Webasto BlueCool Premium Series Operation And Installation Instructions Manual
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Webasto BlueCool Premium Series Operation And Installation Instructions Manual

Chilled water marine air conditioning systems
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Webasto BlueCool Premium (WBCP) Series
Chilled Water Marine Air Conditioning Systems
Operation And Installation Instructions
To find an authorized Webasto marine installation center near you, please call (800) 860-7866 toll free or visit our web site at:
www.webasto.us

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Summary of Contents for Webasto Webasto BlueCool Premium Series

  • Page 1 Webasto BlueCool Premium (WBCP) Series Chilled Water Marine Air Conditioning Systems Operation And Installation Instructions To find an authorized Webasto marine installation center near you, please call (800) 860-7866 toll free or visit our web site at: www.webasto.us...
  • Page 2 Diagnoisis and repair of malfunctioning, non-functioning or damaged Webasto cooling systems requires special factory training, technical information, special tools and special equipment. • ALWAYS carefully follow Webasto installation instructions and heed all WARNINGS. • Improper installation voids all warranties on this product.

  • Page 3: Table Of Contents

    Webasto BlueCool Premium Series AC Systems Table of Contents Contents Page Warranty Foreword General ..................5 Scope and Purpose .

  • Page 4: Warranty

    The intent of the Webasto warranty is to remedy defects in material and workmanship in the manner provided herein. During the warranty period the exclusive remedy will be for Webasto, at its discretion, to repair or replace those parts which are demonstrated to be defective in material or workmanship.

  • Page 5: Foreword

    Webasto BlueCool Premium Series AC Systems Foreword Foreword 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 accessories list for boats/ships. Scope and Purpose These instructions are intended to support the installation of BlueCool Premium air conditioning units in marine vessels.

  • Page 6: Important Safety Information

    • For information concerning special marine applications or marine applications you are not sure of, contact an authorized Webasto marine dealer or Webasto Product N. A., Inc. directly at: 1-800- 555-4518 (USA) or 1-800-667-8900 (Canada). Webasto Thermo & Comfort N.A., Inc.

  • Page 7: Installation Overview

    Webasto BlueCool Premium Series AC Systems Overview Typical Installation The illustration below shows a typical installation of a self-contained air conditioning unit. Digital Cabin Transition Box + Control Panel Supply Air Grill Flexible Air Duct 2nd Air-Handler Vertical Slimline Model...

  • Page 8: Description And Operation

    DESCRIPTION AND OPERATION Chiller 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.

  • Page 9: Chiller Unit Component Description

    Webasto BlueCool Premium Series AC Systems Overview Chiller Unit Component Description Compressor The compressor is a pump that pressurizes and circulates the refrigerant in the air conditioning system. • Available in 115V or 230V • Powered by shore power or generator •...
  • Page 10 Overview Webasto BlueCool Premium Series AC Systems Expansion Valve Variable valve, placed between condenser and evaporator. Enables a pressure difference between the high and low side of the system. Regulates the volume of the refrigerant passed to the evaporator Fig. 7...
  • Page 11 It does however have some new features for present and future purposes. The new card can be easily identified by the Webasto logo and fuses located on the front of the card. The new card also has additional relays and a second water temperature sensor inlet intended for future use.

  • Page 12: Air Handlers

    Overview Webasto BlueCool Premium Series AC Systems Air Handlers Webasto offers various types and sizes of air handlers to simplify the installation process. Slim Line Cross Flow Air Handler Compact Air Handler 4,000 - 12,000 BTU 4,500 - 24,000 BTU Fig.

  • Page 13: Water Pumps

    Overview Water Pumps Webasto uses two different types of water pumps to circulate fluid through the chiller and seawater circuits, magnetic drive and mechanical. Water pumps are available for 115V and 230V applications. Refer to the Marine Parts Catalog for the correct size and voltage output to fit your needs.

  • Page 14: Optional Cabin Controls

    Overview Webasto BlueCool Premium Series AC Systems Optional Cabin Controls MTH - Mechanical Thermostat The MTH thermostat has a control for setting the desired set-point temperature and a selector to switch between summer and winter operation. – (1) Summer/ Winter Selector –...

