Trouble Shooting BlueCool

Luft-Heizgerte
03/2003
Marine Air Conditioning Systems Fresh-Air Units
Operation Settings Trouble Shooting
BlueCool Classic BlueCool Premium
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. To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and have the appropriate technical documentation, special tools and special equipment. Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly. 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.
CONTENTS CONTENTS
1 Digital Control Panel operation and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 1.2 1.3 2 Operating and programming level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Entering programming menu level 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Entering programming menu level 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Programming Premium Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 2.2 2.3 Programming level 2, Premium Card TECC 4.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Programming level 3 at 29 C, Premium Card TECC 4.25 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Programming level 3 at 15 C, Premium Card TECC 4.25 . . . . . . . . . . . . . . . . . . . . . . . . . 10
Programming Classic Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.1 3.2 3.3 Programming level 2, Classic Card TCC 5.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Programming level 3 at 29 C, Classic Card TCC 5.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Programming level 3 at 15 C, Classic Card TCC 5.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Programming Cabin Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.1 4.2 Cabin Card 6.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CAB V3 Card MTH2/PLANA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programming Fresh-Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Digital Display Fresh-Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cycle Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Blower Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Access Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Visual Error Codes - Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cabin Card 6.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CAB V3 Card MTH2/PLANA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6.1 6.2 Failure codes and trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Controller Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 7.1 7.2 7.3 Classic / Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Premium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Air handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CONTENTS
8 Electrical diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 9 10 11 Classic / Select TCC V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classic / Select TCC V3 WB200 Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classic / Select, multiple units at one pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select, blower speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V3, 1 and 2 compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V3, add-on 3 and 4 compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium, compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V3 with external heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V3 with calorifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V2, 1 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium TECC V2, add-on 3 and 4 compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium, MTH mechanical thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium, CAB V3 controller card + MTH2 thermostat + 3-way valve. . . . . . . . . . . . . . . . . Premium, CAB V3 controller card + Plana thermostat + 3-way valve . . . . . . . . . . . . . . . . . Premium, CAB V3 controller card + Digital Display Panel + 3-way valve . . . . . . . . . . . . . . . Premium, Silent 5-speed for Compact and Slimline air handlers. . . . . . . . . . . . . . . . . . . . . Premium, convert Danfoss into Lizhan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fresh-Air units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 BlueCool Unit Performance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Digital Control Panel operation and settings 1

1.1
Digital Control Panel operation and settings

Operating and programming level 1
Cool cycle mode Read-out (0) Automatic mode Heat cycle mode On / Off
Chiller Control
Cool Auto Heat
Cool cycle mode Automatic operation Heat cycle mode On / Off
Read-out
Higher values (Sun)
Higher values
Function (F)
Lower values (Snow flake)
Blower speed
Set-up / programming
Blower speed
Lower values
ON
Push 1x, display will show ON. During first start-up display will also flash the current frequency (50H = 50 Hz). After INIT, finally the room temperature will appear. Air-blower or chilled water pump (Premium only) will start. Depending on controller setting unit will start in cooling or heating mode. In case error codes appear, see trouble shooting. Push 1x, unit and display will automatically shut-off when running. Push 1x, to memorise new settings during programming. Push 1x, display will return to room temperature when programming. Push 1x, shows b.. for blower setting. Push 2x, shows E.. or H.. for coil or water temperature. Push 3x, shows CODE, enter code for access programming level 2. (Default=64) Classic/Select only Change b.. or enter CODE by pushing up or down key.
OFF MEMO(NENO) RETURN FUNCTION
NEXT LINE DOWN BLOWER SPEED UP
Push 1x, for next line and memorise new setting. Push 1x will show actual setpoint, again to lower setpoint. Shows actual blower speed setting, bA automatic control or b1-b5 manual, adjustable by up or down. Push 1x will show actual setpoint, again to raise setpoint.
During operation failure codes might appear on the display (see troubleshooting), when these are solved, controller will restart within 60 seconds. When the same failure occurs 6 times within 30 minutes the unit will stop completely without restart, LEDs will flash in the display until cause is solved. The counter is reset after 5 minutes of compressor operation. Failure code A01 has a time delay of approximately 40 seconds to avoid cut-out during start-up.
Digital Control Panel operation and settings

1.2 Entering programming menu level 2
When security CODE is activated, push FUNCTION when unit is in operation till CODE appears in the display. Set security CODE by pushing UP or DOWN and confirm with FUNCTION (Default = 64). In case security CODE is not activated you will have direct access. Scroll through settings by pushing FUNCTION, values can be set by UP or DOWN keys and confirmed by FUNCTION for next line. To leave this menu push ON/OFF, MEMO will be shown shortly and new settings will be memorised.
1.3
Entering programming menu level 3
Set setpoint temperature on 15 C or 29 C and switch off the controller. Push UP and DOWN simultaneously till display lights up. Set security CODE when activated by pushing UP or DOWN and confirm with FUNCTION (Default = 64). Scroll through settings by pushing FUNCTION, values can be set by UP or DOWN keys and confirmed by FUNCTION for next line. To leave this menu push ON/OFF, MEMO will be shown shortly and new settings will be memorised.
Programming Premium Unit 2

2.1
Programming Premium Unit

Programming level 2, Premium Card TECC 4.25
Setting Selection of blower speed Water temperature Selection of function mode Cool Only Heat Only Automatic cooling/heating with reverse cycle Automatic cooling/heating with external heater Heat Only with external heater U 1C 2C 3C 4C P L 1L 2L 3L 4L d Reading of voltage supply Choice compressor 1 ON/OFF Choice compressor 2 ON/OFF Choice compressor 3 ON/OFF Choice compressor 4 ON/OFF Priority order for compressors 1-4 Time delay between compressor starts 1-4 Switch off temperature delay for compressor 1 Switch off temperature delay for compressor 2 Switch off temperature delay for compressor 3 Switch off temperature delay for compressor 4 Dehumidification cycle when system turned off (0 = non active; 1 = 1 cycle per 24h; 2 = 2 cycles per 24h ; 3 = 3 cycles per 24h) Time to display table F Choice of chilled water temperature sensor outlet or inlet Temperature difference between compressor starts Max temperature difference between chilled water outlet and inlet 1 1 1 1 123 9 0 0 0 0 0 1 0 0 0 0 0 9 55 55 55 55 3 seconds 1/10 1/10 1/10 1/10 3 F1 F2 F3 F4 F5 0 0 0 0 0 1 1 1 1 Volt C5 use 1 5 Default A Min 0 Max A Unit
Display b H F
t S c E
1 1 15 80
1 0 0 10
12 2 99 99
20 sec.
1/10 1/10

