-position switch
(optional, Compact Cooler 8 only)
Combined heating / airconditioning switch
ON / OFF / ON
15
Compact Cooler 4E / 5 / 5 Lite / 8
3.2 Switching on / Switching off
3.3 Fan power
3.4 Temperature setting with temperature controller, without heating (option)
3.5 Temperature setting with temperature controller, with heating (option Compact Cooler 8)
3.6 Fresh air ventilation flap (option Compact Cooler 8)
3.7 Heating (option Compact Cooler 8)
0
I
I
II
III
approx. 30 °C approx. 30 °C ... approx. 10 °C
0
I
0
I
0
I
0
Replaced by
combined
heating / cooling
switch
I - II - III
II III
I
0
approx. 10 °C
0 I - II - III
16
Compact Cooler 4E / 5 / 5 Lite / 8
4 Troubleshooting
If a fault occurs, check the fuse for
operation and the plug connections for
proper condition and firm seating.
4.1 Faults in the airconditioning / heating
system
Possible causes:
• Defective evaporator or condenser fan
(only evaporator fan on Compact
Cooler 5 Lite)
• Soiled or clogged air filter, condenser,
evaporator or heater heat exchanger
fins (Compact Cooler 5 Lite has no
condenser)
• Loss of refrigerant or too little
refrigerant in the system
• Loss of coolant or too little coolant in
the system
• Air in coolant circuit (bleed circuit via
bleed valve of Compact Cooler 8
system)
The air-conditioning system must be
inspected by an authorised service centre if
the system cuts out continuously.
4.2 Faults in the refrigerant circuit
If malfunctions occur in the refrigerant
system, it must be checked by an authorised
service centre and repaired properly. Under
no circumstances may refrigerant be vented
into the open air (see § 8 CFC-Halon
Prohibition Directive dated 06.05.91).
17
Compact Cooler 4E / 5 / 5 Lite / 8
4.3 Faults in the heating circuit (option Compact Cooler 8)
Symptom Possible cause Remedy
No heat output Pump not running Start engine and check pump connections
Coolant is still cold Wait until engine has reached its operating temperature
Water valve closed Open valve; check electrical connections if a solenoid valve is
used
Water hoses kinked or crushed Eliminate cause of fault, repair any leaks
Water pump pressure too low Coolant does not flow through heat exchanger. Install an
additional or more powerful pump.
Reduced heat
output
Coolant (water /
glycol) leaking
from the roof-top
unit
Air flow rate of the fan is too low Select a higher fan power stage
Too little water flows through the heat
exchanger
Air in heat exchanger Bleed via valve on heat exchanger of heating system
Loose hose connection Check that hose connections are secure and retighten hose
Water hose damaged Install and connect a new hose
Heat exchanger damaged Install and connect an original replacement part
Water line kinked or crushed.
Reroute hoses. Water pump pressure too low (see above for
corrective action). Open water valve in vehicle if applicable.
clamps
(Caution: Note the safety instructions!)
18
Compact Cooler 4E / 5 / 5 Lite / 8
4.4 Faults on the compressor drive unit (Compact Cooler 4E)
Symptom Possible cause Remedy
Compressor does not
work
The compressor does
not work when the
engine is switched off
Voltage below 20 V Switch on the vehicle’s engine and charge the battery
Overload has tripped Switch the air-conditioning system off and then on again.
If the error occurs repeatedly, contact the service centre.
Electric motor fuse (75 A) has tripped
The system is only wired to work when the
engine is running
Electric motor temperature over 96 °C Switch off the system, allow it to cool and then switch it
Check the electric motor fuse and replace it if necessary
Switch on the engine
on again
19
Compact Cooler 4E / 5 / 5 Lite / 8
5 Approvals
The Compact Cooler air-conditioning
systems have been designed and produced
in accordance with EC directives. There are
type approvals in accordance with the EC
directive 72/245/EEC.
Approval number:
e1*72/245*2009/19*1443 *
6 Disposal
Obtain information at the nearest recycling
centre or the service centre on the
applicable disposal regulations and dispose
of your unit accordingly.
7 Warranty Claims
a) The warranty does not cover parts that
are subject to normal wear, or
improper handling. The repair or
replacement of the unit or parts
thereof will not result in an extension
of the warranty period.
The legal regulations apply.
b) Please contact the service centre in
case of a warranty claim with
– Part covered by the warranty
– The warranty card
– The warranty claim
20
Bei mehrsprachiger Ausführung ist Deutsch verbindlich.
In multilingual versions the German language is binding.
Dans le cas d'une version rédigée en plusieurs langues, l'anglais est alors la langue qui fait foi.
Nel caso di una versione plurilingue il tedesco è vincolante.
Este manual esta traducido en varios idiomas, le informamos que sólo la versión en inglés será vinculante.
Webasto AG
Postfach 80
D - 82132 Stockdorf
Germany
National:
Hotline: 01805 951 159
Hotmail: kundencenter@webasto.com
www.webasto.de
International:
www.webasto.com
(€ 0,14/Min. aus dem deutschen Festnetz)
Ident-Nr. 9025057A • 05/11 • Änderungen und Irrtümer vorbehalten • Gedruckt in Italien • © Webasto AG, GCS 2011
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