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Bunk Cooler
BlueCool Truck
Service and Repair Manual
This manual covers BlueCool Truck models with part number:
•
BCT010300A (06/2005 to 06/2006)
•
BCT010300B (06/2006 to 07/2006)
•
BCT010300C (07/2006 to 06/2007)
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Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
–
Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
–
NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
–
ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
–
Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
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Table of Contents
Troubleshooting
Related Manuals for Webasto BlueCool Truck BCT010300A
Summary of Contents for Webasto BlueCool Truck BCT010300A
- Page 1 Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures.
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Page 3: Table Of Contents
Compressor Removal..............27 www.webasto.us Webasto Product N.A., Inc. - Page 4 11.3 Coolant Circulating Pump Replacement............47 12.Warranty www.webasto.us Webasto Product N.A., Inc.
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Page 5: Introduction
Read this manual in its entirety before installing / servicing / repairing this equipment. Failure to follow the instructions and the notes contained therein will lead to all liability being refused by Webasto. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine Webasto service parts. -
Page 6: Vehicle Requirements (Installation Review)
Dry Nitrogen Gas (Bottled) with Regulator and Safety Relief Device - for Pressure Tests • Digital Multi-Meter - Should be a good quality V A O meter. • Digital Thermometer Tester - Core temp. sensor - Now available from Webasto under part # BCT010249A. • Basic Mechanic’s Tools Webasto Product N.A., Inc. -
Page 7: General Description
110 volts AC required to drive the refrigeration compressor. Where the vehicle is equipped with the optional shore- power accessory kit, the power inverter will be bypassed whenever the shore-power accessory kit is active. Figure 3. Cold Storage Assembly www.webasto.us Webasto Product N.A., Inc. -
Page 8: Air-Handler Assembly
9 – Warm Coolant Return Hose sensor mounted on the control module’s circuit board. Temperature is regulated by controlling the circulation pump. Figure 5. Cold Transfer System Figure 7. Control Module with Plate and Knobs Shown Webasto Product N.A., Inc. www.techwebasto.com... -
Page 9: Digital Core Temperature Sensor
The digital core temperature sensor’s performance can only be analyzed through the use of a special tool available from Webasto. Figure 9. Ambient Temperature Thermostat Figure 8. Digital Core Temperature Sensor www.webasto.us Webasto Product N.A., Inc. -
Page 10: High/Low Refrigerant Pressure Switch
External Thermal Protector and Cover Figure 10. High/Low Refrigerant Pressure Switch Switch Points (High/Low Pressure Switch) High pressure: 326 psi (22.5 bar) Low pressure: 29 psi (2.0 bar) Hermetic Compressor Assembly Figure 11. External Thermal Protector Webasto Product N.A., Inc. www.techwebasto.com... -
Page 11: Functional Description
Key OFF: With the key OFF (engine stopped), regardless the internal storage core temperature, power output from the control module (connector X1, position 5) to the control relay IS NOT provided. (See Section 3.3, “Discharge Mode”) www.webasto.us Webasto Product N.A., Inc. -
Page 12: Discharge Mode (Bunk Cooling)
A. Sleeper Air-handler Cover B. Fully Adjustable Cool Air Outlet Vents - Position as desired. C. Control Panel D. Temperature Control E. Fan Speed Control F. Warm Air Inlet Grid Figure 13. Air-handler Webasto Product N.A., Inc. www.techwebasto.com... -