2.2 Programming level 3 at 29 C, Premium Card TECC 4.25
Setting Lower cut-out value in cool mode for chilled water temperature outlet Cut-in value in cool mode for chilled water temperature outlet Higher cut-out value in heat mode for chilled water temperature outlet Cut-in value in heat mode for chilled water temperature outlet Calibration chilled water temperature Time for display standby Calibration of chilled water temperature inlet Calibration of air temperature Calibration of voltage under 50 Hz Select function of relais Operating as staging relay Controlling 3 way valve air handler by TECC card Alarm indication Cycle indication A b c d E F Calibration of voltage under 60 Hz Program Version Lower cut-out value in cool mode for chilled water temperature inlet Cut-in value in cool mode for chilled water temperature inlet Higher cut-out value in heat mode for chilled water temperature inlet Cut-in value in heat mode for chilled water temperature inlet Default 4 7 40 37 0 15 0 0 0 0 0 1 2 3 -10 4.2* 6 9 40 37 0 2 30 27 15 18 49 52 For C5 use -30 50 Min 0 2 30 27 -55 5 -55 -55 -30 0 Max 15 18 49 52 55 99 55 55 50 3 Unit 1/10 minutes 1/10 1/10
Display 0 1 2 3 4 5 6 7 8 9

2.3 Programming level 3 at 15 C, Premium Card TECC 4.25
Setting Cut-out value for low voltage Remote control activated/deactivated Choice of small relay setting indicating heat/cool cycle 0 = C1 + T1 closed at heat cycle (F4, F5). C1 + R1 closed at cool cycle (F1, F3, F4). C1 + R1 closed at system block. 00 Chiller 1 = For fault messages, system block (A01, A02, A09 etc.) C1 + R1 closed, no faults. C1 + T1 closed, system block/ failures. 3 4 5 6 7 8 9 A b C D E Choice of thermostatic regulation or permanent ventilation Choice of internal/external air temperature sensor Choice of temperature reading in C or F Calibration of blower speed 5 Calibration of blower speed 4 Calibration of blower speed 3 Calibration of blower speed 2 Calibration of blower speed 1 Access code for programming levels Duration of heat cycle in dehumidification mode Duration of cool cycle in dehumidification mode Delay before first start 0 0 0 70 40 35 29 23 0 1 1 1 Default 195 0 0 Min 160 0 0 Max 210 1 1 Unit Volt
Display 0 1 2
0 for C5
0 0 0 1 1 1 1 1 0 1 1 1
1 1 1 70 70 70 70 70 99 99 99 20 minutes minutes seconds
10
Programming Classic Unit 3

3.1
Programming Classic Unit

Programming level 2, Classic Card TCC 5.25
Setting Selection of blower speed Selection of function mode Reading of voltage supply Choice compressor 1 ON/OFF Dehumidification cycle when system turned off (0 = non active; 1 = 1 cycle per 24h; 2 = 2 cycles per 24h ; 3 = 3 cycles per 24h) Time to display table F 1 0 Default A 3 Min 0 1 0 0 0 1 3 Max A 5 Volt Unit
Display b F U 1C d
20 sec.
3.2
Programming level 3 at 29 C, Classic Card TCC 5.25

Setting Lower cut-out value in cool mode for evaporator temperature Cut-in value in cool mode for evaporator temperature Higher cut-out value in heat mode for evaporator temperature Cut-in value in heat mode for evaporator temperature Calibration evaporator temperature Time for display standby Time delay for first compressor start Calibration of air temperature Calibration of voltage under 50 Hz Time delay for compressor restart after end of cycle cut-out Calibration of voltage under 60 Hz Program version Mode choice for pump exit Minimum voltage for pump exit Maximum voltage for pump exit Mode choice for water valve exit Default 0 7 45 38 0 15 1 0 0 2 0 v5.2* 0 12 18 1 0 12 12 0 1 18 18 1 Volt Volt Min -4 2 30 27 -55 5 1 -55 -30 1 -30 Max 15 18 50 47 55 99 20 55 50 99 50 minutes Unit 1/10 minutes seconds 1/10
Display 0 1 2 3 4 5 6 7 8 9 A B C D E F
11
Programming Classic Unit

3.3 Programming level 3 at 15 C, Classic Card TCC 5.25
Setting Cut-out value for low voltage Remote control activated/deactivated Choice of blower type 0 = blower speed regulated 1 = blower speed uninterrupted Choice of thermostatic regulation or permanent ventilation Choice of internal/external air temperature sensor Choice of temperature reading in C or F 0 = C, 1 = F Calibration of blower speed 5 Calibration of blower speed 4 Calibration of blower speed 3 Calibration of blower speed 2 Calibration of blower speed 1 Access code for programming levels Duration of heat cycle in dehumidification mode Duration of cool cycle in dehumidification mode Default 195 0 1 Min 160 0 0 Max 210 1 1 Unit Volt
Display 0 1 2
3 4 5 6 7 8 9 A b C D
1 0 0 70 40 35 29 23 64 1 1
0 0 0 1 1 1 1 1 0 1 1
1 1 1 70 70 70 70 70 99 99 99 minutes minutes
12
Programming Cabin Controls 4

4.1
Programming Cabin Controls

Cabin Card 6.25
4.1.1 Setting
Display b H F d Setting Selection of blower speed Water temperature Selection of function mode Dehumidification cycle when system turned off (0 = non active; 1 = 1 cycle per 24h; 2 = 2 cycles per 24h ; 3 = 3 cycles per 24h) Time to display table F 1 0 1 0 3 3 Default A Min 0 Max A Unit
20 sec.
4.1.2 Programming level 3 at 29 C, Cabin Card 6.25

Display 4 5 6 7 b Setting Calibration chilled water temperature Time for display standby Time delay for first start Calibration of air temperature Program version Default 0 15 5 0 v6.2* Min -55 5 1 -55 Max 55 99 20 55 1/10 Unit 1/10 seconds

Display 1 2 3 4 5 6 7 8 9 A b C D Setting Remote control activated/deactivated Choice of blower type Choice of thermostatic regulation or permanent ventilation Choice of internal/external air temperature sensor Choice of temperature reading in C or F 0 = C, 1 = F Calibration of blower speed 5 Calibration of blower speed 4 Calibration of blower speed 3 Calibration of blower speed 2 Calibration of blower speed 1 Access code for programming levels Duration of heat cycle in dehumidification mode Duration of cool cycle in dehumidification mode Default 0 1 0 0 0 70 40 35 29 23 0 1 1 Min 0 0 0 0 0 1 1 1 1 1 0 1 1 Max 1 2 1 1 1 70 70 70 70 70 99 99 99 minutes minutes Unit
13
Programming Cabin Controls

4.2 CAB V3 Card MTH2/PLANA
Version CAB 9.03 Display SP tF 1 2 3 Setting Speed Position selector switch 00 = blower off Setting fan speed level 1 (low) Setting fan speed level 2 Setting fan speed level 3 (high) Default SP... (0/1/2/3) 01 23 35 70 Air Handler
14
Programming Fresh-Air 5 Programming Fresh-Air