  • Page 15: Chiller Control Digital Display

    Overview Chiller Control Digital Display All Webasto air conditioning units are controlled by a Digital Display 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 <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 unit and attached accessories (blowers, pumps, etc.), as well as it normal functioning.
  • Page 16 Overview Webasto BlueCool Premium Series AC Systems 2004 Series Digital Display The WEBASTO <CHILLER CONTROL> 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.
  • Page 17 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.
  • Page 18 Overview Webasto BlueCool Premium Series AC Systems Chiller Control Digital Display 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.
  • Page 19 Webasto BlueCool Premium Series AC Systems Overview Table 1: Chiller Control Secondary Commands Command Display Readout Setting(s) ATTENTION The following functions need validation before a new value is accepted. Press the <F> key and go to the next function line. Validation will occur automatically when the display goes back to room temperature readout.

  • Page 20: Digital Cabin Blower Control

    Webasto BlueCool Premium Series AC Systems Digital Cabin Blower Control (See Figure 25) 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.
  • Page 21 Webasto BlueCool Premium Series AC Systems Overview Cabin Control Secondary Commands The <F> key gives immediate access to commands and displays necessary for day-to-day operation. When pushing the <F> key you will see a code which indicates the type of command or display and the present value.

  • Page 22: Installation

    Installation Webasto BlueCool Premium Series AC Systems INSTALLATION Installation and Positioning of Seawater Pump Seawater Cooling Install the pump/strainer assembly as close as possible to the center of the boat, with a minimum of 25 cm below the water surface. Mount the pump in such a way, that the water flow from the pump to the unit is always running up, this will prevent air bubbles in the line, making bleeding the system much easier.

  • Page 23: Chilled Water System Installation

    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.
  • Page 24 Webasto BlueCool Premium Series AC Systems Added Heat-Exchangers ATTENTION Refer to Figure 27 for an example of a Water-to-Water exchanger specially adapted for fuel heaters (Webasto, etc.) The TECC controller card is configured to except additional heat-exchangers in the chilled water circuit of various types: •...
  • Page 25 Webasto BlueCool Premium Series AC Systems Installation Chilled Water Piping and Accessories Chilled water piping can be in rigid plastic tubing and/or flexible reinforced hoses. Internal dimensions SHORT RADIUS ELBOW of tubing should be in conformity with piping as supplied by WEBASTO.
  • Page 26 Anti-freeze Solution CAUTION! Webasto will void the product warranty if a glycol/water mixture (20/25% glycol + 70/75%fresh water) in the chilled water circuit is not maintained. It is imperative to add approx. 20 TO 25% pure glycol to the chilled water circuit to avoid accidental freezing of the system during the winter.
  • Page 27 Installation Webasto BlueCool Premium Series AC Systems Refilling after leak Never refill system with fresh water only; besure to always maintain glycol mixture ofbetween. 20 and 25% glycol - 75/80% freshwater. Cooling Flow Rates CHILLER FLOW RATE CHILLER FLOW RATE HCSC12/D 10 l/min (2.64 gl.

  • Page 28: Air Ducting - Ventilation

    Installation Webasto BlueCool Premium Series AC Systems Air Ducting - Ventilation Air-Ducts Flexible air-ducts need to be of good quality with sufficiently strong steel or plastic reinforcement. Spiral type ducts should be extended to their maximum possible length to obtain max. interior smoothness.
  • Page 29 Avoid 90° turns directly from blower outlets all costs as they introduce severe restrictions in the air flow. All WEBASTO blowers (except on 24000 BTU models) can be rotated through 45° steps so as to obtain a straight-line outlet from the blower. See Figure 33 for approved installation.
  • Page 30 Return air should be filtered to avoid accumulation of dust on the coil fins. This can be obtained by 2 means: • Install WEBASTO supplied return air grills which include a filter element behind the grills. • Install a filtering element just in front of the return air coil surface.

  • Page 31: Standard Electrical Accessories

    Webasto BlueCool Premium Series AC Systems Installation Standard Electrical Accessories Figure 37 contains the minimum standard control elements delivered with all WBCP units. Electrical contents: control box; display cable; digital control panel (external air sensor is optional). ELECTRICAL CONTROL BOX DIGITAL DISPLAY PANEL (2 ea.)
  • Page 32 Installation Webasto BlueCool Premium Series AC Systems Minimum Cable Sections per Chiller Model (Ground Wires not shown) Table 3: Model Description Voltage Phase Section mm2 SINGLE COMPRESSOR UNITS WBCP20 - SCROLL 2 x 2.5 mm2 WBCP24 - SCROLL 2 x 2.5 mm2...

  • Page 33: Programming

    Webasto BlueCool Premium Series AC Systems Programming Programming Access Entering Programming Mode To enter programming mode: 1. Turn on the unit by pressing the <On / Off> key (5). 2. Raise or lower the setpoint temperature to 29° C (85° F) or 15° C (59° F).