Page 13: Technical Data
Table 1. Technical Data - BlueCool System 4.1.2 Technical Data of the Refrigeration Compressor Specifications A/C Compressor BTU/hr 7040 BTU/hr (2.06 kW) Rated Voltage 115 Volts Maximum Continuous Current 12.6 amp. @ 115 Volts Table 2. Technical Data - A/C Compressor www.webasto.us Webasto Product N.A., Inc. -
Page 14: Technical Data Of The Circulating Pump
Table 3. Technical Data - Circulating Pump 4.2 Dimensions 4.2.1 Refrigeration/Cold Storage Assembly 559 mm (22 in.) 660.5mm (26 in.) 648 mm 711 mm (25.5 in.) (28 in.) 127mm (5 in.) 838mm (33 in.) Figure 14. Dimensions - Refrigeration/Cold Storage Assembly Webasto Product N.A., Inc. www.techwebasto.com... -
Page 15: Air-Handler Assembly
Technical Data 4.2.2 Air-handler Assembly 616.4 mm (24.26 in.) 179.8 mm (7.04 in.) 498.5 mm (19.62 in.) 623.6 mm (24.55 in.) 203.94 mm (8.03 in.) 509.22 mm (20.05 in.) Figure 15. Dimensions - Air-handler Assembly www.webasto.us Webasto Product N.A., Inc. -
Page 16: Troubleshooting - Bluecool Truck Electrical System
5.1 General Information This section describes how to identify and remedy faults If the actions listed in the following tables do not restore on the BlueCool Truck System. proper operation, consult your authorized Webasto dealer. Troubleshooting work demands precise CAUTION... - Page 17 2. For refrigerant leaks found in the area of the Thermal Expansion Valve located on the storage core unit, contact Webasto Product North America at 1-800-432-8371 for further information concerning the repair or replacement of the storage core assembly.
- Page 18 Ensure inverter battery cables are installed as recommended in Correct cable connections as recommended by the BlueCool Installation manual P/N BCT010031B Webasto. If inverter continues to fault out, call Webasto Product N.A., Inc. at 1-800-555-4518 Compressor overheat/ Check refrigerant pressures. Possible over-charge or blockage.
- Page 19 Ambient Thermostat (X7) and System Control Relay (X10) Not Used Black 20GA - Storage Core Digital Temperature Sensor White 20GA - Storage Core Digital Temperature Sensor Figure 17. 12 volt positive reference signal to control module - charging mode www.webasto.us Webasto Product N.A., Inc.
- Page 20 Red 12GA - Constant Power Positive (Fused 20 amp.) Not Used > 30 min. Key Switch Position To Inverter ON/OFF Circuit Figure 19. 12 Volt input signal from control module to system control relay (through pressure sensor and ambient thermostat) Webasto Product N.A., Inc. www.techwebasto.com...
- Page 21 ON/OFF Circuit Figure 21. Switched 12 volt output from Pin-30 of relay X10 to condenser fan Pin-1 of connector X9 and Pin-86 of inverter switching relay X11 (ground on Pin-85 of relay X10 and X11) www.webasto.us Webasto Product N.A., Inc.
- Page 22 OFF before testing for continuity through the relay. The relay must be energized or To Inverter the system must be active when preforming ON/OFF Circuit this test. Figure 23. Power inverter switching relay function check (continuity) Webasto Product N.A., Inc. www.techwebasto.com...
- Page 23 Checking continuity through ambient temperature thermostat Continuity Key Switch Position Figure 24. Ambient temperature thermostat checks (continuity) Checking continuity through high/low refrigerant pressure switch Continuity Key Switch Position Figure 25. High/low refrigerant pressure switch checks (continuity) www.webasto.us Webasto Product N.A., Inc.
- Page 24 Figure 26. DC to AC power inverter performance check (AC voltage) Checking condenser fan circuit Volts DC V DC Key Switch Position > 30 min. To Condenser Fan Figure 27. Condenser fan circuit checks (DC voltage) Webasto Product N.A., Inc. www.techwebasto.com...