The <F> key also gives access to such parameters as: reheat 1/2 on/off time delay between Fresh-Air Blower start and Extraction Blower start-up differential between Reheat 1/2 cut-in and reference setpoint. See also page 2 - Programming procedures.
The Fresh-Air controller cards allows the end-user to precisely control the fresh-air temperature introduced into the different volumes of the vessel. It also allows humidity control. Basically the end-user sets a differential between the outside air temperature and the air temperature he wants to introduce into the vessel. There is also a ceiling limit which can be programmed separetly to avoid that the freshair temperature becomes too cold and uncomfortable during night operation when outside temperatures drops too low.
Cool cycle mode Automatic operation Heat cycle mode On / Off Read-out (0)
Higher values (Sun)
Function (F)
Lower values (Snow flake)
Blower speed
5.1
Digital Display Fresh-Air Control
The Fresh-Air Control display will give the following immediate read-outs : 1) Normal Read-out: Air-out temperature after treatment. Push <F> key to obtain (examples): 2) 3) 4) 5) 6) 2b 3 = Extraction Blower setting 1b 3 = Fresh-Air blower setting H 9.6 = chilled water temp. read-out E 35.2 = outside air temp. read-out U232 = AC voltage input reading
5.2
Start-up Procedures
When starting up the Fresh-Air control the Fresh-air blowers will operate at the lowest possible speed setting to draw down the air-out temperature as quickly as possible to the reference set-point and to eliminate accumulated moisture in the air-ducting. After the start-up period the Fresh-Air blower speed will resume operation at the speed setting as initially programmed. Speed setting of the Fresh-Air and Extraction Air blowers can be different so as to obtain the desired over-pressure in the vessel.
15
Programming Fresh-Air
5.3 Cycle Determination
Example of operating window setting - Fresh-Air Control - Cool Cycle

Reference Setpoint Reheat 2 cuts in at 20 - cuts out at 22 Cooling Coil 3 way valve cuts out at 20 and cuts in again at 22 Reheat 1 cuts in at 22 - cuts out at 24 Outside air temperature
20C
22C
24C
35C
Differential = 16 C - Prog. Line 0 - Sun Key
Reference Setpoint Ceiling Limit = 20 - i.e. reference setpoint will always be 20 C or higher
Example of operating window setting - Fresh-Air Control - Heat Cycle

Reheat 2 cuts out at 22 - cuts in at 21.5 Reheat 1 cuts out at 24 - cuts in at 22 Heating Coil 3 way valve cuts out at 24 and cuts in again at 22
Outside air temperature
5C
Differential = 18 C - Prog. Line 2 - Sun Key
21.5C
22C
24C
Reference Setpoint
Reference Setpoint Ceiling Limit = 24 - i.e. reference setpoint will always be 24 C or lower
Here-above drawings explain the operating window with the associated setpoints and reheat differentials. The choice between heat cycle and cool cycle is done automatically by the controller card depending on the chilled water temperature as recorded by the controller card. The switching temperature is determines by the programming lines 3 and 4 (snow key). Factory settings are as following: Lower ceiling : 18 C Higher ceiling : 20 C This means that below 18 C chilled water temperature the fresh-air controller considers that cool cycle operation is required; above 20 C the controller switches to heat cycle operation. Between 18 C and 20 C the controllers suspends controlling activity and waits to see which cycle is definitely adopted.
5.5
Access Code
The end-user can deny access to all program settings by introducing an access code (see page 8 - code <b>). Blower speed and setpoints always remain accessible. Once an access code is validated, the digital panel will show <Code> if the end-user tries to access other functions then blower speed or set-point. To gain full access push the sun key to reach the code number as programmed and push the <F> key again to gain access to full program settings.
5.6
Visual Error Codes - Digital Display
5.4
Blower Speed Regulation
The following malfunctions will be displayed directly on the digital display by a code and will be followed by a system halt. 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 switch or by temporarily cutting out the AC supply to the system.
As already explained blower speed can be set in a differential way between the Fresh-Air blowers (1b) and the Extraction Blowers (2b). In addition the Fresh-Air blowers can be set manually on a fixed speed without any reference to the chilled water temperature and/or outside/inside air temperatures or start-up procedure. This choice can be made in programming mode (sun key - line 9).
16
List of error-codes and nature of malfunction: Code <AAA> : Persistent low voltage (voltage below 185 V) for more than 5 seconds. <A09> - absent or defective external air sensor <A10> - absent or defective treated air sensor <EEEE> - absent or defective chilled water sensor Code A02 : Check the straps on HP/BP connectors 1 20 = max lower ceiling of reference setpoint cool cycle. Mini = 10 - max = 30 C. 2 18 = temperature differential in C for heat cycle operation. Max = 35 C - mini = 10 C. 3 24 = max. higher ceiling for reference setpoint heat cycle. Mini = 10 - max. = 35 C. 4 0.0 = temp. read out calibration chilled water sensor (from -9.9 to +9.9 C). 5 15 = number of minutes before the Digital Display switches into sleep mode. Max. = 99 minutes. 6 0.0 = outside air temperature sensor calibration. 7 0.0 = air-out (after treatment) temperature calibration. 8 00 = AC voltage reading calibration 50 Hz. 9 01 = choice between normal procedure Fresh-Air blower operation of manual fixed speed. 0 = manual speed regardless of all operating procedures. a 00 = AC voltage reading calibration - 60 Hz B) Programming through Sun Key To enter this programming mode, first switch off Display by on/off key, then push Sun Key for 3 seconds. You will now enter Sun Key programming mode as following: 0 16 = temperature differential in C for cool cycle operation. Max = 25 C - mini = 5 C.
5.7
Programming Parameters
Three levels of programming parameters are available to the end user: A) through <F> (Function) key 2b 3 = Extraction blower(s) - 5 manual speeds can be programmed - last setting is memorized. 1b 3 = Fresh-Air blowers - 5 manual speeds can be programmed - last setting is memorized. 1r01 = reheat N 1 activated. 1r00 = reheat N1 on standby. 2r01 = reheat N 2 activated. 2r00 = reheat N 2 on standby. L 09 = time delay between 1b (Fresh-air blower) and 2b (Extraction blowers) in seconds. 1L2.0 = temperature differential reheat N 1 operation as measured from reference setpoint (2.0 C). 2L2.5 = temperature differential reheat N 2 operation as measured from reference setpoint (2.5 C). d 0 = number of dehumidifying cycles per 24 Hours (if such cycle is programmed in absence - see programming by snow key). t 1 = number of minutes before display switches back to airout temperature read-out after the <F> key is used.
17
C) Programming through Snow Key To enter this programming mode, first switch off Display by on/off key, then push Snow Key for 3 seconds. You will now enter Snow Key programming mode as following: 0185 = AC voltage low safety cut-out (185 V) 1 0 = infrared remote control disabled. 1 1 = infrared remote control enabled. 2 1 = type of blower used: 0 = standard centrifugal 1 = cross-flow 3 18 = lower ceiling switch-over window between cool and heat cycle (18) 4 20 = higher ceiling switch-over window between cool and heat cycle (20) 5 00 = Temperature read-out in Celsius or Fahrenheit 0 = Celsius 1 = Fahrenheit 6 70 = calibration blower speed N 5 7 40 = calibration blower speed N 4 8 29 = calibration blower speed N 3 9 29 = calibration blower speed N 2 a 23 = calibration blower speed N 1 b 64 = programming access code-locked 00 = no access code required 01 to 99 = access code required c 01 = duration of dehumidifying heat cycle in minutes d 01 = duration of dehumidifying cool cycle in minutes.
18
5.8 Cabin Card 6.25
5.8.1 Setting
Display b H F d Setting Selection of blower speed Water temperature Selection of function mode Dehumidification cycle when system turned off (0 = non active; 1 = 1 cycle per 24h; 2 = 2 cycles per 24h ; 3 = 3 cycles per 24h) Time to display table F 1 0 1 0 3 3 Default A Min 0 Max A Unit
20 sec.