  • Page 34: Description Of Chiller Control Programming Codes - Setpoint At 85° F (29° C)

    Programming Webasto BlueCool Premium Series AC Systems Table 4: Description of Chiller Control Programming Codes - setpoint at 85° F (29° C) Factory Code # Description Optional Settings Setting Functions accessible by raising the setpoint to 85° F (29° C) Code <0 >...
  • Page 35 Webasto BlueCool Premium Series AC Systems Programming Table 4: Description of Chiller Control Programming Codes - setpoint at 85° F (29° C) Factory Code # Description Optional Settings Setting Code <9 > Functioning principle of staging relay:0 = 1 = functions as the relay functions as a staging relay.

  • Page 36: Description Of Chiller Control Programming Codes - Setpoint At 59° F (15° C)

    Programming Webasto BlueCool Premium Series AC Systems Table 5: Description of Chiller Control Programming Codes - setpoint at 59° F (15°C) Factory Code # Description Optional Settings Setting Functions accessible when lowering the setpoint temperature to 59° F (15°C) Code <0 >...

  • Page 37: Description Of Blower Control Programming Codes - Setpoint At 85° F (29° C)

    Webasto BlueCool Premium Series AC Systems Programming Table 5: Description of Chiller Control Programming Codes - setpoint at 59° F (15°C) Factory Code # Description Optional Settings Setting Code <8 > Modification speed No. 3 Code <9 > Modification speed No. 2 Code <A>...

  • Page 38: Description Of Blower Control Programming Codes - Setpoint At 59° F (15° C)

    Programming Webasto BlueCool Premium Series AC Systems Table 7: Description of Blower Control Programming Codes - setpoint at 59° F (15°C) Factory Code # Description Optional Settings Setting Functions accessible when lowering the setpoint temperature to 59° F (15°C) Code <1 >...

  • Page 39: Blower Speed Setting Calibration

    / or low water flow through the condenser. Maintenance, Routine Checks and Troubleshooting: CAUTION! Always use genuine Webasto service and replacement parts to ensure trouble-free operation of the system. ATTENTION Some troubleshooting requires comprehensive knowledge about structure and theory of operation of the air conditioning components and should only be performed by authorized Webasto trained specialists.

  • Page 40: Visual Error Codes - Digital Display

    Do not persist with manual restarts in such cases as this may cause major damage to the principal components (compressors, pumps, etc.) Shut the system off and call a Webasto Authorized Dealer or call Webasto at – 1-800- 860-7866 Webasto Thermo &...
  • Page 41 Webasto BlueCool Premium Series AC Systems Troubleshooting Table 8: Error Codes Code Description Code <AAA> Persistent low voltage (voltage below 195V AC for 230V units and 90V AC for 115V units) for more than 5 seconds. <A01> BP (low pressure) cut out - compressor 1 •...

  • Page 42: Schematics

    Schematics Webasto BlueCool Premium Series AC Systems Digital Cabin Control Electrical and Other Connections - Cab Webasto Thermo & Comfort N.A., Inc. www.techwebasto.com...

  • Page 43: Electrical Schematic - Electronic Thermostat + 3 Speed Regulator

    Webasto BlueCool Premium Series AC Systems Schematics WIRING DIAGRAM - MTH THERMOSTAT + 3 SPEED BLOWER CONTROL WEBASTO 3 110/220V SPEED Supply Controller Card AIRHANDLER /BLOWER On/Off Switch Internal Wire Connectors Heat/Cool 3 Speed WEBASTO PREWIRED RJ45 CABLE Selector Selector www.webasto.us...

  • Page 44: Example No. 1 - Small 18000 Btu Chiller - Central Location + 2 Air-Handlers

    Schematics Webasto BlueCool Premium Series AC Systems TYPICAL SCHEMATIC EXAMPLES OF CHILLED WATER CIRCUITS EXAMPLE N° 1 - SMALL 18000 BTU CHILLER - CENTRAL LOCATION + 2 AIR-HANDLERS HCSC18/D - 18000 BTU EXPANSION TANK - SHUT-OFF VALVE D12 = INTERIOR DIAM. 15 MM - 5/8"...

  • Page 45: Example No. 3 - Catamaran With Wbcp36D - Central Location + 6 Air-Handlers

    Webasto BlueCool Premium Series AC Systems Schematics EXAMPLE N° 3 - CATAMARAN WITH WBCP36/D - CENTRAL LOCATION + 6 AIR-HANDLERS www.webasto.us Webasto Thermo & Comfort N.A., Inc.