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Page 25: Malfunctions With System In Discharge Mode And Vehicle Key Off (Sleeper Cooling)
(brown wire). Refer to Fig. 30, on pg. 25. Power or ground not present? Open circuit. Repair or replace harness. Checking air circulation fan circuits Volts DC V DC Key Switch Position Figure 28. Air circulation fan circuit checks (variable output DC voltage) www.webasto.us Webasto Product N.A., Inc. - Page 26 Ambient Thermostat (X7) and System Control Relay (X10) Not Used Black 20GA - Storage Core Digital Temperature Sensor White 20GA - Storage Core Digital Temperature Sensor Figure 29. Control module output to circulation pump circuit checks (DC voltage) Webasto Product N.A., Inc. www.techwebasto.com...
- Page 27 ™ Troubleshooting – BlueCool Truck Electrical System Checking circulation pump circuit at pump Volts DC V DC Key Switch Position To Main System Harness To Circulation Pump Figure 30. Circulation pump circuit checks (DC voltage) www.webasto.us Webasto Product N.A., Inc.
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Page 28: Troubleshooting - Refrigerant Compressor
Never energize the system unless: 1) the protective terminal cover is securely fastened, and 2) the compressor is properly connected to ground. Fig. 31 and Fig. 32, on pg. 27 illustrates the means of fastening the protective terminal cover. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 29: Refrigerants And Other Chemicals
Expose service personnel to toxic gas. To avoid serious injury or death, be sure to remove and recover all refrigerant before removing the compressor. Figure 32. Thermal protection (3) and hermetically sealed terminals (4) shown with protective cover removed. www.webasto.us Webasto Product N.A., Inc. -
Page 30: System Flushing, Purging, And Pressure Testing For Leaks
Relief Device NITROGEN 175 PSIG Setting Webasto recommends that the system be serviced using a flush and purge station such as a Robinair ® unit or similar equipment designed for R134a refrigerant systems. -
Page 31: System Charging
If such an explosion occurs, the resulting blast can kill or seriously injure anyone in www.webasto.us Webasto Product N.A., Inc. -
Page 32: Troubleshooting Table - Refrigerant Compressor And Related Components
Compressor electrical problems, such as thermal protector or See “Identifying Compressor Electrical Problems” run capacitor not working properly. on page 31. Discharge pressure too high. Suction pressure too high. Return gas too warm. Check condenser fan for malfunction Webasto Product N.A., Inc. www.techwebasto.com... -
Page 33: Identifying Compressor Electrical Problems
WARNING compressor if one of the terminal pins is ejected from the hermetic terminal. This can occur as a result of a ground fault in the compressor. The oil and refrigerant spray can be ignited www.webasto.us Webasto Product N.A., Inc. -
Page 34: Checking For A Ground Fault (A Short To Ground)
If a ground fault exists, keep the power off and replace the compressor. See “System Cleanup and Compressor Replacement After Compressor Failure” starting on page 36. If the compressor is not replaced immediately, mark and red tag the compressor to indicate there is a ground Webasto Product N.A., Inc. www.techwebasto.com... -
Page 35: Checking For Continuity And Proper Resistance
See “System Cleanup and Compressor Replacement After Compressor Failure” starting on page 36. If the resistance is correct, leave the leads off and follow the instructions in the next section to check other compressor electrical components. www.webasto.us Webasto Product N.A., Inc. -
Page 36: Checking For Other Electrical Problems In Single Phase Motors
Check for continuity across the thermal protector. If there is no continuity, Protector then the thermal protector may be tripped. Wait at least 5 minutes, then check continuity again. If there is still no continuity, replace the thermal protector. Webasto Product N.A., Inc. www.techwebasto.com... - Page 37 • Use of incorrect run capacitor. Replace with proper run capacitor. • Line voltage is too high (greater than 110% of rated voltage). • Rust-through of capacitor housing or severe corrosion of terminals. Replace with new capacitor (Webasto now offers a weather protected replacement). Step 5: Reconnect Run Capacitor Reconnect the run capacitor into circuit as before.