Display 4 5 6 7 b Setting Calibration chilled water temperature Time for display standby Time delay for first start Calibration of air temperature Program version Default 0 15 5 0 v6.2* Min -55 5 1 -55 Max 55 99 20 55 1/10 Unit 1/10 seconds

Display 1 2 3 4 5 6 7 8 9 A b C D Setting Remote control activated/deactivated Choice of blower type Choice of thermostatic regulation or permanent ventilation Choice of internal/external air temperature sensor Choice of temperature reading in C or F 0 = C, 1 = F Calibration of blower speed 5 Calibration of blower speed 4 Calibration of blower speed 3 Calibration of blower speed 2 Calibration of blower speed 1 Access code for programming levels Duration of heat cycle in dehumidification mode Duration of cool cycle in dehumidification mode Default 0 1 0 0 0 70 40 35 29 23 0 1 1 Min 0 0 0 0 0 1 1 1 1 1 0 1 1 Max 1 2 1 1 1 70 70 70 70 70 99 99 99 minutes minutes Unit
19
5.9 CAB V3 Card MTH2/PLANA
Version CAB 9.03 Display SP tF 1 2 3 Setting Speed Position selector switch 00 = blower off Setting fan speed level 1 (low) Setting fan speed level 2 Setting fan speed level 3 (high) Default SP... (0/1/2/3) 01 23 35 70 Air Handler
20
Trouble Shooting 6
6.1
Trouble Shooting
Failure codes and trouble shooting
Possible cause Low voltage cut-out. Power supply was over 5 sec lower than controller setting. Probably caused by long length power supply cable or overload. Defective pressure sensor or open/short circuit. COOLING MODE: - Insufficient evaporator water flow (Premium) or air flow (Classic). - Air lock in water circuit (Premium) or broken circulation pump. HEATING MODE: - Insufficient seawater flow or seawater to cold. - Blocked sea-water strainer or not primed. Solution Check setting, default 195 V. Don't set below 195 V to avoid damages to the compressor or to expire warranty. Improve power supply. Check wiring or replace pressure sensor on Schrader valve. Check water or air flow. T evaporator in/out minimum 4K. Bleed Premium water system; check pump operation. Check discharge water volume. V= 8 l/min (or > 30,000 BTU V= 18 l/min). T in/out minimum 4K. When T seawater < 4 C: preheating necessary. Clean strainer and bleed seawater circuit. Refrigerant leak check.
Failure Description code AAA Low Voltage
A01
Low pressure cut-out compressor 1 (Classic > 20.000 BTU) 15 - 35 PSI / 1 - 2.4 bar
Lack of refrigerant. A02 High pressure cut-out compressor 1 350 - 250 PSI / 24 - 17.24 bar
Defective pressure sensor or open/short Check sensor and wiring. Replace sensor circuit. on Schrader if necessary. COOLING MODE: - Insufficient seawater cooling or defective circulation pump. - Blocked seawater strainer or not primed. HEATING MODE: - Insufficient evaporator water flow (Premium) or air flow (Classic). - Air lock in chilled water circuit (Premium) or broken circulation pump. Check discharge water volume. V= 8 l/min (or > 30,000 BTU V= 18 l/min). Clean strainer and bleed sea-water circuit. Check water or air-flow. T evaporator in/out minimum 4K. Bleed chilled water system or check pomp operation. See A01
A03
Low pressure cut-out compressor 2 (Premium only) High pressure cut-out compressor 2 (Premium only) Low pressure cut-out compressor 3 (Premium only) High pressure cut-out compressor 3 (Premium only)
See A01
A04
See A02
See A02
A05
See A01
See A01
A06
See A02
See A02
21
Trouble Shooting
Failure Description code A07 Low pressure cut-out compressor 4 (Premium only) High pressure cut-out compressor 4 (Premium only) Cabin temperature sensor failure (internal and external) Evaporator temperature sensor failure. Possible cause See A01 Solution See A01
A08
See A02
See A02
A09
Broken internal or external temperature Replace sensor or controller. sensor, open/short circuit, not present or In case of external sensor try to reprogram programmed wrong. to internal sensor first to determine failure. Defective water temperature sensor Check wiring or replace sensor. (Premium), evaporator sensor (Classic) or Water infiltration (condense) can cause a open/short circuit. read-out derivation or erratic functioning before an error code occurred.
A10
CA11
All compressors manually Compressor(s) programmed not active in Check settings. At least one compressor off. controller setting. should be programmed active. C01=ON C00=OFF Fan standby. Blower operation from TECC card or cabin controller impossible. Discharge temperature higher than set point on cooling or lower on heating. Run compressor/unit for a certain time to reach required discharge temperature. Blower fan will start and blinking error code bA11 will disappear automatically.
bA11
tA11
Tlow (in cool mode, deicing) or Thigh (in heat mode) limit exceeded.
Compressor stopped to defrost or to cool Compressor exceeded limits. Automatic down in heat mode. restart, no complete system halt. Code <tA11> visible in the display instead of evaporator coil temperature. Press <F> key (5) to read out evaporator coil temperature or code <tA11> (F key line E). Check controller settings to be set default (29 C line 0, 1, 2 and 3). Check controller settings, see 29 C settings line F. Check water flow, T evaporator in/out minimum 4K. Bleed water system or check pump operation.
EA11
T between chilled water Insufficient evaporator water flow. IN/OUT above limit (Premium only).
init
Initialization procedure or Setting DIP switches not according to the Check setting DIP switches. system block. number of compressors. Defective wiring, open/short circuit. Check control panel controller cable and connections. Replace defective cable, panel or controller card. Repair or replace fuse, open/short circuit or replace printboard.
n/a
No output on printboard. Defective fuse or open/short circuit on specific circuit.
Printboard damaged by high voltage (for Replace printboard. Premium RT1 burnt) Broken electronic relay (TRIAC) Replace defective TRIAC or printboard (operation of TRIAC can easily be tested with a 40 W light bulb).
22
Trouble Shooting
Failure Description code n/a Possible cause Solution Repair wiring or replace defective compressor.
Compressor not running. Broken compressor or open/short circuit compressor wiring.
Compressor overload or broken Overload Wait a certain time to cool down or Protector (OLP) on top of the compressor. replace defective OLP. Compressor settings incorrect. Check settings, at least one compressor should be programmed active. C01=ON C00=OFF
n/a
Seawater pump(s) running directly after power up controller. Compressor starts or stops continuously.
Wiring pump 1 (seawater) mixed-up with Check wiring. pump 2 (chilled water). Lack of chilled water. Check for leaks in water system. Ensure air or water flow (see A01 and/or A02). Lack of refrigerant mostly recognized by a low static pressure before start-up and non-fluctuating LP associated with a low HP pressure reading. Check for refrigerant leaks, repair if necessary and charge required amount of refrigerant. Operate the unit in heat cycle. Intervention by a refrigerant specialist might be necessary. Technical Memo available. To be determined by a refrigerant specialist. Technical Memo available. To be determined by a refrigerant specialist.
n/a n/a
No or insufficient cooling Bad air flow or water flow, or heating performance. filthy or blocked circulation. Lack of refrigerant.
Oil lock.
Blocked refrigerant circuit. (Drier, capillary or expansion valve). Bad compressor. n/a Pumps running continuously.
Remove R56 + C24 and/or R57 + C27 When additional relays are used to from the printboard. operate pumps a small leaking current from the printboard may operate the relay continuously. Check for interference by direct sunlight, heat radiation from components near to the sensor. Calibrate sensor. Replace defective sensor. Repair or replace fuse, open/short circuit or replace print board. Check fan by testing with direct current on fan. Replace fan if still not running. Check if blower setting is not at B0. Put blower setting to B1 - BA.
n/a
Inaccurate temperature Temperature sensor not installed on the right position, interference by read-out of room / environment or read-out deviation. ambient temperature, water temperature (premium) or evaporator temperature (classic). Blower not running. Defective fuse or open/short circuit on specific circuit.
n/a
23
Trouble Shooting
6.2 Capacitors
6.2.1 Run capacitor