  • Page 46: Example No. 4 - M/Y With Wbcp72/D Twin - Stern Location + 10 Air-Handlers

    Schematics Webasto BlueCool Premium Series AC Systems EXAMPLE N° 4 - M/Y WITH WBCP72/D TWIN - STERN LOCATION + 10 AIR-HANDLERS Webasto Thermo & Comfort N.A., Inc. www.techwebasto.com...

  • Page 47: Wiring Diagram Wbcp Units - 230V 1 Phase - 16000 To 30000 Btu- 1 Compressor

    Webasto BlueCool Premium Series AC Systems Schematics WIRING DIAGRAM WBCP UNITS - 230V 1 PHASE - 16000 TO 30000 BTU- 1 COMPRESSOR (For single compressors 36 to 48000 BTU, a power-relay is used - refer to drawing on next page) ATT.

  • Page 48: Wiring Diagram Wbcp Condensing Units - 1/3 Phase - Compressors 1 And 2

    Schematics Webasto BlueCool Premium Series AC Systems WIRING DIAGRAM WBCP CONDENSING UNITS - 1/3 PHASE - COMPRESSORS 1 AND 2 ATT. DIPSWITCH SETTINGS BLACK = PUSHED DOWN OPEN Webasto Thermo & Comfort N.A., Inc. www.techwebasto.com...

  • Page 49: Wiring Diagram Wbcp Condensing Units - 1/3 Phase - Compressors 3 And 4

    Webasto BlueCool Premium Series AC Systems Schematics WIRING DIAGRAM WBCP CONDENSING UNITS - 1/ 3 PHASE - COMPRESSORS 3 AND 4 ATT. DIPSWITCH SETTINGS BLACK = PUSHED DOWN OPEN www.webasto.us Webasto Thermo & Comfort N.A., Inc.

  • Page 50: Power Supply Schematic - Chiller Units Twin/Ci - Single Phase 230V

    Schematics Webasto BlueCool Premium Series AC Systems POWER-SUPPLY Schematic - CHILLER UNITS TWIN/CI - SINGLE PHASE 230V POWER RELAY COMPRESSOR 1 TO CONNECTORS COMP1 - TECC CARD MAIN SUPPLY COMPR. 1 MAIN SUPPLY COMPR. 2 POWER RELAY COMPRESSOR 2 MAIN SUPPLY TECC + ACCESSORIES...

  • Page 51: Power Supply Schematic - Chiller Units Twin/Ci - 3 Phase 400V

    Webasto BlueCool Premium Series AC Systems Schematics POWER-SUPPLY Schematic - CHILLER UNITS TRI/CI - 3 PHASE 400V POWER RELAY COMPRESSOR 1 TO CONNECTORS COMP1 - TECC CARD MAIN SUPPLY COMPR. 1 POWER REALY COMPRESSOR 2 MAIN SUPPLY COMPR. 2 TO CONNECTORS COMP2 - TECC CARD MAIN SUPPLY COMPR.

  • Page 52: Automatic Staging Relay - Secondary 230V On-Board Functions

    Schematics Webasto BlueCool Premium Series AC Systems AUTOMATIC STAGING RELAY - SECONDARY 230V ON-BOARD FUNCTIONS TECC - CHILLER - CONTROLLER CARD 230V POWER-RELAY - CONTACTS NORMALLY CLOSED 230V ON-BOARD SUPPLY - TO AUTOMATICALLY STAGED FUNCTIONS WIRING SCHEMATIC - RUNNING CAPACITORS FOR BLOWER MOTORS - ECOFIT/EBM...

  • Page 53: Wiring Schematic - Tecc Ver. 3 Controller Card

    Webasto BlueCool Premium Series AC Systems Schematics TECC VER. 3 Controller Card COMP1N VALVEN FANN COMP2N FUSE FUSE 220N FUSE FUSE 220N 220PH FUSE TERRE TERRE 220PH PUMP1 PUMP2 VALVE COMP1 COMP2 www.webasto.us Webasto Thermo & Comfort N.A., Inc.
  • Page 54 Webasto BlueCool Premium Series AC Systems NOTES: Webasto Thermo & Comfort N.A., Inc. www.techwebasto.com...
  • Page 55 Webasto BlueCool Premium Series AC Systems Documentation Feedback Form Detailed user feedback is extremely valuable to us in producing accurate, comprehensive, and useful documentation. Please complete the relevant parts of the form below; your comments and suggestions will help us improve our documentation.
  • Page 56 Webasto Thermo & Comfort N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org. 09/2007 Rev. 08/2018 P/N 5001375b...

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