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Page 38: Compressor Replacement And System Service
Contamination). A single installation of liquid and Alternate method of removing moisture and non- suction line filter-driers should clean up the system. condensable material from the systems is: If, however, the discharge line or the suction line shows Webasto Product N.A., Inc. www.techwebasto.com... - Page 39 In the case of Compressor Housing Contamination, little change should be noted. The pressure drop will, in most instances, be below that tolerable for a permanent installation as described in “Install Replacement www.webasto.us Webasto Product N.A., Inc.
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Page 40: Circuit Diagrams
™ Circuit Diagrams 8. Circuit Diagrams Figure 35. Wiring Schematic (Early Version) Webasto Product N.A., Inc. www.techwebasto.com... -
Page 41: Component Replacement - Refrigeration Unit
Before replacement of components, a thorough compressor. Webasto recommends that the system troubleshooting and diagnosis of the BlueCool Truck be serviced using a recovery, recycling and system must be conducted to identify the reason for the... -
Page 42: Condenser Replacement
2. Remove refrigeration unit cover. Be sure refrigerant is recovered using the Torque appropriate equipment before removing the 11.0 lb-in. condenser. Webasto recommends that the system be serviced using a recovery, recycling and recharging station such as a Robinair unit or ®... -
Page 43: Thermal Expansion Valve (Txv) Replacement
TXV. burs. Clean up with fine emory or crocus cloth. Webasto recommends that the system be serviced 10. Coat storage core pipes and new O-rings with POE using a recovery, recycling and recharging station oil and place O-rings on storage core pipes. -
Page 44: Pressure Switch Replacement
5. Remove the 4 bolts securing the condenser fan appropriate equipment before removing the assembly to the back-wall of the enclosure. pressure switch. Webasto recommends that the system be serviced using a recovery, recycling and 6. Lift the fan assembly up and out. -
Page 45: Ambient Temperature Switch Replacement
5. Apply an anti-corrosive electrical grease to the terminals and connect to switch. 6. If necessary, re-secure to the run-capacitor with a wire tie as before. 7. Perform system checks to ensure proper operation. Figure 42. Ambient temperature switch replacement www.webasto.us Webasto Product N.A., Inc. -
Page 46: Component Replacement Air-Handler Assembly
2. Carefully disconnect the four 2-pin fan plugs from 4. Remove panel. control unit receptacles. A IR C O N D IT IO N IN G Installation Figure 45. Control unit removal - Step 1 1. Reassembly in reverse order of removal. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 47: Fan Replacement
Figure 47. Control unit removal - Step 3 Installation Before handling the new control unit, discharge any possible static electrical charge from your body by touching a grounded metal surface. 1. Reassembly in reverse order of removal. www.webasto.us Webasto Product N.A., Inc. -
Page 48: Coolant Circuit
7. Allow coolant pump to continue circulating coolant for 15 min. During this time, check hose connections for signs of leakage. 8. Turn system off and install air-handler cover. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 49: Heat Exchanger Replacement
Refer to Fig. 53, on pg. 48 for correct installation of circulating pump. 1. Reassembly in reverse order of removal. 2. Refer to Sec. 11.1 "Bleeding System After Repair" on page 46 for circuit purging instructions. Figure 51. Heat exchanger replacement - Step 2 www.webasto.us Webasto Product N.A., Inc. - Page 50 ™ Coolant Circuit 85° 0° 0° Correct Wrong Figure 53. Circulating pump - orientation Webasto Product N.A., Inc. www.techwebasto.com...
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Page 51: Warranty
Terms and Conditions 1. The quality and operation of Webasto BlueCool products are warranted by Webasto for a period of (3) three years, beginning from the date of installation, and not to exceed (4) years from the date of invoice to the installer. - Page 52 ™ Warranty Webasto Product N.A., Inc. www.techwebasto.com...
- Page 53 ™ Warranty www.webasto.us Webasto Product N.A., Inc.
- Page 54 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us Org. 02/2007 Rev. 2/2012 Ver. BCT_ABC © 2012 Webasto Product N.A., Inc. www.techwebasto.com...