A run capacitor is installed to offset the magnetic field in the stator windings of a electric motor. When the run capacitor fails, the rotor will block on LRA (locked rotor amperage) and refuses to start running. Start attempts will result in cutout by overload protection, repeated failed start-ups and ignored overload cut-outs will eventually lead to motor failures instead of a simple capacitor replacement.
6.2.4 Trouble shooting controller cards

The AC-output of a controller card is done through electronic relays also called TRIACS mounted against an heatsink for cooling. All TRIACS are protected by slow fuses except the main compressor outlets COMP1 and COMP2. TRIAC failures can cause electrical problems. a) a TRIAC remains open, no active current on the AC outlet connector.
6.2.2 Start capacitor

A start capacitor is installed to offset the wave signal frequency during start-up. Capacitor failures will lock the rotor on LRA (locked rotor amperage) and refuses to start running a electric motor. Start attempts will result in cut-out by overload protection, repeated failed starts and ingnored verload cut-outs will eventually lead to complete motor failures instead of a simple capacitor replacement. Start capacitor failures will most likely cause excessive voltage drops on startup and/or when running.
b) a TRIAC remains closed, continuously AC output present on the connector. When there is a presumption of a TRIAC failure first check the protective fuses to be OK. TRIAC failures are more likely as a OPTO-COUPLER failure (I.e. the electronic device that interfaces the micro-processor with the power Triac). OPTOCOUPLER failures are more wise to return to the factory for repair and testing. Replacing a TRIAC BTA26 can be done easily by unwelding and replaced at low cost, therefore to be available on stock. To test the AC output of a TRIAC on a outlet connector is important to test this with a electronic ballast such as a 40 Watt light-bulb for example. An electronic volt/multi-meter is not adequate to test because a TRIAC is generally allowed to leak current to deceive a electronic meter. Only when necessary a complete controller card can be replaced. Before replacing a card make sure that the amperage draw on the AC-output is in relation to the operation conditions shown as I [A] in the tabel with capacitors. Use only slow-blow fuses as replacement for all controllers!
6.2.3 Trouble shooting capacitors

Broken capacitors will cause a rotor blockage on LRA, allowing a rotor only to turn slowly or cause excessive voltage drops. 1) When there is a presumption of a broken run capacitor first disable one of the wires of the start capacitor when applied. 2) Try to start the motor/compressor again, if there is still a LRA blockage replace the run capacitor. 3) If the motor/compressor attempts to start after a capacitor replacement and runs apparently normal, check the running amps to see if there are no damages to the motor windings. When the amp read-out is fare above normal, the windings are damaged and the motor or compressor should be replaced. 4) Re-connect the start capacitor and test again to see if start-up and running is normal. Faulty start capacitors will give excessive voltage drops on start-up and/or when running. Replace start capacitor if necessary.
24
Controller Cards 7
7.1
Controller Cards
Classic / Select
Fuses V2 series
WBCL000828 Fuses V3 series: F1 Print board 315 mA F2 Pump 3.15 A F3 Valve 3.15 A F4 Fan 3.15 A
Dipswitch settings V2 series
CPAC - TCC Controller V2 < 2004
CPAC - TCC Controller V3 2004 >
7.2
Premium
WBCL000864 Fuses V2 series
Fuses V3 series: F1 Print board 315 mA F2 Fan 6.3 A F3 Valve 3.15 A F4 Pump 1 SW 3.15 A F5 Pump 2 CW 3.15 A Dipswitch settings V2 series 1 and 2 compressors Chiller - TECC Controller V2 < 2006 Chiller - TECC Controller V3.1 2006 > 3 and 4 compressors
25
Controller Cards
7.3 Air handler
WBCL000860
Air handler - CAB Controller V2 < 2005
Air handler - CAB Controller V3.1 2005 - 2006
Air handler - CAB Controller V3.2 2006 >
Fuses V3 models: F1 Print board 315 mA F2 Fan 6.3 A
26
8.1
br bl br bl
Start capacitor (only for 16,000 BTU and more)
115/230V AC switch board
br bl sw
Run capacitor Capacitor and resistor pump *)
Electrical diagrams
Classic / Select TCC V3
Blower
Display
comp
External air temp. sensor Evaporator temp. sensor
Pressure switches LP only for 16,000 BTU and more
fan
bl br sw gn
bl ws
ws sw sw rt
valve
Seawater pump
pump
4-way rev. valve
gr ge
Capacitor and resistor pump *)
Cable colours bl br ge gn gr rt sw ws blue brown yellow green grey red black white
*) In case a relay is used, the controller should be without related capacitor and resistor
Fuses: F1 print 315mA (115V 630mA) F2 fan 3.15A F3 valve 3.15A F4 pump 1 SW 3.15 A
Electrical diagrams
27
comp
valve
fan
pump
28
Display External air temp. sensor Evaporator temp. sensor
8.2
Electrical diagrams
bl
TCC pump outlet
br
Classic / Select TCC V3 WB200 Pump Kit

Seawater pump
FUSE / VOLTAGE SETTING:

Cable colours bl br blue brown
IMPORTANT For proper operation TCC controller settings at setpoint 29 C, line <c> must be set at 01
8.3
Common seawater pump
TCC pump outlet unit 1
Classic / Select, multiple units at one pump
IMPORTANT The TCC controller card of each unit should be without capacitor and resistor at the related output. Remove if necessary!
Electrical diagrams
29
30 Blower speed controller card mounted in grille base
8.4
115/230V AC supply from splitair units electrical box
Electrical diagrams
GND
Select, blower speed controller
Splitair blower module
Blower electrical terminals
8.5

SW RT
Display External air temp. sensor Chilled water temp. sensor Not used
SW RT
Pressure switches
Relay Comp. 1
Blower
pump 2 N fan N
valve N
pump 1 N
Premium TECC V3, 1 and 2 compressors
Relay Comp. 2
WS
Capacitor and resistor pump 1 *) valve Capacitor and resistor pump 2 *) fan
SW
GE
Seawater pump
pump 2
pump 1
4-way rev. valve
GE
Chilled water pump
4-way rev. valve
Cable colours Fuses: F1 PCB 315mA (115V 630mA) F2 fan 6.3A F3 valve 3.15A F4 pump 1 SW 3.15A F5 pump 2 CW 3.15A bl br ge gn gr rt sw ws blue brown yellow green grey red black white
Electrical diagrams
31
valve N
Fuses 4 comp add-on: F1 Comp. 4 3.15A F2 Comp. 3 3.15A
valve
32
GE
8.6
115/230V AC switch board 4-way rev. valve 1
Display
GE
Electrical diagrams
4-way rev. valve 2

External air temp. sensor Chilled water temp. sensor Not used
Cable colours
GE
4-way rev. valve 3
GE
bl br ge gn gr rt sw ws
blue brown yellow green grey red black white
4-way rev. valve 4
Premium TECC V3, add-on 3 and 4 compressors
SW RT
SW RT
Fuses TECC V3: F1 PCB 315mA (115V 630mA) F2 fan 6.3A F3 valve 3.15A F4 pump 1 SW 3.15A F5 pump 2 CW 3.15A 4 comp. add-on
Pressure switches
Relay Comp. 3
Relay Comp. 4
8.7
Compressor 115/230V 1PH
TECC Comp Outlet

SW
Start Capacitor Run Capacitor
Premium, compressors
Compressor 115/230V 1PH AC Switch Board Main AC
TECC Comp Outlet
Cable colours Compressor 208/400V 3PH AC Switch Board
bl br sw
blue brown black
Main AC
SW
TECC Comp Outlet
Electrical diagrams
33
pump 2 N fan N
valve N
fan
pump 2
IMPORTANT For external heater operation set TECC controller at F-04, setpoint 15 C 2-00 and 29 C 9-03.
pump 1
valve
34
Display External air temp. sensor Chilled water temp. sensor Not used
8.8
Electrical diagrams
Cable colours
bl br gr or
blue brown grey orange
Premium TECC V3 with external heater
pump 1 N
Fuses: F1 PCB 315mA (115V 630mA) F2 fan 6.3A F3 valve 3.15A F4 pump 1 SW 3.15A F5 pump 2 CW 3.15A
External heater control
Danfoss 3-way valve 230V cool / ext. heater
8.9
AC switch board
SW RT
Display
SW RT
External air temp. sensor Chilled water temp. sensor Not used
Pressure switches
Premium TECC V3 with calorifier
Relay Comp. 1
Blower
pump 2 N fan N
valve N
pump 1 N
Relay Comp. 2
SW
WS
fan
Capacitor and resistor pump 1 *) Capacitor and resistor pump 2 *)
GR GE
4-way rev. valve
Clixon / Thermostat
Heater element
Seawater pump
Calorifier **)
GR GE
pump 2 pump 1 valve
Chilled water pump
4-way rev. valve
Cable colours Fuses: F1 PCB 315mA (115V 630mA) F2 fan 6.3A F3 valve 3.15A F4 pump 1 SW 3.15A F5 pump 2 CW 3.15A bl br ge gn gr rt sw ws blue brown yellow green grey red black white **) IMPORTANT In case a calorifier is used set TECC controller at setpoint 15 C 2-00
Electrical diagrams
35
Electrical diagrams
8.10 Premium TECC V2, 1 compressor
36
Electrical diagrams
8.11 Premium TECC V2, add-on 3 and 4 compressors
37
38
115/230V AC Switch Board MTH Thermostat Blower
Electrical diagrams
8.12 Premium, MTH mechanical thermostat
SW
Cable colours bl br gn sw blue brown green black
230V AC switch board
Thermostat
Display (program only!)
CAB V3 3-speed
Not used Speed selection switch
Blower
SW
Fan
SW
3-way valve 230V
Danfoss 3-way valve 230V Fuses: F1 PCB 315mA F2 fan 3.15A Cable colours bl br ge gn gr rt sw ws or blue brown yellow green grey red black white orange
8.13 Premium, CAB V3 controller card + MTH2 thermostat + 3-way valve
Electrical diagrams
39
40
Display (program only!)
Electrical diagrams
230V AC switch board
Thermostat
CAB V3 3-speed
Not used Speed selection switch
Blower
SW
Fan
SW
3-way valve 230V
Danfoss 3-way valve 230V Fuses: F1 PCB 315mA F2 fan 3.15A Cable colours bl br ge gn gr rt sw ws or blue brown yellow green grey red black white orange
8.14 Premium, CAB V3 controller card + Plana thermostat + 3-way valve
Heater element
Display
CAB V3 Digital
External air temp. sensor Valve Chilled water temp. sensor Heat Fan
Danfoss 3-way valve (230V only)
SW
Blower
3-way valve (230V only)
SW
8.15 Premium, CAB V3 controller card + Digital Display Panel + 3-way valve
Fuses: F1 PCB 315mA (115V 630mA) F2 fan 3.15A
Cable colours bl br ge gn gr rt sw ws or blue brown yellow green grey red black white orange
Electrical diagrams
41
Electrical diagrams
8.16 Premium, Silent 5-speed for Compact and Slimline air handlers
Below diagram is OK for index A silent 5-speed controls For an index B you must set code 2 at15 C to <2 03> Very important: WBCL000373A can only pilot the A version silencers and are not fowards compatible. WBCL000373B can only pilot the B version silencers and are not backwards compatible.
42
Electrical diagrams
8.17 Premium, convert Danfoss into Lizhan
43
Electrical diagrams
8.18 Fresh-Air units
Fresh-Air V3 wiring
44
Electrical diagrams
45
Electrical diagrams
46
Unit model with Rotary compressor Voltage I [A] 2.1 4.2 5.5 2.5 2.5 6.5 2.5 9 2.5 2.5 11 2.5 2.5 4 9 25 7.5 25 45 uF 55 uF 6.5 20 35 uF 32 60 uF 5.6 20 30 uF 4.4 16 35 uF WBCL000109 WBCL000182 WBCL000184 WBCL000109 WBCL000108 WBCL000183 25 50 uF WBCL000107 4.4 16 35 uF WBCL000109 n/a DST5/HS600 DST5/HS600 DST5/HS600 DST5/HS600 DST5/HS600 DST5/HS600 DST5/HS600 20 45 uF WBCL000108 n/a 3.2 12 30 uF WBCL000182 n/a 2.8 10 25 uF WBCL000181 n/a n/a n/a n/a n/a WBCL000001 WBCL000001 WBCL000001 WBCL000001 WBCL000001 WBCL000001 WBCL000001 16 40 uF WBCL000110 n/a n/a 16 40 uF WBCL000110 n/a n/a 8 20 uF WBCL000180 n/a n/a Fuse [A] RUN Part number START Part number WBCL002260 WBCL002268 WBCL002269 WBCL002261 WBCL002262 WBCL002270 WBCL002263 WBCL002271 WBCL002263 WBCL002264 WBCL002272 WBCL002265 WBCL002266 WBCL002267 230V 1Ph 230V 1Ph 230V 1Ph 115V 1 Ph 230V 1Ph 230V 1Ph 115V 1 Ph 230V 1Ph 115V 1 Ph 230V 1Ph 230V 1Ph 115V 1 Ph 115V 1 Ph 230V 1Ph 2.5 Cable size [mm2]
Compressor type
Part number
Each compressor
Capacitors
Classic 5
RM5460HNE
Classic 5
RM460GQ84
Classic 6,5
RM465GQ84
Compressors
Classic 7
LG-NK125P
Classic 9
LG-NK164P
Classic 9
LG-QK125C
Classic12
LG-NK185P
Classic12 / Premium 12Mono - 24Twin
LG-QK164C
Premium 12Mono - 24Twin
LG-NK185P
LG-NJ236P
LG-QK191C
Classic20 / Premium 20Mono - 40Twin - 60Tri
LG-NJ282P
Classic24 / Premium 24Mono - 50Twin - 72Tri - 100Qtr
LG-NP362P
Classic30 / Premium 30Mono - 60Twin - 90Tri - 120Qtr
LG-NP407P
Compressors
47
48
Part number Voltage I [A] 60 uF 10 60 uF 11.5 60 uF 13.5 60 uF 15 40 60 uF WBCL000184 DST6 WBCL009502 DST6 40 55 uF WBCL000183 DST6 WBCL009502 DST6 32 50 uF WBCL000107 DST6 WBCL009502 DST6 WBCL000027 WBCL000027 WBCL000027 WBCL000027 WBCL000027 WBCL000027 32 45 uF WBCL000108 DST5/HS600 WBCL000001 WBCL009502 DST5/HS600 WBCL000001 Fuse [A] RUN Part number START Part number WBCL009504 WBCL009399 WBCL009487 WBCL009397 WBCL009488 WBCL009396 WBCL009489 WBCL009401 WBCL009492 WBCL009494 WBCL009496 WBCL009498 WBCL002283 WBCL009499 WBCL009500 WBCL009386 WBCL009386B WBCL009389 WBCL009389B WBCL009387 WBCL009387B WBCL009388 WBCL009388B 400V 3Ph 400V 3Ph 400V 3Ph 4 4 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 400V 3Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 230V 1Ph 4 Cable size [mm2] Each compressor Capacitors
Unit model with Scroll compressor
Compressor type
LG-HQ 028P
Compressors
Premium 30Mono - 60Twin - 90Tri - 120Qtr
Copeland-ZR28
Premium 36Mono - 72Twin - 108Tri
LG-HQ 034P
Copeland-ZR34
LG-HQ 040P
Copeland-ZR40
LG-HR 049P
Copeland-ZR48
LG-HQ 028Y
LG-HQ 034Y
LG-HQ 040Y
LG-HR 049Y
Premium 60Mono - 180Tri - 240Qtr
LG-HR 061Y
Premium 216Tri -288Qtr
LG-HR 073Y
Premium 252Tri -336Qtr
LG-HR 081Y
Premium 384Qtr
Copeland-ZR90K3E
Copeland-ZR94KCE
Premium 448Qtr
Copeland-ZR11M3E
Copeland-ZR108M3E
Premium 504Qtr
Copeland-ZR12M3E
???
Premium 572Qtr
Copeland-ZR16M3E
Copeland-ZR144KCE
10
Blowers 230 V 2 uF 2.5 uF 4 uF 6 uF 6 uF 12 uF WBCL007041 Fresh-Air48-Special24 WBCL000070 CPAC30-Compact 30000-FreshAir24 0.85 1.25 WBCL000070 CPAC16/20-Compact 16000/20000 0.87 4 4 6 WBCL000018 CPAC12/24-Compact 12000/24000 0.65 3 WBCL000009 CPAC9-Compact 9000 0.57 3 WBCL000017 CPAC5/7-Compact 4500/6000 0.35 2
Part number
Capacitor
Part number
Unit model
I [A]
Fuse [A]
Ecofit 2GRE15 120x62R
WBCL007020
Blowers
WBCL007021
Including capacitor, insulated
WBCL007022
WBCL007023
WBCL007025
WBCL007024
Blowers 115 V 6 uF 8 uF 18 uF 24 uF WBCL000016 WBCL000012 WBCL000008 WBCL000070
Partnumber
Capacitor
Partnumber
Unit model CPAC5/6.5-Compact 4500/6000 CPAC 9-Compact 9000 CPAC12/24-Compact 12000/24000 CPAC16/20-Compact 16000/20000
I [A] 0.7 1.15 1.3 1.75
Fuse [A] 3 6 6 8
WBCL007030
WBCL007031
WBCL007032
WBCL007033
Blowers
49
BlueCool Unit Performance Report 11 BlueCool Unit Performance Report

: .................... : .................... : R22 / R407 Report date : ....................
Unit type Serial number Refrigerant Check before unit start-up: T ambient compressor P discharge circuit I / II T ambient outside Check running in Cool cycle: U Compressor I Compressor Frequency T seawater inlet T seawater outlet Volume seawater Height seawater outlet Inside diameter suction line Inside diam. outlet through-hull Height seawater inlet Inside diameter discharge line Inside diam. inlet through-hull Pump total discharge head Type / size strainer Number of strainers Max.Strainer flow-rate 4. 5. 6. 7. 8. 9. 9a. 10. 11. 12. 13. 14. T condenser inlet T condenser outlet T liquid T evaporator inlet T evaporator outlet T suction T bulb expansion valve P suction T discharge P discharge T chilled water inlet T chilled water outlet Air handler(s) (Fan coil) T blower air inlet T blower air outlet T water air handler inlet T water air handler outlet
: .................... C : .................... / .................... bar : .................... C
Circuit I : .................... : .................... : .................... : .................... : .................... : .................... : : : : : : : .................... .................... .................... .................... .................... .................... ....................
Circuit II .................... .................... ....................
Gauging site in drawing
Volts Amps Hz
1. 2. 3.
.................... C .................... C ltr/min. (at unit or through-hull) m (above water level) mm mm m below water level mm mm m
: ............................................................ : .................... pieces : .................... ltr/min each : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... I ............... ............... ............... ............... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... II ............... C ............... C ............... C ............... C C C C C C C C bar C bar C C IV ............... ............... ............... ...............
15. 16. 17. 18.
: : : :
C C C C
III ............... C ............... C ............... C ............... C
C C C C
50
BlueCool Unit Performance Report

Check running in Heat cycle: Circuit I
Gauging site in drawing
Circuit II .................... .................... .................... Volts Amps Hz
U Compressor I Compressor Frequency T seawater inlet T seawater outlet Volume seawater Height seawater outlet Inside diameter suction line Inside diam. outlet through-hull Height seawater inlet Inside diameter discharge line Inside diam. inlet through-hull Pump total discharge head Type / size strainer Number of strainers Max.Strainer flow-rate
: .................... : .................... : .................... : .................... : .................... : .................... : : : : : : : .................... .................... .................... .................... .................... .................... ....................
1. 2. 3.
.................... C .................... C ltr/min. (at unit or through-hull) m (above water level) mm mm m below water level mm mm m
: ............................................................ : .................... pieces : .................... ltr/min each : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... : .................... I ............... ............... ............... ............... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... .................... II ............... C ............... C ............... C ............... C C C C C C C C bar C bar C C IV ............... ............... ............... ...............
4. 5. 6. 7. 8. 9. 9a. 10. 11. 12. 13. 14.
T condenser inlet T condenser outlet T liquid T evaporator inlet T evaporator outlet T suction T bulb expansion valve P suction T discharge P discharge T chilled water inlet T chilled water outlet Air handler(s) (Fan coil) T blower air inlet T blower air outlet T water air handler inlet T water air handler outlet
15. 16. 17. 18.
: : : :
C C C C
III ............... C ............... C ............... C ............... C
C C C C
Conclusion: .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
51

Controller settings Main menu
Function .. .. b.. H / E.. F.. U.. 1C.. 2C.. 3C.. 4C.. P.. L.. 1L.. 2L.. 3L.. 4L.. d t Description Room temperature Setpoint temperature Fan speed Temperature Cycle mode Line current Compressor 1 on/off Compressor 2 on/off Compressor 3 on/off Compressor 4 on/off Compressor sequence Start delay compressors Temp. comp. 1 off Temp. comp. 2 off Temp. comp. 3 off Temp. comp. 4 off Dehumidifying Display time AC AH 1 AH 2 AH 3 AH 4
29 C menu
0 1 2 3 4 5 6 7 8 9 A b c d E F Temp. low cut-out Temp. low cut-in Temp. high cut-out Temp. high cut-in Calibration H/E temp. sensor Time [min] to sleep mode Start delay unit Calibration room temp sensor Calibration AC 50 Hz Setting R2 Calibration AC 60 Hz Software version Pump 1 continuous/staged Lower VDC pump 1 Higher VDC pump 1
15 C menu
0 1 2 3 4 5 6 7 8 9 A b c d Low AC voltage cut-out Remote control Setting R1/Blower type Blower setting Internal / external room temp. sensor Fahrenheit or Celsius Setting fanspeed level 5 Setting fanspeed level 4 Setting fanspeed level 3 Setting fanspeed level 2 Setting fanspeed level 1 Set security CODE Dehumidifying time heating Dehumidifying time cooling
52
Classic
Refrigeration cycle
16
15
7 9 10 9a 11 12
Premium
18.3 8 13
18.2
18.1
2 3
16.3
16.2
16.1
15.3 14
15.2
15.1
17.3 7
17.2
17.1 6 5 1
53

Gauging sites
3 1 2
1. Temperature seawater inlet 2. Temperature seawater outlet 3. Flow seawater 4-II
5-I 5-II
4-I
4. Temperature condenser inlet 4-I : circuit I 4-II : circuit II
5. Temperature condenser outlet 5-I : circuit I 5-II : circuit II
8-II
6-II
6-I 8-I 6. Temperature liquid 6-I : circuit I 6-II : circuit II 8. Temperature evaporator outlet 8-I : circuit I 8-II : circuit II
54

For proper measurement of temperature at point 13 and 14, the tubular insulation has to be removed or pushed aside.
8 9a 10 12
14 7 6. 7. 8. 9a. Temperature liquid circuit II Temperature evaporator inlet circuit II Temperature evaporator outlet circuit II Temperature bulb expansion valve circuit II 10. Pressure suction circuit II 12. Pressure discharge circuit II 14. Temperature chilled water outlet circuit II
11 9a 13-II
12 13-I
9a 9 8-I
14-I
9. Temperature suction circuit I 9a. Temperature bulb expansion valve circuit I 11. Temperature discharge circuit I
8-I.
Temperature evaporator outlet circuit I 13-I. Temperature chilled water inlet circuit I 13-II. Temperature chilled water inlet circuit II 14-I. Temperature chilled water outlet circuit I
55
Webasto Product International NL Constructieweg 47 NL - 8263 BC Kampen The Netherlands Phone: +31 (0) 38 337 11 37 Fax: +31 (0) 38 332 51 81 E-mail: info-nl@webasto.com Internet: http://www.webasto.com http://dealers.webasto.com
Ident-No. xxxxxxxA 11/10 Errors and omissions excepted Printed in The Netherlands Webasto AG, GCS 2010

Trouble Shooting BlueCool

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Trouble Shooting BlueCool

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Luft-Heizgerte

Marine Air Conditioning Systems Fresh-Air Units

Operation Settings Trouble Shooting

BlueCool Classic BlueCool Premium

Digital Control Panel operation and settings 1

Digital Control Panel operation and settings

Cool cycle mode Automatic operation Heat cycle mode On / Off

Higher values (Sun)

Lower values (Snow flake)

OFF MEMO(NENO) RETURN FUNCTION

NEXT LINE DOWN BLOWER SPEED UP

Digital Control Panel operation and settings

Entering programming menu level 3

Programming Premium Unit 2

Programming Premium Unit

Programming Premium Unit

Programming Premium Unit

1 1 1 70 70 70 70 70 99 99 99 20 minutes minutes seconds

Programming Classic Unit 3

Programming Classic Unit

Programming level 3 at 29 C, Classic Card TCC 5.25

Programming Classic Unit

Programming Cabin Controls 4

Programming Cabin Controls

4.1.2 Programming level 3 at 29 C, Cabin Card 6.25

4.1.3 Programming level 3 at 15 C, Cabin Card 6.25

Programming Cabin Controls

Programming Fresh-Air 5 Programming Fresh-Air

Higher values (Sun)

Lower values (Snow flake)

Digital Display Fresh-Air Control

Example of operating window setting - Fresh-Air Control - Cool Cycle

Example of operating window setting - Fresh-Air Control - Heat Cycle

Outside air temperature

Visual Error Codes - Digital Display

Blower Speed Regulation

5.8.2 Programming level 3 at 29 C, Cabin Card 6.25

5.8.3 Programming level 3 at 15 C, Cabin Card 6.25

Failure Description code AAA Low Voltage

No output on printboard. Defective fuse or open/short circuit on specific circuit.

Compressor not running. Broken compressor or open/short circuit compressor wiring.

6.2.1 Run capacitor

6.2.4 Trouble shooting controller cards

6.2.2 Start capacitor

6.2.3 Trouble shooting capacitors

Dipswitch settings V2 series

CPAC - TCC Controller V2 < 2004

CPAC - TCC Controller V3 2004 >

Air handler - CAB Controller V2 < 2005

Air handler - CAB Controller V3.1 2005 - 2006

Air handler - CAB Controller V3.2 2006 >

Fuses V3 models: F1 Print board 315 mA F2 Fan 6.3 A

115/230V AC switch board

Classic / Select TCC V3

External air temp. sensor Evaporator temp. sensor

Pressure switches LP only for 16,000 BTU and more

4-way rev. valve

Capacitor and resistor pump *)

TCC pump outlet

Classic / Select TCC V3 WB200 Pump Kit

FUSE / VOLTAGE SETTING:

115/230V AC switch board

Common seawater pump

TCC pump outlet unit 1

Capacitor and resistor pump 1 ) Capacitor and resistor pump 2 )